Mold for manufacturing filling members

Abstract

A mold for producing a filler member from a liquid ceramic composition, the mold comprising a first part and a second part, the first and / or second mold parts being elastically deformable, the first part and / or second part comprising a plurality of open mold cavities, the first and second parts being operable to engage to form a closed mold cavity, the mold being operable to move from an open position in which the first and second parts are partially spaced apart by deformation of the mold parts and the mold cavity is open at that position, to a partially closed position in which the mold cavity is partially closed at that position by reducing deformation of the mold parts, and then to a closed position in which the first and second parts are engaged to close the mold cavity at that position by further reducing deformation of the mold parts.

Description

[Technical field]

[0001] The present invention relates to a mold for use in producing packing elements for packed beds, in particular supports for catalysts and supported catalysts. More particularly, the present invention relates to a mold for use in producing ceramic catalyst supports and supported catalysts for use in processes such as steam reforming and the production of direct reduced iron. [Background technology]

[0002] Metal catalysts used in industrial processes such as steam reforming and the production of direct reduced iron are more active when divided into fine particles to increase the metal surface area. A high metal surface area can be maintained during such reactions by spreading the metal particles across a refractory support. Another advantage of using catalyst supports in such processes is that only small amounts of the more expensive catalytic metal need be dispersed on large amounts of abundant, inexpensive support material, significantly reducing the cost of the catalyst material required on a commercial scale.

[0003] In many such processes, the reactions requiring the catalyst are very fast and are confined to the pellet surface. The reactions are therefore dependent on the surface area of ​​the supported catalyst geometry. Furthermore, supported catalysts with low internal surface area (BET) and very small internal pore volume generally suffer from low activity in such processes. The strength of the support is also important, as damage during loading, operation and unloading of the supported catalyst can reduce activity and increase delays and costs. For example, in the Midrex process for direct reduced iron (DRI), the catalyst can be subjected to high levels of mechanical handling and thermal cycling, as is the case with steam reforming catalysts. Furthermore, the supported catalyst should provide good heat transfer properties while keeping pressure drop low.

[0004] Supports for catalysts in such industrial processes are typically made by extrusion, pelleting or granulation of ceramic powders followed by firing of the compacts.

[0005] However, such methods have been found to be limited in the geometries and physical properties of the supports that can be delivered, for example, such supports cannot achieve high strength without sacrificing low surface area and poor porosity in the geometry. Summary of the Invention [Problem to be solved by the invention]

[0006] Thus, there is a need for improved supports for catalysts that have a good combination of desirable properties that can be economically produced.It is therefore an object of embodiments of the present invention to address one or more of the above or other problems. [Means for solving the problem]

[0007] According to a first aspect of the present invention, there is provided a mould for producing a filler member from a liquid ceramic composition, the mould comprising a first part and a second part, the first and / or second mould parts being elastically deformable, the first part and / or the second part comprising a plurality of open mould cavities, the first and second parts being operable to engage to form a closed mould cavity, and the mould being operable to move from an open position in which the first and second parts are partially spaced apart by deformation of the mould parts and the mould cavity is open at that position, to a partially closed position in which a portion of the mould cavity is closed at that position by reducing deformation of the mould parts, and then to a closed position in which the first and second parts are engaged such that the mould cavity is closed at that position by further reducing deformation of the mould parts.

[0008] According to a second aspect of the present invention, a. placing a mold including a first part and a second part, the first part and / or the second part being elastically deformable, the first part and / or the second part including a plurality of open mold cavities, and in an open position, the first and second parts are partially separated by deforming the mold parts such that the mold cavities are open; b. contacting the mould parts with the liquid ceramic composition, suitably by contacting a portion of the mould where the first and second parts abut; c. moving the mold to a partially closed position by reducing deformation of the mold parts such that a portion of the mold cavity is closed and a portion of the liquid ceramic composition is retained within the closed mold cavity; d. moving the mold to a closed position by further reducing deformation of the mold parts such that the first and second parts are engaged to close the further mold cavity and a further portion of the liquid ceramic composition is retained in the further closed mold cavity to produce a molded body; e. Optionally, heating the compact; f. demolding the molded body; and g. optionally sintering the compact to produce the infill member.

[0009] According to a third aspect of the present invention there is provided a moulding apparatus for use in producing a filler member from a liquid ceramic composition, suitably for use in the process of the second aspect of the present invention, the moulding apparatus comprising a mould according to the first aspect of the present invention and a guide member operable to position the mould in an open position.

[0010] According to a fourth aspect of the present invention, there is provided a packing member for use in a packed bed, preferably for use as a catalyst support in a packed bed reactor, obtainable by a process according to the second aspect of the present invention and / or in a mould apparatus according to the third aspect of the present invention, by moulding a liquid ceramic composition in a mould according to the first aspect of the present invention.

[0011] The first and second parts may each include a plurality of open mould cavities. Suitably, the mould cavities of the first and second parts may be open partial mould cavities, and the first and second parts of the mould are operable to engage such that the partial mould cavities of the first part align with the partial mould cavities of the second part to form a closed enlarged mould cavity. An "open" mould cavity, as used herein, may mean that the filler member or moulding body or part thereof is operable to be removed from the mould cavity through the same hole through which the liquid ceramic composition is directed into the mould cavity. A "closed" mould cavity, as used herein, may mean that the liquid ceramic composition is held within the mould cavity such that it cannot be removed from the mould cavity.

[0012] The mould cavity may include a texturing operable to create a surface structure on the filler member. Suitably, a surface of the mould cavity operable to contact the liquid ceramic composition during moulding may include a texturing.

[0013] The mould cavity may include a pin operable to form a hole in the filler member, such as a hole extending through the filler member. Suitably, the mould cavity may include at least two pins, for example at least three or at least four pins. The pin may be located on a bottom surface of the mould cavity and extend upwardly towards an opening of the mould cavity. The pin may be substantially centrally located on a bottom surface of the mould cavity. The pin may be cylindrical.

[0014] Suitably, the first and / or second deformable mould parts may be formed from a polymeric material such as silicone, which may be formed from a two-part silicone composition comprising a silicone resin and a hardener or catalyst.

[0015] The material forming the first and / or second mould parts may have a Shore hardness of at least 5, such as at least 10, or at least 15, such as at least 20. The material forming the first and / or second mould parts may have a Shore hardness of 40 or less, such as 35 or less, or 32 or less, such as 30 or less. The material forming the first and / or second mould parts may have a Shore hardness of 5 to 40, such as 10 to 35, or 15 to 32, such as 20 to 30. Advantageously, it has been found that materials having a Shore hardness within the above mentioned ranges maintain sufficient shape and rigidity whilst providing a mould which is flexible to allow for effective moulding according to the invention. As described herein, Shore hardness was measured using ASTM D2240 Type A.

[0016] The material forming the first and / or second mold parts may have a shrinkage of 1% or less, such as 0.5% or less, or 0.4% or less, such as 0.3% or less. Advantageously, it has been found that materials having shrinkage within the above ranges provide a mold with improved matching between the mold parts. As described herein, shrinkage may suitably refer to the amount of dimensional change over a week, such as a month or three months.

[0017] The mold may further include a member forming a reservoir. In the open position, the first and second parts may be spaced apart such that the reservoir member forms a reservoir cavity. In the partially closed position, the location of the reservoir cavity may move relative to the mold cavity and / or the volume of the reservoir cavity may be reduced.

[0018] The reservoir member may be operable to form a reservoir cavity capable of receiving and holding the liquid ceramic composition. The reservoir cavity need not be a mold cavity such that in the closed position the reservoir cavity is not substantially operable to hold a portion of the composition or to form a molded product.

[0019] The reservoir members may include a first reservoir member disposed on a first mould part and a second reservoir member disposed on a second mould part, the first and second reservoir members operable to co-engage to form a reservoir cavity. Suitably, the first and second reservoir members may be male and female reservoir members, such that the male reservoir member is operable to be received within the female reservoir member to form the reservoir cavity. The male reservoir member may be in the form of a tongue and the female reservoir member may be in the form of a groove. Suitably, the male and female reservoir members may be operable to form a tight fit when engaged. By "tight fit" herein is meant a fit operable to prevent the liquid ceramic composition from passing through the engaged reservoir members.

[0020] The first and / or second mould parts may comprise a reservoir member, suitably a tongue or groove extending along both sides of the mould cavity of the mould part, suitably a longitudinally extending reservoir member. Suitably, the first and second mould parts may each comprise a mould cavity, the first reservoir member comprising a tongue extending along both sides of the mould cavity of the mould part and the second reservoir member comprising a groove extending along both sides of the mould cavity of the mould part. The reservoir members of the mould parts may further comprise a base reservoir member extending between the side reservoir members. The base reservoir member may extend laterally along the mould part. The base member may be located below the mould cavity of the mould part. Suitably, the first reservoir member may comprise a base tongue extending between the tongues on both sides and / or the second reservoir member may comprise a base groove extending between the grooves on both sides. Such a reservoir member configuration may be U-shaped, with the side reservoir members extending longitudinally along the mold parts and the base reservoir members extending laterally along the mold parts between the side reservoir members. The base reservoir members may provide the bottom inner surface or base of the reservoir cavity in use. The side reservoir members may provide the sides of the reservoir cavity in use. The surfaces of the mold parts extending between the side reservoir members, which may also contain the mold cavity, may provide the front and rear surfaces of the reservoir cavity. Typically, the reservoir cavity includes a mouth. The mouth may extend between the ends of the side reservoir members that are not connected to the base reservoir member. Suitably, the mouth of the reservoir cavity may extend laterally across the mold parts, typically substantially parallel to the base reservoir members.

[0021] Suitably, the first and / or second mould parts may include a plurality of mould cavities in a group. The side reservoir members may be arranged to extend along either side of the group. The base member may be arranged to extend below the group.

[0022] The reservoir member of the mold part may be disposed on the same plane as the mold cavity. The reservoir member of the mold part may be disposed such that engagement of the reservoir member is operable to align a portion of the mold cavity on the mold part to form an enlarged mold cavity in the closed position.

[0023] As a result, when the mould is in the open position, the reservoir members may be operable to engage to form a reservoir cavity operable to receive the liquid ceramic composition through the mouth of the reservoir cavity and then retain the liquid ceramic composition in the reservoir cavity. Suitably, the mould cavity may be located within the first reservoir cavity when the mould is in the open position. The mould cavity may also be located outside the first reservoir cavity when the mould is in the open position. As the mould is moved from the open position to the partially closed position and then to the closed position, the reservoir members of the mould parts may be operable to further engage such that the reservoir cavity moves along the group of mould cavities to close the now filled mould cavity in the first reservoir cavity and transfer the remaining composition into the relocated reservoir cavity and into the new mould cavity. This movement may continue until the reservoir members are fully engaged, suitably by engagement between the mould parts over the mould cavity to close the mould cavity. Typically, the reservoir cavity has a volume that is smaller than the combined volume of the mold cavities of the mold.

[0024] The mould parts may include a retaining member operable to assist in maintaining alignment of the mould parts. The mould parts may include a retaining member operable to assist in maintaining alignment of the mould parts during dispensing of the liquid ceramic composition into the mould. The dosing retaining member may be spaced from the mould cavity and / or the reservoir cavity, e.g. not providing an inner surface of the reservoir cavity. Typically, the dosing retaining member is not directly attached to the reservoir member. The dosing retaining member may include cooperating members disposed on the first and second mould parts. Suitably, the cooperating dosing retaining members may be male and female such that the male retaining member may be received within the female retaining member to assist in alignment of the mould parts. The male retaining member may be a tongue and the female matching member may be a groove. The mould part retaining member may be disposed longitudinally below the mould cavity, suitably below the base of the reservoir cavity. The retaining member may extend laterally along the mould parts, substantially parallel to the base of the reservoir cavity or the base reservoir member. Advantageously, the use of a dose retention member allows for the formation of a larger initial reservoir cavity whilst maintaining good alignment of the mould parts.

[0025] The mould parts may include post-dosing retention members operable to assist in maintaining alignment of the mould cavities after dosing of the liquid ceramic composition. The post-dosing retention members may be located outside the reservoir cavities, for example so as not to provide an inner surface of the reservoir cavities. The post-dosing retention members may include cooperating members located on the first and second mould parts. Suitably, the cooperating post-dosing retention members may be male and female such that the male retention member can be received within the female retention member to assist in maintaining alignment of the mould parts. The male retention member may be a tongue and the female matching member may be a groove. The post-dosing retention members may be located laterally adjacent to the group of mould cavities. The retention members may extend laterally along the mould parts. The post-dosing retention members may include a set of a plurality of retention members on each side of the group of mould cavities, suitably located laterally adjacent to the group of mould cavities. The set of retention members may include at least two retention members, for example at least three retention members, each spaced longitudinally along the mould part. Advantageously, the use of a post-dose retention member allows for improved retention of alignment between the mold parts after dispensing of the composition.

[0026] The mould parts may include recesses disposed over the mould cavities, suitably over groups of mould cavities and / or over the mouths of the reservoir cavities. Typically the recesses may be elongate and extend substantially parallel to the bases of the reservoir cavities or base reservoir members. The recesses may be operable to receive any excess composition contained within the reservoir cavities when the mould parts reach the closed position.

[0027] The mould parts may include guide members. Suitably, the guide members may extend outwardly from the mould parts. The mould parts may include guide members arranged on two opposing faces of the mould part, suitably on each of two opposing side faces of the mould part. The mould parts may include at least three guide members, for example at least four, at least five or at least six guide members on each of the two opposing faces of the mould part. The faces of the mould parts may include guide members arranged towards opposing ends of the faces and intermediate guide members arranged between the end guide members.

[0028] The mould part may include a reinforcing member, suitably the reinforcing member may be more rigid than the body of the mould part. The reinforcing member may be at least partially disposed within the mould part body. The reinforcing member may extend substantially from one end of the mould part body to another end, for example to the opposing ends. The reinforcing member may protrude from the mould part to provide a guide member. Suitably the reinforcing member may protrude on opposing sides of the mould part to provide a guide member on the opposing sides of the mould part. As a result, a guide member may be provided by the protruding reinforcing member.

[0029] The filling member may be formed from a cast molding composition or slip, such as a clay or non-clay castable composition, a liquid cement or a gel cast composition. The liquid ceramic composition may then be a gel cast composition, suitably the composition may comprise a ceramic material, an organic binding component and optionally a pore forming component.

[0030] The organic binder component may be operable to be substantially removed from the filler member after molding of the filler member, preferably by heat treatment, more preferably during firing of the filler member.

[0031] The organic bonding component may comprise a polymerisable component, suitably the polymerisable component may comprise a polymerisable monomer and a cross-linking member, the bonding component being operable to polymerise to form a (co)polymer.

[0032] The polymerizable monomer may comprise one or more types of ethylenically unsaturated monomers, such as acrylic monomers or derivatives thereof, such as acrylamide monomers, and / or vinyl monomers, such as monomers selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM), hydroxyethylacrylamide (hEAM) and / or N-vinyl-2-pyrrolidinone (NVP). Preferably, the polymerizable monomer comprises one or more acrylamide monomers, more preferably monomers selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM) and hydroxyethylacrylamide (hEAM). Most preferably, the polymerizable monomer comprises MAM.

[0033] The cross-linking member may be selected from one or more diethylenically unsaturated monomers, such as diacryl monomers or derivatives thereof, such as diacrylamide monomers, acrylic salts, and / or polyethylene glycol substituted acrylic monomers. The cross-linking member may be selected from one or more of poly(ethylene glycol) dimethacrylate (PEGDMA), N,N'-methylene bis(acrylamide) (BIS), ammonium acrylate, and PEG methylethyl methacrylate (PEGMEM), preferably one or more of poly(ethylene glycol) dimethacrylate (PEGDMA), and N,N'-methylene bis(acrylamide) (BIS).

[0034] The organic bonding component may be formed from 40-95 wt% of polymerizable monomer and 60-5 wt% of crosslinking member, for example, 50-90 wt% of polymerizable monomer and 50-10 wt% of crosslinking member, or 55-85 wt% of polymerizable monomer and 45-15 wt% of crosslinking member, or 60-80 wt% of polymerizable monomer and 40-20 wt% of crosslinking member, for example, 65-75 wt% of polymerizable monomer and 35-25 wt% of crosslinking member.

[0035] The composition may further comprise a polymerization accelerator operable to accelerate polymerization of the binding moiety. The polymerization accelerator may be any suitable accelerator. For example, the accelerator may be tetramethylethylenediamine (TEMED).

[0036] The composition may further include an initiator operable to initiate polymerization of the binding component. The initiator may be any suitable initiator. The initiator may be a free radical initiator. For example, the initiator may be ammonium persulfate and / or potassium persulfate.

[0037] The pore-forming material may be operable to be removed from the filler member after shaping of the filler member, preferably by heat treatment, more preferably during firing of the filler member. The pore-forming material may be selected from one or more of microbeads, starch, seeds and / or cellulose.

[0038] The pore forming material is D 10 The pore-forming material may have a particle size distribution in which D is 5 to 100 μm, preferably 10 to 75 μm, more preferably 15 to 50 μm, and most preferably 20 to 40 μm. 50 The diameter of the pore-forming material may be 50 to 200 μm, preferably 75 to 175 μm, more preferably 90 to 160 μm, and most preferably 100 to 150 μm. 90 The thickness may be 120 to 300 μm, preferably 150 to 270 μm, more preferably 170 to 250 μm, and most preferably 185 to 235 μm.

[0039] The ceramic material may be a refractory ceramic material. The ceramic material may include aluminum oxide, aluminum silicate, magnesium aluminate, calcium aluminate, zirconia, silica, titanate, carbon and / or magnesium oxide.

[0040] Ceramic materials are D 10The pore-forming material may have a particle size distribution in the range of 0.1 to 20 μm, preferably 0.5 to 10 μm, more preferably 1 to 5 μm, and most preferably 1.5 to 3 μm. 50 The diameter of the pore-forming material may be 0.5 to 30 μm, preferably 1 to 25 μm, more preferably 1.5 to 20 μm, and most preferably 2 to 15 μm. 90 The thickness may be 10 to 100 μm, preferably 15 to 80 μm, more preferably 20 to 70 μm, and most preferably 25 to 60 μm.

[0041] The ceramic material may be a ceramic powder. The ceramic powder may be ball milled or spray dried. Advantageously, it has been found that ball milled or spray dried ceramic powders provide easier casting behavior.

[0042] The composition or packing member may include a promoter operable to increase the reactivity of the main reaction and / or reduce undesirable side reactions. The promoter may be selected from one or more of oxides of lanthanum, copper, magnesium, manganese, potassium, calcium, zirconium, barium, cerium, sodium, lithium, molybdenum, yttrium, cobalt, and chromium.

[0043] The composition may further comprise a carrier, for example an aqueous carrier. Suitably the composition may be an aqueous ceramic slurry.

[0044] The composition may include further additives.For example, the composition may include a dispersant such as a polymer salt, for example a salt of polyacrylic acid, preferably an ammonium salt of polyacrylic acid.Suitable dispersants may be selected from one or more of Ecodis P90, Narlex LD42 and Dispex A40.

[0045] The composition may contain 0.1 to 10% by weight of polymerizable monomer, preferably 0.5 to 8% by weight, more preferably 1 to 6% by weight, for example 1.5 to 5% by weight, most preferably 2 to 4% by weight, of the dry weight of the composition.

[0046] The composition may comprise 0.1 to 10% by weight of the crosslinking member, preferably 0.5 to 8% by weight, more preferably 0.75 to 6% by weight, for example 1 to 5% by weight, most preferably 1 to 4% by weight, of the dry weight of the composition.

[0047] The composition may comprise 50-95 wt%, preferably 50-90 wt%, more preferably 55-85 wt%, most preferably 60-80 wt% of the ceramic material by dry weight of the composition. The filler member may comprise at least 75 wt%, preferably at least 85 wt%, more preferably at least 90 wt%, for example at least 95 wt%, most preferably at least 97 wt% of the ceramic material by dry weight of the composition.

[0048] The composition may comprise >0-40% by weight of the pore-forming member, preferably 0.5-30% by weight, more preferably 2-25% by weight, for example 3-20% by weight, most preferably 4-15% by weight, of the pore-forming member by dry weight of the composition.

[0049] The composition may contain from 0.1 to 5%, preferably from 0.5 to 4 wt%, more preferably from 0.75 to 3.5 wt%, and most preferably from 1 to 3 wt% of initiator by dry weight of the composition.

[0050] The composition may contain up to 5% by weight of the accelerator by dry weight of the composition, preferably up to 3% by weight, more preferably up to 2% by weight, and most preferably up to 1.5% by weight.

[0051] The composition may contain 0.1 to 10%, preferably 0.5 to 8 wt%, more preferably 0.75 to 6 wt%, most preferably 1 to 5 wt% of dispersant by dry weight of the composition.

[0052] The composition may have a solids content of 45 to 99% by weight of the total composition, for example 50 to 95% by weight, preferably 55 to 90% by weight, and most preferably 60 to 85% by weight.

[0053] The composition may be formed by combining a preformed aqueous bonding component with the ceramic composition. Suitably, the aqueous bonding component may include a polymerizable monomer, a cross-linking member, and water.

[0054] Before the liquid ceramic composition contacts the mold, the composition may be contacted with an initiator and, optionally, a polymerization accelerator.

[0055] The packing elements of the present invention may be inert packing elements. As a result, the inert packing elements may be substantially free of catalytic material. Advantageously, the use of inert packing elements according to the present invention in the catalyst bed provides improved heat transfer and turbulent gas flow, which helps the reaction medium further along the reactor to be at the appropriate temperature for the desired reaction.

[0056] The packing member or support of the present invention may be a supported catalyst comprising a catalytic material that may be operable to provide catalytic activity in a desired process to which the supported catalyst is applied.

[0057] The catalytic material may comprise one or more transition metals, suitably transition metal oxides, and / or a metal selected from a noble metal, suitably an alloy thereof. The catalytic material may comprise a metal selected from one or more of iron, nickel, silver, gold, platinum, ruthenium, vanadium, molybdenum, and cobalt.

[0058] The composition may be mixed prior to placement in a mold to form a homogenous slurry, suitably prior to addition of the initiator and optionally the accelerator. The composition may be mixed after addition of the initiator and optionally the accelerator to form a homogenous slurry.

[0059] The mould is preferably a casting mould. The mould may be operable to form a surface structure on the moulded body.

[0060] The formed body produced by step (c) may be dried by baking the body at ≧40° C., such as ≧50° C., or ≧55° C., or ≧60° C. Suitably the body may be baked for ≧10 hours, such as ≧15 hours, or ≧20 hours, for example ≧24 hours.

[0061] The compact may be fired at ≧1000° C., preferably ≧1200° C., more preferably ≧1400° C., most preferably ≧1500° C. Suitably, the compact may be fired until substantially all of the binder and pore forming composition is removed from the support or supported catalyst.

[0062] The packing member may be impregnated with the catalytic material by dipping the packing member into a solution of the catalytic material. The dipped packing member may be dried after dipping.

[0063] Advantageously, the present invention allows the shaped support or supported catalyst body to be removed from the mold while still in a relatively resilient shape and can be more easily handled, resulting in lower scrap rates than other types of casting techniques.

[0064] The guide member of the apparatus of the invention may be operable to guide the mould to an open configuration by deforming the mould parts, suitably by receiving the guide member on the mould. Suitably the guide member may include a portion operable to place the mould in a closed position, or at least a partially closed position, and a portion operable to place the mould in a position where the mould parts are at least partially spaced apart in the open position. The mould may be operable to move within the guide member from the closed portion of the guide member to the spaced portion of the guide member. Typically the guide member is operable to place the mould in an open position where parts of the mould parts abut and parts of the mould parts spaced apart, suitably in a position where the mould cavity opens while the dose retaining member is engaged and the reservoir cavity is formed. The guide member may be operable to place the mould in a position where the mould cavity opens while the dose retaining member is engaged and / or parts of the mould parts abut and the open mould cavity and / or the reservoir cavity is located on the abutment of the engaged dose retaining member and / or mould parts. The guide member may further include a drive member operable to move the die through the guide portion of the guide member.

[0065] The molding apparatus may further include a dispensing member operable to dispense the liquid ceramic composition into the mould. Suitably, the dispensing member may be disposed on the guide portion of the guide member.

[0066] The packing member may be a catalyst support, suitably a ceramic catalyst support. The packing member may be a supported catalyst.

[0067] The packing member of the present invention may be a cast packing member, for example a gel cast packing member.

[0068] The filling material is ≧0.7cm 2 / cm 3 and a side crushing strength of ≥ 250 kgf, e.g., ≥ 1 cm 2 / cm 3GSA of ≥ 1.2 cm 2 / cm 3 GSA of ≥ 1.3 cm 2 / cm 3 GSA of ≥ 1.4 cm 2 / cm 3 The filler member may have a GSA of ≧275 kgf, preferably ≧300 kgf, more preferably ≧325 kgf, and most preferably ≧350 kgf.

[0069] Filling material is ≧1.5cm 2 / cm 3 GSA of ≥ 150kgf, and side breaking strength of ≥ 1.7cm 2 / cm 3 GSA of ≥ 1.9 cm 2 / cm 3 GSA of ≥ 2.1 cm 2 / cm 3 GSA of ≥ 2.3 cm 2 / cm 3 The filler member may have a GSA of ≧170 kgf, preferably ≧185 kgf, more preferably ≧200 kgf, and most preferably ≧215 kgf.

[0070] Filling material is ≧3cm 2 / cm 3 GSA of ≥ 60kgf, and side breaking strength of ≥ 3.3cm 2 / cm 3 GSA of ≥ 3.6 cm 2 / cm 3 GSA of ≥ 3.9 cm 2 / cm 3 GSA of ≥ 4.2 cm 2 / cm 3 The filler member may have a GSA of ≧70 kgf, preferably ≧80 kgf, more preferably ≧90 kgf, and most preferably ≧100 kgf.

[0071] GSA is calculated herein by measuring the external dimensions of the filler member, including all macrostructural and surface structural features, and calculating the surface area. The calculated surface area is then divided by the calculated volume of the filler member. Appropriate 3D modeling software can be used to provide these calculations quickly and accurately.

[0072] The lateral crush strength is expressed herein as a value in kgf. It is the maximum load recorded at the failure point of a specimen when compressed and crushed between two parallel, flat, hardened steel plates of a minimum diameter of 80 mm. One plate is fixed to a load cell and recording device, the other is attached to a ram moving at a controlled speed of 5 mm / min. An initial trial test is performed to determine the dimension in which the filler member is weakest. A lateral crush test is then performed in the weakest direction.

[0073] The packing member may have a porosity of ≧6%, preferably ≧15%, more preferably ≧20%, most preferably ≧25%. The packing member may have a porosity of 6-50%, preferably 15-40%, more preferably 20-35%, most preferably 25-30%. Suitably, the support may have a porosity of ≧15%, more preferably ≧20%, most preferably ≧25%. The support may have a porosity of 15-50%, more preferably 20-40%, most preferably 25-35%.

[0074] Porosity is measured herein by mercury intrusion porosimetry using ASTM D4284-12(2017)e1, Standard Test Method for Determining Pore Volume Distribution of Catalysts and Catalyst Carriers by Mercury Intrusion Porosimetry.

[0075] The filler member may have a macrostructure and a surface structure on the outer surface of the macrostructure. Typically, the surface structure of the filler member is formed during the molding step of the filler member, i.e. the step in which the filler member body is formed by suitable texturing in the mould cavity. As a result, preferably, the surface structure is not post-processed after the molding of the filler member body.

[0076] The macrostructures may be in the shape of, for example, trilobes, quadralobes or pentalobes, a ring, a sphere, a cube, a cuboid, a cylinder, or a cog.

[0077] The cog macrostructure includes a plurality of castellations extending radially outward. The cog macrostructure may have a transverse cross-section, excluding the castellations, that is substantially circular, triangular, square or rectangular, etc. At least some, and preferably all, of the castellations may be tapered along the depth and / or width of the castellation, preferably each castellation may taper in the same direction as the other castellations of the cog, suitably the widest width and deepest depth of the castellation may be towards the same end of the castellation.

[0078] The macrostructures may have a recessed upper and / or lower surface, suitably at least 30%, such as at least 40% or at least 50% of the upper and / or lower surface being recessed. It will be appreciated that holes extending through the macrostructures are not recesses in the upper and / or lower surface in accordance with the present invention.

[0079] Advantageously, it has been found that cog macrostructures having tapered castellations and / or recessed upper or lower surfaces provide improved packing density in combination with reduced interlocking.

[0080] The spherical macrostructure may comprise at least one linear valley, such as at least two, at least three or at least four linear valleys, on the outer surface of the macrostructure. Preferably, the spherical macrostructure comprises at least two, such as at least three or at least four linear parallel valleys. Preferably, the valleys are substantially the transverse cross-section of a hemisphere.

[0081] The macrostructure may be monolithic or may include one or more holes extending through the macrostructure. Preferably, the filler member includes at least one hole extending through the macrostructure, and more preferably, the macrostructure includes at least three holes. The macrostructure may be a honeycomb structure. The holes in the macrostructure may be straight cut or faceted.

[0082] The packing member may comprise a plurality of surface structures, suitably a plurality of repeating surface structures. Preferably the packing member comprises at least 5 surface structures, suitably portions of repeating surface structures, more preferably at least 10, such as at least 15, or at least 20, most preferably at least 25.

[0083] By surface structure is meant raised and / or recessed portions on the carrier, the height of which is substantially smaller than the width / diameter of the filler member macrostructure. Such surface structure may be considered as a textured surface on the filler member macrostructure. The surface structure may be considered as not including microscopic surface roughness. For example, the filler member may consist of a cubic macrostructure having a width of 32 mm and a length of 50 mm. The outer surface of this filler member may include a plurality of surface structures in the form of a plurality of repeating identical discrete peaks, each peak having a height of 2 mm. It will be appreciated that conventional features of a macrostructure, such as the multiple castellations of a cog or the lobes of a multi-lobe, are not considered to be surface structures according to the present invention.

[0084] The surface structures may be in the form of ridges and / or mountains.

[0085] The ridge may be in the form of an annular ridge, said annular ridge being not limited to a circular shape. The annular ridge may be substantially circular in shape or in the form of a regular convex polygon, such as a triangle, a square, a pentagon, a hexagon, a heptagon, an octagon, a nonagon or a decagon. Preferably, the annular ridge is in the form of a regular convex polygon, more preferably a pentagon, a hexagon or a heptagon, most preferably a hexagon. The portion of the surface structure extending between the annular ridges may be flat, oblique and / or curved. For example, the portion of the surface structure extending between the annular ridges may be in the form of an inverted pyramid. The surface structure may comprise a plurality of attached annular ridge structures, suitably interconnected annular ridge structures, such that the ridges of at least a first annular surface structure form parts of a second annular surface structure.

[0086] The peak-shaped surface structures may be recessed into the macrostructure or may protrude outwardly from the macrostructure. The peaks may be curved, pyramidal and / or stepped peaks. The stepped peaks may include 2 to 10 steps, for example 3 to 8 steps. The peaks may be interconnected such that adjacent peaks abut or fuse together.

[0087] The median average height of the surface structures of the filler member may be 10mm or less, preferably 7mm or less, more preferably 6mm or less, most preferably 5mm or less.

[0088] The median average height of the surface structures of the filler member may be at least 0.1 mm, such as at least 0.3 mm, preferably at least 0.5 mm, more preferably at least 0.7 mm, and most preferably at least 0.8 mm. The height of the surface structures is measured herein using a caliper with depth measuring capability.

[0089] The packing element may have a maximum dimension of 1000mm or less, such as 750mm or less, or 500mm or less, preferably 400mm or less. The packing element may comprise a width / diameter of 500mm or less, such as 300mm or less, or 200mm or less, preferably 150mm or less, more preferably 100mm or less, most preferably 50mm or less.

[0090] The median average height of the surface structures of the packing member may be 40% or less of the width / diameter of the packing member, such as 30% or less, preferably 25% or less, more preferably 20% or less, most preferably 15% or less.

[0091] The surface structure may extend on at least two surfaces of the filler member, for example at least the side and top and / or bottom surfaces.

[0092] The surface structure may extend over at least 50%, such as at least 60%, preferably at least 70%, more preferably at least 80%, and most preferably at least 85% of the side of the packing member. The surface structure may extend over at least 50%, such as at least 60%, preferably at least 70%, more preferably at least 80%, and most preferably at least 85% of the outer surface of the packing member. Where the surface structure includes repeating successive ridges, such as annular ridges, the surfaces extending between the ridges are included as part of the surface structure for purposes of this calculation, even if the surface is substantially flat or where the ridges are not interconnected.

[0093] Advantageously, the molds and processes of the present invention allow for the economically viable production of packing members that have improved geometric surface area while still providing excellent strength. Furthermore, the strength and / or porosity of the packing members that can be efficiently produced using the present invention can be modified while keeping the same shape, thereby reducing the need and cost of redesign. Furthermore, the packing members can provide highly porous supports while still providing excellent strength. Most advantageously, the packing members can provide improved geometric surface area combined with excellent strength and high levels of porosity. The improved geometric surface area of ​​the packing members is particularly advantageous for applications where catalytic reactions are carried out on the surface.

[0094] The packing members may also provide other improved properties, such as a high heat transfer coefficient in combination with improved packing.

[0095] The packing members may also be used to provide superior packing characteristics with low pressure drop. The packing members can provide improved packing density while maintaining optimal gas flow.

[0096] According to a fifth aspect of the present invention there is provided a method for producing a mould according to any of the first to third aspects of the present invention, the method comprising: a. Optionally, generating a digital model of a negative of the mold; b. Producing a negative mold by a model using additive manufacturing, preferably printing with a 3D printer; c. forming a mold from the negative mold.

[0097] According to a sixth aspect of the present invention there is provided a method for producing a packing element, such as a support for a catalyst or a support catalyst, the packing element may be a packing element according to the fourth aspect of the present invention, the method comprising the steps of: a. Optionally generating a digital model of a negative of a mold according to any of the first to third aspects of the present invention; b. Producing a negative mold by a model using additive manufacturing, preferably printing with a 3D printer; c. forming a mold from the negative; d. Casting the mould composition, suitably as defined in relation to the fourth aspect of the invention, suitably according to the process of the second aspect of the invention, to form a packing member or supported catalyst.

[0098] According to a seventh aspect of the present invention, there is provided a reactor comprising a catalyst bed, the catalyst bed comprising a packing member according to the fourth aspect of the present invention.

[0099] According to an eighth aspect of the present invention, there is provided a reaction medium comprising a catalyst bed, the catalyst bed comprising a packing member according to the fourth aspect of the present invention.

[0100] Suitably, the reactor or reaction medium may be for the production of synthesis gas such as ammonia, methanol, hydrogen, aqueous hydrogen peroxide and / or oxo alcohols, direct reduction of iron (DRI), endothermic gas generation, catalytic partial oxidation, or autothermal reforming.

[0101] According to a ninth aspect of the present invention there is provided the use of a packing member according to the fourth aspect of the present invention as a catalyst support.

[0102] According to a tenth aspect of the present invention there is provided a method for producing synthesis gas such as ammonia, methanol, hydrogen, hydrogen peroxide and / or oxo alcohols comprising use of a reactor comprising a catalyst bed, the catalyst bed comprising a packing element according to the fourth aspect of the present invention to produce synthesis gas.

[0103] According to an eleventh aspect of the present invention, there is provided a method for producing direct reduced iron comprising use of a reactor comprising a catalyst bed, the catalyst bed comprising packing members according to the fourth aspect of the present invention.

[0104] According to a twelfth aspect of the present invention, there is provided a method for generating an endothermic gas comprising the use of a reactor comprising a catalyst bed, the catalyst bed comprising a packing element according to the fourth aspect of the present invention.

[0105] According to a thirteenth aspect of the present invention, there is provided a method for catalytic partial oxidation comprising the use of a reactor comprising a catalyst bed, the catalyst bed comprising a packing element according to the fourth aspect of the present invention.

[0106] According to a fourteenth aspect of the present invention, there is provided a method for autothermal reforming comprising the use of a reactor comprising a catalyst bed, the catalyst bed comprising a packing member according to the fourth aspect of the present invention.

[0107] Any numerical range recited herein is intended to include all subranges incorporated herein. The singular includes the plural and vice versa. For example, although the specification refers to "a" first part and "a" second part, "an" open mold cavity, "a" reservoir forming member, and the like, one or more of each of these and any other components can be used. As used herein, the term "polymer" refers to oligomers and both homopolymers and copolymers, and the prefix "poly" refers to the plural.

[0108] The use of "mold" herein is intended to refer to a container having a hollow portion that is used to impart a shape to a liquid composition as it hardens into a solid. A mold may be, for example, a cast, die, or mold.

[0109] The use of "longitudinal" and "lateral" herein refers to the reservoir cavity, where longitudinal refers to an axis extending substantially through the mouth and base of the cavity, and "lateral" refers to an axis extending substantially perpendicular to the longitudinal axis.

[0110] All of the features contained in this specification may be combined in any combination of any of the above aspects.

[0111] For a better understanding of the present invention, and to show how embodiments thereof may be usefully carried into effect, reference will now be made, by way of example, to the following drawings in which:

[0112] The invention will now be described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0113] [Figure 1] 1 shows a top perspective view of a first embodiment of a mold according to the present invention; [Diagram 2]FIG. 2 shows a top view of a second embodiment of a mold according to the present invention. [Figure 3A] 1 shows a top perspective view of a first embodiment of a mold apparatus formed from a mold according to a second embodiment in an open position. [Figure 3B] FIG. 3B shows a top view of the mold apparatus of FIG. 3A. [Figure 4A] 3B shows a top perspective view of the mold assembly of FIG. 3A with the mold in a partially closed position. [Figure 4B] FIG. 4B shows a top view of the mold apparatus of FIG. 4A. [Diagram 5] 1 shows a filling member according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0114] 1 shows a mold 10 according to a first embodiment of the present invention. Mold 10 is substantially cuboid and is formed from a first mold part 100 and a second mold part 200. First mold part 100 and second mold part 200 each contain approximately half the mass of mold 10 and each are formed from an elastically deformable two-part silicone-based rubber.

[0115] The first mold part 100 is formed from a substantially cubical body 102. The body 102 has a rectangular inner surface and a rectangular outer surface. When the mold parts are mated, the inner surface forms the inner surface of the mold and the outer surface forms the outer surface of the mold. The body 102 also has a rectangular front surface, a rear surface, and two side surfaces.

[0116] The inner surface of the body 102 has a group of twelve discrete, generally hemispherical partial mold cavities 104 that contain surface texturing on the molding surface of the cavities. The mold cavities are arranged in groups of four rows with three cavities 104 per row. The partial cavities 104 are spaced equidistant from adjacent mold cavities to form a grid arrangement laterally centered on the inner surface. A first row is positioned proximate to, parallel to, but spaced from the edge of the inner surface adjacent the front surface of the body 102, and a last (fourth) row is positioned proximate to, parallel to, but spaced from the edge of the inner surface adjacent the rear surface. The first row is closer to each said edge than the last row. Side reservoir member tongues 106a and 106b extending along either side of the grid of partial cavities 104 protrude. The side reservoir member tongues 106a, 106b are generally cuboidal in shape with a convex upper surface and extend longitudinally along the inner surface from the edge adjacent the front surface to just after the last row of partial cavities 104. The side reservoir members 106a, 106b are connected at their bottom ends (i.e., the end proximal to the rear surface of the body 102) via a base reservoir member tongue 106c. The base reservoir member 106c is the same height as the side reservoir members 106a and 106b and extends laterally across the inner surface to connect the reservoir members 106a and 106b. The reservoir members 106a, 106b are integrally connected at each end of the base reservoir member 106c to form a generally U-shaped enclosure that encloses the grid of partial cavities 104 on both sides and at the bottom (i.e., the ends proximal to the rear face of the body 102). This enclosure forms part of the reservoir cavity 108 in which the partial cavities 104 are located. The reservoir cavity has a laterally extending mouth in the form of an open end that extends between the ends of the side reservoir members that are not connected to the base reservoir member. As a result, the mouth is located between the first row of partial cavities and an edge of the inner face adjacent the front face of the body 102.

[0117] The mold part 100 further has two sets of three post-dosing cubic shaped retaining members 110a,b integrally formed with the inner surface and side reservoir members on two sides. Each of the post-dosing retaining members extends outwardly from the inner surface and side reservoir. The first set of retaining members 110a is disposed along the outer surface (relative to the reservoir cavity) of the side reservoir member 106a, and the second set of retaining members 110b is disposed opposite the first set on the outer surface of the side reservoir member 106b. The three retaining members of each set 110a and b are spaced equidistant longitudinally from adjacent retaining members of the set on the inner surface, with each retaining member diametrically opposite a corresponding retaining member on the opposing side reservoir member.

[0118] The inner surface of the body 102 is formed from a dose retention tongue member 112 that is spaced from, underlies and extends parallel to the base reservoir member 106c and proximate to and extends parallel to but spaced from the edge of the inner surface adjacent the rear surface. The dose retention member 112 is a generally cuboidal protrusion that extends laterally across the body 102 and is spaced from the side edges.

[0119] An elongated recess 114 is located on the inner surface between the mouths of the reservoir cavities 108, proximate to but spaced from the edge of the inner surface adjacent the front face of the body 102. The recess 114 is centrally and relatively laterally positioned on the inner surface between and spaced from the side edges of the body 102. The recess 114 is generally oval in shape. The recess 114 is generally coextensive with the width of the reservoir cavity mouth.

[0120] The first mold part 100 also has three cylindrical, spaced apart reinforcing rods 116 that extend laterally from one side through the center of gravity of the body 102 to the other side at three different points along the body 102. The rods 116 protrude from either side such that there are three protrusions on either side of the first mold part 100 to act as guide members. The rods 116 are spaced equidistant along the longitudinal length of the body 102.

[0121] The second mold part 200 (not shown) is the same as the first mold part 100, but has inwardly extending female equivalents of the reservoir member and the retaining member. As a result, the second mold part 200 has a corresponding female retaining member 206 (not shown), which is a cuboidal groove in the body 202 (not shown) suitable for receiving the reservoir member of the first mold part 100, and also has female retaining members 210 (not shown) and 212 (not shown) into which the male retaining members 110, 112 can fit to engage and maintain the first and second mold parts 100, 200 in alignment. When the first mold cavity 100 and the second mold part cavity 200 are engaged together, the partial cavities 104, 204 close to form an enlarged, generally spherical mold cavity 304 (not shown).

[0122] In use, the mold 10 is placed in an open position and the first mold part 100 and the second mold part 200 are deformed and spaced apart such that the dose retention members 112, 212 are co-engaged to maintain the first and second mold parts 100, 200 in alignment. In this configuration, the front faces of the mold parts are spaced apart and the rear faces of the mold parts are not spaced apart.

[0123] In this initial configuration, the point where the mold parts meet can receive the liquid ceramic composition by pouring the liquid composition over the spaced-apart front faces of the mold parts and into the mouth of the reservoir cavity 108. The received liquid composition is maintained within the cavity 108 and also enters and fills the mold cavities 104, 204 that are within the initial reservoir cavity.

[0124] The mold 10 can then be moved to a partially closed position by gradually reducing the deformation of the mold parts to allow the mold parts to abut higher. This action engages the side reservoir members 106, 206 further upwards from the base reservoir member towards the mouth of the reservoir cavity. This closes the original reservoir cavity, which encloses a portion of the now filled mold cavity, but by further engaging the mold parts, the reservoir cavity is moved further towards the front face of the mold 10. Any remaining composition not captured by the originally filled mold cavity is transferred upwards by the group of cavity members into the previously empty open mold cavity.

[0125] Mold parts 100, 200 can then be moved to the closed position by further reducing deformation of the mold parts to fully engage the mold parts, thereby closing the reservoir cavity and also closing all of the mold cavities such that the liquid ceramic composition is maintained within closed mold cavity 304. Any excess composition is captured within recess 114.

[0126] The composition is held in mold cavity 304, optionally with heating of the compact, until a compact is produced.

[0127] The compact can then be demolded and the compact fired to produce the filler member.

[0128] Figures 2A and 2B show a second embodiment of a mold 20 according to the present invention. The mold 20 is substantially cuboidal and has a first mold part 300 and a second mold part 400 as shown in Figures 2A and 2B. The first mold part 300 and the second mold part 400 are largely structurally identical to the first mold part 100 and the second mold part 200 of the first embodiment, in particular both being elastically deformable. The mold 20 has all of the features as described in the first embodiment, unless otherwise specified below.

[0129] The first and second mold parts 300 and 400 respectively include a greater number of partial cavities 305 and 405. There are eleven linear co-terminal parallel rows of partial cavities 305, 405 with fifteen cavities per row.

[0130] The tongues 306a and 306b of the side reservoir members are placed on the first mold part 300 and extend longitudinally along the inner surface from just after the last row of partial cavities 305 to an edge of the inner surface adjacent the front surface of the body 302. The tongues 306a and 306b of the side reservoir members and the tongue 306c of the base reservoir member thereby enclose the partial cavities 305 and the elongated recess 314 placed on the inner surface of the body 302. The side reservoir members 406a and 406b are similarly placed on the second mold part 400.

[0131] The number of post-dosing cubic shaped retention members 310a,b integral with the inner and side reservoir members 306a,b on two sides has been increased to seven on each side compared to the first embodiment. There are also seven corresponding female retention members 410a,b on the second mold part 400. There are eight evenly spaced stiffening rods 316 extending laterally through the center of gravity of each mold part as in the first embodiment.

[0132] 3 and 4 show a first embodiment of a mould assembly according to the present invention. The mould assembly is formed from a mould assembly according to the second embodiment described above and two guide members 450. The guide members 450 are fixed in a vertical orientation. Each guide member 450 has two cube-shaped grooves 452 running longitudinally therethrough at a slight incline such that the distance between the two grooves 452 is smaller at the bottom of the guide member 450 than at the top of the guide member 450. The grooves of each guide member are positioned directly towards and facing the corresponding grooves of the other guide member.

[0133] The reinforcing rods 316, 416 can fit into the grooves 452 on each side of the mold parts so that the mold 20 can be advanced along the grooves and maintained vertically, with the front faces of the mold parts 300 and 400 facing upward and the rear faces facing downward.

[0134] In use, the mold 20 is placed in the open position by moving the mold up the guide member 450 until the rods 316 and 416 enter the grooves 452 at the bottom of the guide member and the front faces of the mold parts 300 and 400 are toward the top of the guide member 450 (FIG. 3A). As the mold parts 300 and 400 are moved up the guide member 450, the mold parts 300 and 400 deform such that they move apart at their tops to provide an open position. In this position, the dosing retaining members 312, 412 are cooperatively engaged at the bottom ends of the mold to maintain the first and second mold parts 300, 400 in alignment.

[0135] In the open position, the mold can receive a liquid ceramic molding composition by dropping the liquid composition from a dispensing member disposed on the spaced-apart front faces of the mold parts into the mouth 454 of the reservoir cavity 308. The received liquid composition is maintained within the initial reservoir cavity 308 and fills any mold cavities 305, 405 within the initial reservoir cavity.

[0136] The mold 20 can then be moved to a partially closed position as shown in Figures 4A and 4B by the mold moving down the guide members along the grooves to reduce deformation of the mold parts in order to incrementally further engage the side reservoir members 306, 406 and the inner mold surfaces from the base reservoir member upwards towards the mouth of the reservoir cavity. In the partially closed position, the side reservoir members and the inner mold surfaces are further engaged in order to move the mold 20 further upwards towards the front surface of the mold parts. This action closes the first reservoir cavity, thereby also closing the filled mold cavity that was located within the first reservoir cavity. The repositioned reservoir cavity carries with it any remaining composition that was not captured by the first filled mold cavity. This has the effect of transferring a portion of the liquid ceramic composition higher up the group of cavity members, thereby allowing the composition to move from the repositioned reservoir cavity 308 into the previously empty open mold cavity that has now fallen into the repositioned reservoir cavity 308. The repositioned reservoir cavity may also receive additional composition from the dispensing member. In the partially closed position, the base of the reservoir cavity is eventually formed by the abutment of the inner surfaces of the mold parts as deformation of the mold parts reduces.

[0137] The mold parts 300, 400 can then be moved to the closed position by further reducing deformation of the mold parts until they are fully engaged, thereby closing the reservoir cavity 308 and also closing all of the mold cavities to maintain the liquid ceramic composition in the closed mold cavity. Any excess composition is captured in the recesses 314, 414.

[0138] As an example, a supported catalyst was produced using a mold apparatus 30 and a molding composition was formed by mixing the ingredients provided below using the following method.

[0139] Alumina powder, pore former and dispersant were mixed to form a powder mixture. An aqueous monomer solution containing chain forming monomers, chain cross-linking monomers and water was added to the powder mixture to form an aqueous slurry. A catalyst and initiator were then added to the aqueous slurry. The amounts of each component in the resulting slurry were as follows: amount Alumina Powder 475 Pore ​​former 60g Dispersant 12.25g Polymerizable monomer 16.3g Cross-linking members 8.2 Catalyst 3ml Initiator 8ml 135g water

[0140] The resulting aqueous slurry was then dispensed into the reservoir cavity of the mold 20 from a dispensing member disposed above the mold 20 while the mold 20 was in the open position. More aqueous slurry was then added and the mold 20 was gradually moved from the open position to a partially closed position. The mold 20 was then placed in the closed position. Once the slurry had gelled into a plurality of solid compacts within the closed enlarged mold cavity, the compacts were then demolded. At this point, the compacts had a rubbery, jelly-like consistency. The compacts were then dried at room temperature for 24 hours. The dried compacts were then fired to 1450° C., at which point the binder and pore formers had burned off leaving solid porous filler members.

[0141] The filler member is then filled with the catalytic material Ni(NO3) 2 After soaking in an aqueous solution containing , it was dried at 500 ° C. This saturation step of the catalytic material was repeated two more times to produce the supported catalyst.

[0142] The resulting carrier catalyst had a macrostructure and surface structure as shown in carrier catalyst 500 in FIG. 5. The carrier catalyst 500 has a cylindrical cog-shaped macrostructure with a plurality of holes (five total) extending through the longitudinal length of the carrier and a plurality of spaced apart, longitudinally oriented castellations (ten total) projecting radially outward from the carrier. The macrostructure of the carrier catalyst 500 further includes a recess 502 on the top surface of the carrier 500. Each of the cog castellations tapers in depth such that the carrier catalyst 500 has a maximum outer width F (38.0 mm) at the base to a minimum outer width E (35.1 mm) at the top surface of the carrier catalyst 500. Each castellation further tapers in width from the widest point at the base of the carrier catalyst 500 to a minimum width at the top surface of the carrier catalyst 500.

[0143] The support catalyst 500 has a surface structure extending over substantially the entire exterior surface of the support catalyst 500. The surface structure is in the form of generally interconnected hexagonally shaped ridges 502.

[0144] In this manner, packing members with improved properties can be produced using the high quality, open vertical packing required for the period of time required to achieve economically viable production.

[0145] Attention is given to all documents and literature filed contemporaneously or prior to this application and which are in the public domain herewith with respect to this application, the contents of all documents and literature being incorporated herein by reference.

[0146] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations in which at least some of such features and / or steps are mutually exclusive.

[0147] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), unless expressly stated otherwise, may be replaced by alternative features serving the same, equivalent or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.

[0148] The invention is not limited to the details of the above embodiments, but extends to any novel or any novel combination of features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel or any novel combination of method or process steps so disclosed.

Claims

1. 1. A mold for producing a filler member from a liquid ceramic composition, the mold comprising a first part and a second part, the first and / or second mold parts being elastically deformable, the first part and / or the second part comprising a plurality of open mold cavities, the first and second parts being operable to engage to form a closed mold cavity, the mold being operable to move from an open position in which the first and second mold parts are partially spaced apart by deformation of the mold parts and at which the mold cavity is open, to a partially closed position in which a portion of the mold cavity is closed at which position by reducing the deformation of the mold parts, and then to a closed position in which the first and second parts are engaged by further reducing the deformation of the mold parts and at which the mold cavity is closed.

2. The mold of claim 1 , wherein the first and second mold parts each include a plurality of open mold cavities.

3. 3. The mold of claim 2, wherein the mold cavities of the first and second mold parts are open partial mold cavities, and the first and second parts of the mold are operable to engage such that the partial mold cavity of the first part aligns with the partial mold cavity of the second part to form a closed enlarged mold cavity.

4. A mould according to any preceding claim, wherein the mould cavity includes a texturing operable to create a surface structure on the filler member.

5. A mold according to any one of claims 1 to 4, wherein the deformable mold parts are formed from a polymeric material.

6. The mold described in claim 5, wherein the polymeric material is silicone.

7. 7. The mold of claim 5 or 6, wherein the deformable mold parts are formed from a two-part silicone composition comprising a silicone resin and a hardener or catalyst.

8. A mold according to any one of the preceding claims, wherein the material forming the first and / or second mold parts has a Shore hardness of at least 5.

9. 9. The mold of claim 8, wherein the material forming the first and / or second mold parts has a Shore hardness of at least 15.

10. A mold according to any one of the preceding claims, wherein the material from which the first and / or second mold parts are formed has a Shore hardness of 40 or less.

11. 11. The mold of claim 10, wherein the material forming the first and / or second mold parts has a Shore hardness of 32 or less.

12. 12. A mould according to any one of claims 1 to 11, wherein the mould further comprises a reservoir-forming member, and in the open position the first and second parts are operable to be spaced apart such that the reservoir-forming member forms a reservoir cavity.

13. The mold of claim 12, wherein in the partially closed position, a location of the reservoir cavity is operable to move relative to the mold cavity and / or a volume of the reservoir cavity is reduced.

14. A mould according to any one of the preceding claims, wherein the material from which the first and / or second mould parts are formed has a shrinkage of 1% or less.

15. A mould according to any preceding claim, wherein the mould parts include co-retaining members operable to help maintain alignment of the mould parts.

16. A mold according to any one of claims 1 to 15, wherein the mold parts include reinforcing members.

17. The mold of claim 16 , wherein the reinforcing members protrude from the mold parts to provide guide members.

18. A molding apparatus for use in producing a filler member from a liquid ceramic composition, the molding apparatus comprising a mold according to any one of claims 1 to 17 and a guide member operable to position the mold in the open position.

19. 20. The molding apparatus of claim 18, wherein the guide members are operable to position the mold in an open position in which portions of the mold parts are abutting and portions of the mold parts are spaced apart.

20. A molding apparatus as described in claim 19, wherein when in the open position, the mold is operable to receive a portion of the molding composition from a dosing member disposed on the mold.

21. 1. A method for producing a packing member for use in a packing bed, comprising the steps of: Arranging a mould comprising a first part and a second part, the first part and / or the second part being elastically deformable, the first part and / or the second part comprising a plurality of open mould cavities, in an open position the first and second parts are partially separated by deforming the mould parts such that the mould cavities are open, the mould may be a mould according to any one of claims 1 to 17 or a moulding apparatus according to any one of claims 18 to 20; b. contacting the mould parts with a liquid ceramic composition, suitably contacting the parts of the mould where the first and second parts abut; c) moving the mold to a partially closed position by reducing the deformation of the mold parts such that a portion of the mold cavity is closed and a portion of the liquid ceramic composition is retained within the closed mold cavity; d. moving the mold to a closed position by further reducing the deformation of the mold parts such that the first and second parts are engaged to close a further mold cavity and a further portion of the liquid ceramic composition is maintained in the further closed mold cavity to produce a compact; e. Optionally, heating the compact; f. demolding the molded body; g. optionally, firing the compact to produce a filler member.

22. A method as described in claim 21, wherein step b contacts the mold parts with a liquid ceramic composition, suitably contacting portions of the mold where the first and second parts abut by dispensing the liquid ceramic composition from above the mold.

23. 20. A cast packing member formed from molding a liquid ceramic composition in a mould according to any one of claims 1 to 17, in a forming apparatus according to any one of claims 18 to 20, or by the method of claim 21 or 22, the packing member being for use in a packing layer.

24. The packing member of claim 23, wherein the packing member is for use as a catalyst support in a packed bed reactor.

25. 25. A filling member according to claim 23 or 24, wherein the filling member is formed from a cast moulding composition or slip.

26. The filling member of claim 25, wherein the filling member is formed from a clay or non-clay castable composition, a liquid cement or a gel cast composition.

27. 27. The filling member of claim 25 or 26, wherein the filling member is formed from a gel cast composition.

28. 30. The filling member of claim 27, wherein the gel cast composition comprises a ceramic material, an organic binder component, and optionally a pore-forming component.

29. 29. The filling member of claim 28, wherein the organic bonding component comprises a polymerizable component, the bonding component being operable to polymerize to form a (co)polymer.

30. The filler member of claim 29, wherein the organic bonding component comprises a polymerizable monomer and a cross-linking member.

31. 31. The filler member of claim 30, wherein the polymerizable monomer comprises one or more ethylenically unsaturated monomers.

32. The filling member of claim 31, wherein the polymerizable monomer comprises one or more acrylic monomers or derivatives thereof.

33. A filling member as described in claim 31 or 32, wherein the polymerizable monomer includes one or more acrylamide monomers.

34. A filling member described in any one of claims 31 to 33, wherein the polymerizable monomer includes a monomer selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM), hydroxyethylacrylamide (hEAM) and N-vinyl-2-pyrrolidinone (NVP).

35. A filling member according to any one of claims 30 to 34, wherein the cross-linking member is selected from one or more diethylenically unsaturated monomers, acrylic salts and / or polyethylene glycol substituted acrylic monomers.

36. The filling member of claim 35, wherein the diethylenically unsaturated monomer is selected from a diacrylic monomer or a derivative thereof.

37. A filling member as described in claim 35 or 36, wherein the diethylenically unsaturated monomer includes a diacrylamide monomer.

38. A filler member according to any one of claims 28 to 37, wherein the ceramic material comprises aluminium oxide, aluminium silicate, magnesium aluminate, calcium aluminate, zirconia, silica, titanate, carbon and / or magnesium oxide.

39. The method of claim 21 or 22, wherein the filling member is formed from a cast molding composition or slip.

40. The method of claim 39, wherein the filling member is formed from a clay or non-clay castable composition, a liquid cement or a gel cast composition.

41. The method of claim 39 or 40, wherein the filling member is formed from a gel cast composition.

42. The method of claim 41, wherein the gel cast composition comprises a ceramic material, an organic binder component, and optionally a pore-forming component.

43. The method of claim 42, wherein the organic bonding component comprises a polymerizable component, the bonding component being operable to polymerize to form a (co)polymer.

44. The method of claim 43, wherein the organic bonding component comprises a polymerizable monomer and a cross-linking member.

45. The method of claim 44, wherein the polymerizable monomer comprises one or more types of ethylenically unsaturated monomers.

46. ​​The method of claim 45, wherein the polymerizable monomer comprises one or more acrylic monomers or derivatives thereof.

47. The method of claim 45 or 46, wherein the polymerizable monomer comprises one or more acrylamide monomers.

48. The method of any one of claims 45 to 47, wherein the polymerizable monomer comprises a monomer selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM), hydroxyethylacrylamide (hEAM), and N-vinyl-2-pyrrolidinone (NVP).

49. The method of any one of claims 44 to 48, wherein the cross-linking member is selected from one or more diethylenically unsaturated monomers, acrylic salts and / or polyethylene glycol substituted acrylic monomers.

50. The method of claim 49, wherein the diethylenically unsaturated monomer is selected from a diacryl monomer or a derivative thereof.

51. The method of claim 49 or 50, wherein the diethylenically unsaturated monomer comprises a diacrylamide monomer.

52. The method of any one of claims 42 to 51, wherein the ceramic material comprises aluminum oxide, aluminum silicate, magnesium aluminate, calcium aluminate, zirconia, silica, titanate, carbon and / or magnesium oxide.

53. A reactor comprising a catalyst bed, the catalyst bed comprising the packing member according to any one of claims 23 to 38.

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