Process for forming a catalyst carrier

Abstract

A carrier, which comprises non-platelet alumina and/or a bond material, has a surface area of at least 1.3 m 2 /g, a total pore volume and a pore size distribution such that at least 80% of the total pore volume is contained in pores with diameters in the range of from 0.1 to 10 μm, and at least 80% of the pore volume contained in the pores with diameters in the range of from 0.1 to 10 μm is contained in pores with diameters in the range of from 0.3 to 10 μm, and a process for the preparation of a carrier which comprises forming a mixture comprising: a) from 50 to 95 weight percent of a first particulate α-alumina having a median particle size (d 50 ) of from 5 to 100 μm; b) from 5 to 50 weight percent of a second particulate α-alumina having a d 50 which is less than the d 50 of the first particulate α-alumina and which is in the range of from 1 to 10 μm; and c) an alkaline earth metal silicate bond material; weight percent being based on the total weight of α-alumina in the mixture; and firing the mixture to form the carrier.

1 - 28 . (canceled) 
     
     
         29 . A process for the preparation of a carrier, which comprises forming a mixture comprising:
 a) from 50 to 95 weight percent of a first particulate α-alumina having a median particle size (d50) of from 5 to 100 μm;   b) from 5 to 50 weight percent of a second particulate α-alumina having a d50 which is less than the d50 of the first particulate α-alumina and which is in the range of from 1 to 10 μm; and   c) an alkaline earth metal silicate bond material;   weight percent being based on the total weight of α-alumina in the mixture; and   firing the mixture to form the carrier.   
     
     
         30 . A process as claimed in  claim 29 , wherein
 the carrier has an alumina content of at least 95 weight percent,   the mixture comprises:   
       a) from 60 to 90 weight percent, relative to the total weight of α-alumina in the mixture, of a first particulate α-alumina having a median particle size (d50) of from 10 to 40 μm; 
       b) from 10 to 40 weight percent, relative to the total weight of α-alumina in the mixture, of a second particulate α-alumina having a median particle size (d50) of from 2 to 8 μm; and 
       c) an alkaline earth metal silicate bond material comprising from 0.2 to 2 weight percent, calculated as the total weight of alkaline earth metal oxide and silicate, as SiO2, relative to the total weight of α-alumina in the mixture; 
       magnesium silicate or a combination of a magnesium compound and a silica compound, in which combination the atomic ratio of magnesium to silicon is in the range of 0.9 to 1.2, and 
       from 0.5 to 5 weight percent of an alumina hydrate, calculated as Al2O3, relative to the total weight of α-alumina in the mixture, and
 the process comprises shaping the mixture into formed bodies and firing the formed bodies at a temperature of from 1250 to 1550° C. 
 
     
     
         31 . (canceled)