Monolithic catalyst with a metal carrier

Abstract

Monolithic catalysts with a metal carrier that includes a catalytically coated matrix having at least one stack of several sheet-metal strips of corrugated or alternately corrugated and flat metal strips folded or intertwined with one another are described. The free ends of the metal strips are connected by a joining process with a surrounding jacket tube of any required cross-section. The monolithic catalyst is produced very economically and with a catalytic coating that has a uniform thickness. The at least one stack of sheet-metal strips required for the monolithic catalyst with a metal carrier is assembled from coated metal ribbons cut to length so as to form metal stacks. The stacks may be folded and/or intertwined with themselves or with one another so as to form the matrix. The matrix with intertwined and coated strips is inserted into the jacket tube and the free ends of the metal strips are secured by joining to the jacket tube. The coated metal strips may be formed by coating long metal ribbons with catalytic coating in a continuous operation prior to cutting the ribbons to the required length. The metal ribbon is also preferably corrugated prior to the coating step but can also be corrugated after the coating step. In another embodiment, the matrix is formed of a single, continuous and at least partially corrugated metal strip which is folded on to itself so as to form a stack arrangement.