Jan J. Verstraete

The efficiency of supported catalysts depends on the porous microstructure of their solid support, which regulates mass transfer, exposure to the active phase, and mechanical strength. Here, we focus on the manufacturing of a specific type of catalytic support, $\gamma$-alumina extrudates, by a kneading-extrusion process. In this process, a paste is initially formed by blending and subsequently kneading a boehmite powder, an aluminum oxide hydroxide precursor of $\gamma$-alumina, with various liquids before undergoing extrusion. The crucial step in this process is the kneading step, which allows control over the textural and mechanical properties of the extrudate. The present experimental study aims to measure the impact of the kneading step on boehmite pastes prepared using a pilot kneader. The pastes are obtained by mixing boehmite powder subsequently with an acid and a basic solution in a two-step process known as peptization and neutralization. In this study, kneading is conducted at various mixing speeds and durations while monitoring the torque exerted by the boehmite paste on the kneader blades. Moreover, samples are extracted from the pilot kneader at various stages of the kneading process, and their textural properties are determined by both nitrogen sorption and mercury intrusion porosimetry. Our findings show that, at fixed composition, the textural properties of boehmite pastes are controlled by the overall deformation accumulated during kneading. Conversely, for a fixed accumulated deformation, the pH sets the textural properties. Finally, we identify an empirical control parameter that captures the combined effects of pH and accumulated deformation on the key textural attributes of boehmite pastes. These results set the stage for a systematic design approach of boehmite-based catalyst supports.