Catalyst assembly providing high surface area for nitric acid and/or HCN synthesis

A catalyst assembly is disclosed which comprises a plurality of foraminous wire mesh sheets disposed in intimate nested relation to each other along their broad surfaces, the wire sheets defining a non-planar cross-section which consists of a plurality of undulating corrugations. The border of the catalyst assembly is flattened to allow for secure installation in an ammonia converter. The invention includes individual sheets that are stacked adjacent each other, as well as pads comprising multiplicities of sheets that are edge bonded to each other to form integral units. The catalyst assemblies of the present invention provide a combination of increased surface area and reduced pressure drop that is unique and contributes to improve useful life and corresponding reductions in cost and down time. The catalyst assemblies may be easily manufactured and installed and may be prepared in a variety of sizes and shapes to suit the dimensions and requirements of differing reactors. The invention extends to methods of fabrication of the catalyst assemblies, as well as to methods of treating ammonia employing the assemblies.