Method for Producing a Catalytically Active Moulded Body and Catalytically Active Moulded Body

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This patent describes a method for manufacturing a catalytically active molded body using additive manufacturing (i.e., 3D printing) techniques. A powder made from an alloy containing at least two different elements is used to shape the body. After forming the desired geometry, one element (the 'second element') is selectively removed from the alloy using a fluid (such as an acid or base), creating a porous surface structure composed mainly of the remaining element (the 'first element'). This process results in a catalytically active, robust, and geometrically customizable structure suitable for use in catalytic reactions.

Use CasesContent extracted from patent full text and abstract with AI.

• Catalyst supports for chemical reactors (e.g., for hydrogenation and dehydrogenation reactions)
• Catalytic conversion of gases such as CO and CO2 (e.g., methanol synthesis)
• Methanol steam reforming for hydrogen production
• Oligomerization and hydrolysis reactions in chemical plants
• Custom-shaped catalysts for flow reactors and microreactors in industrial settings
• Catalyst structures in fuel cells or energy storage applications
• Catalytic materials for environmental remediation (e.g., exhaust gas cleaning)

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the production of catalysts in complex and customizable geometries through additive manufacturing (3D printing)
• Creates integrated, robust structures that avoid the wear and handling issues of traditional catalyst powders or coatings
• Allows targeted activation and porosity, which can be optimized for specific reactions and improved mass transfer
• Reduces manufacturing complexity and cost by integrating shaping and activation in fewer steps
• Provides structurally stable catalysts that retain their geometry and performance over time
• Potential for improved catalytic efficiency due to optimized surface area and controlled porosity
• Can be tailored to different metals and reactions by changing alloy composition and removal fluids

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a method for producing a catalytically active moulded body (1), comprising the following steps: providing a powder produced from an alloy, wherein the alloy comprises a first element and a second element that is different from the first element, which can be selectively removed from the alloy by means of a fluid phase; producing the moulded body (1) from the powder according to a predetermined geometry by means of an additive shaping method; and selectively removing at least one portion of the second element from the alloy with the fluid phase, such that the first element remains and a porous structure is formed at least on a surface of the moulded body (1).