Catalysts having enhanced stability, efficiency and/or activity for alkylene oxide production

a technology of alkylene oxide and catalyst, which is applied in the direction of physical/chemical process catalyst, metal/metal-oxide/metal-hydroxide catalyst, bulk chemical production, etc., can solve the problems of catalyst replacement or regeneration, loss of production time, time, productivity and materials, and unacceptable low efficiency and/or activity of catalyst, etc., to achieve the effect of improving the activity, efficiency and/or stability of the resultant catalys

Inactive Publication Date: 2007-05-17
DOW TECH INVESTMENTS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0016] While the present invention should be understood as being unconstrained by any particular theory, it is believed that the zirconium silicate (commonly referred to as zircon), added as an ingredient with other raw materials used to form the carrier support, survives the rigors of the calcining process without being oxidized or otherwise undergoing a substantial chemical change, and thereby becomes an integral part of the modified carrier, ultimately contributing to the favorable and unexpected characteristics observed in catalysts of the present invention employing such modified carriers.
[0017] A key distinguishing feature of the present invention is the use of zirconium silicate with other raw materials to modify the inert, refractory solid support (such ...

Problems solved by technology

When the efficiency and/or activity of a catalyst has declined to an unacceptably low level, typically the reactor must be shut down and partially dismantled to remove the catalyst.
This results in losses in time, productivity and materials, for...

Method used

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  • Catalysts having enhanced stability, efficiency and/or activity for alkylene oxide production

Examples

Experimental program
Comparison scheme
Effect test

example 1

Catalyst 1 and Comparative Catalyst 2

[0087] Eighty cubic centimeters of each catalyst (61.4 g.) was charged to an autoclave reactor and tested under Air Process Conditions—I (Table I). Outlet ethylene oxide was set to 1.2 mole percent until day 6 when it was increased to 1.4 mole percent. Table IV compares the performance of the catalyst containing 2 weight percent zircon (Catalyst 1) with one containing no zircon (Comparative Catalyst 2). The catalyst containing zircon has higher initial efficiency and lower initial temperature (higher activity).

TABLE IVExample 1 Catalyst PerformanceEfficiency %Temp. ° C.2 Mlb5 Mlb7 Mlb2 Mlb5 Mlb7 MlbEO / CFEO / CFEO / CFEO / CFEO / CFEO / CFCatalyst 176.474.771.7260269280Catalyst 274.873.471.6266274281(comparative)

example 2

Catalyst 3 and Comparative Catalyst 4

[0088] An equal weight (63.5 g.) of each catalyst was charged to an autoclave reactor and tested under the Air Process Conditions—I described in Table I. The outlet ethylene oxide was set to 1.4 mole percent and temperature and efficiency monitored as the catalysts aged. Table V compares performance of the two catalysts as a function of pounds of EO produced per cubic foot of catalyst. Although the initial efficiency is lower than the comparative catalyst, over time, the zircon-containing catalyst ages in efficiency and temperature at a slower rate.

TABLE VExample 2 Catalyst PerformanceEfficiency %Temp. ° C.8 Mlb20 Mlb35 Mlb8 Mlb20 Mlb35 MlbEO / CFEO / CFEO / CFEO / CFEO / CFEO / CFCatalyst 378.277.777.2249253256Catalyst 479.978.475.9243251259(comparative)

example 3

Catalyst 5 and Comparative Catalyst 6

[0089] An equal weight (63.5 g.) of each catalyst was tested in an autoclave under Oxygen Process Conditions—I (Table I). Outlet ethylene oxide concentration was set to 1.0 mole percent. Catalyst 5 has higher efficiency and lower temperature compared to Comparative Catalyst 6, which does not contain zircon.

TABLE VIExample 3 Catalyst PerformanceEfficiency (%)Temp. (° C.)1 Mlb2.5 Mlb1 Mlb2.5 MlbEO / CFEO / CFEO / CFEO / CFCatalyst 580.480.0232230Catalyst 676.677.7253253(comparative)

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Abstract

A catalyst for the manufacture of alkylene oxide, for example ethylene oxide, by the vapor-phase epoxidation of alkene containing impregnated silver and at least one efficiency-enhancing promoter on an inert, refractory solid support, said support incorporating a sufficient amount of zirconium component (present and remaining substantially as zirconium silicate) as to enhance at least one of catalyst activity, efficiency and stability as compared to a similar catalyst which does not contain the zirconium component.

Description

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60 / 511,975, filed Oct. 16, 2003.FIELD OF INVENTION [0002] This invention relates to catalysts for the epoxidation of alkene, especially ethylene, to the corresponding alkylene oxide, for example, ethylene oxide, which have enhanced stability, efficiency and / or activity by incorporating sufficient amount of a zirconium component substantially as zirconium silicate. BACKGROUND OF THE INVENTION [0003] The production of alkylene oxide, such as ethylene oxide, by the reaction of oxygen or oxygen-containing gases with ethylene in the presence of a silver-containing catalyst at elevated temperature is an old and well-known art. For example, U.S. Pat. No. 2,040,782, dated May 12, 1936, describes the manufacture of ethylene oxide by the reaction of oxygen with ethylene in the presence of silver catalysts which contain a class of metal-containing promoters. In Reis...

Claims

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Application Information

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IPC IPC(8): B01J23/50B01J23/48B01J21/06B01J23/66B01J23/68B01J37/00B01J37/02C07D301/10
CPCB01J21/066B01J23/50B01J23/66B01J23/686B01J23/688C07D301/10B01J35/1042B01J35/1076B01J37/0018B01J37/0201B01J37/0203B01J35/1009Y02P20/52
Inventor SERAFIN, JULIANA G.LIU, ALBERT C.SEYEDMONIR, SEYED R.SOO, HWAILISZYMANSKI, THOMAS
Owner DOW TECH INVESTMENTS
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