CA2173240C

CA2173240C - Catalyst carrier

Info

Publication number: CA2173240C
Application number: CA002173240A
Authority: CA
Inventors: William H. Gerdes; Donald J. Remus; Thomas Szymanski; James A. Wolford
Original assignee: Norton Chemical Process Products Corp
Current assignee: Saint Gobain Norpro Corp
Priority date: 1994-09-13
Filing date: 1994-09-13
Publication date: 1999-04-06
Anticipated expiration: 2014-09-13
Also published as: CA2173240A1

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.

Description

CA 02173240 1998-12-1~

CATALYST CARRIER

This invention relates to catalyst carriers and specifically to catalyst carriers based on alumina that may be used as supports for metal and metal oxide catalyst components of use in a variety of chemical reactions.
Background of the Invention The use of alumina based catalyst carriers has previously been described in a number of patents including USPP 5,100,859; 5,055,442; 5,037,794; and 4,874,739. Such carriers have a wide variety of potential applications in the catalytic field and are especially useful where the alumina base is alpha alumina.
A catalyst support needs to possess, in combination, at least a minimum surface area on which the catalytic component may be deposited, high water absorption and crush strength. The problem is that usually an increase in one can mean a reduction in another property. Thus high crush strength may mean low porosity. Often the balance is achieved by trial and error making the catalyst carrier art even more unpredictable than other chemical process art.
A way has now been found to design carriers with more confidence as to the final property balance. The carriers of the invention have an excellent balance of crush strength, abrasion resistance, porosity and catalytic performance that make them ideal for a range of catalytic applications. They are based on alpha alumina and the novel process by which they are made assures high porosity and excellent crush strength.
Descri~tion of the Invention The present invention provides a novel alpha alumina based catalyst carrier having a crush strength, (as measured on a Compton Tensile Tester, model 50-OP), of at least 51b (2.28N) and a settled packing density, (as CA 02173240 1998-12-1~
.

measured by ASTM D-4699-87, modified by the use of cylinder with an inside diameter of 3.75in (9.53cm) and a length of 18in (45.7cm), of at least 381b/ft3 (608kg/m3) which comprises first and second alpha alumina components with a first alpha alumina component in the form of particles having an average 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.
The alpha alumina generated in situ is readily distinguished from the pre-formed alpha alumina particles present in the carrier of the invention. In a photomicrograph of the carrier the pre-formed alpha alumina appears as clearly identifiable individual particles with no internal porosity.
The invention also comprises a process for the production of a catalyst carrier which comprises:
i) forming a mixture comprising:
a. at least one alpha alumina component with an median particle size of 3 to 8 microns and:
b. a hydrated precursor of alpha alumina in an amount sufficient to provide from 5 to 60% by weight of the total weight of alpha alumina in the catalyst carrier product;
c. from 5 to 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 seeded precursor of alpha alumina to alpha alumina so as to produce a catalyst CA 02173240 1998-12-1~

carrier in which alpha alumina particles with a median particle size of from 3 to 8 microns are dispersed in a matrix of alpha alumina derived from the seeded precursor material.
The catalyst carrier of the invention comprises a number of alpha alumina components chosen to contribute to the desired physical properties, including porosity, pore volume, crush strength and the like. Often a combination of two different alpha aluminas is preferred, one component having larger particles mixed with a second component having smaller particles, in weight ratios of from 10:90 to 90:10. The objective of this is to end up with a surface area, (in this document a reference to "surface area" is understood to mean the BET surface area measured using nitrogen or krypton as the adsorbed gas), in the finished product of from 0.4 to 5 m2/gm. The surface area in the finished carrier is somewhat less than the free alumina particles. Thus a convenient mixture may comprise for example, two types of alpha alumina particles, the first having a surface area of about 1 m2/gm and the second having a surface area of 3 to 5 m2/gm.
The precursor of alpha alumina is preferably based on boehmite but good results are also obtained if the precursor comprises a mixture of boehmite with an aluminum trihydrate such as gibbsite or bayerite. Where such a mixture is used it is often preferred to use a weight ratio of the monohydrate, (boehmite), to trihydrate of from 1:10 to 1:3 and more preferably from 1:8 to 1:4. It is often preferred that, when a sol is formed from the precursor by addition of water, a sub-micron particle sized see material is also added. This has the effect of reducing the temperature at which the transition to alpha alumina occurs and reduces the crystal size of the alpha alumina produced upon transformation.
The seed used can be any material that is effective .

CA 02173240 1998-12-1~

to produce nucleation sites in the precursor so as to reduce the transition temperature at which a transition alumina converts to alpha alumina. Seeds that accomplish this goal generally have the same crystal lattice type as alpha alumina itself and lattice dimensions that do not differ by too much from those of alpha alumina. Clearly the most convenient seed is alpha alumina itself and sub-micron sized particles of alpha alumina are the preferred seed. It is however possible to use other seeds such as alpha ferric oxide and chromium oxide and certain complex oxides of titanium.
The alpha alumina formed from the preferred seeded precursor when the extruded mixture is fired generally has a much finer crystal size than the alpha alumina particles with which the seeded precursor is mixed unless, during firing, it is maintained at a high temperature for a prolonged period. As produced, the seeded sol-gel material has a sub-micron crystal structure but if it is held at temperatures over 1400~C for extended periods, crystal growth begins and the size differentiation may become less apparent.
The carrier of the invention preferably has a porosity of at least 50~ and more desirably from 60 to 75~. The porosity is related to the surface area which is preferably from 0.4 to 5, and more preferably from 0.6 to 1.2 square meters/gram.
It is often found advantageous to add titania to the mixture to be extruded in an amount that represents from 0.05 to 1.0~, and more preferably from 0.08 to 0.6~ of the weight of the fired carrier. Certain forms of alumina and bond material may also contain titania as impurities or components. The contribution of such forms of titania are not included in the amounts specified above. The titania can be added as the dioxide, as a titanate or as a precursor of titania.

~ H--2630/1 . 217~2~0 In the ~ollowing description all the above options are understood to be included under the term "titania" It is believed that the titania may function as a form of crystai growth inhibitor in the alpha alumina formed as a result of the conversion of the seeded precursor.
The titania is preferably in the form of a powder with a relatively high surface area such from 8 to 300 square meters/gram. In practice the preferred titanias have an amorphous or anatase structure as the rutile structure commonly has a much smaller surface area.
Commercial pigment grades of titania can often give good results.
When the carrier comprises a titania component, it is often found that surface areas are in the lower end of the ranges discussed above. In spite of this lower surface area such carriers give good results in terms of ~ -the performance of catalysts supported on the carrier. 7~ t~
While it would appear that the alpha alumina formed , from the seeded precursor acts in some sense as a matrix binder holding the rest of the alpha alumina particles together,~ ~s~usu~lly preferred~to add a ceramic bond material to the mixture to give added strength to the fired carrier. Conventional ceramic bond materials can be used and after firing these typically comprise -~
components, (expressed as the oxides), such as silica, alumina, alkaline earth metal oxides, alkali metal oxides, iron oxide and titanium oxide, with the first two being the dominant components.
Pescription of Preferred Em~odiments The invention is further described with reference to the following examples which are for the purposes of ' illustration only and are not intended to imply any necess~ry-limitation an t~e essential scope of the invention .,~

21 7324~
W096/08309 T~/US94/09775 Example 1 - ; I
This Example details the preparation of the carriers made using the formulations described in the following Examples.
The ceramic components are mixed with a bhrn-out material, (walnut shell flour), and boric acid for about a minute. Water and the seed component are added, the water being in an amount that is necessary to make the mixture extrudable. Generally this is about 3jO% by weight. The mixture is mixed for about two tolfour minutes and then about 5% by weight based on the weight of the ceramic components, of vaseline is added as an extrusion aid. The mixture is then mixed for a further 2 to 4 minutes before being extruded in the ~orm o~ hollow cylinders and dried to less than 2~ uncombined water.
These were then fired in a tunnel kiln with a maximum temperature of about 1500~C for about 4 hours.
Exam~le 2 In this Example three carriers according to the invention are described in terms of their formulation, (Table 1) and their physical properties and catalytic performance when used in conjunction with a standard commercial catalyst to produce ethylene oxide, (Table 2 ) .
The performance is compared against a standard commercial catalyst/carrier combination using the same catalyst.

6 1.
SL~BSlmJ~~ S~P~VI~ ~

~ W096/08309 ~ ~ 7 3 2 ~ ~ PCT~S94/09775 CARRIER COMPOSITION CARRIER A CARRIER B CARRIER C
ALPHA #1 * 46.6% 45.2~ 46.6%
. ALPHA #2 * 18.7~ 18.7% 28.0%
ALPHA #3 * (SEED) 0.9% 0.9% 0.9%
GIBBSITE * 28.0% 28.0% 18.7%
BOEHMITE * 4.5% 4.5% 4.5%
CERAMIC BOND * 1.3% 2.7% 1.3%
ORGANIC BURNOUT ** 11% 16% 11%
10 PETROLEUM JELLY ** 5~ 5% 5%
BORIC ACID ** 0.15% 0.15% 0.15%
WATER about 30% about 30% about 30%
* indicates "ceramic components" and percentages given are based on î~o% of the ceramic components.
** percentages are based on total weight of ceramic components.
Water is added in an amount to make the above mixture extrudable.
"Alpha #l" is a commercial alpha alumina that has a median particle size of 3 to 3.4 microns, a BET surface area of about 0.9 to about 1.4 m2/gm~ a crystallite size of 1.6 to 2.2 microns and a soda content of 0.02 to 0.06%.
"Alpha #2" is an alpha alumina with a median particle 25 size of 4.0 to 8.0 microns, a surface area of 3.0 to 5.0 m2/gm, a crystallite size of from 0.4 to 0.8 micron and a soda content of 0.1 to 0.3%
"Alpha #3" is an alpha alumina that was used as the seed for the gibbsite and boehmite precursors of alpha alumina. Its median particle size was less than 0.1 micron.
The gibbsite had a median particle size of from 4.0 to 20 microns and the boehmite was dispersible as a sol.
The ceramic bond contained components, (expressed as the oxides), in the following approximate proportions: 60%
silica, 29% alumina, 3% of calcium oxide, 2% of magnesia, 4% of alkali metal oxides and less than 1% each of ferric UTE S~T ~R~

CA 02l73240 l998-l2-l~

The gibbsite had a median particle size of from 4.0 to 20 microns and the boehmite was dispersible as a sol. The ceramic bond contained components, (expressed as the oxides), in the following approximate proportions: 60 silica, 29~ alumina, 3~ of calcium oxide, 2~ of magnesia, 4~ of alkali metal oxides and less than 1~ each of ferric oxide and titania.

PROPERTY CARRIER A CARRIER B CARRIER C
Select. (1) +1.05/-0.05 +1. 05/-6.5 +1.25/-2 Surface Area 1.15 m2/gm 0. 912 m2/gm 0. 97 m2/gm Pack. Density 733. 7 kg/m3 775. 4 kg/m3 736.9 kg/m3 Crush Strength 6 .18 N 6. 94 N 8.10 N
Attrition 21. 7% 18.09~ 19.8~

The above Table includes certain measurement criteria that are used throughout this specification to describe the results obtained. Where these are not further explained in the context, they have the meanings described below:
(1) "Selectivity" This is measured using a standard catalyst formulation deposited on the carrier and assessed against the selectivity shown by the same standard catalyst on a standard carrier. In each case a standard gas flow containing ethylene, oxygen and inert gases and comprising 25~ by volume of ethylene was passed over the catalyst.
The standard conditions are those to achieve a conversion of 40~ of the oxygen content of the flow. Clearly if the selectivity of the standard can be exceeded by even a small amount, this is an advantage. This is even more attractive if it can be achieved at a lower temperature.
The standard catalyst/carrier combination, under the conditions of the evaluation had a selectivity of 81. 2~

~ ~1173240 W096/08309 PCT~S94/09775 "Pack. Density" is the settled packing density as measured by ASTM D-4699-87, modified as described above, or the equivalent.
The "Crush Strength", (occasionally called "C.S."), of the carrier is measured as described above.
"Attrition" is the amount of catalyst weight loss measured using ASTM D-4058-92.
The "surface area" is the BET surface area measured using nitrogen or krypton as the adsorbate.
As can be seen, the carriers in accordance with the invention allow a higher degree of selectivity to the desired product while operating at a lower temperature.
These improvements are considered extremely significant.
Example 3 In the pair of experiments that comprise this Example, the effect of the presence of the sol-gel derived component is determined.
The formulations that were used to make the carriers is set forth in Table 3 and the physical properties and selectivity, (assessed as in Example 2) are described in Table 4.

SU~ttTl~E Sff~T t~ULE ~6 W096/~8309 ~1 7 3 ~ ~ O PCTIS9Jl~9775 COMPONENT WITH SOL-GEL NO SOL-GEL
C0MPONENT Wt% COMPON:NT Wt%
ALPHA ALUMINA #1 48.7 50.6 ALPIA ALUMINA #2 42.25 48.1 ALPHA ALUMINA SEED 0.5 0 DISPERSIBLE BOEHMITE 7.25 o CERAMIC BOND 1.3 1.3 PETROLEUM JELLY 5.0 5.0 FORMIC ACID 2.4 2.4 BORIC ACID 0.15 0.15 The carrier cont~ ning the sol-ge_ component, (shown in the first column), is a carrier according to the invention. The other is given for comparative purposes.
The all7~;n.7s used are as indicated in Table 1. In both formulations water was added to make the mixture extrudable, (about 30~). The weights of the last three components in the chart are based on 100 parts by weight of the ceramic components.

SUBSTITUTE SHEET (RULE 26) INVENTION INVENTION
WATER ABSORPTION ~ 41.5 47.8 PACK, DENSITY (KG/M3) 756.1 719.3 CRUSH STRENGTH (N) 6.90 5.11 SURFACE AREA (M2/GM) 1.18 1.47 ( o C ) ACID LEACHABLES (ppm) sodium potassium 138 174 calcium 80 104 aluminum 132 188 SELECTIVITY +0.2 -1 The packing density, crush strength, selectivity and surface area were measured as described in Table 2. The water absorption is a measure of the increase in weight of the carrier after being immersed in water and weighed.
The results indicate that the crush strength of the carrier of the invention is significantly increased by the presence of the sol-gel component while maintaining the surface area at over 1.1 m2/gm. The selectivity of a standard catalyst supported on the carrier of the invention is slightly better than the standard but significantly better than the same catalyst supported on a carrier without the sol-gel component. The carrier can therefore be expected to have a longer life than carriers made without the seed component.
Example 4 This Example illustrates the performance of a carrier evaluated in the same way as is described in Example 2.

~ H-2630/l ~ 1 7 3 2 ~ O

The carrier comprised:
40~ by weight of alpha alumina particles with a median particle size of about 3 to 3.5 microns and a surface area of about 1 */gm;
52.1% by weight of gibbsite;
o.9% of alpha alumina seed particles with a median particle size of less than about 0.1 micron; '' 6% by weight of boehmite;
1% by weight of a ceramic bond; and 2.4% of formic acid.
The formulation comprised in addition the additives described in Example 2, (burnout material, petroleum jelly and boric acid), and water is added to make the formulation extrudable.
The carrier had a surface area of 1.06 m2/gm., a crush strength of 15.4..-lb (6.90.N) and packing density of 51.2 lb/ft3 (820.2 kg/m3). All these properties are measured as described in Example 2. . ~ ;
The carrier, when evaluated as described in Example 2 had a selectivity increase of 0.5 which was obtained at - a.temper~tllr~that was.?3~C lower.. than for the.. standard.~ c S.
Exam~le 5 ." This Example describes the effect of adding titania to a carrier formulation according to the invention. The formulations used are set out in Table 5 and the properties are described in Table 6.

:-,-'.: .. ' '~1 .', .

, ;~ ~ . s . .

A?A~?, ~ ~?~ ?~ .

CA 02l73240 l998-l2-l~

CARRIER COMPOS. CARRIER D CARRIER E CARRIER F CARRIER G
ALPHA #1 * 46.6~ 46.6% 46.6~ 46.6 ALPHA #2 * 28% 28~ 28% 28%
ALPHA #3 * 0.9% 0.9% 0.9% 0.9%
(SEED) GIBBSITE * 18.7% 18.7~ 18.7~ 18.7 BOEHMITE * 4.5% 4.5~ 4.5% 4.5 CERAMIC BOND * 1.3~ 1.3% 1.3~ 1.3%
TiO2 * 0.1~ 0.2~ 0.1~ 0.2 ORG. BURNOUT ~ 11% 11 PET. JELLY ~ 5~ 5~ 5~ 5 BORIC ACID ~ 0.15~ 0.15% 0.15% 0.15 WATER (to make about 30~ about 30% about 30~ about 30 extrudable) * indicates "ceramic components" and percentages given are based on lO0~ of the ceramic components.
** percentages are based on total weight of ceramic components.
The "D" and "E" carriers were fired at 1420~C and the "F" and "G" carriers were fired at 1480~C. The components were all as described in Example 2. The titanium oxide was in a hydrated form and had a surface area of about 250 m2/gm.

CARRIER D CARRIER E CARRIER F CARRIER G
SELECTIVITY +0.7/-7 +0.8/-11 +0.7/-8 +1.3/-8 S.A. (M2/GM) 1.15 1.01 0.86 0.70 P.D. (KG/M3) 770.7 815.9 848.1 770.7 C.S.(N) 5.64 6.67 8.06 6.90 wo ~G,~a~3 ~ 1 7 3 2 4 ~ PCT~S94/09775 -at elevated temperatures. There are many such processes in the petrochemical industry but the present carrier has proved itself particularly suitable in the catalytic formation of ethylene oxide from a gas streamlcomprising s ethylene and oxygen. The utility of the present invention is however not so limited.
Example 6 This Example details the preparation of the carriers.
The exact identification of the components is~ given in Table 7 below. The mixing process used was as follows.
The ceramic components are mixed with a burn-out material, (walnut shell flour), and boric acid for about a minute. Water and the seed component are added, the w~ter being in an amount that is necessary to make the mixture extrudable. Generally this is about 30~ by weight. The mixture is mixed for about two to four minutes and then about 5% by weight based on the weight of the ceramic components, of vaseline is added as an extrusion aid. The mixture is then mixed for a further 2 to 4 minutes before being extruded in the form of hollow cylinders and dried to less than 2% uncombined water.
These were then fired in a tunnel kiln with a maximum temperature of about 1500~C for about 4 hours.

SUBSllTUTE SHEET (RULE ~5 I

~ W096/08309 i~ 7 3 2 g O PCT~S94/09775 CARRIER COMPOS. CARRIER H CARRIER I CARRIER J
ALPH~ #1 * 45.5% 46.0% 46.0%
ALPH~ #2 * 28% 27.6% 27.6%
ALPHA #3 * (SEED) 2.0% 2.2% 2.2%
GIBBSITE * 18.7% 18.4% 18.4%
BOEHMITE * 4.5% 4.5% 4.5%
CERAMIC BOND * 1.3~ 1.3% 1.3%
Tio2 * 0.6% 0.4% 0.4%
ORG. BURNOUT ** 11% 15% 11%
PET. JELLY ** 5% 5% 24~
BORIC ACID ** 0.15% 0.15% 0.15%
WATER (to make about 30% about 30% about 30%
extrudable) x indicates "ceramic components" and percentages given are based on 100% of the ceramic components.
** percentages are based on total weight of ceramic components.
Water is added in an amount to make the above mixture extrudable.
"Alpha #1" is a commercial alpha alumina that has a median particle size of 3 to 3.4 microns, a BET surface area of about 0.9 to about 1.4 m2/gm, a crystallite size of 1.6 to 2.2 microns and a soda content of 0.02 to 0.06%.
"Alpha #2" is an alpha alumina with a median particle size of 4.0 to 8.0 microns, a surface area of 3.0 to 5.0 m2/gm, a crystallite size of from 0.4 to 0.8 micron and a soda content of 0.1 to 0.3%
"Alpha~3i' is an~a12ph~ alumina that was used as the seed for the gibbsite and boehmite precursors of alpha alumina. Its median particle size was less than 0.1 SUBSTITUTE SHE~T (RULE 26) ~ H-2630/1 ~3~
micron.
The gibbsite had a median particle size of from 4.0 to 20 microns and the boehmite was dispersible as a sol.
The titanium oxide was in a hydrated form and had a surface area of about 250 m2/gm.

The ceramic bond contained components, (expressed as the oxides), in the following approximate proportions: 60%
silica, 29% alumina, 3% of calcium oxide, 2% of magnesia, 4% of alkali metal oxides and less than 1% each of ferric oxide and titania.
All the carriers were fired at 1390~C.

CARRIER H . CARRIER I CARRIER J
SELECTIVITY +1.2/-12 +1.3/-8 +1.2/-6 S.A. (M2/GM) 0.66 0.78 0.72 P.D. (LB/FT3) 50.14 51.8 48.6 C.S. (LB) 17.9 18.5 15.3 . . . :~ - - i;

Claims

1. An alpha alumina based catalyst carrier having a crush strength of at least 5 lb (2.24N) and a packing density of at least 38 lb/ft3 (608.8 kg/m3) 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 0.4 to 4 microns providing from 95 to 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.

2. A catalyst carrier according to Claim 1 in which the first alpha alumina component comprises a larger particle size component and a smaller particle size component in which the larger component provides from 10 to 90% by weight of the first component weight in the form of particles with a median particle size less than 4 and greater than 2.5 microns and a average crystallite size of from 1.5 to 2.5 microns, and a smaller component providing from 90 to 10% by weight of the first component in the form of particles with a median particle size greater than 4 and less than 10 microns and an average crystallite size of from 0.4 to 0.8 micron.

3. A catalyst carrier according to Claim 1 in which the second alpha alumina component is generated by a seeded sol-gel process.

4. A catalyst carrier according to Claim 3 in which the sol-gel alumina is seeded with an effective amount of sub-micron alpha alumina seed.

5. A catalyst carrier according to Claim 1 which further comprises from 0.08 to 1.0 %, based on the weight of alumina in the carrier, of added titania.

6. A catalyst carrier according to Claim 5 in which the.
titania has a surface area of at least 8 square meters per gram.

7. A catalyst carrier according to Claim 1 comprising a pore volume of from 0.3 to 0.6 cc. Hg/gram.

8. A catalyst carrier according to Claim 1 which further comprises a ceramic bond material in an amount that is from 1 to 3% of the weight of the alumina components, expressed as alpha alumina, in the carrier.

9. A catalyst carrier according to Claim 1 wherein the first alpha alumina component has two constituents including:
i) a first constituent providing from 40 to 80%
by weight of the first alpha alumina component and having a median particle size of from 3 to 4 microns; and ii) a second constituent providing from 20 to 60% of the weight of the first alpha alumina component and having a median particle size of from 4 to 8 microns;
said first alpha alumina component providing from 95 to 65% of the total weight of alpha alumina in the carrier.

10. A catalyst carrier according to Claim 9 which further comprises from 0.05 to 1.0 % by weight of titania.

11. A process for the production of a catalyst carrier which comprises:
i) forming a mixture comprising:
a. at least one alpha alumina component with an median particle size of from 3 to 8 microns and:
b. a seeded, hydrated precursor of alpha alumina in an amount sufficient to provide from 5 to 60% by weight of the total weight of alpha alumina in the catalyst carrier product;
c. from 5 to 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 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 3 to 8 microns are dispersed in a matrix of alpha alumina derived from the seeded precursor material.

12. A process according to Claim 11 in which the precursor of alpha alumina comprises a boehmite.

13. A process according to Claim 11 in which the precursor of alpha alumina comprises alumina trihydrate.

14. A process according to Claim 11 in which the precursor of alpha alumina is seeded with sub-micron sized particles of alpha alumina in an amount that is from 0.2 to 5% by weight based on the total alumina weight, measured as alpha alumina, in the catalyst carrier.

15. A process according to Claim 11 in which from 0.05 to 0.6% based on the total weight of alumina in the formulation expressed as alpha alumina, of titania is added to the mixture to be extruded.

16. A process according to Claim 11 in which a ceramic bond material is added to the extrudable mixture in an amount that is from 1 to 3% of the weight of the alumina components, expressed as alpha alumina, in the mixture.

17 A process according to Claim 11 in which the mixture formed in step i) comprisess a. an alpha alumina having a first component with a median particle size of from 2 to 4 microns and a second component with a median particle size of 4 to 8 microns;
b. a seeded, hydrated precursor of alpha alumina in an amount sufficient to provide from 5 to 60% by weight of the total weight of alpha alumina in the catalyst carrier product;
c. from 5 to 40%, based on the weight of the alpha alumina, of a burnout material;
d. from 1 to 3% based on the weight of alumina in the composition expressed as alpha alumina, of a ceramic bond material;
e. from 0.05 to 1.0% 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.

18. A process according to Claim 17 in which the precursor of alpha alumina comprises a boehmite.

19. A process according to Claim 17 in which the precursor-of alpha alumina further comprises from 10 to 35% by weight of alumina trihydrate, measured as the alpha alumina equivalent, based on the total weight of alpha alumina in the carrier product.

20. A process according to Claim 17 in which the precursor of alpha alumina is seeded with a sub-micron sized particles of alpha alumina in an amount that is from 0.2 to 5% by weight based on the total alumina weight, measured as alpha alumina, in the catalyst carrier.