Catalyst carrier
First Claim
1. An alpha alumina based catalyst carrier having a crush strength of at least 5 pounds and a packing density of at least 38 pounds/cubic foot which comprises first and second alpha alumina components with a first alpha alumina component in the form of particles having an median crystallite size of from about 0.4 to about 4 microns providing from about 95 to about 40% of the total weight of alpha alumina in the carrier and a second alpha alumina component generated in situ by a sol-gel process and providing the balance of the alpha alumina in the carrier.
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Accused Products
Abstract
A catalyst carrier that is comprised of relatively large alpha alumina particles dispersed in matrix that comprises an alpha alumina formed in situ by a sol-gel process has excellent crush resistance while retaining good porosity and catalytic performance.
68 Citations
20 Claims
- 1. An alpha alumina based catalyst carrier having a crush strength of at least 5 pounds and a packing density of at least 38 pounds/cubic foot which comprises first and second alpha alumina components with a first alpha alumina component in the form of particles having an median crystallite size of from about 0.4 to about 4 microns providing from about 95 to about 40% of the total weight of alpha alumina in the carrier and a second alpha alumina component generated in situ by a sol-gel process and providing the balance of the alpha alumina in the carrier.
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9. A catalyst carrier having a crush strength of at least 5 pounds and a settled pack density of at least 35 pounds/cubic foot which comprises first and second alpha alumina components;
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wherein the first alpha alumina component has two constituents including; i) a first constituent providing from about 40 to about 80% by weight of the first alpha alumina component and having a median particle size of from about 3 to about 4 microns; and ii) a second constituent providing from about 20 to about 60% of the weight of the first alpha alumina component and having a median particle size of from about 4 to about 8 microns; said first alpha alumina component providing from about 95 to about 65% of the total weight of alpha alumina in the carrier and; a second alpha alumina component generated in situ by a sol-gel process and providing the balance of the alpha alumina in the carrier. - View Dependent Claims (10)
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11. A process for the production of a catalyst carrier which comprises:
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i) forming a mixture comprising; a. at least one alpha alumina component with an median particle size of from 3 to about 8 microns and; b. a hydrated precursor of alpha alumina in an amount sufficient to provide from about 5 to about 60% by weight of the total weight of alpha alumina in the catalyst carrier product; c. from about 5 to about 40%, based on the weight of the alpha alumina, of a burnout material; and d. water in sufficient quantity to extrude the above mixture; ii) extruding the mixture into the desired shapes; and iii) firing to convert the precursor of alpha alumina to alpha alumina so as to produce a catalyst carrier in which alpha alumina particles with a median particle size of from about 3 to about 8 microns are dispersed in a matrix of alpha alumina derived from the precursor material. - View Dependent Claims (12, 13, 14, 15, 16)
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17. A process for the production of a catalyst carrier which comprises:
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i) forming a mixture comprising; a. an alpha alumina having a first component with a median particle size of from about 2 to about 4 microns and a second component with a median particle size of about 4 to about 8 microns; b. a seeded, hydrated precursor of alpha alumina in an amount sufficient to provide from about 5 to about 60% by weight of the total weight of alpha alumina in the catalyst carrier product c. from about 5 to about 40%, based on the weight of the alpha alumina, of a burnout material; d. from about 1 to about 3% based on the weight of alumina in the composition expressed as alpha alumina, of a ceramic bond material; e. from about 0.05 to about 0.5% by weight, based on the total alumina weight in the mixture expressed as alpha alumina, of titania; and f. water in sufficient quantity to extrude the above mixture; ii) extruding the mixture into the desired shape; and iii) firing to convert the seeded precursor of alpha alumina to alpha alumina so as to produce a catalyst carrier in which alpha alumina particles with a median particle size of from about 3 to about 8 microns are dispersed in a matrix of alpha alumina derived from the seeded precursor material. - View Dependent Claims (18, 19, 20)
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Specification