Ethylene oxide catalyst and process for preparing the catalyst
First Claim
1. An ethylene oxide catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver, a promoting amount of alkali metal and a promoting amount of rhenium and a promoting amount of rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a suitable support having a surface area ranging from about 0.05 to about 10 m2 /g.
1 Assignment
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Accused Products
Abstract
This invention relates to an ethylene oxide catalyst having an improved selectivity which catalyst comprises silver, a promoting amount of alkali metal, a promoting amount of rhenium and a promoting amount of rhenium co-promotor selected from sulfur, molbydenum, tungsten, chromium and mixtures thereof supported on a porous refractory support.
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Citations
136 Claims
- 1. An ethylene oxide catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver, a promoting amount of alkali metal and a promoting amount of rhenium and a promoting amount of rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a suitable support having a surface area ranging from about 0.05 to about 10 m2 /g.
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2. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium promoter, measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof supported on a porous, refractory support;
- the combination of silver, alkali metal promoter, rhenium promoter, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
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3. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof, supported on a porous, refractory support wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
- View Dependent Claims (15, 16, 17, 18)
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4. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support;
- the combination of silver, alkali metal promoter, rhenium and rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
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5. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptooxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
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22. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium promoter, measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g;
- the combination of silver, alkali metal promoter, rhenium promoter, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
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23. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof, supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
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24. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g;
- the combination of silver, alkali metal promoter, rhenium and rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
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25. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, alkali metal promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
- 26. An ethylene oxide catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver, a promoting amount of a higher alkali metal comprising potassium, rubidium, cesium, or mixtures thereof, a promoting amount of rhenium and a promoting amount of a rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof, supported on a suitable support having a surface area ranging from about 0.05 to about 10 m2 /g.
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27. An ethylene oxide catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver, a promoting amount of a higher alkali metal selected from the group consisting of potassium, rubidium, cesium and mixtures thereof, a promoting amount of rhenium and a promoting amount of a rhenium co-promoter selected from the group consisting of sulfur, molybdenum, tungsten, chromium and mixtures thereof, supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g.
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28. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element per kilogram of total catalyst, of a rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof supported on a porous, refractory support;
- the combination of silver, higher alkali metal promoter, rhenium promoter, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
- View Dependent Claims (57, 58, 59, 60, 61, 62, 63, 64, 65)
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29. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
- View Dependent Claims (69)
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30. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support;
- the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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31. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof, supported on a porous, refractory support wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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32. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of a higher alkali metal promoter selected from potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/gm;
- the combination of silver, higher alkali metal, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
- View Dependent Claims (66, 67, 68, 70, 71, 72)
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33. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of a higher alkali metal promoter selected from potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/gm wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, higher alkali metal, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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34. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of a higher alkali metal promoter selected from potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/gm;
- the combination of silver, higher alkali metal, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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35. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of a higher alkali metal promoter selected from potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molbydenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/gm wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, higher alkali metal, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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36. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element per kilogram of total catalyst, of a rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g;
- the combination of silver, higher alkali metal promoter, rhenium promoter, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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37. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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38. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g;
- the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
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39. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising silver, a higher alkali metal promoter comprising potassium, rubidium, cesium or mixtures thereof, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof, supported on a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g wherein the rhenium is applied to the support in the form of a perrhenate or rhenium heptoxide and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
- 73. An ethylene oxide catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof on a porous refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g.
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74. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of cesium promoter, from about 0.2 to about 5 millimoles of rhenium promoter, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/gm;
- the combination of silver, cesium promoter, rhenium promoter, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
- View Dependent Claims (83)
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75. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of cesium promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/g wherein the rhenium is applied to the support as ammonium or alkali metal perrhenate or rhenium heptoxide or mixtures thereof and the rhenium co-promoter is applied to the support in the form of an oxidic compound or an oxyanion;
- the combination of silver, cesium promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
- View Dependent Claims (84)
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76. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of cesium promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/gm;
- the combination of silver, cesium, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
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77. A catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen comprising from about 1 to about 25 percent by weight of total catalyst of silver, from about 50 to about 1000 parts by weight, measured as the metal, per million parts by weight of total catalyst of cesium promoter, from about 0.2 to about 5 millimoles of rhenium, measured as the metal, per kilogram of total catalyst in a form which is extractable in a dilute (20 millimolar) aqueous solution of sodium hydroxide and from about 0.2 to about 5 millimoles measured as the element, per kilogram of total catalyst, of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof supported on a porous refractory support comprising alpha alumina having a surface area ranging from about 0.1 to about 3 m2 /g and a water pore volume ranging from about 0.25 to about 0.55 cc/g wherein the rhenium is applied to the support as ammonium or alkali metal perrhenate or rhenium heptoxide or mixtures thereof and the rhenium co-promoter is applied to the support as a sulfate, sulfite, sulfonate, molybdate, tungstate, chromate and mixtures thereof;
- the combination of silver, cesium promoter, rhenium, rhenium co-promoter and support affording a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
- 87. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support with a catalytically effective amount of silver, a promoting amount of alkali metal, a promoting amount of rhenium and a promoting amount of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof.
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88. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen which comprises impregnating a porous refractory support with one or more solutions comprising silver, alkali metal, rhenium and/or a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof wherein the concentration of the silver (measured as the metal) in the solution ranges from about 1 g/l to the solubility limit of silver in the solution, the concentration of alkali metal (measured as the metal) in the solution ranges from about 1×
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
10-3 g/l to about 20 g/l and the concentration of rhenium co-promoter (measured as the element) ranges from about 1×
10-3 g/l to about 20 g/l to provide the catalyst with a catalytically effective amount of silver, a promoting amount of alkali metal, a promoting amount of rhenium, and a promoting amount of rhenium co-promoter.
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
- 89. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support with one or more solutions comprising solvent having silver compound(s) dissolved therein, and/or alkali metal compound(s) dissolved therein and/or rhenium-containing compound(s) dissolved therein and/or rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof dissolved therein sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver compound(s), measured as the metal, from about 20 to about 1500 ppm by weight of alkali metal compound(s), measured as the metal, from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the metal, of rhenium-containing compound(s) and from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the element, of rhenium co-promoter compound(s) to provide the catalyst with a catalytically effective amount of silver, a promoting amount of alkali metal, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
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90. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support with one or more solutions comprising silver ions, alkali metal ions, rhenium-containing ions, rhenium co-promoter ions selected from ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the carrier from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of alkali metal compound(s), from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, alkali metal promoter, rhenium, rhenium co-promotor and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
-
91. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support with one or more solutions comprising silver ions, alkali metal ions, rhenium-containing ions, rhenium co-promoter ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of alkali metal compound(s), from about 0.2 to about 5 millimoles of rhenium compound(s), measured as the metal, per kilogram of total catalyst, said rhenium compound(s) providing in the final catalyst rhenium in a form which is extractable in a dilute (20 millimolar) aqueous sodium hydroxide solution and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter compound(s) selected from compound(s) containing sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
-
92. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina with a catalytically effective amount of silver, a promoting amount of higher alkali metal comprising potassium, rubidium, cesium or mixtures thereof, a promoting amount of rhenium and a promoting amount of rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium and mixtures thereof.
-
93. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina with one or more solutions comprising silver, higher alkali metal selected from the group consisting of potassium, rubidium, cesium and mixtures thereof, rhenium and/or rhenium co-promoter selected from the group consisting of sulfur, molybdenum, tungsten, chromium and mixtures thereof wherein the concentration of the silver (measured as the metal) in the solution ranges from about 1 g/l to the solubility limit of silver in the solution, the concentration of alkali metal (measured as the metal) in the solution ranges from about 1×
- 10-3 to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
10-3 g/l to about 20 g/l and the concentration of rhenium co-promoter (measured as the element) ranges from about 1×
10-3 g/l to about 20 g/l to provide the catalyst with a catalytically effective amount of silver, a promoting amount of higher alkali metal, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
- 10-3 to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
-
94. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina with one or more solutions comprising solvent having silver compound(s) dissolved therein, and/or higher alkali metal compound(s) selected from compound(s) of potassium, rubidium, cesium and mixtures thereof dissolved therein and/or rhenium-containing compound(s) dissolved therein and/or rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof dissolved therein sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver compound(s), measured as the metal, from about 20 to about 1500 ppm by weight of higher alkali metal compound(s), measured as the metal, from about 0.2 to about 5 millimoles per kilogram of total catalyst of rhenium-containing compound(s), measured as the metal and from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the element, of rhenium co-promoter compound(s) to provide a catalyst with a catalytically effective amount of silver, a promoting amount of higher alkali metal, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
-
95. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina with one or more solutions comprising silver ions, higher alkali metal ions selected from the group consisting of ions of potassium, rubidium, cesium and mixtures thereof, rhenium-containing ions, rhenium co-promoter ions selected from ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of higher alkali metal compound(s) selected from compound(s) of potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
-
96. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina with one or more solutions comprising silver ions, higher alkali metal ions selected from the group consisting of ions of potassium, rubidium, cesium and mixtures thereof, rhenium-containing ions, rhenium co-promoter ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of higher alkali metal compound(s) selected from compound(s) of potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, said rhenium-containing compound(s) providing in the final catalyst rhenium in a form which is extractable in a dilute (20 millimolar) aqueous sodium hydroxide solution and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) containing sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, higher alkali metal, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
-
97. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina with a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof.
-
98. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen which comprises impregnating a porous refractory support comprising alpha alumina with one or more solutions comprising silver, cesium, rhenium and/or rhenium co-promoter selected from the group consisting of sulfur, molybdenum, tungsten, chromium and mixtures thereof wherein the concentration of the silver (measured as the metal) in the solution ranges from about 1 g/l to the solubility limit of silver in the solution, the concentration of cesium (measured as the metal) in the solution ranges from about 1×
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
10-3 g/l to about 20 g/l and the concentration of rhenium co-promoter (measured as the element) ranges from about 1×
10-3 g/l to about 20 g/l to provide the catalyst with a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
-
99. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which comprises impregnating a porous refractory support comprising alpha alumina with one or more solutions comprising solvent having silver compound(s) dissolved therein, cesium compound(s) dissolved therein, rhenium-containing compound(s) dissolved therein and rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof dissolved therein sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of the silver compound(s), measured as the metal, from about 20 to about 1500 ppm by weight of cesium compound(s) measured as the metal, from about 0.2 to about 5 millimoles per kilogram of total catalyst of rhenium-containing compound(s), measured as the metal, and from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the element, of rhenium co-promoter compound(s) to provide the catalyst with a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
- 100. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina with one or more solutions comprising silver ions, cesium ions, rhenium-containing ions, rhenium co-promoter ions selected from ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal per million parts by weight of total catalyst, of cesium, from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, cesium, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
-
101. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina with one or more solutions comprising silver ions, cesium ions, rhenium-containing ions, rhenium co-promoter ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof, sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of cesium compound(s), from about 0.2 to about 5 millimoles of a rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, said rhenium-containing compound(s) providing in the final catalyst rhenium in a form which is extractable in a dilute (20 millimolar) aqueous sodium hydroxide solution and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter compound(s) containing sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, cesium, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
-
122. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support having a surface area ranging from about 0.05 to about 10 m2 /g with a catalytically effective amount of silver, a promoting amount of alkali metal, a promoting amount of rhenium and a promoting amount of a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof.
-
123. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen which comprises impregnating a porous refractory support having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver, alkali metal, rhenium and/or a rhenium co-promoter selected from sulfur, molybdenum, tungsten, chromium and mixtures thereof wherein the concentration of the silver (measured as the metal) in the solution ranges from about 1 g/l to the solubility limit of silver in the solution, the concentration of alkali metal (measured as the metal) in the solution ranges from about 1×
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
10-3 g/l to about 20 g/l and the concentration of rhenium co-promoter (measured as the element) ranges from about 1×
10-3 g/l to about 20 g/l to provide the catalyst with a catalytically effective amount of silver, a promoting amount of alkali metal, a promoting amount of rhenium, and a promoting amount of rhenium co-promoter.
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
-
124. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising solvent having silver compound(s) dissolved therein, and/or alkali metal compound(s) dissolved therein and/or rhenium-containing compound(s) dissolved therein and/or rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof dissolved therein sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver compound(s), measured as the metal, from about 20 to about 1500 ppm by weight of alkali metal compound(s), measured as the metal, from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the metal, of rhenium-containing compound(s) and from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the element, of rhenium co-promoter compound(s) to provide the catalyst with a catalytically effective amount of silver, a promoting amount of alkali metal, a promoting amount of rhenium and a promoting amount(s) of rhenium co-promoter(s).
-
125. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver ions, alkali metal ions, rhenium-containing ions, rhenium co-promoter ions selected from ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the carrier from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of alkali metal compound(s), from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s), selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
-
126. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver ions, alkali metal ions, rhenium-containing ions, rhenium co-promoter ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of alkali metal compound(s), from about 0.2 to about 5 millimoles of rhenium compound(s), measured as the metal, per kilogram of total catalyst, said rhenium compound(s) providing in the final catalyst rhenium in a form which is extractable in a dilute (20 millimolar) aqueous sodium hydroxide solution and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter compound(s) selected from compound(s) containing sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, alkali metal promoter, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from alkali metal, rhenium and rhenium co-promoter.
-
127. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with a catalytically effective amount of silver, a promoting amount of higher alkali metal comprising potassium, rubidium, cesium or mixtures thereof, a promoting amount of rhenium and a promoting amount of rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium and mixtures thereof.
-
128. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver, higher alkali metal selected from the group consisting of potassium, rubidium, cesium and mixtures thereof, rhenium and/or rhenium co-promoter selected from the group consisting of sulfur, molybdenum, tungsten, chromium and mixtures thereof wherein the concentration of the silver (measured as the metal) in the solution ranges from about 1 g/l to the solubility limit of silver in the solution, the concentration of alkali metal (measured as the metal) in the solution ranges from about 1×
- 10-3 to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
10-3 g/l to about 20 g/l and the concentration of rhenium co-promoter (measured as the element) ranges from about 1×
10-3 g/l to about 20 g/l to provide the catalyst with a catalytically effective amount of silver, a promoting amount of higher alkali metal, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
- 10-3 to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
-
129. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising solvent having silver compound(s) dissolved therein, and/or higher alkali metal compound(s) selected from compound(s) of potassium, rubidium, cesium and mixtures thereof dissolved therein and/or rhenium-containing compound(s) dissolved therein and/or rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof dissolved therein sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver compound(s), measured as the metal, from about 20 to about 1500 ppm by weight of higher alkali metal compound(s), measured as the metal, from about 0.2 to about 5 millimoles per kilogram of total catalyst of rhenium-containing compound(s), measured as the metal and from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the element, of rhenium co-promoter compound(s) to provide a catalyst with a catalytically effective amount of silver, a promoting amount of higher alkali metal, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
-
130. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver ions, higher alkali metal ions selected from the group consisting of ions of potassium, rubidium, cesium and mixtures thereof, rhenium-containing ions, rhenium co-promoter ions selected from ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of higher alkali metal compound(s) selected from compound(s) of potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, higher alkali metal promoter, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
-
131. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver ions, higher alkali metal ions selected from the group consisting of ions of potassium, rubidium, cesium and mixtures thereof, rhenium-containing ions, rhenium co-promoter ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of higher alkali metal compound(s) selected from compound(s) of potassium, rubidium, cesium and mixtures thereof, from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, said rhenium-containing compound(s) providing in the final catalyst rhenium in a form which is extractable in a dilute (20 millimolar) aqueous sodium hydroxide solution and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) containing sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, higher alkali metal, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from higher alkali metal, rhenium and rhenium co-promoter.
-
132. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous refractory support comprising alpha alumina having a surface are ranging from about 0.05 to about 10 m2 /g with a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter comprising sulfur, molybdenum, tungsten, chromium or mixtures thereof.
-
133. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and oxygen which comprises impregnating a porous refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver, cesium, rhenium and/or rhenium co-promoter selected from the group consisting of sulfur, molybdenum, tungsten, chromium and mixtures thereof wherein the concentration of the silver (measured as the metal) in the solution ranges from about 1 g/l to the solubility limit of silver in the solution, the concentration of cesium (measured as the metal) in the solution ranges from about 1×
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
10-3 g/l to about 20 g/l and the concentration of rhenium co-promoter (measured as the element) ranges from about 1×
10-3 g/l to about 20 g/l to provide the catalyst with a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
- 10-3 g/l to about 12 g/l, the concentration of the rhenium (measured as the metal) ranges from about 5×
-
134. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which comprises impregnating a porous refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising solvent having silver compound(s) dissolved therein, cesium compound(s) dissolved therein, rhenium-containing compound(s) dissolved therein and rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof dissolved therein sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of the silver compound(s), measured as the metal, from about 20 to about 1500 ppm by weight of cesium compound(s) measured as the metal, from about 0.2 to about 5 millimoles per kilogram of total catalyst of rhenium-containing compound(s), measured as the metal, and from about 0.2 to about 5 millimoles per kilogram of total catalyst, measured as the element, a rhenium co-promoter compound(s) to provide the catalyst with a catalytically effective amount of silver, a promoting amount of cesium, a promoting amount of rhenium and a promoting amount of rhenium co-promoter.
-
135. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver ions, cesium ions, rhenium-containing ions, rhenium co-promoter ions selected from ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal per million parts by weight of total catalyst, of cesium, from about 0.2 to about 5 millimoles of rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst of rhenium co-promoter compound(s) selected from compound(s) of sulfur, molybdenum, tungsten, chromium and mixtures thereof and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, cesium, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
-
136. A process for preparing a catalyst for the vapor phase production of ethylene oxide from ethylene and molecular oxygen which process comprises impregnating a porous, refractory support comprising alpha alumina having a surface area ranging from about 0.05 to about 10 m2 /g with one or more solutions comprising silver ions, cesium ions, rhenium-containing ions, rhenium co-promoter ions containing sulfur, molybdenum, tungsten, chromium and mixtures thereof or mixtures of any of the aforementioned ions thereof, sufficient to deposit on the support from about 1 to about 25 percent by weight of total catalyst of silver, from about 20 to about 1500 parts by weight, measured as the metal, per million parts by weight of total catalyst, of cesium compound(s), from about 0.2 to about 5 millimoles of a rhenium-containing compound(s), measured as the metal, per kilogram of total catalyst, said rhenium-containing compound(s) providing in the final catalyst rhenium in a form which is extractable in a dilute (20 millimolar) aqueous sodium hydroxide solution and from about 0.2 to about 5 millimoles, measured as the element, per kilogram of total catalyst, of rhenium co-promoter compound(s) containing sulfur, molybdenum, tungsten, chromium and mixtures thereof;
- and after impregnation, reducing the silver on the support to metallic silver to cause the combination of silver, cesium, rhenium, rhenium co-promoter and support to have a higher selectivity to ethylene oxide at a given oxygen conversion level than is obtained under the same reaction conditions with the same combination of silver and support and none, one or two of the promoters selected from cesium, rhenium and rhenium co-promoter.
Specification