Catalyst composition useful in the catalytic reduction of sulfur compound contained in a gas stream and a method of making and using such composition

1. A method of making a catalyst composition useful in the catalytic reduction of sulfur compounds contained in a gas stream, wherein said method comprises: incorporating into a formed alumina particle a group VI metal component in an amount in the range upwardly to 20 wt. % based on the metal component being in the oxide form and the total weight of the catalyst composition, and a group VIII metal component in an amount in the range upwardly to 10 wt. % based on the metal component being in the oxide form and the total weight of the catalyst composition, wherein said formed alumina particle comprises alumina having more than 10% of its total pore volume that is contained within the pores having a pore diameter greater than 10,000 Å, and having more than 10% and less than 70% of the total pore volume that is contained within pores having a diameter of less than 70 Å, to thereby provide an intermediate; and calcining said intermediate to thereby provide said catalyst composition.

2. A method as recited in claim 1 , wherein said alumina has more than 15% of its total pore volume that is contained within the pores having a pore diameter greater than 10,000 Å; wherein more than 50% of said alumina is in the form of η-alumina; and wherein less than 60% of the total pore volume of said catalyst composition is contained within the pores of said catalyst composition having a pore diameter less than 70 Å.

3. A method as recited in claim 1 , wherein said alumina particle comprises alumina balls formed from an alumina powder by a disk-pan agglomerator.

4. A method as recited in claim 3 , wherein said alumina balls have a nominal diameter between 1.5 mm and 15 mm.

5. A method as recited in claim 3 , wherein said alumina balls are formed from a powder of an alumina predecessor, selected from the group consisting of hydragillite, bayerite, boehmite, pseudoboehmite, and a hydrated alumina.

6. A method as recited in claim 1 , wherein said alumina particle of said catalyst composition is selected from the group consisting of ρ-alumina, χ-alumina, η-alumina, λ-alumina, κ-alumina, θ-alumina, δ-alumina, and α-alumina.

7. A method as recited in claim 6 , wherein at least 50% of said catalyst composition comprises η-alumina.

8. A method as recited in claim 7 , wherein at least 75% of said catalyst composition comprises η-alumina.

9. A method as recited in claim 8 , wherein at least 90% of said catalyst composition comprises η-alumina.

10. A method as recited in claim 1 , wherein either or both of said group VI metal component and said group VIII metal component are incorporated into said alumina particle through an incipient wetness impregnation method.

11. A method as recited in claim 10 , wherein said incipient wetness impregnation method uses an impregnation solution comprising a metal compound selected from the group consisting of group VIII metal acetates, group VIII metal carbonates, group VIII metal nitrates, group VIII metal hydroxides, and group VIII metal sulfates.

12. A method as recited in claim 11 , wherein said metal compound has a concentration between 0.01 moles per liter and 100 moles per liter.

13. A method as recited in claim 10 , wherein said wetness impregnation method uses an impregnation solution comprising a metal compound selected from the group consisting of ammonium heptamolybdate, and ammonium dimolybdate.

14. A method as recited in claim 13 , wherein said metal compound has a concentration between 0.01 moles per liter and 100 moles per liter.

15. A method as recited in claim 1 , wherein said alumina particle, before said calcining step, is dried at a drying temperature between 75° C. and 250° C.

16. A method as recited in claim 1 , wherein said calcining step occurs at a temperature between 300° C. and 800° C.

17. A method as recited in claim 1 , wherein said alumina has more than 25% of its total pore volume that is contained within the pores having a pore diameter greater than 10,000 Å°.

18. A method as recited in claim 17 , wherein the ratio of the total pore volume that is contained in pores having a pore diameter greater than 10,000 Å to the total pore volume that is contained in pores having a pore diameter less than 70 Å exceeds 0.6.

19. A method as recited in claim 18 wherein said alumina has more than 35% of its total pore volume that is contained within the pores having a pore diameter greater than 10,000 Å.