Synthetic spinels and processes for making them

• US 5,108,979 A
• Filed: 02/25/1991
• Issued: 04/28/1992
• Est. Priority Date: 02/25/1991
• Status: Expired due to Term

• Current Assignee: Intercat Inc. (Johnson Matthey PLC)
• Original Assignee: Intercat Inc. (Johnson Matthey PLC)
• Inventors: Magnabosco, Louis M., Demmel, Edward J.
• Primary Examiner(s): SHINE, WILLIAM
• Application Number:
  US07/660,808
• Time in Patent Office: 428 Days
• Field of Search: 502/303, 502/304, 502/306, 502/307, 502/316, 502/319, 502/324, 502/338, 502/341, 502/342, 502/524
• US Class Current: 502/304
• CPC Class Codes: B01J 21/005 Spinels
• CPC Class Codes: B01J 23/005 Spinels
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01B 13/185 Preparing mixtures of oxides
• CPC Class Codes: C01F 7/162 Magnesium aluminates
• CPC Class Codes: C01P 2002/32 spinel-type (AB2O4)
• CPC Class Codes: C01P 2004/64 Nanometer sized, i.e. from 1-100 nanometer
• CPC Class Codes: Y10S 502/524 Spinel

Abstract

Spinels can be synthesized by uniformly dispersing predetermined quantities of ingredient compounds whose particles have sizes no greater than about 5 nanometers in a liquid medium, arresting the ingredient compounds in a solid matrix by spray drying said liquid medium and then calcining the resulting particles to form a solid solution of oxides of said compounds in a crystalline lattice which is substantially free of undesired complex compounds of the ingredient compounds.

Claims

1. A process for making a synthetic spinel having the general formula R²⁺ O.R₂³⁺ O₃, said process comprising:

(1) mixing, to a homogeneous consistency;

(i) a composition of R²⁺ [A] ("the R²⁺ [A] composition") having a R²⁺ [A] compound whose chemical particles are in a size range from molecular size to particles having average diameters not greater than about 5 nanometers, (ii) a composition of R³⁺ [B] ("the R³⁺ [B] composition") having a R³⁺ [B] compound whose chemical particles are also in a size range from molecular size to particles having average diameters not greater than about 5 nanometers, and mixed such that the starting ratio of R²⁺ atoms to R³⁺ atoms is from about 0.5 to about 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium constitutes from about 50 to about 90 weight percent of said total mixture and wherein;

(i) R²⁺ is a first metallic atom having a first, positive, oxidation state, (ii) R³⁺ is a second metallic atom having a second, positive, oxidation state higher than the first positive oxidation state of the first metallic atom, and (iii) the R²⁺ [A] compound is introduced to the R³⁺ [B] compound in the form of a R²⁺ [A] composition having a pH from about 3.5 to about 6.5 and [A] and [B] are nonmetallic atoms which each carry a net negative charge when respectively chemically bonded to the R²⁺ and R³⁺ metallic atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic atoms of [A] and [B];

(2) spray-drying the total mixture under conditions such that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the R²⁺ [A] compound and the R³⁺ [B] compound through the liquid medium, (ii) segregation of the R²⁺ [A] compound and the R³⁺ [B] compound into discrete enclaves within a resulting synthetic spinel is precluded and (iii) finely divided, solid, particles are obtained wherein the starting ratio of R²⁺ atoms to R³⁺ atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of R²⁺ oxide (R²⁺ O) and R³⁺ oxide (R₂³⁺ O₃) having a range of molecular ratios of R²⁺ O to R₂³⁺ O₃ from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the R²⁺ O and in the R₂³⁺ O₃) and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of R²⁺ and R³⁺.

2. The process of claim 1 which further comprises desiccating the particles resulting from the spray drying at a temperature higher than the boiling point of the liquid medium for a period from about 0.2 hours to about 24.0 hours in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of R²⁺ atoms to R³⁺ atoms.

3. The process of claim 1 wherein the non-metallic atoms [A] and [B] are each covalently linked combinations of nonmetallic atoms;

and wherein R²⁺ is a metal selected from the group consisting of magnesium, zinc, iron and manganese, R³⁺ is a metal selected from the group consisting of aluminum, iron, cerium, manganese and lanthanum, [A] is a combination of nonmetallic atoms selected from the group consisting of nitrate, acetate ethylate, alkoxide, [B] is a combination of nonmetallic atoms selected from the group consisting of nitrate, oxide, acetate, chromate, hydroxide and alkoxide and the liquid medium is selected from the group consisting of water, alcohols having carbon chains containing up to 20 carbon atoms, acetone and ether.

4. The process of claim 1 wherein the R²⁺ [A] compound is a magnesium acetate solution having a pH of about 4.0 and the R³⁺ [B] compound is an alumina sol whose alumina particles have average diameters of about 2 nanometers and which are dispersed through the use of an acid selected from the group consisting of acetic acid and nitric acid.

5. The process of claim 1 wherein a composition containing a compound .R²⁺ [C] is mixed with the R²⁺ [A] and R³⁺ [B] compositions in order to form a spinel having a crystalline lattice wherein a portion of R²⁺ atoms are replaced by .R²⁺ atoms.

6. The process of claim 1 wherein a composition containing a cerium compound Ce[E] is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

7. The process of claim 1 wherein a composition containing a vanadium compound V[E] is mixed with the R²⁺ [A] and R³⁺ 8 B] compositions as part of the total mixture.

8. The process of claim 1 wherein the calcining is carried out in a temperature range between about 1,000 degrees Fahrenheit and about 1,950 degrees Fahrenheit for from about 60 minutes to about 240 minutes.

9. The process of claim 1 wherein additional amounts of a liquid medium are added in order to bring the liquid medium of the total mixture to the 50 to 90 weight percent.

10. The process of claim 1 wherein production of the total mixture is accompanied by a vigorous mixing action to promote a uniform distribution of the R²⁺ [A] and R³⁺ [B] compositions in the total mixture.

11. The process of claim 1 wherein a gas evolution agent is added to the total mixture before said mixture undergoes spray drying.

12. The process of claim 1 wherein a viscosity agent selected from the group consisting of starch and gum arabic is added to the total mixture before it undergoes spray drying.

13. The process of claim 1 wherein the pH of the total reaction mixture is adjusted by the use of an acid.

14. A process for making a synthetic spinel having the general formula Mg O.Al₂ O₃, said process comprising:

(1) mixing, to a homogeneous consistency;

(i) a liquid composition of magnesium (Mg[A], "the magnesia") having a Mg[A] compound whose chemical particles are in a size range from molecular size to particles having average diameters of no more than about 5 nanometers, (ii) a liquid composition of aluminum (Al[B], "the alumina") having an Al[B] compound whose chemical particles are also in a size range from molecular size to particles having average diameters no more than about 5 nanometers, and mixed such that the starting ratio of magnesium atoms to aluminum atoms is substantially from 0.5 to 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium constitutes from about 50 to about 90 weight percent of said total mixture and wherein the Mg[A] compound is introduced to the Al[B] compound in the form of a magnesia composition having a pH from about 3.5 to 6.5 and [A] and [B] are nonmetallic atoms which carry a net negative charge when respectively chemically bonded to the magnesia and alumina atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic atoms of [A] and [B];

(2) spray drying the total mixture under such conditions that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the magnesia and the alumina through the liquid medium, (ii) segregation of the magnesia and the alumina into discrete enclaves within a resulting synthetic spinel is precluded and (iii) finely divided, solid, particles are obtained wherein the starting ratio of magnesium atoms to aluminum atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of magnesium oxide (MgO) and aluminum oxide (Al₂ O₃) having a range of molecular ratios of MgO to Al₂ O₃ from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the MgO and in the Al₂ O₃) and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of magnesium and aluminum.

15. The process of claim 14 wherein the anhydrous particles are substantially free of discernable complex compounds of magnesium and aluminum.

16. The process of claim 14 which further comprises desiccating the particles obtained from the spray drying at temperatures substantially higher than the boiling point of the liquid medium for a period of from about 0.2 hours to about 24.0 hours in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of magnesium atoms to aluminum atoms.

17. The process of claim 14 wherein the nonmetallic atoms [A] and [B] are each covalently linked combinations of nonmetallic atoms and wherein (i) the magnesia compound is selected from the group consisting of magnesium nitrate, magnesium acetate, magnesium oxide, magnesium hydroxide, magnesium hydroxynitrate, magnesium hydroxyacetate, magnesium ethylate and (ii) the alumina compound is selected from the group consisting of aluminum nitrate, aluminum hydroxyacetate, aluminum acetate, aluminum hydroxide and aluminum oxide, and (iii) the liquid medium is selected from the group consisting of water, alcohols having less than twenty carbon atoms, ether and acetone.

18. The process of claim 14 wherein additional amounts of a liquid medium are added in order to bring the liquid medium of the total mixture to the 50 to 90 weight percent.

19. The process of claim 14 wherein a composition containing a compound .R²⁺ [C] and a composition containing a compound .R³⁺ [D] are mixed with the magnesia and alumina compositions in order to form a spinel having a crystalline lattice wherein a portion of magnesium atoms are replaced by .R²⁺ atoms and a portion of the aluminum atoms are replaced by .R³⁺ atoms

20. The process of claim 14 wherein a composition containing a cerium compound Ce[E] is mixed with the magnesia and alumina compounds as part of the total mixture.

21. The process of claim 14 wherein a composition containing a vanadium compound V[E] is mixed with the magnesia and alumina compounds as part of the total mixture.

22. The process of claim 14 wherein the magnesia composition is a magnesium acetate solution having a pH of about 4.0 and the alumina composition is an alumina sol whose alumina particles have average diameters of about 2 nanometers and which are dispersed through the use of an acid selected from the group consisting of acetic acid and nitric acid.

23. The process of claim 14 wherein the calcining is carried out in a temperature range between about 1,000 degrees Fahrenheit and about 1,950 degrees Fahrenheit for from about 60 minutes to about 240 minutes.

24. The process of claim 14 wherein a gas evolution agent is added to the total mixture before said mixture undergoes spray drying.

25. The process of claim 14 wherein a viscosity agent selected from the group consisting of starch and gum arabic are added to the total mixture before it undergoes spray drying.

26. The process of claim 14 which further comprises establishing that the synthetic spinel is free of complex compounds of magnesium and complex compounds of aluminum by noting the results of test criteria selected from the group consisting of:

(i) the occurrence in an x-ray diffraction test of a single angular peak for the value of a R²⁺ /R³⁺ ratio corresponding to continuous linear variation, (ii) an exceeding of a value of standard deviation of micro-quantitative analyses and (iii) a change in temperature to indicate the occurrence of a chemical reaction.

27. A spinel having the general formula R²⁺ O.R³⁺ O₃, made by a process comprising:

(1) mixing, to a homogeneous consistency;

(i) a composition of R²⁺ [A] ("the R²⁺ [A] composition") having a R²⁺ [A] compound whose chemical particles are in a size range from molecular size to particles having average diameters not greater than about 5 nanometers, (ii) a composition R³⁺ [B] ("the R³⁺ [B] composition") having a R³⁺ [B] compound whose chemical particles are also in a size range from molecular size to particles having average diameters not greater than about 5 nanometers, and mixed such that the starting ratio of R²⁺ atoms to R³⁺ atoms is from about 0.5 to about 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium constitutes from about 50 to about 90 weight percent of said total mixture and wherein (i) R²⁺ is a first metallic atom having a first, positive, oxidation state, (ii) R³⁺ is a second metallic atom having a second, positive, oxidation state higher than the first positive oxidation state of the first metallic atom and (iii) the R²⁺ [A] compound is introduced to the R³⁺ [B] compound in the form of a R²⁺ [A] composition having a pH from about 3.5 to about 6.5 and [A] and [B] are nonmetallic atoms which carry a net negative charge when respectively chemically bonded to the R²⁺ and R³⁺ metallic atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic atoms of [A] and [B];

(2) spray drying the total mixture under conditions such that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the R²⁺ A] compound and the R³⁺ [B] compound through the liquid medium, (ii) segregation of the R²⁺ [A] compound and the R³⁺ [B] compound into discrete enclaves within a resulting synthetic spinel is precluded, (iii) finely divided, solid, particles are obtained wherein the starting ratio of R²⁺ atoms to R³⁺ atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of R²⁺ oxide (R³⁺ O) and R³⁺ oxide (R₂³⁺ O₃) having a range of molecular ratios of R³⁺ O to R₂³⁺ O₃) from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the R²⁺ O and in the and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of R²⁺ and R³⁺.

28. The spinel of claim 27 made by a process which further comprises adjusting the pH of the total reaction mixture by use of an acid.

29. The spinel of claim 27 made by a process which further comprises desiccating the particles obtained from the spray drying at temperatures substantially higher than the boiling point of the liquid medium in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of R²⁺ atoms to R³⁺ atoms.

30. The spinel of claim 27 made by a process which further comprises use of non-metallic elements [A] and [B] which are each covalently linked combinations of nonmetallic atoms and wherein R²⁺ is a metal selected from the group consisting of magnesium, zinc, iron and manganese, R³⁺ is a metal selected from the group consisting of aluminum, iron, cerium, manganese, lanthanum, and chromium, [A] is a combination of nonmetallic atoms selected from the group consisting of nitrate, acetate ethylate, alkoxide, and [B] is a combination of non-metallic atoms selected from the group consisting of nitrate, acetate, oxide, chromate, alkoxide and hydroxide.

31. The spinel of claim 27 made by a process which further comprises use of a composition containing a .R²⁺ [C] compound which is mixed with the R²⁺ [A] and R³⁺ [D] compositions in order to form a spinel having a crystalline lattice wherein a portion of the R²⁺ atoms are replaced by .R²⁺ atoms.

32. The spinel of claim 27 made by a process which further comprises use of a compound .R²⁺ [C] and a compound .R³⁺ [D] which are mixed with the R²⁺ [A] and R³⁺ [B] compounds in order to form a spinel having a crystalline lattice wherein a portion of the R²⁺ atoms are replaced by .R²⁺ atoms and a portion of the R³⁺ atoms are replaced by .R³⁺ atoms.

33. The spinel of claim 27 made by a process which further comprises use of a composition containing a cerium compound Ce[E] which is mixed with the R²⁺ [A] and R³⁺ B] compositions as part of the total mixture.

34. The spinel of claim 27 made by a process which further comprises use of a composition containing a vanadium compound V[E] which is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

35. The spinel of claim 27 made by a process which further comprises use of a R²⁺ [A] composition which is a magnesium acetate solution having a pH of about 4.0 and a R³⁺ [B] composition which is an alumina sol whose alumina particles have average diameters of about 2 nanometers.

36. A spinel having the general formula MgO. Al₂ O₃, made by a process comprising:

(1) mixing, to a homogeneous consistency;

(i) a composition of magnesium (Mg[A], "the magnesia") having a Mg[A] compound whose chemical particles are in a size range from molecular size to particles having average diameters no more than about 5 nanometers, (ii) a composition of aluminum (Al[B], "the alumina") having an Al[B] compound whose chemical particles are also in a size range from molecular size to particles having average diameters no more than about 5 nanometers, and mixed such that the starting ratio of magnesium atoms to aluminum atoms is substantially from 0.5 to 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium constitutes from about 50 to about 90 weight percent of said total mixture and wherein the Mg[A] compound is introduced to the Al[B] compound in the form of a magnesia composition having a pH from about 3.5 to about 6.5 and [A] and [B] are each nonmetallic elements which bear a net negative charge when respectively chemically bonded to the magnesia and alumina atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic elements of [A] and [B];

(2) spray drying the total mixture under conditions such that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the magnesia and the alumina through the liquid medium, (ii) segregation of the magnesia and the alumina into discrete enclaves within a resulting synthetic spinel is precluded, and (iii) finely divided, solid, particles are obtained wherein the starting ratio of magnesium atoms to aluminum atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid particles under conditions which produce crystals of a solid solution of magnesium oxide (MgO) and aluminum oxide (Al₂ O₃) having a range of molecular ratios of MgO to Al₂ O₃ from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the MgO and in the Al₂ O₃) and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of magnesium and aluminum.

37. The spinel of claim 36 which is made by a process which further comprises use of an acid to adjust the pH of the total mixture.

38. The spinel of claim 36 made by a process which further comprises desiccating the particles obtained from the spray drying at temperatures substantially higher than the boiling point of the liquid medium in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of magnesium atoms to aluminum atoms.

39. The spinel of claim 36 made by a process which further comprises use of non-metallic atoms [A] and [B] which are each covalently linked combinations of nonmetallic atoms and wherein [A] is a combination of nonmetallic atoms selected from the group consisting of nitrate, acetate ethylate, hydroxynitrate, hydroxyacetate, oxide hydroxide and alkoxide and [B] is a combination of nonmetallic elements selected from the group consisting of nitrate, acetate, oxide, chromate, hydroxide, hydroxynitrate, hydroxyacetate, and alkoxide.

40. The spinel of claim 36 which shows its freedom from complex compounds of magnesium and of aluminum by test criteria selected from the group consisting of:

(i) the occurrence in an x-ray diffraction test of a single angular peak for the value of a R²⁺ /R³⁺ ratio corresponding to continuous linear variation, (ii) an exceeding of a value of standard deviation of micro-quantitative analyses and (iii) neither the release nor the absorption of energy to indicate the occurrence of a chemical reaction.

41. The spinel of claim 36 made by a prooess which further comprises mixing a composition containing a R²⁺ [C] compound with the magnesia and the aluminum in order to form a spinel having a crystalline lattice wherein a portion of the magnesium atoms are replaced by .R²⁺ atoms.

42. The spinel of claim 36 made by a process which further comprises mixing a composition containing a compound .R²⁺ [C] and a composition containing a compound .R³⁺ [D] with the magnesia and alumina in order to form a spinel having a crystalline lattice wherein a portion of the magnesium atoms are replaced by .R²⁺ atoms and a portion of the aluminum atoms are replaced by .R³⁺ atoms.

43. The spinel of claim 36 made by a process which further comprises mixing a composition containing a cerium compound Ce[E] with the magnesium and alumina compositions as part of the total mixture.

44. The spinel of claim 36 made by a process which further comprises use of a composition containing a vanadium compound V[E] which is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

45. The spinel of claim 36 made by a process wherein the magnesia composition is a magnesium acetate solution having a pH of about 4.0 and the alumina composition is an alumina sol whose alumina particles have average diameters of about 2 nanometers.

46. The spinel of claim 36 made by a process which further comprises impregnating the spinel with a vanadium solution and then re-calcining said spinel.

47. A process for making a synthetic spinel having the general formula R² O.R₂³⁺ O₃, said process comprising:

(1) mixing, to a homogeneous consistency;

(i) a composition of R²⁺ [A] ("the R²⁺ O[A] composition") having a R²⁺ [A] compound whose chemical particles are in a size range from molecular size to particles having average diameters not greater than about 5 nanometers, (ii) a composition of R³⁺ [B] ("the R³⁺ [B] composition") having a R³⁺ [B] compound whose chemical particles are of a size greater than 5 nanometers, but less than about 60 nanometers, and which have a three dimensional crystalline lattice structure having three axes wherein the crystalline lattice structure having three axes has lattice spacings which are unequal along at least two of the three axes, and which can be broken down into particles having ultimate crystallite sizes of less than about 5 nanometers by physico-chemical forces applied during a mixing step of said process, and mixed such that the starting ratio of R²⁺ atoms to R³⁺ atoms is from about 0.5 to about 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium is capable of breaking down particles of R³⁺ [B] compound to ultimate crystallite sizes of less than 5 nanometers and which constitutes from about 50 to about 90 weight percent of said total mixture and wherein;

(i) R²⁺ is a first metallic atom having a first, positive, oxidation state, (ii) R³⁺ is a second metallic atom having a second, positive, oxidation state higher than the first positive oxidation state of the first metallic atom, and (iii) the R²⁺ [A] compound is introduced to the R³⁺ [B] compound in the form of a R²⁺ [A] composition having a pH from about 3.5 to about 6.5 and [A] and [B] are comprised of nonmetallic atoms which carry a net negative charge when they are, respectively, chemically bonded to the R²⁺ and R³⁺ metallic atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic atoms of [A] and [B];

(2) spray-drying the total mixture under conditions such that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the R²⁺ [A] compound and the R³⁺ [B] compound through the liquid medium, (ii) segregation of the R²⁺ [A] compound and the R³⁺ [B] compound into discrete enclaves within a resulting synthetic spinel is precluded and (iii) finely divided, solid, particles are obtained wherein the starting ratio of R²⁺ atoms to R³⁺ atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of R²⁺ oxide (R²⁺ O) and R³⁺ oxide (R₂³⁺ O₃) having a range of molecular ratios of R²⁺ O to R₂³⁺ O₃ from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the R²⁺ O and in the and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of R²⁺ and R³⁺.

48. The process of claim 47 which further comprises desiccating the particles resulting from the spray drying at a temperature higher than the boiling point of the liquid medium for a period from about 0.2 hours to about 24.0 hours in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of R²⁺ atoms to R^R3+ atoms.

49. The process of claim 47 wherein the non-metallic atoms [A] and [B] are each covalently linked combinations of nonmetallic atoms;

and wherein R²⁺ is a metal selected from the group consisting of magnesium, zinc, iron and manganese, R³⁺ is a metal selected from the group consisting of aluminum, iron, cerium, manganese and lanthanum, [A] is a combination of nonmetallic atoms selected from the group consisting of nitrate, acetate ethylate, alkoxide, [B] is a combination of nonmetallic atoms selected from the group consisting of nitrate, oxide, acetate, chromate, hydroxide and alkoxide and the liquid medium is selected from the group consisting of water, alcohols having carbon chains containing up to 20 carbon atoms, acetone and ether.

50. The process of claim 47 wherein the R²⁺ [A] compound is a magnesium acetate solution having a pH of about 4.0 and the R³⁺ [B] compound is an alumina sol whose alumina particles have ultimate crystallite sizes having average diameters of about 2 nanometers and which are dispersed through the use of an acid selected from the group consisting acetic acid and nitric acid.

51. The process of claim 47 wherein a composition containing a compound .R²⁺ [C] is mixed with the R²⁺ [A] and R³⁺ [B] compositions in order to form a spinel having a crystalline lattice wherein a portion of R²⁺ atoms are replaced by atoms.

52. The process of claim 47 wherein a composition containing a cerium compound Ce[E] is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

53. The process of claim 47 wherein a composition containing a vanadium compound V[E] is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

54. The process of claim 47 wherein the calcining is carried out in a temperature range between about 1,000 degrees Fahrenheit and about 1,950 degrees Fahrenheit for from about 60 minutes to about 240 minutes.

55. The process of claim 47 wherein additional amounts of a liquid medium are added in order to bring the liquid medium of the total mixture to the 50 to 90 weight percent.

56. The process of claim 47 wherein production of the total mixture is accompanied by a vigorous mixing action to promote a uniform distribution of the R²⁺ [A] and R³⁺ [B] compositions in the total mixture and to promote formation of ultimate crystallite sizes of the R²⁺ [A] and R³⁺ [B] compounds.

57. The process of claim 47 wherein a gas evolution agent is added to the total mixture before said mixture undergoes spray drying.

58. The process of claim 47 wherein a viscosity agent selected from the group consisting of starch and gum arabic is added to the total mixture before it undergoes spray drying.

59. The process of claim 47 wherein the pH of the total reaction mixture is adjusted by the use of an acid.

60. A process for making a synthetic spinel having the general formula Mg O.Al₂ O₃, said process comprising:

(1) mixing, to a homogeneous consistency;

(i) a liquid composition of magnesium (Mg[A], "the magnesia") having a Mg[A] compound whose chemical particles are in a size greater than 5 nanometers, but less than about 60 nanometers, and which have a three dimensional crystalline lattice structure having three axes wherein the crystalline lattice structure having three axes has lattice spacings which are unequal along at least two of the three axes, and which can be broken down into particles having ultimate crystallite sizes of less than about 5 nanometers by physico-chemical forces applied during a mixing step of said process, (ii) a liquid composition of aluminum (Al[B], "the alumina") having an Al[B] compound whose chemical particles are also in a size greater than 5 nanometers, but less than about 60 nanometers, and which have a three dimensional crystalline lattice structure having three axes wherein the crystalline lattice structure having three axes has lattice spacings which are unequal along at least two of the three axes, and which can be broken down into particles having ultimate crystallite sizes of less than about 5 nanometers by physico-chemical forces applied during a mixing step of said process, and mixed such that the starting ratio of magnesium atoms to aluminum atoms is substantially from 0.5 to 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium is capable of breaking down the particles of the R²⁺ [A] compound and the R³⁺ [B] compound to their respective ultimate crystallite sizes and which constitutes from about 50 to about 90 weight percent of said total mixture and wherein the Mg[A] compound is introduced to the Al[B] compound in the form of a magnesia composition having a pH from about 3.5 to 6.5 and [A] and [B] are nonmetallic atoms which carry a net negative charge when respectively chemically bonded to the magnesia and alumina atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic atoms of [A] and [B];

(2) spray drying the total mixture under such conditions that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the magnesia and the alumina through the liquid medium, (ii) segregation of the magnesia and the alumina into discrete enclaves within a resulting synthetic spinel is precluded and (iii) finely divided, solid, particles are obtained wherein the starting ratio of magnesium atoms to aluminum atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of magnesium oxide (MgO) and aluminum oxide (Al₂ O₃) having a range of molecular ratios of MgO to Al₂ O₃ from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the MgO and in the Al₂ O₃) and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of magnesium and aluminum.

61. The process of claim 60 wherein the anhydrous particles are substantially free of discernable complex compounds of magnesium and aluminum.

62. The process of claim 60 which further comprises desiccating the particles obtained from the spray drying at temperatures substantially higher than the boiling point of the liquid medium for a period of from about 0.2 hours to about 24.0 hours in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of magnesium atoms to aluminum atoms.

63. The process of claim 60 wherein the nonmetallic atoms [A] and [B] are each covalently linked combinations of nonmetallic atoms and wherein (i) the magnesia compound is selected from the group consisting of magnesium nitrate, magnesium acetate, magnesium oxide, magnesium hydroxide, magnesium hydroxynitrate, magnesium hydroxyacetate, magnesium oxide, magnesium hydroxide, magnesium hydroxynitrate, magnesium hydroxyacetate, magnesium ethylate and (ii) the alumina compound is selected from the group consisting of aluminum nitrate, aluminum hydroxynitrate aluminum hydroxyacetate, aluminum acetate, aluminum hydroxide and aluminum oxide, and (iii) the liquid medium is selected from the group consisting of water, alcohols having less than twenty carbon atoms, ether and acetone.

64. The process of claim 60 wherein additional amounts of a liquid medium are added in order to bring the liquid medium of the total mixture to the 50 to 90 weight percent.

65. The process of claim 60 wherein a composition containing a compound .R²⁺ [C] and a composition containing a compound .R³⁺ [D] are mixed with the magnesia and alumina compositions in order to form a spinel having a crystalline lattice wherein a portion of magnesium atoms are replaced by R²⁺ atoms and a portion of the aluminum atoms are replaced by R³⁺ atoms.

66. The process of claim 60 wherein a composition containing a cerium compound Ce[E] is mixed with the magnesia and alumina compounds as part of the total mixture.

67. The process of claim 60 wherein a composition containing a vanadium compound V[E] is mixed with the magnesia and alumina compounds as part of the total mixture.

68. The process of claim 60 wherein the magnesia composition is a magnesium acetate solution having a pH of about 4.0 and the alumina composition is an alumina sol whose alumina particles are obtained from ores selected from the group consisting of boehmite and psuedo-boehmite and have average diameters of up to about 60 nanometers and which are dispersed through the use of an acid selected from the group consisting of an acid selected from the group consisting of acetic acid and nitric acid.

69. The process of claim 60 wherein the calcining is carried out in a temperature range between about 1,000 degrees Fahrenheit and about 1,950 degrees Fahrenheit for from about 60 minutes to about 240 minutes.

70. The process of claim 60 wherein a gas evolution agent is added to the total mixture before said mixture undergoes spray drying.

71. The process of claim 60 wherein a viscosity agent selected from the group consisting of starch and gum arabic are added to the total mixture before it undergoes spray drying.

72. The process of claim 60 which further comprises establishing that the synthetic spinel is free of complex compounds of magnesium and complex compounds of aluminum by noting the results of test criteria selected from the group consisting of:

(i) the occurrence in an x-ray diffraction test of a single angular peak for the value of a R²⁺ /R³⁺ ratio corresponding to continuous linear variation, (ii) an exceeding of a value of standard deviation of micro-quantitative analyses and (iii) a change in temperature to indicate the occurrence of a chemical reaction.

73. A spinel having the general formula R²⁺ O.R³⁺ O₃, made by a process comprising:

(1) mixing, to a homogeneous consistency;

(i) a composition of R²⁺ [A] ("the R²⁺ [A] composition") having a R²⁺ [A] compound whose chemical particles are in a size range from molecular size to particles having average diameters not greater than about 5 nanometers, (ii) a composition R³⁺ [B] ("the R³⁺ [B] composition") having a R³⁺ [B] compound whose chemical particles are of a size greater than 5 nanometers, but less than about 60 nanometers, and which have a three dimensional crystalline lattice structure having three axes wherein the crystalline lattice structure having three axes has lattice spacings which are unequal along at least two of the three axes, and which can be broken down into particles having ultimate crystallite sizes of less than about 5 nanometers, and mixed such that the starting ratio of R²⁺ atoms to R³⁺ atoms is from about 0.5 to about 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium is capable of breaking down the particles of the R³⁺ [B] compound to ultimate crystallite sizes of less than 5 nanometers and which constitutes from about 50 to about 90 weight percent of said total mixture and wherein (i) R²⁺ is a first metallic atom having a first, positive, oxidation state, (ii) R³⁺ is a second metallic atom having a second, positive, oxidation state higher than the first positive oxidation state of the first metallic atom and (iii) the R²⁺ [A] compound is introduced to the R³⁺ [B] compound in the form of a R²⁺ [A] composition having a pH from about 3.5 to about 6.5 and [A] and [B] are nonmetallic atoms which carry a net negative charge when respectively chemically bonded to the R²⁺. and R³⁺ metallic atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic atoms of [A] and [B];

(2) spray drying the total mixture under conditions such that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the R²⁺ [A] compound and the R³⁺ [B] compound through the liquid medium, (ii) segregation of the R²⁺ [A] compound and the R³⁺ [B] compound into discrete enclaves within a resulting synthetic spinel is precluded, (iii) finely divided, solid, particles are obtained, and (iv) wherein the starting ratio of R²⁺ atoms to atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of R²⁺ oxide (R²⁺ O) and R³⁺ oxide (R₂³⁺ O₃) having a range of molecular ratios of R²⁺ O to (R₂³⁺ O₃) from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the R²⁺ O and in the R₂³⁺ O₃) and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of R²⁺ and R³⁺.

74. The spinel of claim 73 made by a process which further comprises adjusting the pH of the total reaction mixture by use of an acid.

75. The spinel of claim 73 made by a process which further comprises desiccating the particles obtained from the spray drying at temperatures substantially higher than the boiling point of the liquid medium in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of R²⁺ atoms to R³⁺ atoms.

76. The spinel of claim 73 made by a process which further comprises use of non-metallic elements [A] and [B] which are each covalently linked combinations of nonmetallic atoms and wherein R²⁺ is a metal selected from the group consisting of magnesium, zinc, iron and manganese, R³⁺ is a metal selected from the group consisting of aluminum, iron, cerium, manganese and lanthanum, [A] is a combination of nonmetallic atoms selected from the group consisting of nitrate, acetate ethylate, alkoxide, and [B] is a combination of non-metallic atoms selected from the group consisting of nitrate, acetate, oxide, chromate, alkoxide and hydroxide.

77. The spinel of claim 73 made by a process which further comprises use of a composition containing a .R²⁺ [C] compound which is mixed with the R²⁺ [A] and R³⁺ [D] compositions in order to form a spinel having a crystalline lattice wherein a portion of the R²⁺ atoms are replaced by .R²⁺ atoms.

78. The spinel of claim 73 made by a process which further comprises use of a compound .R²⁺ [C] and a compound .R³⁺ [D] which are mixed with the R²⁺ [A] and R³⁺ [B] compounds in order to form a spinel having a crystalline lattice wherein a portion of the R²⁺ atoms are replaced by R²⁺ atoms and a portion of the R³⁺ atoms are replaced by .R³⁺ atoms.

79. The spinel of claim 73 made by a process which further comprises use of a composition containing a cerium compound Ce[E] which is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

80. The spinel of claim 73 made by a process which further comprises use of a composition containing a vanadium compound V[E] which is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

81. The spinel of claim 73 made by a process which further comprises use of a R²⁺ [A] composition which is a magnesium acetate solution having a pH of about 4.0 and a R³⁺ [B] composition which is an alumina sol whose alumina particles have ultimate crystallite sizes having average diameters of about 2 nanometers.

82. A spinel having the general formula MgO. Al₂ O₃, made by a process comprising:

(1) mixing, to a homogeneous consistency;

(i) a composition of magnesium (Mg[A], "the magnesia") having a Mg[A] compound whose chemical particles are in a size greater than 5 nanometers, but less than about 60 nanometers, and which have a three dimensional crystalline lattice structure having three axes wherein the crystalline lattice structure having three axes has lattice spacings which are unequal along at least two of the three axes, and which can be broken down into particles having ultimate crystallite sizes of less than about 5 nanometers by physicochemical forces applied during a mixing step of said process, (ii) a composition of aluminum (Al[B], "the alumina") having an Al[B] compound whose chemical particles are also in a size greater than 5 nanometers, but less than about 60 nanometers, and which have a three dimensional crystalline lattice structure having three axes wherein the crystalline lattice structure having three axes has lattice spacings which are unequal along at least to of the three axes, and which can be broken down into particles having ultimate crystallite sizes of less than about 5 nanometers, and mixed such that the starting ratio of magnesium atoms to aluminum atoms is substantially from 0.5 to 1.25 and (iii) such amounts of a liquid medium necessary to produce a total mixture having a pH from about 3.5 to about 6.5 and wherein the liquid medium is capable of breaking down the particles of the R²⁺ [A] compound and the R³⁺ [B] compound to their respective ultimate crystallite sizes and which constitutes from about 50 to about 90 weight percent of said total mixture and wherein the Mg[A] compound is introduced to the Al[B] compound in the form of a magnesia composition having a pH from about 3.5 to about 6.5 and [A] and [B] are nonmetallic atoms which bear a net negative charge when respectively chemically bonded to the magnesia and alumina atoms and which, when subjected to prolonged heating in the presence of oxygen at elevated temperatures of calcination, will form gaseous oxides of the nonmetallic elements of [A] and [B];

(2) spray drying the total mixture under conditions such that;

(i) the liquid medium is flashed to a gaseous state at such a rate as to arrest migration of the magnesia and the alumina through the liquid medium, (ii) segregation of the magnesia and the alumina into discrete enclaves within a resulting synthetic spinel is precluded and (iii) finely divided, solid, particles are obtained wherein the starting ratio of magnesium atoms to aluminum atoms of the total mixture is substantially maintained in said particles; and

(3) calcining the finely divided, solid, particles under conditions which produce crystals of a solid solution of magnesium oxide (MgO) and aluminum oxide (Al₂ O₃) having a range of molecular ratios of MgO to Al₂ O₃ from about 1.0 to about 2.5 and drive off, as gases, substantially all other elements present in the crystal (i.e., other than those elements contained in the MgO and in the Al₂ O₃) and thereby producing a synthetic spinel which contains no more than about 5% by weight complex compounds of magnesium and aluminum.

83. The spinel of claim 82 which is made by a process which further comprises use of an acid to adjust the pH of the total mixture.

84. The spinel of claim 82 made by a process which further comprises desiccating the particles obtained from the spray drying at temperatures substantially higher than the boiling point of the liquid medium in order to remove any residual amounts of the liquid medium and thereby obtaining, in the form of a powder, anhydrous particles which still maintain the starting ratio of magnesium atoms to aluminum atoms.

85. The spinel of claim 82 made by a process which further comprises use of non-metallic atoms [A] and [B] which are each covalently linked combinations of nonmetallic atoms and wherein [A] is a combination of nonmetallic atoms selected from the group consisting of nitrate, acetate ethylate, hydroxynitrate, hydroxyacetate, oxide hydroxide and alkoxide and [B] is a combination of nonmetallic elements selected from the group consisting of nitrate, hydroxynitrate, hydroxyacetate, acetate, oxide, chromate, hydroxide, hydroxynitrate, hydroxyacetate, and alkoxide.

86. The spinel of claim 82 which shows its freedom from complex compounds of magnesium and of aluminum by test criteria selected from the group consisting of:

(i) the occurrence in an x-ray diffraction test of a single angular peak for the value of a R²⁺ /R³⁺ ratio corresponding to continuous linear variation, (ii) an exceeding of a value of standard deviation of micro-quantitative analyses and (iii) neither the release nor the absorption of energy to indicate the occurrence of a chemical reaction.

87. The spinel of claim 82 made by a process which further comprises mixing a composition containing a .R³⁺ [C] compound with the magnesia and the aluminum in order to form a spinel having a crystalline lattice wherein a portion of the magnesium atoms are replaced by .R²⁺ atoms.

88. The spinel of claim 82 made by a process which further comprises mixing a composition containing a compound .R²⁺ [C] and a composition containing a compound .R³⁺ [D] with the magnesia and alumina in order to form a spinel having a crystalline lattice wherein a portion of the magnesium atoms are replaced by .R²⁺ atoms and a portion of the aluminum atoms are replaced by .R³⁺ atoms.

89. The spinel of claim 82 made by a process which further comprises mixing a composition containing a cerium compound Ce[E] with the magnesium and alumina compositions as part of the total mixture.

90. The spinel of claim 82 made by a process which further comprises use of a composition containing a vanadium compound V[E] which is mixed with the R²⁺ [A] and R³⁺ [B] compositions as part of the total mixture.

91. The spinel of claim 82 made by a process wherein the magnesia composition is a magnesium acetate solution having a pH of about 4.0 and the alumina composition is an alumina sol whose alumina particles have ultimate crystallite sizes having average diameters of about 2 nanometers.

92. The spinel of claim 82 made by a process which further comprises impregnating the spinel with a vanadium solution and then re-calcining said spinel.