MULTI-LOBED POROUS CERAMIC BODY AND PROCESS FOR MAKING THE SAME

• US 20150209774A1
• Filed: 04/02/2015
• Published: 07/30/2015
• Est. Priority Date: 12/29/2010
• Status: Active Grant

• Current Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain)
• Inventors: Covey, John David, Richard, Michael A
• Granted Patent: US 9,694,355 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01J 23/50 Silver
• CPC Class Codes: B01J 23/688 with manganese, technetium or rhenium
• CPC Class Codes: B01J 35/00 Catalysts, in general, characterised by their form or physical properties
• CPC Class Codes: B01J 35/394 Metal dispersion value, e.g. percentage or fraction
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 35/612 less than 10 m2/g
• CPC Class Codes: B01J 35/633 less than 0.5 ml/g
• CPC Class Codes: B01J 35/69 bimodal
• CPC Class Codes: B01J 37/0201 Impregnation
• CPC Class Codes: B01J 37/024 Multiple impregnation or coating
• CPC Class Codes: C07C 213/04 by reaction of ammonia or amines with olefin oxides or halohydrins
• CPC Class Codes: C07C 215/08 with only one hydroxy group and one amino group bound to the carbon skeleton
• CPC Class Codes: C07C 29/106 of oxiranes
• CPC Class Codes: C07C 41/03 by reaction of oxirane rings with hydroxy groups
• CPC Class Codes: C07D 301/04 with air or molecular oxygen
• CPC Class Codes: C07D 301/08 in the gaseous phase

Abstract

A carrier having at least three lobes, a first end, a second end, a wall between the ends and a non-uniform radius of transition at the intersection of an end and the wall is disclosed. A catalyst comprising the carrier, silver and promoters deposited on the carrier and useful for the epoxidation of olefins is also disclosed. A method for making the carrier, a method for making the catalyst and a process for epoxidation of an olefin with the catalyst are also disclosed.

Claims

1. A packed catalyst bed comprising catalyst particles, said catalyst particles comprising silver and promoters useful for the epoxidation of ethylene, said silver and promoters deposited on a shaped porous ceramic body comprising a first end, a second end, and a wall disposed between and intersecting said ends, said wall comprising at least three lobes and three valleys formed in the length of the wall, said lobes rounded at the intersection of said first end and said wall and said valleys not rounded at the intersection of said first end and said wall, each valley located between two of said lobes, and wherein said catalyst bed has a silver loading of at least 50 kg of silver/m³ of catalyst bed.

2. The packed catalyst bed of claim 1 wherein said catalyst bed has a silver loading of at least 150 kg of silver/m³ of catalyst bed.

3. The packed catalyst bed of claim 1 wherein said catalyst bed has a silver loading of at least 200 kg of silver/m³ of catalyst bed.

4. The packed catalyst bed of claim 1 wherein said catalyst bed has a silver loading of at least 250 kg of silver/m³ of catalyst bed.

5. The packed catalyst bed of claim 1 wherein said catalyst bed has a silver loading of at most 850 kg of silver/m³ of catalyst bed.

6. The packed catalyst bed of claim 1 wherein said catalyst bed has a silver loading of at most 600 kg of silver/m³ of catalyst bed.

7. The packed catalyst bed of claim 1 wherein said catalyst bed has a silver loading of at most 550 kg of silver/m³ of catalyst bed.

8. The packed catalyst bed of claim 1 wherein said silver on said catalyst particles exceeds 8 weight percent of the weight of the catalyst.

9. The packed catalyst bed of claim 1 wherein said silver on said catalyst particles exceeds 10 weight percent of the weight of the catalyst.

10. The packed catalyst bed of claim 1 wherein said silver on said catalyst particles exceeds 12 weight percent of the weight of the catalyst.

11. The packed catalyst bed of claim 10 wherein said catalyst bed has a silver loading of at least 250 kg and of at most 550 kg of silver/m³ of catalyst bed.