Epoxidation processes

• US 8,716,504 B2
• Filed: 09/06/2013
• Issued: 05/06/2014
• Est. Priority Date: 04/21/2009
• Status: Active Grant

• Current Assignee: Dow Technology Investments LLC (Dow, Inc.)
• Original Assignee: Dow Technology Investments LLC (Dow, Inc.)
• Inventors: Liu, Albert C., Soo, Hwaili
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US14/020,528
• Publication Number:
  US 20140012019A1
• Time in Patent Office: 242 Days
• Field of Search: 549/534, 549/536, 502/241, 502/250, 502/254, 502/255, 502/355, 502/415, 502/439
• US Class Current: 549/534
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/6567 Rhenium
• CPC Class Codes: B01J 35/612 less than 10 m2/g
• CPC Class Codes: B01J 35/635 0.5-1.0 ml/g
• CPC Class Codes: B01J 35/657 larger than 1000 nm
• CPC Class Codes: B01J 37/0201 Impregnation
• CPC Class Codes: B01J 37/0203 the impregnation liquid containing organic compounds
• CPC Class Codes: B01J 37/0207 Pretreatment of the support
• CPC Class Codes: B01J 37/0213 Preparation of the impregnating solution
• CPC Class Codes: B01J 37/26 Fluorinating
• CPC Class Codes: C07C 213/04 by reaction of ammonia or amines with olefin oxides or halohydrins
• CPC Class Codes: C07C 29/00 Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
• CPC Class Codes: C07C 41/03 by reaction of oxirane rings with hydroxy groups
• CPC Class Codes: C07D 301/10 with catalysts containing silver or gold
• CPC Class Codes: C07D 317/36 Alkylene carbonates; Substituted alkylene carbonates

Abstract

The present invention provides rhenium-promoted epoxidation catalysts based upon shaped porous bodies comprising a minimized percentage of their total pore volume being present in pores having diameters of less than one micron, and a surface area of at least about 1.0 m²/g. Processes of making the catalysts and using them in epoxidation processes are also provided.

Claims

1. An epoxidation process, comprising reacting, under epoxidation conditions, a feed comprising ethylene and oxygen in the presence of an epoxidation catalyst comprising silver and a promoting amount of rhenium deposited on a shaped porous body, wherein the shaped porous body comprises less than 20% of its total pore volume being present in pores having diameters of less than 1 micron, and a surface area of at least about 1.3 m²/g, wherein the catalyst exhibits a higher activity and/or selectivity when used in the process than a catalyst supported on shaped porous bodies having a greater percentage of their total pore volume in pores having diameters of less than one micron.

2. The process of claim 1, carried out in the gas phase.

3. The process of claim 2, conducted at a temperature of from 200°

C. to 300°

C.

4. The process of claim 2 or 3, conducted at a pressure of from ambient to 3.0 MPa.

5. The process of claim 1, further comprising converting the ethylene oxide produced into a 1,2-diol, 1,2-diol ether, a 1,2-carbonate, or alkanolamine.

6. The process of claim 5, wherein the conversion comprises reacting the ethylene oxide with water and/or alcohol to produce one or more 1,2-diols or 1,2-diol ethers.

7. The process of claim 6, wherein reaction of ethylene oxide and water is conducted in the presence of an acidic catalyst comprising 0.5 wt. % to 1.0 wt. % sulfuric acid.

8. The process of claim 6 or 7, wherein the process is conducted in the liquid phase at a temperature of from 50°

C. to 70°

C.

9. The process of claim 6 or 7, wherein the process is conducted in the gas phase at a temperature of from 130°

C. to 240°

C.

10. The process of claim 5, wherein the conversion comprises reacting the ethylene oxide with ammonia to produce one or more alkanolamines.

11. The process of claim 10, wherein anhydrous ammonia is used and a monoalkanolamine is produced.

12. The process of claim 5, wherein the conversion comprises reacting the ethylene oxide with carbon dioxide to provide a 1,2-carbonate.