Sulfated zirconia hydroxide shaping by extrusion is studied based on elucidating the impact of zeta-potential and rheological characteristics on physical and chemical properties of technical catalysts. Zeta potential measurements of sulfated zirconium hydroxide prior and after poly­(vinyl alcohol) (PVA) additions were made. Rheological curves of sulfated zirconium hydroxide suspensions with different amounts of PVA were recorded at different zeta-potential values. The addition of PVA nonlinearly decreased shear yield stress. Experimental data were quantified with the Krieger–Dougherty equation. The influence of a boehmite-type binder on the zeta-potential confirmed that the surface properties of the particles to a large extent are determined by the presence of binder. The pore structure of shaped catalysts was unaffected by rheological parameters when zeta-potential is close enough to zero. At the same time deviations of the zeta potential from the zero-value afforded more uniform pore size distribution.

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