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Abstract

The present invention relates to a process for making novel catalysts, catalyst supports, and adsorbers comprising synthetic hydrotalcite-like binders, having a sheet-like morphology and a sheet broadness to thickness ratio of at least 50 and a formula Mg.sub.1-x Al.sub.x (OH).sub.2.xA.sup.-. mH.sub.2 O where A.sup.- is a mono carboxylic anion of the form RCOO.sup.- where R is C.sub.n H.sub.2n+1 and n=0-5, and x and m are numbers satisfying the following conditions: 0.2<=x<=0.4 0.0<=m<=4 This hydrotalcite-like material is combined with an inorganic material to form shapes which have good mechanical strength. The process includes starting with a synthesis mixture having magnesium (divalent cation) to aluminum (trivalent cation) molar ratio between 1:1 and 10:1, mono carboxylic anion to aluminum (trivalent cation) molar ratio between 0.1:1 to 1.2:1 and optionally added other anions. The process further includes reacting a mixture containing magnesium and aluminum cations and mono carboxylic anions in an aqueous slurry at a temperature of at least 40.degree. C. and a pH of at least 7. The crystallized hydrotalcite product is then spray dried. This spray dried product is mixed with an inorganic material and water to form a plasticized mixture. The plasticized mixture is formed into various shapes. These shapes are then dried to remove water, calcined, steam treated, or otherwise tailored to the requirements of its specific application.

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