Porous bulbs made from slip-cast kaolin as catalyst supports for microchannel reactors are described. The platelike surfaces of the naturally occurring kaolinite mineral are decorated with catalyst by infiltration with metal salts, decomposed and reduced in situ for nucleation and growth. 

The process of making the ceramic bulbs with nanoparticles using nickel acetate is described in detail. High catalyst loading up to 75 mg/cm³ was achieved, giving on the order of 10¹⁵ 25 nm nanoparticles per cm³ with high total surface area on the order of 2 x 10⁶ m²/m³, making these catalytic membranes competitive with the best microchannel reactors. 

The microstructure of ceramic bulbs made from two different types of clays, before and after nickel infusion is investigated, and the gas permeation flux as a function of applied differential pressure is presented.

References:
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