Scientific Design Company, Inc.

Michael Di Mare

Wojciech L Suchanek

Jean Adam

Paul E Ellis, Jr

A precursor mixture for producing a porous body, wherein the precursor mixture comprises: (i) at least one milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) non-silicate powder that functions as a binder of the alpha alumina powders, and (iii) at least one burnout material having a particle size of 1-10 microns and a decomposition temperature of less than 550&#xb0; C., with the proviso that a burnout material having a decomposition temperature of 550&#xb0; C. or greater is excluded from the precursor mixture.

Porous bodies with enhanced pore architecture prepared without a high-temperature burnout material

Oxalic acid is employed in a precursor mixture containing at least one milled alpha alumina powder having a particle size of 0.1 to 6 microns, boehmite powder that functions as a binder of the alpha alumina powders, and at least one burnout material having a particle size of 1-10 microns to provide a porous body having enhanced pore architecture in which extrusion cracks can be reduced. The presence of oxalic acid in such as precursor mixture can reduce and even eliminate NOx emission during a high temperature heat treatment process.

Porous bodies with enhanced pore architecture prepared with oxalic acid

A porous body with enhanced fluid transport properties and crush strength is provided. The porous body includes the porous body includes at least 80 percent alpha alumina and having a pore volume from 0.3 mL/g to 1.2 mL/g, a surface area from 0.3 m/g to 3.0 m/g, and a pore architecture that provides at least one of a tortuosity of 7 or less, a constriction of 4 or less and a permeability of 30 mdarcys or greater, wherein the porous body is a cylinder comprising at least two spaced apart holes that extend through an entire length of the cylinder. The porous body has a flat plate crush strength improved by more than 10% over a porous body cylinder having a same outer diameter and length, but having only a single hole.

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Morristown, NJ, United States of America

Michael Di Mare