Novel extrudates based on the multiscale packing of alumina particles and boehmite or aluminophosphate binders

•Multiscale packing of alumina particles was used on the preparation of new extrudates.•The cohesion of the packing was ensured by boehmite and aluminophosphate binders.•Materials with low binder content and good mechanical strength were obtained.•Porous materials with the novel microstructure are interesting as catalyst supports.

Porous extrudates consisting of a packing of model spherical alumina particles with different median diameters (1.7 μm and 19 μm) were prepared. Peptized boehmite and aluminophosphate binders were used in order to ensure the cohesion of the materials. Combined effect of the multiscale packing of porous alumina particles contributed to generate supports with low binder content and good mechanical strength. The resulted microstructure is very attractive for porous materials such as catalyst supports and adsorbents and can be easily controlled by selecting relevant filler particles.

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