Ethylene oxide catalyst and process
First Claim
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1. A catalyst suitable for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver and a promoting amount of alkali metal(s) deposited on a carrier prepared by a process which comprises:
- a) providing a mixture consisting essentially of;
i) ceramic components comprising at least about 80 percent by weight of alpha alumina, from about 0.01 percent by weight to about 10 percent by weight (measured as the oxide, MO) of an alkaline earth metal oxide, from about 0.01 percent by weight to about 10 percent by weight (measured as the silica) of a silicon oxide, and from about zero to about 15 percent by weight (measured as the dioxide) of zirconium in the form of an oxide;
ii) a liquid carrier medium in an amount to render the mixture shapable; and
iii) a total amount of from zero to about 15 percent by weight of ceramic bond, lubricant and/or forming aids;
b) shaping the mixture to form a carrier precursor;
c) drying the carrier precursor to remove the liquid from the carrier medium; and
d) firing the precursor to form a carrier with a porosity of from about 15 percent to about 60 percent, wherein the particle sizes of the ceramic components are chosen such that the packing density of the dried precursor is not greater than that of the fired carrier.
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Abstract
This invention relates to an ethylene oxide catalyst which contains silver and one or more alkali metal promoters supported on a carrier prepared by a process comprising the use of ceramic particle components with particle sizes chosen to ensure that a desired degree of porosity is obtained without the use of organic burnout materials.
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Citations
26 Claims
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1. A catalyst suitable for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver and a promoting amount of alkali metal(s) deposited on a carrier prepared by a process which comprises:
- a) providing a mixture consisting essentially of;
i) ceramic components comprising at least about 80 percent by weight of alpha alumina, from about 0.01 percent by weight to about 10 percent by weight (measured as the oxide, MO) of an alkaline earth metal oxide, from about 0.01 percent by weight to about 10 percent by weight (measured as the silica) of a silicon oxide, and from about zero to about 15 percent by weight (measured as the dioxide) of zirconium in the form of an oxide;
ii) a liquid carrier medium in an amount to render the mixture shapable; and
iii) a total amount of from zero to about 15 percent by weight of ceramic bond, lubricant and/or forming aids;
b) shaping the mixture to form a carrier precursor;
c) drying the carrier precursor to remove the liquid from the carrier medium; and
d) firing the precursor to form a carrier with a porosity of from about 15 percent to about 60 percent, wherein the particle sizes of the ceramic components are chosen such that the packing density of the dried precursor is not greater than that of the fired carrier. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
- a) providing a mixture consisting essentially of;
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13. A catalyst suitable for the vapor phase production of ethylene oxide from ethylene and oxygen comprising a catalytically effective amount of silver and a promoting amount of alkali metal deposited on a carrier prepared by a process which comprises:
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a) providing a mixture consisting essentially of; i) ceramic components comprising at least about 90 percent by weight of alpha alumina, from about 0.01 percent by weight to about 10.0 percent by weight (measured as the oxide, MO) of an alkaline earth metal oxide, from about 0.01 percent by weight to about 10.0 percent by weight (measured as the silica) of a silicon oxide, and from about zero to about 15 percent by weight (measured as the dioxide) of zirconium in the form of an oxide; ii) a liquid carrier medium in an amount to render the mixture shapable; and iii) a total amount of from zero to about 15 percent by weight of ceramic bond, lubricant and/or forming aids; b) shaping the mixture to form a carrier precursor; c) drying the carrier precursor to remove the liquid from the carrier medium; and d) firing the precursor to form a carrier with a porosity of from about 15 percent to about 60 percent, wherein the particle sizes of the ceramic components are chosen such that the packing density of the dried precursor is not greater than that of the fired carrier. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A process for the production of ethylene oxide wherein ethylene is contacted in the vapor phase with an oxygen-containing gas at ethylene oxide forming conditions at a temperature in the range of from about 180°
- C. to about 330°
C. in the presence of a catalyst comprising a catalytically effective amount of silver and a promoting amount of alkali metal deposited on a carrier prepared by a process which comprises;
a) providing a mixture consisting essentially of;
i) ceramic components comprising at least about 80 percent by weight of alpha alumina, from about 0.01 percent by weight to about 10 percent by weight (measured as the oxide, MO) of an alkaline earth metal oxide, from about 0.01 percent by weight to about 10 percent by weight (measured as the silica) of a silicon oxide, and from about zero to about 15 percent by weight (measured as the dioxide) of zirconium in the form of an oxide;
ii) a liquid carrier medium in an amount to render the mixture shapable; and
iii) a total amount of from zero to about 15 percent by weight of ceramic bond, lubricant and/or forming aids;
b) shaping the mixture to form a carrier precursor;
c) drying the carrier precursor to remove the liquid from the carrier medium; and
d) firing the precursor to form a carrier with a porosity of from about 15 percent to about 60 percent, wherein the particle sizes of the ceramic components are chosen such that the packing density of the dried precursor is not greater than that of the fired carrier.
- C. to about 330°
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26. A process for the epoxidation of olefins having no allylic hydrogens wherein an olefin having no allylic hydrogen is contacted in the vapor phase with an oxygen-containing gas at epoxide forming conditions at a temperature in the range of from about 75°
- C. to about 325°
C. in the presence of an organic halide and a catalyst comprising a catalytically effective amount of silver and a promoting amount of alkali metal deposited on a carrier prepared by a process which comprises;
a) providing a mixture consisting essentially of;
i) ceramic components comprising at least about 80 percent by weight of alpha alumina, from about 0.01 percent by weight to about 10 percent by weight (measured as the oxide, MO) of an alkaline earth metal oxide, from about 0.01 percent by weight to about 10 percent by weight (measured as the silica) of a silicon oxide, and from about zero to about 15 percent by weight (measured as the dioxide) of zirconium in the form of an oxide;
ii) a liquid carrier medium in an amount to render the mixture shapable; and
iii) a total amount of from zero to about 15 percent by weight of ceramic bond, lubricant and/or forming aids;
b) shaping the mixture to form a carrier precursor;
c) drying the carrier precursor to remove the liquid from the carrier medium; and
d) firing the precursor to form a carrier with a porosity of from about 15 percent to about 60 percent, wherein the particle sizes of the ceramic components are chosen such that the packing density of the dried precursor is not greater than that of the fired carrier.
- C. to about 325°
Specification