Process for the manufacture of spheroidal bodies by selective agglomeration

Abstract

This invention relates to the preparation of small spheroidal solid agglomerates. More particularly, the process produces strong solid spheroidal agglomerates containing alumina or a mixture of alumina and at least one other inorganic material, which process comprises: (a) mixing at high speed a portion of alumina or a mixture of alumina and at least one other inorganic material in the form of hydrophilic mircon-sized particles in a water-immiscible liquid thereby forming a dispersion; (b) gradually adding to the dispersion an aqueous acidic phase while continuing the high-speed mixing until substantially spherical micro-agglomerates form within the water-immiscible liquid; (c) subjecting the micro-agglomerates to agitation in a vessel having a hydrophobic inner surface at a speed low enough to achieve substantially uniformly sized spheroidal agglomerates; (d) drying the agglomerates to produce hardened spheroidal uniformly sized agglomerates; and (e) optionally further separating the agglomerates by size. Optionally, the aqueous phase in step (b) may include the soluble salts of catalytic metals, and bases and/or colloidal-sized inorganic particles. These spheroidal particles can have either smooth surfaces or polylobe surfaces depending on the conditions of preparation. They have diameters generally between 1 to 5 mm and are useful as catalysts, or catalyst supports. Catalytic components may subsequently be deposited on the support.

Dependencies are inferred from the claim text.