Abstract: An improved Claus catalyst is provided in the form of activated alumina in which sodium oxide concentration, LOI and surface area of the catalyst are carefully controlled to achieve increased sulfur conversion. Sulfur recovery is enhanced by choosing an alumina catalyst having properties which minimize chemisorption of sulfur dioxide on the catalyst at reaction conditions. Sodium oxide may be present in an amount of 0.1 to 2.5 wt % of the catalyst (1100.degree. C. calcined basis). The catalyst desirably has a surface area greater than 100 m.sup.2 /g (BET) and an LOI (hydroxyl content as determined by heating from 400.degree. to 1100.degree. C.) between 2.0 and 6.0 wt %. A method of producing the catalyst and a method of using the catalyst are also provided.

Abstract: A method is provided for forming stable dispersions of boehmite alumina in water containing a peptizing acid by mixing said alumina with dilute aqueous acid solutions and treating the alumina prior to dispersion by heating at temperatures of from about 250.degree. F. to 700.degree. F. and pressures of from about 10 psig to about 2000 psig in the presence of up to 80 weight percent of water based upon the total alumina for a period of time sufficient to stabilize the alumina to the extent necessary. Dispersions can be prepared which will remain fluid up to days longer than will those prepared from the untreated alumina.

Abstract: Catalyst carrier produced by a process of dehydrating alumina hydrate, granulating and roasting at 150.degree..about.850.degree. C. to yield particles; and curing said particles in an aqueous solution of caustic alkali or in an aqueous solution of sodium aluminate or in a mixture of both under a saturated steam pressure of 120.degree.-200.degree. C.; and said manufacturing process.

Abstract: A pseudoboehmite having properties suitable for incorporation into a matrix for a zeolite containing catalyst and the process for producing the same from an aluminum sulfate derived gel.

Abstract: An alumina particle and a method of its manufacture. The alumina particle comprises a spheroidal alumina particle of about 1/16 inch in diameter and a crush strength of from about 13 to about 16 pounds. The method comprises preparing a mixture of an acidic alumina hydrosol and an ammonia percursor at below gelation temperature, dispersing the mixture as droplets in a water-immiscible liquid at a temperature and for a time to effect at least partial gelation of the hydrosol to form hydrogel particles, contacting the hydrogel particles with a liquid having a pH no greater than about 7 and an osmotic pressure sufficient to prevent disintegration of the hydrogel particles, aging the hydrogel particles in an aqueous solution having a pH greater than 7, and thereafter drying and calcining the hydrogel particles.

Abstract: Spheroidal alumina particulates having bifold porosity are prepared by (i) intimately admixing, at a pH of less than about 7.5, (a) a sol of a member selected from the group consisting of ultrafine boehmite and pseudo-boehmite, said sol being devoid of amorphous alumina and the concentration by weight thereof, in content by weight of Al.sub.2 O.sub.3, being between 5 and 25%, with (b) from 30 to 95% by weight, based upon the total solids content of the admixture, of spheroidal alumina particulates essentially completely in at least one of the phases eta, gamma, delta and theta, such particulates having a micropore volume ranging from about 0.4 to 1 cm.sup.3 /g, a specific surface ranging from about 100 to 350 m.sup.2 /g, and particle diameters ranging from about 1 to 50 microns; (ii) prilling said intimate admixture into spheroidal particulates and gelling the same; and then, (iii) recovering, drying and calcining said gelled particulates at a temperature of from 550.degree. to 1100.degree. C.

Abstract: Method of producing pseudoboehmite by reacting an aluminum salt with an aluminate.

Abstract: A catalyst is provided which comprises a hydrogenation component and a support comprising agglomerates of alumina having initially not more than 0.20 cubic centimeters per gram of its pore volume in pores greater than about 400 Angstroms in diameter and a minor amount of silica. A process for the hydroconversion of hydrocarbonaceous oils utilizing the catalyst is also provided.

Abstract: A method of manufacturing spherical alumina comprising preparing a basic aluminum chloride solution having an aluminum concentration in the range of from 7 wt.% to 12 wt.% and a weight ratio of aluminum to chloride in the range of from 0.3 to 0.8 by reacting gibbsite with an aqueous hydrochloric acid solution at an elevated temperature, preparing an alumina hydrosol having an aluminum concentration in the range of from 9 wt.% to 15 wt.% and a weight ratio of aluminum to chloride in the range of from 0.8 to 1.5 by reacting the thus prepared solution with metallic aluminum at an elevated temperature, commingling this hydrosol with a gelling agent, dispersing the resulting mixture in the form of droplets in a suspending medium thereby to form hydrogel particles, ageing the thus obtained particles in said suspending medium and then an aqueous ammonia, washing with water, drying and calcining. The thus obtained spherical alumina is substantially free from sodium in spite of employing gibbsite as raw material.

Abstract: A thermally stable, pure transition alumina extrudate suitable for use as a catalyst support has a uniquely defined bimodal pore size distribution and very good mechanical properties. Most of the surface area is in a micropore region having pores of less than 500 Angstrom units, a pore volume of 0.60 to 0.80 cm..sup.3 /g., a narrowly defined effective pore volume distribution within this region and a median pore diameter which can be controlled within the range of 90-210 Angstrom units. The macropore region made of pores having diameters of 1,000- 10,000 Angstrom units has a pore volume of at least 0.10 cm..sup.3 /g. These two pore volumes are essentially connected directly to each other. The extrudates can be strengthened by acidic additives and given increased thermal stability by adding rare earth oxides.

Abstract: A catalyst carrier comprising gamma alumina wherein the apparent bulk density is in the range of from 0.65 g/cc to 0.71 g/cc, the total pore volume is in the range of from 0.55 cc/g to 0.65 cc/g, the content of pores having a diameter in the range of from 60A to 110A occupies at least 75% of the total pore volume, the surface area is in the range of from 210 m.sup.2 /g to 250 m.sup.2 /g and the attrition loss is less than 0.5 wt. %. This sort of catalyst carrier can be namufactured through a series of steps of: (a) preparing a first alumina hydrosol having an aluminum concentration in the range of from 9.8 wt. % to 14.4 wt. % and a weight ratio of aluminum to chloride in the range of from 0.95 to 1.20, (b) preparing a second alumina hydrosol having an aluminum concentration in the range of from 9.5 wt. % to 13.0 wt. % and a weight ratio of aluminum to chloride in the range of from 0.85 to 0.

Abstract: The production process for pseudoboehmite from leach liquors produced in the acid treatment of clays, which liquors contain Fe and alkaline earth ions.

Abstract: A method for preparing a high-surface area catalyst consisting of high-surface area support material coated on an inert core. The inert core is partially wetted with a wetting agent and a powdered, high-surface area coating is then applied to the core. The coated core can be dried and calcined, and additional catalytic elements can be added by impregnating the core with solutions containing such elements.

Abstract: A novel aluminous composition prepared by impregnating porous gamma alumina with aluminum hydride and subsequently heating the impregnated alumina to a temperature of from about 300.degree. C. to about 900.degree. C. in a non-oxidizing environment. The composition is useful as a catalyst in reactions catalyzed by acid catalysts.

Abstract: A process for the preparation of a very hard catalyst carrier from a mixture of aluminum oxides which in addition to .alpha.-Al.sub.2 O.sub.3 contains other modifications, preferably .gamma.-Al.sub.2 O.sub.3. The .alpha.-Al.sub.2 O.sub.3 is first pretreated with an acid, base and/or metal salt solution and is then mixed with the other aluminum oxides or their intermediates.

Abstract: The invention relates to a new highly reactive alumina and the method of preparing it. The alumina is characterized by an amorphous structure and a specific surface of greater than 600 m.sup.2 /g. It is prepared by thermal decomposition of the double carbonate of aluminum and ammonium of the formula AlNH.sub.4 CO.sub.3 (OH).sub.2 at a temperature of between about 200.degree. and 500.degree. C.Aluminum hydroxychlorides of the formula Al.sub.2 (OH).sub.x Cl.sub.6-x can be prepared from it.

Abstract: Spheroidal alumina particles have a combination of high macroporosity, surface area, crush strength and low attrition loss and bulk density. The particles are prepared by an improved external gelation oil-drop process. In the process a slurry of alumina, preferably a microcrystalline boehmite-pseudoboehmite intermediate, is prepared in an acidic aqueous medium and droplets of the slurry are passed through air into a column containing an upper body of water-immiscible liquid and ammonia and a lower body of aqueous coagulating agent. Catalysts employing the particles as a support and having catalytic agents distributed at controlled depths in the particle have excellent initial and sustained activity and durability, especially for eliminating pollutants in automotive exhaust streams.

Abstract: A monolithic support for a catalyst suitable for use in controlling carbon monoxide emission is prepared by forming a homogeneous, fluid semi-solid mass by admixing colloidal .gamma. alumina, .alpha. alumina monohydrate and ceramic fibres with fluidizing and binding agents, water and a mineral acid, said acid being used in an amount sufficient to convert said .alpha. Al.sub.2 O.sub.3 monohydrate into a gel, forming the mass into a body of the desired shape, drying the body to substantially remove the added water, at least 10% of said added water being removed at a temperature lower than 50.degree. C., and heat-treating the dried body at 800.degree.-1000.degree. C.

Abstract: A catalyst is provided which comprises a hydrogenation component and a support comprising agglomerates of alumina having initially not more than 0.20 cubic centimeters per gram of its pore volume in pores greater than about 400 Angstroms in diameter and a minor amount of silica. A process for the hydroconversion of hydrocarbonaceous oils utilizing the catalyst is also provided.

Abstract: High surface area alumina, and a method of preparing them. More specifically, a method of preparing aluminas having a surface area of from about 300 square meters per gram to about 700 square meters per gram, by preparing a first solution of an aluminum alkoxide and an organic solvent selected from the group consisting of ethers, ketones, aldehydes, and mixtures thereof, admixing the first solution with a second solution comprising water and an organic solvent selected from the group consisting of ethers, ketones, aldehydes, and mixtures thereof, to form a solid material, and drying and calcining the solid material to recover alumina. Also, an alumina with an average micropore diameter of from about 20 angstroms to about 100 angstroms, and a total pore volume of from about 0.35 ml/g to about 1 ml/g.

Abstract: A method of preparing spheroidal alumina particles of improved physical stability is disclosed. Alumina hydrogel particles prepared by the oil-drop method are aged in the forming oil at atmospheric pressure conditions and at a temperature of from about 95.degree. to 105.degree. C. until the hydrogel spheres achieve a pH in excess of 6 to about 7.5. The forming oil is thereafter displaced with an ammonium salt-buffered aqueous ammoniacal solution, and the hydrogel spheres aged therein for a brief period. After further aging in an aqueous ammoniacal solution in accordance with prior art practice, the spheres are water-washed, dried and calcined.

Abstract: Improved .gamma.-alumina suitable for use as a catalyst carrier having high mechanical strength, a large specific surface area, and a substantially uniform pore size distribution in a relatively small portion of the pore size range below 500 A. Said alumina is produced by first establishing a seed aluminum hydroxide hydrogel having a pH of between 6 and 10 and then repetitively and sequentially adding an aluminum compound to adjust the pH to less than 5 or more than 11 to dissolve crystallites of aluminum hydroxide followed by addition of a neutralizing agent to return the hydrogel to the pH range from about 6 to 10 to cause pseudo-boehmite crystallites to grow. After a sufficient number of repetitions of said sequential addition, sparse aggregates of crystallites of the desired structure are formed. These are dried and calcined to produce the said alumina.

Abstract: A novel aluminous composition prepared by impregnating porous gamma alumina with aluminum hydride and subsequently heating the impregnated alumina to a temperature of from about 300.degree. C. to about 900.degree. C. in a non-oxidizing environment. The composition is useful as a catalyst in reactions catalyzed by acid catalysts.

Abstract: A catalyst carrier high in strength and suitable for use in internal combustion engines is produced by transforming a boehmite into .gamma.-alumina at a high temperature, transforming the .gamma.-alumina into .alpha.-alumina at a high temperature and sintering the .alpha.-alumina, boehmite having been prepared by forming a large number of agglomerates of adequate size from powdered aluminum hydroxide (Al.sub.2 O.sub.3.3H.sub.2 O) and contacting the agglomerates with water vapor at a high temperature and a high pressure to transform the aluminum hydroxide into boehmite.

Abstract: A method of preparing high surface area-high average bulk density spheroidal alumina particles is disclosed. Spheroidal alumina hydrogel particles prepared by the oil drop method are aged in an aqueous ammoniacal solution containing from about 4 to about 20 wt. % ammonium salt, and thereafter water-washed, dried and calcined to yield high surface area spheroidal alumina particles having an average bulk density of from about 0.6 to about 0.8 grams per cubic centimeter.

Abstract: Spheroidal alumina particles have a combination of high macroporosity, surface area, crush strength and low attrition loss and bulk density. The particles are prepared by an improved external gelation oil-drop process. In the process a slurry of alumina, preferably a microcrystalline boehmite-pseudoboehmite intermediate, is prepared in an acidic aqueous medium and droplets of the slurry are passed through air into a column containing an upper body of water-immiscible liquid and ammonia and a lower body of aqueous coagulating agent. Catalysts employing the particles as a support and having catalytic agents distributed at controlled depths in the particle have excellent initial and sustained activity and durability, especially for eliminating pollutants in automotive exhaust streams.

Abstract: A method for preparing an alumina having controlled pore volume distribution is disclosed. The method requires the presence of 0.1-15% by weight of a water soluble aliphatic polycarboxylic acid having from 2-12 carbon atoms based on the dry weight of Al.sub.2 O.sub.3, during alumina precipitation. The resultant calcined alumina has a pore volume distribution such that:A. Nitrogen desorption measurements indicate that less than 10% of the total pores as determined by said method fall between 100-1200A in diameter;B. Nitrogen adsorption measurements indicate that between 10-50% of the total pore volume as determined fall between 100-1200A in diameter; andC. Mercury penetration porisimetry indicates that less than 10% of the total pores as determined by both nitrogen desorption and mercury methods fall between 100-50,000A in diameter.

Abstract: Alumina having a low loose bulk density is obtained by hydrolyzing aluminum alkoxides with water in the presence of lithium hydroxide or lithium salts yielding lithium ions. The amount of density reduction is proportional to the amount of lithium ion present.

Abstract: An improved method for increasing alumina pore volumes said alumina being produced by the hydrolysis of aluminum alkoxides, the improvement comprising diluting the aluminum alkoxide, prior to entering the hydrolysis reactor, with an alkanol containing from 2 to 8 carbon atoms and injecting the dilute solution into the reactor at high velocities.

Abstract: A highly porous alumina having a large surface area and a low bulk density is prepared by hydrolyzing an aluminum alcoholate at a temperature of 40.degree. to 90.degree. C. in an aqueous solution containing 8 to 30% by weight of a compound which upon drying or activating splits out NH.sub.3 and/or CO.sub.2, there being used 0.5 to 3 parts by weight of the compound per 10 parts of aluminum alcoholate. The aluminum oxyhydrate paste formed by the hydrolysis is separated from the alcohol phase, in a given case is also purified, and subsequently dried or activated.

Abstract: Process for controlling the porosity of aluminas during the preparation thereof; by forming by extrusion of alumina in the presence of an organic solvent such as an alcohol.The aluminas so prepared are suitable for use as catalyst or preferably as catalyst carriers.

Abstract: Disclosed is a process for preparing shaped alumina particles for catalysts or catalyst supports by passing droplets of an aqueous slurry of a rehydratable alumina composition through a shaping medium, such as a column of water-immiscible liquid. The alumina composition undergoes rehydration while being shaped as it passes through the shaping medium, and accordingly, firm, discrete alumina bodies are produced.

Abstract: The preparation of an ultra-stable, high surface area alpha-alumina catalyst and catalyst support suitable for use in high temperature processes such as petroleum refining processes, e.g., resid cat cracking and steam reforming, is disclosed. The process comprises impregnating high surface area gamma-alumina having narrow pores with a carbonaceous material that readily chars to form carbon. The impregnated alumina is then heated to a temperature sufficient to induce charring, following which the gamma-alumina is converted to alpha-alumina by further heating. The carbon is subsequently removed by oxidation. The alpha-alumina thus produced can withstand temperatures up to at least about 1000.degree. C. in the presence of steam without substantial loss of surface area.

Abstract: The method of preparing granulated activated alumina consists in that alumina trihydrate is decomposed by bringing it in contact with a bed of a solid heat carrier having the temperature of 350.degree. to 600.degree. C., the contact time being from 0.05 to 0.5 second, to obtain a product of decomposition in the form of amorphous aluminium hydroxide. Said decomposition product is mixed with water into a suspension having the concentration of 100-500 g/liter, calculating with reference to aluminium oxide, and hydrated at a temperature of 20.degree.-100.degree. C. and the pH of 5 to 12 for 0.5 to 10 hours. The hydrated decomposition product is then treated with an acid, that can form water-soluble basic salts of aluminium, at a temperature of 20.degree. to 150.degree. C., granulated, dried at a temperature of 20.degree. to 150.degree. C., and calcined at a temperature of 400.degree. to 600.degree. C.

Abstract: A low soda pseudoboehmite gel is provided by reacting a NaAlO.sub.2 solution with a NaHCO.sub.3 solution having a concentration of less than 75 grams/liter and preferably less than 50 grams/liter. The soda content of the resulting AlO(OH) gel can be further lowered by repeated washing and/or redispersing (repulping) in water and/or further neutralization with a carboxylic acid having 1 to 6 carbon atoms.

Abstract: An alumina composition comprising a microcrystalline boehmite-pseudoboehmite intermediate having from about 70 to about 85 weight percent of the total amount of Al.sub.2 O.sub.3 present in crystalline form. The composition is prepared by adding aluminum sulfate and sodium aluminate solutions to a mixture of water and aluminum sulfate solution to precipitate alumina and adjusting the pH to a pH higher than the precipitation pH. The reactant concentrations, and rates of addition, temperatures, and pH's in the precipitation are specifically controlled to form the boehmite-pseudoboehmite intermediate.

Abstract: High macro-pore content spheres (>1000A) are produced by use of a rotating wheel, wherein dry alumina is dropped onto the wheel under a peptizing spray misted onto the wheel through an atomizing device. Compressive stresses normally encountered in procedures such as pelletizing are avoided, thereby preserving macro-pores. Size of spheres can be adjusted by altering, for example, the angle at which the wheel rotates.

Abstract: The present invention relates to a catalyst carrier characterized by the fact that it comprises a substance which promotes a transition of an alumina that can be converted to .alpha.-alumina, which substance is located near the surface of a carrier composed mainly of alumina and which carrier is subjected to a heat treatment under appropriate conditions, thereby causing the transition of said alumina to .alpha.-alumina, with those pores near the surface made larger in diameter than those pores located more deeply within the carrier. The invention also includes a method of manufacturing said catalyst carrier.

Abstract: An improvement in the method of preparing alumina by water hydrolysis of aluminum alkoxides is disclosed. Briefly, the improvement comprising admixing the water and aluminum alkoxide under high velocity conditions prior to passing the resulting admixture to the reactor. The improved process results in a product having improved physical properties, particularly pore volume and bulk density.

Abstract: Hydrocarbons are converted by contacting them at hydrocarbon conversion conditions with a selectively sulfided acidic multimetallic catalytic composite comprising a combination of catalytically effective amounts of a platinum group component, a sulfided rhenium component and a halogen component with a porous carrier material formed from Ziegler alumina. The platinum group component, sulfided rhenium component and halogen component are present in the multimetallic catalytic composite in an amount, calculated on an elemental basis, corresponding to about 0.01 to about 2 wt. % platinum group metal, about 0.01 to about 2 wt. % rhenium, about 0.1 to about 3.5 wt. % halogen and sulfur in an amount at least sufficient to provide an atomic ratio of sulfur to rhenium of at least about 0.5:1.

Abstract: The invention is addressed to very light alumina-based agglomerated bodies, the porosity of which comprises pores of large dimensions. These bodies are produced from alumina gels which are dehydrated in hot gas streams so that the amount of water remaining, which can be measured by calcination at high temperature, is from 8 t0 35% of the weight of the treated gels; the treated gels to which other components can be added are agglomerated by any known means. These bodies can be used in particular in adsorption, catalysis, and chromatography.

Abstract: Disclosed is a method for forming shaped catalysts from a rehydratable alumina composition. The method includes a staged rehydration procedure to stabilize the rehydratable alumina to facilitate extrusion processing.

Abstract: Pseudo-boehmite having a bulk density of about 0.05 to 0.2 g/cc, an oil absorption of about 2.5 to 6.0 cc/g, a pore volume of about 2.0 to 7.0 cc/g over a pore diameter range of 176.mu. to 0.0035.mu. and a specific surface area of about 200 to 500 m.sup.2 /g, and a process for producing the same; useful as a filler, an absorbent, a catalyst, a filtering agent and a base material for composites; prepared by mixing alkali aluminate and halohydrin together at a low temperature, heating for reaction the resulting mixture, cooling the reacting solution, separating the resulting precipitate by filtration and, if desired subjecting the precipitate to washing with an organic solvent followed by drying.

Abstract: A process for the preparation of finely divided dispersible alpha-alumina monohydrate (boehmite) from alumina trihydrate is disclosed. The alumina trihydrate is calcined thereby increasing the surface area through a partial dehydration. The calcined intermediate is slurried in water and autoclaved to achieve crystallization and rehydration. Conventional drying methods are used to obtain the particles. The particle size of the product is much smaller than that of the starting raw material.

Abstract: Aluminum alkoxides are hydrolyzed at low temperatures using high injection velocities and are then vacuum stripped at or below 80.degree. C to produce .beta.-alumina trihydrates in large proportion. The .beta.-alumina trihydrate can then be converted to eta alumina.

Abstract: A process for the catalytic reforming of a naphtha fraction is disclosed. A naphtha fraction and hydrogen are commingled and passed in contact with an alumina-supported reforming catalyst at reforming conditions. The alumina support is characterized by a novel method of preparation affording an improved reforming process. The preparation comprises admixing an alpha-alumina monohydrate with an alkaline solution having a pH of at least about 7.5 and forming a stable suspension. A salt of a strong acid, or a solution of a salt of a strong acid, is admixed with the suspension to form a paste or dough which is subsequently extruded, dried and calcined to form said alumina support.

Abstract: A catalyst is provided which comprises a hydrogenation component composited with an alumina support prepared by reacting an alkali metal aluminate with an aliphatic dicarboxylic acid, e.g. oxalic acid.

Abstract: Alumina catalyst carriers are produced by bonding pre-fired gibbsite with microcrystalline boehmite. Superior strength of the product is achieved by use of gibbsite fired to an L.O.I. at 1000.degree. C of 8% or less, or preferably less than 4%.

Abstract: A method for preparing a hydrotreating catalyst having a controlled pore distribution is disclosed. The method requires adding to the alumina prior to forming from 0.1 to 15% by weight of a water soluble polycarboxylic acid having from 2 - 22 carbon atoms. The resulting formed alumina support after being calcined has a pore volume distribution such that most of the pore volume in pores greater than 200 A in diameter as measured by Mercury penetration porosimitry is substantially eliminated. The pore volume as measured by nitrogen adsorption in the range of between 100 A and 1200 A is reduced. The polycarboxylic acid may be added to the catalyst carrier prior to forming in different ways such as by dissolving the catalytically active metals with the water soluble polycarboxylic acid and then impregnating hydrothermally or by pore volume or by adding a water soluble polycarboxylic acid salt to the hydrous or xero gel after precipitation.

Abstract: An alumina composition particularly useful as a catalyst support or carrier material is disclosed. The alumina is characterized by a method of preparation which comprises admixing an alpha-alumina monohydrate with an alkaline solution having a pH of at least about 7.5 and forming a stable suspension. A salt of a strong acid is commingled with the suspension to form a paste or dough which is subsequently formed into extrudates, and dried and calcined.