Abstract: A new structured vanadium catalyst(SVC) with inner intercrossed and regularly lined gas flow channels was designed and manufactured.The pressure-drop of the new catalyst was 2/3 lower than a commercial extruded vanadium catalyst.The slurry for the mould shaping during the manufacture of the new structured catalyst was specially processed.It increased the mechanical strength of the catalyst by 10 times.Stress distribution calculation showed that stress concentration existed in the channel corners.The maximum stress was 8—8.5 fold higher than the press force.The structured catalyst manufactured in optimal condition possessed comparable activity with the commercial catalyst and mechanical strength of 1.1 MPa.