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The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention incl

The invention describes microchannel apparatus and catalysts that contain a layer of a metal aluminide or are made in a process in which a metal aluminide layer is formed as an intermediate. Certain processing conditions have surprisingly been found to result in superior coatings. The invention includes chemical processes conducted through apparatus described in the specification. Other catalysts and catalyst synthesis techniques are also described.

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1. A method of conducting a chemical reaction in a reactor, the reactor comprising complex microchannels defined by at least one microchannel wall and a layer of aluminide disposed over the at least one microchannel wall, wherein the complex microchannel comprises a rectangular cross-section and whe

1. A method of conducting a chemical reaction in a reactor, the reactor comprising complex microchannels defined by at least one microchannel wall and a layer of aluminide disposed over the at least one microchannel wall, wherein the complex microchannel comprises a rectangular cross-section and wherein the thickness of the coating at a corner of the rectangle is within 25% of the coating thickness measured at the midpoint between two corners of the rectangle; wherein the reactor further comprises a layer of alumina disposed over the layer of aluminide; and a catalytic material disposed over the layer of alumina, and further wherein the reactor comprises a manifold that is connected to at least two complex microchannels, wherein the manifold comprises a manifold wall that is coated with an aluminide layer;the method comprising a step of passing a reactant into the complex microchannel and reacting the reactant in the complex microchannel to form at least one product. 2. The method of claim 1 wherein the complex microchannel is an interior microchannel that comprises one or more of the following characteristics: at least one contiguous microchannel having at least one angle of at least 45° with respect to itself, a length of 20 cm or more along with a height or width of 2 mm or less, at least one microchannel that splits into at least 2 sub-microchannels in parallel, one of at least 2 adjacent microchannels having an adjacent length of at least one cm that are connected by plural orifices along a common microchannel wall where the areas of the orifices amounts to 20% or less of the area of the microchannel wall in which the orifices are located and where each orifice is 1.0 mm2 or smaller, and one of at least 5 parallel microchannels having a length of at least 1 cm and having openings to an internal manifold wherein the internal manifold comprises at least one dimension that is no more than three times the minimum height or width of the parallel microchannels. 3. The method of claim 1 wherein the manifold comprises features that tend to equalize flow through the at least two complex microchannels. 4. The method of claim 1 further comprising a heat transfer microchannel adjacent to at least one of the at least two complex microchannels wherein the heat transfer microchannel contains a heat exchange fluid; and further comprising a step of exchanging heat between the heat transfer microchannel and the at least one complex microchannel. 5. A method of conducting a chemical reaction in a microchannel reactor or separator, comprising: a microchannel defined by at least one microchannel wall;a post-assembly coating of aluminide disposed over the at least one microchannel wall,a layer alumina disposed over the layer of aluminide; anda catalytic material disposed over the layer of alumina, wherein the microchannel has a rectangular cross-section and wherein the thickness of the coating at a corner of the rectangle is within 25% of the coating thickness measured at the midpoint between two corners of the rectangle; the method comprising a step of passing a reactant into the complex microchannel and reacting the reactant in the microchannel to form at least one product. 6. The method of claim 5 wherein the microchannel is an interior microchannel that comprises one or more of the following characteristics: at least one contiguous microchannel having at least one angle of at least 45° with respect to itself, a length of 20 cm or more along with a height or width of 2 mm or less, at least one microchannel that splits into at least 2 sub-microchannels in parallel, one of at least 2 adjacent microchannels having an adjacent length of at least one cm that are connected by plural orifices along a common microchannel wall where the areas of the orifices amounts to 20% or less of the area of the microchannel wall in which the orifices are located and where each orifice is 1.0 mm2 or smaller, and one of at least 5 parallel microchannels having a length of at least 1 cm and having openings to an internal manifold wherein the internal manifold comprises at least one dimension that is no more than three times the minimum height or width of the parallel microchannels. 7. A method of forming a catalyst, comprising: providing an article comprising an aluminide surface;adding a sintering aid to alumina to form an alumina layer with sintering aid disposed over the aluminide surface; andheating the article with an alumina layer with sintering aid; and subsequently depositing a catalyst material. 8. The method of claim 7 wherein the sintering aid comprises at least one element selected from the group consisting of Na, Li, and B. 9. The method of claim 8 wherein the sintering aid comprises at least 0.5 weight percent of an element selected from the group consisting of Na, Li, and B. 10. The method of claim 8 wherein the alumina is a surface layer comprising alumina and the surface layer is then coated with a sintering aid solution prior to the step of heating. 11. A method of forming protected surfaces, comprising: providing an article comprising an aluminide surface;heating the article comprising an aluminide surface to at least about 800° C. in an inert or reducing atmosphere; and, subsequently,exposing the aluminde surface to an oxidizing gas at a temperature of at least about 800° C. to grow an oxide layer. 12. The method of claim 11 comprising heating the article comprising an aluminide surface to at least about 1000° C. in an inert or reducing atmosphere; and, subsequently, exposing the aluminde surface to an oxidizing gas at a temperature of at least about 1000° C. to grow an oxide layer. 13. The method of claim 11 comprising heating the article comprising an aluminide surface to at least about 900° C. in an inert or reducing atmosphere; and, subsequently, exposing the aluminde surface to an oxidizing gas at a temperature of 1000 to 1100° C. to grow an oxide layer. 14. The method of claim 13 wherein the step of exposing the aluminde surface to an oxidizing gas is conducted at a temperature of 1025 to 1075° C. 15. The method of claim 11 wherein the step of exposing the aluminide surface to an oxidizing gas produces a thermally-grown oxide layer that is 1 μm thick or less. 16. A method of separating a mixture comprising at least two components in a separator, the separator comprising a complex microchannel defined by at least one microchannel wall and a layer of aluminide disposed over the at least one microchannel wall, wherein the complex microchannel comprises a rectangular cross-section and wherein the thickness of the coating at a corner of the rectangle is within 25% of the coating thickness measured at the midpoint between two corners of the rectangle; comprising: a step of passing a fluid comprising at least two components into the complex microchannel, preferentially separating at least one of the at least two components within the complex microchannel. 17. The method of claim 16 wherein the step of preferentially separating at least one of the at least two components within the complex microchannel comprises adsorption, distillation, or reactive distillation.