Catalyst support

Abstract

A support for a catalyst is described. The carrier is used in a packed bed reactor for the production of alkylene oxides. The support comprises a ceramic material, the pore size distribution of the support is that < = 2% of pores have a pore size < = 0.1 [mu] m, and / or the support has a specific surface area of at least 1.5 m2 / g, and / or the support has a total pore volume > = 0.4 cm3 / g. A catalyst comprising the support and a method for producing an alkylene oxide are also described.

Description

Technical Field

[0001] The present invention relates to a carrier and a supported catalyst for a catalyst. More specifically, the present invention relates to a carrier and a supported catalyst for producing alkylene oxide. The present invention extends to a method for producing alkylene oxide using the catalyst. Background Art

[0002] Ethylene oxide is an important industrial chemical used as a disinfectant, sterilant and fumigant, and is also an intermediate in the production of ethylene glycol, polyethylene glycol and various amines.

[0003] Ethylene oxide is produced in large quantities worldwide by direct catalytic oxidation of ethylene using oxygen or air in the presence of a silver catalyst. This oxidation reaction occurs readily but tends to go further than desired, completely oxidizing the feed ethylene and product ethylene oxide to a mixture of carbon dioxide and water. Therefore, the main focus of the catalyst in this process is selectivity, that is, the ability to produce as much of the desired ethylene oxide as possible and minimize carbon dioxide and water.

[0004] Typically, the catalyst used in this process is a supported silver catalyst containing about 7% to 20% silver. The catalyst shape is usually produced by extruding a ceramic paste or pellet, which is then dried and calcined to a temperature sufficient to provide the required strength.

[0005] Catalyst supports with high specific surface area can increase activity and allow higher volumes to be produced, however using common catalyst production methods increasing surface area is often achieved by reducing pore diameter, thereby losing the desired selectivity. To increase surface area, the size of the support pellets is often reduced, but this increases the pressure drop through the packed bed, which is limited by the capacity of the production facility.

[0006] Therefore, there is a need for further improvements in catalysts for producing alkylene oxides.It is therefore an object of various aspects of the present invention to address one or more of the above or other problems. Summary of the invention

[0007] According to a first aspect of the present invention, there is provided a carrier for a catalyst, wherein the carrier comprises a surface structure, wherein the carrier comprises a ceramic material; and wherein the pore size distribution of the carrier is: ≤2% of the pores have a pore size ≤0.1 μm, and / or the carrier has a pore size of at least 1.5 μm. 2 / g, and / or the carrier has a specific surface area of ​​≥0.4cm 3 / g total pore volume.

[0008] According to another aspect of the present invention, there is provided a carrier for a catalyst, wherein the carrier comprises a surface structure, and wherein the carrier comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of:

[0009] Particle size fraction Y; and / or particle size fraction Z; and / or the remainder;

[0010] wherein, when particle size fraction Y is present, particle size fraction Y comprises ceramic particles having a D50 particle size of ≤ 40% of the D50 particle size of particle size fraction X,

[0011] Wherein, when particle size fraction Z is present, particle size fraction Z comprises ceramic particles having a D50 particle size of ≥ 300% of the D50 particle size of particle size fraction X.

[0012] According to another aspect of the present invention, there is provided a carrier for a catalyst, wherein the carrier comprises a surface structure, and wherein the carrier comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of:

[0013] a particle size fraction Y comprising ceramic particles having a D50 particle size of at most 1 μm; and / or a particle size fraction Z comprising ceramic particles having a D50 particle size of at least 15 μm; and / or the remainder;

[0014] Wherein, when particle size fraction Y is present, the D50 particle size of particle size fraction Y is smaller than the D50 particle size of particle size fraction X,

[0015] Wherein, when particle size fraction Z exists, the D50 particle size of particle size fraction Z is greater than the D50 particle size of particle size fraction X.

[0016] The support may be a gel casting support.

[0017] The support may have a substantially spherical and / or ellipsoidal macrostructure.

[0018] The pore size distribution of the support may be such that ≤2% of the pores have a pore size ≤0.1 μm, such as ≤1.5%, ≤1%, ≤0.75%, or ≤0.5%. The support advantageously has improved crush strength and provides improved selectivity as a catalyst. The pore size distribution of the support may be such that ≤25% of the pores have a pore size ≥10 μm, such as ≤20%, ≤15%, ≤10%, or ≤5%. The support advantageously has increased catalyst distribution throughout the support, improved selectivity, and increased catalyst life.

[0019] The carrier may have a length of at least 1.5 m 2 / g specific surface area, for example at least 1.6 m 2 / g, at least 1.7m 2 / g or at least 1.8m 2 / g. The carrier may have a maximum of 3m2 / g specific surface area, for example, up to 2.75m 2 / g, up to 2.5m 2 / g, up to 2.25m 2 / g or up to 2.1m 2 / g. The carrier may have a molecular weight of 1.5 to 3 m 2 / g specific surface area, for example, 1.6 to 2.75 m 2 / g, 1.7 to 2.5m 2 / g, 1.8 to 2.25m 2 / g, or 1.8 to 2.1 m 2 / g. The support advantageously provides improved selectivity and increased catalyst life. The support may also provide reduced degradation of reactants.

[0020] The carrier may have a diameter of ≥0.4 cm 3 / g total pore volume, e.g. ≥0.45 cm 3 / g, ≥0.5cm 3 / g or ≥0.55cm 3 / g.

[0021] The ceramic material may include a particle size fraction X and at least one of:

[0022] Particle size fraction Y; and / or particle size fraction Z; and / or the remainder,

[0023] And the D10 particle size of particle size fraction Y (when present) < the D10 particle size of particle size fraction X < the D10 particle size of particle size fraction Z (when present).

[0024] The ceramic material may include a particle size fraction X and at least one of:

[0025] Particle size fraction Y; and / or particle size fraction Z; and / or the remainder,

[0026] And the D50 particle size of particle size fraction Y (when present) < the D50 particle size of particle size fraction X < the D50 particle size of particle size fraction Z (when present).

[0027] The ceramic material may include a particle size fraction X and at least one of:

[0028] Particle size fraction Y; and / or particle size fraction Z; and / or the remainder,

[0029] And the D90 particle size of particle size fraction Y (when present) < the D90 particle size of particle size fraction X < the D90 particle size of particle size fraction Z (when present).

[0030] The carrier may be obtainable from a composition, wherein the composition comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of: a particle size fraction Y and / or a particle size fraction Z.

[0031] It should be understood that when particle size fraction X is present, all references to particle size fraction X throughout the text apply. Similarly, it should be understood that when particle size fraction Y is present, all references to particle size fraction Y throughout the text apply; when particle size fraction Z is present, all references to particle size fraction Z throughout the text apply.

[0032] The D50 particle size of particle size fraction X may be at least 1 μm, such as at least 1.5 μm, at least 1.75 μm, or at least 2 μm. The D50 particle size of particle size fraction X may be at most 10 μm, such as at most 8 μm, at most 6 μm; or at most 4 μm. The D50 particle size of particle size fraction X may be from 1 to 10 μm, such as from 1.5 to 8 μm, from 1.75 to 6 μm, or from 2 to 4 μm.

[0033] The D10 particle size of particle size fraction X may be at least 0.3 μm, such as at least 0.4 μm, or at least 0.5 μm. The D10 particle size of particle size fraction X may be at most 5 μm, such as at most 3 μm, or at most 2.8 μm. The D10 particle size of particle size fraction X may be from 0.3 to 5 μm, such as from 0.4 to 3 μm, or from 0.5 to 2.8 μm.

[0034] The D90 particle size of particle size fraction X may be at least 3 μm, such as at least 4 μm, or at least 5 μm. The D90 particle size of particle size fraction X may be at most 25 μm, such as at most 20 μm, or at most 15 μm. The D90 particle size of particle size fraction X may be from 3 to 25 μm, such as from 4 to 20 μm, or from 5 to 15 μm.

[0035] The D50 particle size of particle size fraction Y may be at least 0.2 μm, such as at least 0.3 μm, at least 0.4 μm, or at least 0.5 μm. The D50 particle size of particle size fraction Y may be at most 1 μm, such as at most 0.9 μm, or at most 0.8 μm. The D50 particle size of particle size fraction Y may be from 0.2 to 1 μm, such as from 0.3 to 0.9 μm, from 0.4 to 0.8 μm, or from 0.5 to 0.8 μm.

[0036] The D10 particle size of particle size fraction Y may be at least 0.1 μm, such as at least 0.2 μm, or at least 0.3 μm. The D10 particle size of particle size fraction Y may be at most 0.5 μm, such as at most 0.4 μm, or at most 0.3 μm. The D10 particle size of particle size fraction Y may be from 0.1 to 0.5 μm, such as from 0.2 to 0.4 μm, or about 0.3 μm.

[0037] The D90 particle size of particle size fraction Y may be at least 1.5 μm, such as at least 1.75 μm, or at least 2 μm. The D90 particle size of particle size fraction Y may be at most 3 μm, such as at most 2.5 μm, or at most 2 μm. The D90 particle size of particle size fraction Y may be 1.5 to 3 μm, such as 1.75 to 2.5 μm, or about 2 μm.

[0038] Particle size fraction Y advantageously increases the crush strength of the support.

[0039] The D50 particle size of particle size fraction Z may be at least 10 μm, such as at least 15 μm, at least 18 μm, or at least 20 μm. The D50 particle size of particle size fraction Z may be at most 50 μm, such as at most 40 μm, or at most 30 μm. The D50 particle size of particle size fraction Z may be from 10 to 50 μm, such as from 15 to 40 μm, from 18 to 30 μm, or from 20 to 30 μm.

[0040] The D10 particle size of particle size fraction Z may be at least 4 μm, for example at least 6 μm, at least 8 μm or at least 10 μm. The D10 particle size of particle size fraction Z may be at most 30 μm, for example at most 20 μm or at most 15 μm. The D10 particle size of particle size fraction Z may be from 4 to 30 μm, for example from 6 to 20 μm, from 8 to 15 μm, or from 10 to 15 μm.

[0041] The D90 particle size of particle size fraction Z may be at least 20 μm, such as at least 25 μm, at least 30 μm, or at least 35 μm. The D90 particle size of particle size fraction Z may be at most 100 μm, such as at most 80 μm, at most 75 μm; or at most 65 μm. The D90 particle size of particle size fraction Z may be from 20 to 100 μm, such as from 25 to 80 μm, from 30 to 75 μm, or from 35 to 65 μm.

[0042] The particle size fraction Z advantageously increases the total pore volume and specific surface area of ​​the support, and increases the selectivity and activity of a catalyst containing a support having the particle size fraction Z described herein.

[0043] When size fraction Y is present, size fraction Y may comprise ceramic particles having a D50 size of ≤40%, e.g., ≤30%, ≤20%, ≤10%, or ≤8%, of the D50 size of size fraction X. When size fraction Z is present, size fraction Z may comprise ceramic particles having a D50 size of ≥300%, e.g., ≥300%, ≥500%, ≥750%, ≥1000%, ≥1250%, or ≥1500%, of the D50 size of size fraction X.

[0044] The support may be obtainable from a composition, wherein the composition comprises a ceramic material and a pore-forming material.

[0045] The porogen may have a D50 particle size of at least 150 μm, such as at least 200 μm, at least 250 μm, at least 300 μm, at least 350 μm or at least 400 μm.The porogen may have a D50 particle size of 150 to 425 μm, such as 150 to 400 μm, or 200 to 350 μm.

[0046] The pore-forming material may include a first pore-forming particle size fraction and a second pore-forming particle size fraction. The D50 particle size of the first pore-forming particle size fraction may be at least 50 μm, for example, at least 60 μm, at least 70 μm, at least 80 μm, or at least 90 μm. The D50 particle size of the first pore-forming particle size fraction may be 50 to 150 μm, for example, 60 to 140 μm, 70 to 130 μm, 80 to 120 μm, or 90 to 110 μm. The D50 particle size of the second pore-forming particle size fraction may be at least 150 μm, for example, at least 200 μm, at least 250 μm, at least 300 μm, at least 350 μm, or at least 400 μm. The D50 particle size of the second pore-forming particle size fraction may be 150 to 425 μm, for example, 150 to 400 μm, or 200 to 350 μm.

[0047] Further, the combination of a pore-forming material having a D50 particle size of at least 150 μm and a ceramic material of particle size fraction Z as disclosed herein advantageously increases the total pore volume and specific surface area of ​​the carrier of the present invention and retains the improved performance.

[0048] The composition may comprise at least 6 wt% porogen, eg, at least 7 wt%, at least 8 wt%, or at least 9 wt%, based on the total weight of the composition.

[0049] The composition may comprise at least 5 wt% of the first pore-forming particle size fraction, e.g., at least 6 wt%, at least 7 wt%, or at least 8 wt%, based on the total weight of the composition. The composition may comprise at least 0.2 wt% of the second pore-forming particle size fraction, e.g., at least 0.4 wt%, at least 0.6 wt%, or at least 0.7 wt%, based on the total weight of the composition.

[0050] The composition may comprise at least 10 wt% of particle size fraction X, e.g., at least 15 wt%, at least 20 wt%, at least 25 wt%, or at least 30 wt%, based on the total weight of the composition. The composition may comprise up to 50 wt% of particle size fraction X, e.g., up to 45 wt%, up to 42 wt%, or up to 40 wt%, based on the total weight of the composition. The composition may comprise from 10 to 50 wt% of particle size fraction X, e.g., from 15 to 45 wt%, from 20 to 42 wt%, from 25 to 40 wt%, or from 30 to 40 wt%, based on the total weight of the composition.

[0051] The composition may comprise at least 0.1 wt% of particle size fraction Y, e.g., at least 0.2 wt% or at least 0.3 wt% by weight of the total weight of the composition. The composition may comprise up to 3 wt% of particle size fraction Y, e.g., up to 2.5 wt%, up to 2 wt%, or up to 1.7 wt% by weight of the total weight of the composition. The composition may comprise from 0.1 to 3 wt% of particle size fraction Y, e.g., from 0.2 to 2.5 wt%, from 0.3 to 2 wt%, or from 0.3 to 1.7 wt% by weight of the total weight of the composition.

[0052] The composition may comprise at least 10 wt% of the particle size fraction Z, e.g., at least 14 wt%, at least 15 wt%, or at least 16 wt%, by the total weight of the composition. The composition may comprise up to 35 wt% of the particle size fraction Z, e.g., up to 30 wt%, up to 28 wt%, or up to 27 wt%, by the total weight of the composition. The composition may comprise from 10 to 35 wt% of the particle size fraction Z, e.g., from 14 to 30 wt%, from 15 to 28 wt%, or from 16 to 27 wt%, by the total weight of the composition.

[0053] Advantageously, due to the low viscosity, the composition has improved processability, thereby reducing the time and cost of manufacturing the carrier.

[0054] The drop test result of the support may be at least 75% survival, such as at least 80%, at least 85%, or at least 90%.The support advantageously has reduced brittleness, improved attrition, and increased catalyst life.

[0055] The carrier may be used for a catalyst for producing alkylene oxide used in a packed bed reactor. The carrier may further be in the form of a supported catalyst by further comprising a catalytic material. The carrier may also be in the form of an inert filler, wherein suitably, the carrier is substantially free of catalyst material.

[0056] According to a second aspect of the present invention, there is provided a supported catalyst for producing alkylene oxide for use in a packed bed reactor, comprising the support described herein.

[0057] The drop test result for the supported catalyst can be at least 75% survival, such as at least 80%, at least 85%, or at least 90%.

[0058] Advantageously, the carrier described herein has a pore size distribution of ≤2% of the pores having a pore size of ≤0.1 μm, so that the carrier has increased crush strength. In addition, when the carrier is a catalyst, the carrier also provides increased selectivity and efficiency for the process. Advantageously, the carrier described herein has a pore size of at least 1.5 μm. 2 / g specific surface area, which provides an improved catalyst loading surface, so that the cost associated with catalyst loading is reduced. In addition, the carrier extends the life of the catalyst by reducing the aggregation and deactivation of the catalytic material on the carrier, and further improves the selectivity and maintains the high efficiency of the catalyst. Advantageously, the carrier described herein has a surface area of ​​≥0.4 cm 3 / g of total pore volume, which provides an improved catalyst loading surface, resulting in reduced costs associated with catalyst loading. In addition, the support extends the life of the catalyst by reducing the aggregation and deactivation of the catalytic material on the support.

[0059] Advantageously, the carrier described herein, when size fraction Y is present, comprises ceramic particles having a D50 size of ≤ 40% of the D50 size of size fraction X, so that the carrier has increased crush strength, increased total pore volume, reduced brittleness, reduced wear and improved drop test. The carrier also provides increased reactivity and catalyst life for the catalyst. The same advantages are observed when the carrier according to the invention has a size fraction Y comprising ceramic particles having a D50 size of at most 1 μm.

[0060] Advantageously, the support described herein, when a particle size fraction Z is present, comprises ceramic particles having a D50 particle size of ≥ 300% of the D50 particle size of the particle size fraction X, so that the support has an increased total pore volume and specific surface area. In addition, the support also provides improved reactivity, increased life and maintains high efficiency of the catalyst, while reducing the production cost of the catalyst. The same advantages are observed when the support according to the invention has a particle size fraction Z comprising ceramic particles having a D50 particle size of at least 15 μm.

[0061] The supports described herein also advantageously have increased attrition and low brittleness as well as increased catalyst life.

[0062] The support / supported catalyst suitably has a macrostructure and a surface structure on the outer surface of the macrostructure.

[0063] The spherical or ellipsoidal macrostructure may include at least one linear groove on the outer surface of the macrostructure, such as at least two, at least three or at least four linear grooves. Preferably, the spherical or ellipsoidal macrostructure includes at least two linear parallel grooves, such as at least three or at least four. Preferably, the cross-section of the groove is substantially hemispherical. When the spherical or ellipsoidal macrostructure includes such linear grooves, the macrostructure can be considered as a sphere or ellipsoid with grooves.

[0064] The macrostructures may be in the form of substantially spherical bodies.

[0065] Advantageously, the carriers described herein have improved heat transfer and reduced pressure drop across the carrier. The uniform packing of the carriers described herein further reduces the pressure drop across the carrier, thereby reducing operating costs. The carriers also show increased life and increased wear.

[0066] The support / supported catalyst may not include a fluidly connected intraparticle channel extending through the support / supported catalyst from a first orifice on a first side of the support / supported catalyst to a second orifice on a substantially opposite second side of the support / supported catalyst.

[0067] When the carrier / supported catalyst does not include the intragranular channel that fluid is connected, the fluid may not be able to flow through the carrier / supported catalyst from the first side of the carrier / supported catalyst to the substantially opposite second side of the carrier / supported catalyst in use. Therefore, in order to make the carrier / supported catalyst fluid pass through, the fluid can be forced to flow around the outer surface of the carrier / supported catalyst. Therefore, in the context of the present invention, the phrase "does not include the intragranular channel that fluid is connected, and the channel extends from the first orifice on the first side of the carrier / supported catalyst through the carrier / supported catalyst to the second orifice on the substantially opposite second side of the carrier / supported catalyst" can be interpreted as indicating that there is basically no fluid flowing through the main body of the carrier / supported catalyst from the first side of the carrier / supported catalyst to the substantially opposite second side of the carrier / supported catalyst in use. It should be understood that this "intragranular channel that fluid is connected" in the context of the present invention does not include the microscopic pores that may be present in the material of the carrier / supported catalyst.

[0068] The support / supported catalyst may not include fluidly connected intra-particle channels extending from the first pore opening to the second pore opening in the support / supported catalyst.

[0069] Advantageously, it has surprisingly been discovered that the combination of the surface structure and the absence of flow channels through the support / supported catalyst body results in increased strength while also increasing flow velocity, thereby directing flow over the surface and providing a more uniform flow for the production of ethylene oxide.

[0070] The maximum dimension of the carrier / supported catalyst may be up to 20 mm, such as up to 17 mm, up to 12 mm, up to 9 mm, up to 7 mm, or up to 6 mm.

[0071] The height, suitably the average height, of the surface structures of the support / supported catalyst may be at most 30%, for example at most 20%, preferably at most 15%, of the largest dimension of the support / supported catalyst.

[0072] "Surface structure" refers to a structure representing the deviation of the external surface shape of a support / supported catalyst from the shape expected based on the macrostructure of the support / supported catalyst. Such surface structure may be significantly smaller than the size of the macrostructure features of the support / supported catalyst. Surface structure can be considered as surface texturing on the macrostructure of the support / supported catalyst. It should be understood that such "surface structure" in the context of the present invention does not include microscopic surface roughness.

[0073] For example, a support / supported catalyst may have a spherical macrostructure with a diameter of 10 mm. The outer surface of the support / supported catalyst is partially and uniformly curved as expected for a spherical macrostructure, but the outer surface of the supported catalyst also includes a plurality of surface structures that deviate from the expected curved shape of the outer surface in the form of 12 discrete protuberances, each of which has a height of 2 mm.

[0074] It should be understood that normal macrostructural features such as cognate castellations or multi-lobed lobes are considered part of the macrostructure and are not considered surface structures according to the present invention.

[0075] The support / supported catalyst may comprise surface structures on at least two sides of the support / supported catalyst.

[0076] The support / supported catalyst may comprise a surface structure extending over ≥20% of the outer surface of the support / supported catalyst, for example over ≥30%, ≥40%, ≥60% or ≥80% of the outer surface.

[0077] "Comprising a surface structure extending thereon" means that at least a specified percentage of the outer surface of the support / supported catalyst deviates from the expected shape of the outer surface of the support / supported catalyst based on the macrostructure. It should be understood that the amount of deviated surface is calculated based on the expected shape of the outer surface and the surface area of ​​the missing portion thereof, rather than based on the surface area of ​​the surface structure. For example, a support / supported catalyst may have an expected outer surface area of ​​314 cm 2 Spherical macrostructure, of which 200cm 2 Deviating from the expected uniform curvature of a spherical macrostructure, the support / supported catalyst therefore comprises a surface structure extending over 63% of the external surface.For the purposes of this calculation, the expected external surface area occupied by any orifices connecting fluid communication channels is added to the sum of the remaining expected external surface area.

[0078] The height of the surface structure of the carrier / supported catalyst is suitably an average height, which may be ≤10 mm, preferably ≤7 mm, more preferably ≤6 mm, and most preferably ≤5 mm. The height of the surface structure of the carrier / supported catalyst is suitably an average height, which may be ≥0.1 mm, for example ≥0.3 mm, preferably ≥0.5 mm, more preferably ≥0.7 mm, and most preferably ≥0.8 mm. The height of the surface structure here is measured using a caliper with a depth measurement function. It should be understood that "height" herein refers to the distance from the lowest point of the surface structure to the highest point of the surface structure.

[0079] The support / supported catalyst may comprise a plurality of repeating surface structures having substantially the same shape. Preferably, the support / supported catalyst comprises at least 5 repeating surface structures, more preferably at least 10, such as at least 15, or at least 20, most preferably at least 25.

[0080] The surface structure may be in the form of ridges, grooves, protrusions and / or depressions.

[0081] The surface structure of ridge or groove form is normally elongated and can be the form of annular ridge / groove, wherein the annular ridge / groove is not limited to annular shape.Annular ridge / groove can be the form of circular or regular convex polygon, for example triangle, square, pentagon, hexagon, heptagon, octagon, nonagon or decagon.Preferably, annular ridge / groove is the form of regular convex polygon, more preferably pentagon, hexagon or heptagon, most preferably hexagon.The outer surface portion included in the annular ridge / groove can be according to the expected shape of the outer surface of the supported catalyst or can be flat, inclined and / or curved.For example, the outer surface portion included in the annular ridge can be the form of inverted cone.Surface structure can comprise the annular ridge / groove structure of a plurality of connections, suitably is the annular ridge / groove structure of interconnection, makes the ridge of at least the first annular surface structure form the part of the second annular surface structure.

[0082] The surface structure in the form of ridges or depressions can be curved, pyramidal and / or stepped ridges / depressions. Stepped ridges / depressions can include 2 to 10 steps, for example 3 to 8 steps. The ridges or depressions can be interconnected so that adjacent ridges / depressions abut or merge together.

[0083] The geometric surface area per unit volume (GSA) of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≥ 8 mm, or > 9 mm, e.g., a support / supported catalyst having a diameter or maximum dimension ≤ 17 mm to ≥ 8 mm) or a packed bed may be ≥ 0.7 cm 2 / cm 3 , for example, GSA ≥ 1 cm 2 / cm 3 , preferably GSA ≥ 1.2cm 2 / cm3 , preferably GSA ≥ 1.3 cm 2 / cm 3 , the most preferred GSA ≥ 1.4 cm 2 / cm 3 .

[0084] The side crush strength of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≥8 mm, or >9 mm, e.g., a support / supported catalyst having a diameter or maximum dimension ≥17 mm to ≥8 mm) may be ≥5 kgf, e.g., ≥6 kgf, preferably ≥7 kgf, more preferably ≥8 kgf, most preferably ≥10 kgf, e.g., ≥50 kgf, e.g., ≥60 kgf, preferably ≥70 kgf, more preferably ≥80 kgf, and most preferably ≥85 kgf.

[0085] The GSA of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤ 9 mm, e.g., ≤ 9 mm to ≥ 7 mm) or the packed bed may be ≥ 1.3 cm 2 / cm 3 , for example ≥1.4cm 2 / cm 3 , preferably GSA ≥ 1.5 cm 2 / cm 3 , preferably GSA ≥ 1.6 cm 2 / cm 3 , the most preferred GSA ≥ 1.7 cm 2 / cm 3 .

[0086] The side crush strength of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤9 mm, e ...

[0087] The GSA of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤ 7 mm, e.g., ≤ 7 mm to ≥ 5 mm) or the packed bed may be ≥ 1.7 cm 2 / cm 3 , e.g. ≥1.8cm 2 / cm 3 , preferably GSA ≥ 1.9cm 2 / cm 3 , preferably GSA ≥ 2.0 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 .

[0088] The side crush strength of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤7 mm, e.g., a support / supported catalyst having a diameter or maximum dimension ≤7 mm, e.g., ≤7 mm to ≥5 mm) may be ≥3 kgf, preferably ≥4 kgf, more preferably ≥5 kgf, most preferably ≥6 kgf or ≥7 kgf, e.g., ≥30 kgf, preferably ≥40 kgf, more preferably ≥50 kgf, most preferably ≥60 kgf or ≥70 kgf.

[0089] The GSA of the support / supported catalyst (e.g., support / supported catalyst having a diameter or maximum dimension of ≤10 mm to ≥5 mm) or the packed bed may be ≥1.2 cm 2 / cm 3 , e.g. ≥1.5cm 2 / cm 3 , preferably GSA ≥ 1.7 cm 2 / cm 3 , preferably GSA ≥ 1.9 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 .

[0090] The side crush strength of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension of ≤10 mm to ≥5 mm) may be ≥3 kgf, preferably ≥5 kgf, more preferably ≥7 kgf, most preferably ≥8 kgf or ≥9 kgf, e.g., ≥30 kgf, preferably ≥50 kgf, more preferably ≥70 kgf, most preferably ≥80 kgf or ≥90 kgf.

[0091] The GSA of a support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≥ 8 mm or > 9 mm, such as ≤ 17 mm to ≥ 8 mm) may be ≥ 0.7 cm 2 / cm 3 , the side crushing strength can be ≥5 kgf, for example ≥5 kgf. Within this range, the geometric surface area per unit volume (GSA) of the carrier / supported catalyst can be ≥0.7 cm 2 / cm 3 , for example, GSA ≥ 1 cm 2 / cm 3 , preferably GSA ≥ 1.2cm 2 / cm 3 , preferably GSA≤1.3cm 2 / cm 3 , the most preferred GSA ≥ 1.4cm 2 / cm 3The side crushing strength can be ≥6kgf, preferably ≥7kgf, more preferably ≥8kgf, most preferably ≥10kgf, for example ≥60kgf, preferably ≥70kgf, more preferably ≥80kgf, most preferably ≥85kgf.

[0092] The GSA of a support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤ 9 mm, such as ≤ 9 mm to ≥ 7 mm) may be ≥ 1.3 cm 2 / cm 3 , the side crushing strength can be ≥30kgf. Within this range, the GSA of the carrier / supported catalyst can be ≥1.4cm 2 / cm 3 , preferably GSA ≥ 1.5 cm 2 / cm 3 , preferably GSA ≥ 1.6 cm 2 / cm 3 , the most preferred GSA ≥ 1.7 cm 2 / cm 3 The side crushing strength can be ≥4kgf, preferably ≥5kgf, more preferably ≥6kgf, most preferably ≥8kgf, for example ≥50kgf, preferably ≥60kgf, more preferably ≥70kgf, most preferably ≥80kgf.

[0093] The GSA of a support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤ 7 mm, such as ≤ 7 mm to ≥ 5 mm) may be ≥ 1.7 cm 2 / cm 3 , the side crushing strength can be ≥3kgf, for example ≥30kgf. Within this range, the GSA of the carrier / supported catalyst can be ≥1.8cm 2 / cm 3 , preferably GSA ≥ 1.9cm 2 / cm 3 , preferably GSA ≥ 2.0 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 The side crushing strength can be ≥4kgf, preferably ≥5kgf, more preferably ≥6kgf, most preferably ≥7kgf, for example ≥40kgf, preferably ≥50kgf, more preferably ≥60kgf, most preferably ≥70kgf.

[0094] The GSA of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension of ≤10 mm to ≥5 mm) or the packed bed may be ≥1.2 cm 2 / cm 3, the side crushing strength can be ≥3kgf, for example ≥30kgf. Within this range, the GSA of the carrier / supported catalyst can be ≥1.5cm 2 / cm 3 , preferably GSA ≥ 1.7 cm 2 / cm 3 , preferably GSA ≥ 1.9 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 The side crushing strength can be ≥5kgf, more preferably ≥7kgf, most preferably ≥8kgf or ≥9kgf, for example ≥50kgf, more preferably ≥70kgf, most preferably ≥80kgf or ≥90kgf.

[0095] The GSA per unit volume herein is calculated by measuring the external dimensions of the support / supported catalyst (including all macrostructural and surface structural features) and calculating the surface area. The calculated surface area is then divided by the calculated volume of the support / supported catalyst. Suitable 3D modeling software can be used to provide these calculations.

[0096] The side crush strength in this article is expressed by a value in kgf. This is the maximum load recorded at the failure point of the sample when squeezed and crushed between two parallel, flat, hardened steel plates with a minimum diameter of 80 mm. One plate is fixed to a load cell and recording device, and the other plate is attached to a pressure head that moves at a controlled speed of 5 mm / minute. An initial test is performed to determine the weakest dimension of the carrier / supported catalyst. The side crush test is then performed in the weakest direction.

[0097] As used herein, total pore volume, pore size, and pore size distribution are measured by mercury intrusion porosimetry using ASTM D4284-12 (2017) e1, Standard Test Method for Determining Pore Volume Distribution of Catalysts and Catalyst Carriers by Mercury Intrusion Porosimetry. It should be understood that reference to pore size is reference to pore diameter.

[0098] As used herein, specific surface area is measured by BET analysis using ASTM-D3663-20, "Standard Test Method for Surface Area of ​​Catalysts and Catalyst Carriers."

[0099] As used herein, particle size includes D10 particle size, D50 particle size, D90 particle size and particle size distribution, which is measured by laser diffraction method using a particle size analyzer "Malvern Mastersizer 3000" with an EV battery attachment.

[0100] Advantageously, the carrier / supported catalysts of the present invention provide improved uniformity in the void space within the packed column while also significantly reducing the flow dead zone relative to the pellet volume. The carrier / supported catalysts can further provide a combination of desired properties, including desired high selectivity (e.g., >90%), long life (e.g., 3 to 4 years), low cost, high attrition and / or high crush strength. In addition, the carrier / supported catalysts provide improved mass transfer. The use of high GSA supports increases activity while maintaining the desired high selectivity, increases yield, and thereby increases facility productivity.

[0101] The carrier / supported catalyst of the present invention can also provide improved geometric surface area while still providing improved strength in the production of alkylene oxide. The carrier / supported catalyst of the present invention can provide improved geometric surface area as well as excellent strength and high total pore volume. The improved geometric surface area of ​​the carrier / supported catalyst is particularly advantageous for surface-based applications of catalytic reactions. The carrier / supported catalyst of the present invention can also provide high heat transfer coefficients and other improved properties.

[0102] The carrier / supported catalyst of the present invention can be a cast carrier / supported catalyst, such as a gel cast carrier / supported catalyst, suitably made by slip casting. Preferably, the surface structure of the carrier / supported catalyst is formed during the molding step of the carrier / supported catalyst (i.e., the step of forming the green compact of the carrier / supported catalyst), suitably formed by a suitable formation provided in a mold shape. Therefore, preferably, the surface structure is not post-processed after the green compact molding of the carrier / supported catalyst.

[0103] Supported / supported catalysts may be obtained by gel casting a composition comprising a ceramic material, an organic binder component and optionally a pore-forming material.

[0104] The supported / supported catalyst may be formed from a cast molding composition, preferably a gel cast molding composition.The supported / supported catalyst may be formed from a molding composition comprising an organic binder component, a ceramic material and optionally a pore-forming material.

[0105] After the support / supported catalyst is molded, the organic binder component may be operatively substantially removed from the support / supported catalyst, preferably by heat treatment, more preferably during calcination of the support / supported catalyst.

[0106] The organic binder component may comprise a polymerisable component suitably including a polymerisable monomer and a cross-linking ingredient, wherein the binder component is operable to polymerise to form a (co)polymer.

[0107] The polymerizable monomer may comprise one or more types of ethylenically unsaturated monomers and / or vinyl monomers, such as acrylic acid monomers or derivatives thereof, such as acrylamide monomers, such as monomers selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM), hydroxyethylacrylamide (hEAM) and / or N-vinyl-2-pyrrolidone (NVP). Preferably, the polymerizable monomer comprises one or more acrylamide monomers, more preferably comprises one or more monomers selected from methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM) and hydroxyethylacrylamide (hEAM). Most preferably, the polymerizable monomer comprises MAM.

[0108] The cross-linking component can be selected from one or more diethylenically unsaturated monomers, such as diacrylic acid monomers or derivatives thereof, such as diacrylamide monomers; acrylates and / or polyethylene glycol-substituted acrylic acid monomers. The cross-linking component can be selected from one or more of poly(ethylene glycol) dimethacrylate (PEGDMA), N,N'-methylenebis(acrylamide) (BIS), ammonium acrylate and PEG methyl ethyl methacrylate (PEGMEM), preferably one or more of poly(ethylene glycol) dimethacrylate (PEGDMA) and N,N'-methylenebis(acrylamide) (BIS).

[0109] The organic binder component can be formed from 40 to 95 wt % of a polymerizable monomer and 60 to 5 wt % of a cross-linking component, for example, 50 to 90 wt % of a polymerizable monomer and 50 to 10 wt % of a cross-linking component, or 55 to 85 wt % of a polymerizable monomer and 45 to 15 wt % of a cross-linking component, or 60 to 80 wt % of a polymerizable monomer and 40 to 20 wt % of a cross-linking component, for example, 65 to 75 wt % of a polymerizable monomer and 35 to 25 wt % of a cross-linking component.

[0110] The composition may also include a polymerization accelerator, which is operable to accelerate the polymerization of the adhesive component. The polymerization accelerator may be any suitable accelerator. For example, the accelerator may be tetramethylethylenediamine (TEMED).

[0111] The composition may also include an initiator, which is operable to initiate polymerization of the adhesive component. The initiator may be any suitable initiator. The initiator may be a free radical initiator. For example, the initiator may be ammonium persulfate and / or potassium persulfate.

[0112] After the support / supported catalyst is molded, the pore-forming material can be operatively removed from the supported catalyst, preferably by heat treatment, more preferably during the calcination of the support / supported catalyst. The pore-forming material can be any suitable pore-forming material known in the art. The pore-forming material can be selected from one or more of microbeads, starch, seed-shaped objects and / or cellulose.

[0113] The ceramic material of the carrier / supported catalyst or composition can be a refractory ceramic material. The ceramic material can include aluminum oxide, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silicon dioxide, titanate, carbon and / or magnesium oxide, or a precursor thereof. The ceramic material can include aluminum oxide, calcium aluminate or a precursor thereof. The ceramic material can include aluminum oxide, such as alpha-alumina or a precursor thereof.

[0114] Ceramic materials may have D 10 The particle size distribution is 0.1 to 20 μm, preferably 0.5 to 10 μm, more preferably 1 to 5 μm, and most preferably 1.5 to 3 μm. 50 It may be 0.5 to 30 μm, preferably 1 to 25 μm, more preferably 1.5 to 20 μm, and most preferably 2 to 15 μm. 90 It may be 10 to 100 μm, preferably 15 to 80 μm, more preferably 20 to 70 μm, and most preferably 25 to 60 μm.

[0115] The ceramic material may be a ceramic powder. The ceramic powder may be ball milled or spray dried. Advantageously, it has been found that ball milled or spray dried ceramic powders make casting easier.

[0116] The composition or carrier / supported catalyst may include a promoter that is operable to increase the reactivity of the primary reaction and / or reduce undesirable side reactions. The promoter may be selected from one or more of the oxides of lanthanum, copper, magnesium, manganese, potassium, calcium, zirconium, barium, cerium, sodium, lithium, molybdenum, yttrium, cobalt and chromium. The promoter may be selected from one or more of the oxides of lanthanum, copper, magnesium, calcium, zirconium, rhenium, tungsten and molybdenum.

[0117] The composition may further comprise a carrier, such as an aqueous carrier. Suitably, the composition is an aqueous ceramic slurry.

[0118] The composition may include further additives. For example, the composition may include a dispersant, such as a polymer salt, such as a polyacrylate, preferably an ammonium salt of polypropylene. Suitable dispersants may be selected from one or more of Ecodis P90, Narlex LD42 and Dispex A40.

[0119] The composition may comprise from 0.1 to 10% polymerisable monomer, preferably from 0.5 to 8 wt%, more preferably from 1 to 6 wt%, for example from 1.5 to 5 wt%, most preferably from 2 to 4 wt% based on the dry weight of the composition.

[0120] The composition may comprise from 0.1 to 10% crosslinking ingredient, preferably from 0.5 to 8 wt%, more preferably from 0.75 to 6 wt%, for example from 1 to 5 wt%, most preferably from 1 to 4 wt% by dry weight of the composition.

[0121] The composition may comprise 50 to 95% ceramic material, preferably 50 to 90 wt%, more preferably 55 to 85 wt%, most preferably 60 to 80 wt%, based on the dry weight of the composition. The supported catalyst may comprise at least 75% ceramic material, preferably at least 85 wt%, more preferably at least 90 wt%, for example at least 95 wt%, most preferably at least 97 wt%, based on the dry weight of the composition.

[0122] The ceramic material of the support / supported catalyst or composition may comprise ≥50% alumina, such as ≥75 wt% alumina, or ≥90 wt% alumina, ≥95 wt% alumina, or ≥99 wt% alumina, based on the weight of the ceramic material.

[0123] The support / supported catalyst may comprise ≥ 50% alumina, such as ≥ 75 wt% alumina, or ≥ 80 wt% alumina, ≥ 85 wt% alumina, or ≥ 90 wt% alumina, based on the weight of the ceramic material.

[0124] The composition may comprise >0 to 40% pore forming component, preferably 0.5 to 30 wt%, more preferably 2 to 25 wt%, for example 3 to 20 wt%, most preferably 4 to 15 wt% by dry weight of the composition.

[0125] The composition may comprise from 0.1 to 5% initiator, preferably from 0.5 to 4 wt%, more preferably from 0.75 to 3.5 wt%, most preferably from 1 to 3 wt%, based on the dry weight of the composition.

[0126] The composition may comprise up to 5% accelerator, preferably up to 3% by weight, more preferably up to 2% by weight, most preferably up to 1.5% by weight, based on the dry weight of the composition.

[0127] The composition may comprise from 0.1 to 10% dispersant by dry weight of the composition, preferably from 0.5 to 8 wt%, more preferably from 0.75 to 6 wt%, most preferably from 1 to 5 wt%.

[0128] The solids content of the composition may be from 45% to 99%, for example from 50 to 95% by weight, preferably from 55 to 90% by weight, most preferably from 60 to 85% by weight, based on the total weight of the composition.

[0129] The composition may be formed by combining a preformed aqueous binder component with the ceramic composition. Suitably, the aqueous binder component comprises a polymerisable monomer, a crosslinking ingredient and water.

[0130] The supported catalyst of the present invention comprises a catalytic material. The catalytic material is operable to provide catalytic activity in the production of alkylene oxides.

[0131] The catalytic material may include a metal, such as a noble metal, such as gold, platinum, rhodium, palladium, ruthenium, rhenium and / or silver; and / or a base metal, such as copper, chromium, iron, cobalt, nickel, zinc, manganese, vanadium, titanium and / or scandium. Typically, the catalytic material may include a noble metal, such as silver.

[0132] The supported catalyst may comprise catalytic material in an amount of ≥5%, such as ≥7 wt% or ≥10 wt% by weight of the supported catalyst. The supported catalyst may comprise catalytic material in an amount of ≤50%, such as ≤40 wt% or ≤20 wt% by weight of the supported catalyst. The supported catalyst may comprise catalytic material in an amount of 5 to 30 wt%, such as 7 to 25 wt% or 10 to 20 wt% by weight of the supported catalyst.

[0133] The supported / supported catalyst may be used in a packed bed reactor for the production of alkylene oxides, such as ethylene oxide, 1,9-decadiene oxide, 1,3-butadiene oxide, 2-butylene oxide, isobutylene oxide, 1-butylene oxide and / or propylene oxide, suitably for ethylene oxide.

[0134] According to a third aspect of the present invention, there is provided a method for producing a carrier and optionally a supported catalyst, the carrier and optionally a supported catalyst being suitably a carrier or a supported catalyst according to the first or second aspect of the present invention, the method comprising the steps of:

[0135] a. contacting a composition for producing a support / supported catalyst with an initiator and an optional polymerization accelerator, the composition being suitably a gel casting composition as defined in relation to the first and second aspects;

[0136] b. placing the resulting composition of step (a) in a mold;

[0137] c. demolding the composition to produce a green body;

[0138] d. Optionally, drying the green body at room temperature or baking the green body at a high temperature;

[0139] e. calcining the green body;

[0140] f. Optionally, contacting the support with a catalytic material.

[0141] The composition may be mixed to form a homogenous slurry before being arranged in the mould, suitably before the addition of the initiator and optional accelerator. The composition may be mixed to form a homogenous slurry after the addition of the initiator and optional accelerator.

[0142] The mould is preferably a casting mould.The mould is operable to form a surface structure on the green body.

[0143] The green body produced in step (c) may be dried by baking the green body at ≥60° C., such as ≥70° C. or ≥90° C. or ≥100° C. Suitably, the green body may be baked for ≥10 hours, such as ≥15 hours or ≥20 hours, such as ≥24 hours.

[0144] The green body may be calcined at ≥ 1000° C., preferably ≥ 1200° C., more preferably ≥ 1400° C., most preferably ≥ 1450° C. Suitably, the green body is calcined until substantially all binder and pore forming material has been removed from the carrier / supported catalyst.

[0145] Advantageously, the present invention enables the support / supported catalyst green body to be removed from the mold while it is still in a relatively rubbery form, allowing for easier handling. This results in lower scrap rates than other types of casting techniques.

[0146] The catalytic material may be disposed on the support by any suitable method. The catalytic material may be applied by solution impregnation, physical vapor deposition, chemical vapor deposition or other suitable technique. Typically, by solution impregnation.

[0147] Aqueous solutions of catalytic materials may be used. For example, suitable solutions may include solutions of silver lactate or silver oxalate (e.g., by reaction of silver hydroxide with oxalic acid, or reaction of silver nitrate or silver oxide with ammonium oxalate). The surface tension of the solution may be adjusted with a suitable surfactant such as laurylamine ethoxylate. The solution may have a surface tension of <50 mN / m.

[0148] The solution may be applied to the support by dipping the support into the solution. The support may be dried at a temperature of from 105°C to 150°C. The support may then be suitably calcined in air, for example at a temperature of from 550°C to 600°C.

[0149] The catalytic material can be disposed directly on the surface of the support or can be bound to an intermediate layer, such as a washcoat. The catalytic material can also be covalently linked to a macromolecular substance, such as a synthetic polymer or a biopolymer, such as a protein or nucleic acid polymer, which can then be disposed directly on the support surface or on an intermediate layer.

[0150] The solution or carrier / supported catalyst may contain an amino compound, which may act as a complex forming agent. The inclusion of an amino compound may promote the decomposition of the metal salt into fine particles that are well dispersed. The amino compound may be selected from ethylenediamine, monoethanolamine and / or diethanolamine.

[0151] The solution or carrier / supported catalyst may contain additives, such as promoters. As used herein, "promoter" may be considered a component that improves aspects of catalyst performance or otherwise promotes the production of a desired product. Promoters are generally not catalytic materials.

[0152] The promoter may be selected from alkali metals or alkaline earth metals, such as rubidium, potassium, lithium, sodium and / or cesium; and / or from transition metals, such as rhenium, molybdenum, tungsten and / or manganese. The promoter may be selected from alkali metals or alkaline earth metals, such as transition metals, such as rhenium, molybdenum, tungsten and / or manganese. Suitably, the promoter may be selected from rubidium and / or cesium.

[0153] The solution may contain an accelerator in an amount of 0.01 to 0.05% by weight of the solution.

[0154] According to a fourth aspect of the present invention, there is provided a method for producing a carrier or supported catalyst, the carrier or supported catalyst being suitably a carrier or supported catalyst according to the first or second aspect of the present invention, the method comprising the following steps:

[0155] a. Optionally, generating a digital model of the support / supported catalyst;

[0156] b. using additive manufacturing to produce a precursor according to the model, preferably using a 3D printer for printing;

[0157] c. forming a mold from the precursor;

[0158] d. cast moulding the moulding composition to form a supported or supported catalyst, the moulding composition suitably being a moulding composition as defined in relation to the first or second aspect; suitably carried out according to the process of the third aspect of the invention.

[0159] According to a fifth aspect of the present invention, there is provided a reactor for producing alkylene oxide, comprising a catalyst bed, wherein the catalyst bed comprises a carrier according to the first aspect of the present invention and / or a supported catalyst according to the second aspect of the present invention.

[0160] The reactor may comprise a plurality of reactor tubes comprising the support and / or supported catalyst according to the invention, suitably ≥ 500 reactor tubes, such as ≥ 1000 reactor tubes.

[0161] According to a sixth aspect of the present invention, there is provided a reactor tube for producing alkylene oxide, comprising a catalyst bed, wherein the catalyst bed comprises a carrier according to the first aspect of the present invention and / or a supported catalyst according to the second aspect of the present invention.

[0162] The height of the reactor tube may be from 2 to 25 meters, for example from 4 to 20 meters or from 6 to 15 meters. The diameter of the reactor tube may be from 5 to 100 mm, for example from 10 to 75 mm or from 15 to 60 mm.

[0163] According to a seventh aspect of the present invention, there is provided a reaction medium for producing alkylene oxide, comprising a catalyst bed, wherein the catalyst bed comprises a carrier according to the first aspect of the present invention and / or a supported catalyst according to the second aspect of the present invention.

[0164] The reaction medium may also comprise an olefin and oxygen or air. The olefin may be selected from ethylene, 1,9-decadiene, 1,3-butadiene, 2-butene, isobutylene, 1-butene and / or propylene, suitably ethylene.

[0165] The reaction medium may contain a diluent such as methane, argon and / or N2, suitably methane and / or argon when oxygen is used and suitably N2 when air is used.

[0166] The reaction medium may also contain carbon dioxide.

[0167] The temperature of the reaction medium may be from 200 to 300 °C, for example from 200 to 275 °C, or from 240 to 275 °C.

[0168] The reaction medium may have a pressure of 1 to 3 MPa.

[0169] The gas hourly space velocity (GHSV) of the reaction medium may be 2000 to 4500 h -1 .

[0170] According to an eighth aspect of the present invention, there is provided a method for producing alkylene oxide, the method comprising producing alkylene oxide using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a carrier according to the first aspect of the present invention and / or a supported catalyst according to the second aspect of the present invention.

[0171] The process may comprise contacting an olefin and oxygen / air with a supported catalyst.The olefin may be selected from ethylene, 1,9-decadiene, 1,3-butadiene, 2-butene, isobutylene, 1-butene and / or propylene, suitably ethylene.

[0172] The method may comprise forming a reaction medium according to the seventh aspect of the invention.

[0173] According to a ninth aspect of the present invention, there is provided an apparatus for producing an alkylene glycol, comprising: a reactor for producing an alkylene oxide according to the fifth aspect of the present invention; and a reactor for producing an alkylene glycol using the alkylene oxide produced by the alkylene oxide reactor.

[0174] According to a tenth aspect of the present invention, there is provided a method for producing an alkylene glycol, which comprises producing an alkylene oxide according to the eighth aspect of the present invention, and then using the produced alkylene oxide to produce an alkylene glycol.

[0175] The supported / supported catalysts of the present invention provide a number of improvements over commercially available supported / supported catalysts disclosed herein and not in accordance with the present invention.

[0176] As used herein, unless otherwise expressly stated, all numerals, such as those representing values, ranges, amounts or percentages, may be understood to begin with the word "about", even if the term does not clearly appear. The term "about" used herein refers to + / -10% of the value. In addition, the representation of the numerical range by the endpoints includes all integers, and in appropriate cases, includes fractions included in the range (for example, when referring to, for example, multiple elements, 1 to 5 may include 1, 2, 3, 4, and when referring to, for example, measurement, 1.5, 2, 2.75 and 3.80 may also be included). The representation of the endpoints also includes the endpoint value itself (for example, from 1.0 to 5.0 including 1.0 and 5.0). In addition, any numerical range described herein is intended to include all subranges included therein.

[0177] The singular encompasses the plural and vice versa. For example, although reference is made herein to "an" organic binder component, "a" ceramic material, "a" pore-forming material, etc., each one or more of these and any other components may be used. As used herein, the term "polymer" refers to oligomers as well as homopolymers and copolymers, and the prefix "poly" refers to two or more. For example, including and similar terms mean including, for example, but not limited to. The terms "comprising / comprises / comprised of" as used herein are synonymous with "including / includes" or "containing / contains" and are inclusive or open-ended and do not exclude additional, unlisted ingredients, elements or method steps. In addition, although the present invention is described as "comprising", the methods, materials and coating compositions detailed herein may also be described as "essentially consisting of" or "consisting of."

[0178] As used herein, the term "and / or" when used in a list of two or more items means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a list is described as including a set of A, B, and / or C, the list may include A alone; B alone; C alone; a combination of A and B; a combination of A and C, a combination of B and C; or a combination of A, B, and C.

[0179] If ranges are provided for a genus, each range may also apply additionally and independently to any one or more listed species of that genus. For example, a composition may comprise from 0.1% to 10%, by total dry weight of the composition, of a polymerizable monomer comprising methacrylamide, the amount of methacrylamide being such that the composition comprises from 0.1 to 10%, by total dry weight of the composition. Similarly, a composition may comprise from 0.1% to 10%, by total dry weight of the composition, of a polymerizable monomer comprising methacrylamide and hydroxyethylacrylamide, the amounts of methacrylamide and hydroxyethylacrylamide being such that the composition comprises from 0.1 to 10%, by total dry weight of the composition. Another example may be where the composition comprises from 0.1% to 10%, by total dry weight of the composition, of a polymerizable monomer comprising methacrylamide and hydroxyethylacrylamide, the amounts of methacrylamide and hydroxyethylacrylamide being such that the composition comprises ≥ 0.1%, by total dry weight of the composition. In addition, for example, the present invention can include 0.1% to 10% by weight of the total solids of the composition of a polymerizable monomer comprising methacrylamide and hydroxyethyl acrylamide, the amount of methacrylamide and hydroxyethyl acrylamide being such that the composition comprises ≤ 6% methacrylamide by weight of the total solids of the composition. Other examples of the above include the ranges provided for organic binders, crosslinking components, ceramic materials, pore-forming components, initiators, accelerators, and dispersants, and all related species, subgenera, and subspecies.

[0180] The following clauses provide further embodiments of the present invention.

[0181] Terms:

[0182] 1. A carrier for a catalyst, wherein the carrier comprises a surface structure, wherein the carrier comprises a ceramic material; and wherein the pore size distribution of the carrier is: ≤2% of the pores have a pore size ≤0.1 μm, and / or the carrier has a pore size of at least 1.5 μm. 2 / g, and / or the carrier has a specific surface area of ​​≥0.4cm 3 / g total pore volume.

[0183] 2. A carrier for a catalyst, wherein the carrier comprises a surface structure, and wherein the carrier comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of:

[0184] Particle size fraction Y; and / or

[0185] Particle size fraction Z;

[0186] and / or remainder;

[0187] wherein, when particle size fraction Y is present, particle size fraction Y comprises ceramic particles having a D50 particle size of ≤ 40% of the D50 particle size of particle size fraction X,

[0188] Wherein, when particle size fraction Z is present, particle size fraction Z comprises ceramic particles having a D50 particle size of ≥ 300% of the D50 particle size of particle size fraction X.

[0189] 3. A carrier for a catalyst, wherein the carrier comprises a surface structure, and wherein the carrier comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of:

[0190] a particle size fraction Y comprising ceramic particles having a D50 particle size of at most 1 μm; and / or

[0191] a particle size fraction Z comprising ceramic particles having a D50 particle size of at least 15 μm;

[0192] and / or remainder;

[0193] Wherein, when particle size fraction Y is present, the D50 particle size of particle size fraction Y is smaller than the D50 particle size of particle size fraction X,

[0194] Wherein, when particle size fraction Z exists, the D50 particle size of particle size fraction Z is greater than the D50 particle size of particle size fraction X.

[0195] 4. A support for a catalyst according to any preceding clause, wherein the support is a gel cast support.

[0196] 5. A carrier for a catalyst according to any of the preceding clauses, wherein the carrier has a substantially spherical and / or elliptical macrostructure.

[0197] 6. A support for a catalyst according to any of the preceding clauses, wherein the support has a pore size distribution such that ≤2% of the pores have a pore size ≤0.1 μm, such as ≤1.5%, ≤1%, ≤0.75% or ≤0.5%, and / or wherein the support has a pore size distribution such that ≤25% of the pores have a pore size ≥10 μm, such as ≤20%, ≤15%, ≤10% or ≤5%.

[0198] 7. A carrier for a catalyst according to any of the preceding clauses, wherein the carrier has a diameter of at least 1.5 m2 / g specific surface area, for example at least 1.6 m 2 / g, at least 1.7m 2 / g, at least 1.8m 2 / g, and / or having a maximum of 3m 2 / g specific surface area, for example, up to 2.75m 2 / g, up to 2.5m 2 / g, up to 2.25m 2 / g or up to 2.1m 2 / g, and / or having a value of 1.5 to 3 m 2 / g specific surface area, for example, 1.6 to 2.75 m 2 / g, 1.7 to 2.5m 2 / g, 1.8 to 2.25m 2 / g, or 1.8 to 2.1 m 2 / g.

[0199] 8. A carrier for a catalyst according to any of the preceding clauses, wherein the carrier has a diameter of ≥ 0.4 cm 3 / g total pore volume, e.g. ≥0.45 cm 3 / g, ≥0.5cm 3 / g or ≥0.55cm 3 / g.

[0200] 9. A support for a catalyst according to any of the preceding clauses, wherein the ceramic material comprises a particle size fraction X and at least one of:

[0201] Particle size fraction Y; and / or

[0202] Particle size fraction Z;

[0203] and / or the remainder,

[0204] and wherein the D50 particle size of particle size fraction Y (when present) < the D50 particle size of particle size fraction X < the D50 particle size of particle size fraction Z (when present).

[0205] 10. A support for a catalyst according to any of the preceding clauses, wherein the support is obtainable from a composition, wherein the composition comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of: a particle size fraction Y and / or a particle size fraction Z.

[0206] 11. A support for a catalyst according to any of the preceding clauses, wherein the D50 particle size of the particle size fraction X is at least 1 μm, such as at least 1.5 μm, at least 1.75 μm or at least 2 μm; and / or the D50 particle size is at most 10 μm, such as at most 8 μm, at most 6 μm; or at most 4 μm; and / or the D50 particle size is from 1 to 10 μm, such as from 1.5 to 8 μm, from 1.75 to 6 μm or from 2 to 4 μm; and / or

[0207] wherein the D10 particle size of particle size fraction X is at least 0.3 μm, such as at least 0.4 μm, or at least 0.5 μm; and / or the D10 particle size is at most 5 μm, such as at most 3 μm, at most 2.8 μm; and / or the D10 particle size is from 0.3 to 5 μm, such as from 0.4 to 3 μm, or from 0.5 to 2.8 μm; and / or

[0208] wherein the D90 particle size of particle size fraction X is at least 3 μm, e.g. at least 4 μm, or at least 5 μm; and / or the D90 particle size is at most 25 μm, e.g. at most 20 μm, or at most 15 μm; and / or the D90 particle size is from 3 to 25 μm, e.g. from 4 to 20 μm, or from 5 to 15 μm.

[0209] 12. A support for a catalyst according to any of the preceding clauses, wherein the D50 particle size of the particle size fraction Y is at least 0.2 μm, such as at least 0.3 μm, at least 0.4 μm, or at least 0.5 μm; and / or the D50 particle size is at most 1 μm, such as at most 0.9 μm, or at most 0.8 μm; and / or the D50 particle size is from 0.2 to 1 μm, such as from 0.3 to 0.9 μm, from 0.4 to 0.8 μm, or from 0.5 to 0.8 μm; and / or

[0210] wherein the D10 particle size of particle size fraction Y is at least 0.1 μm, such as at least 0.2 μm, or at least 0.3 μm; and / or the D10 particle size is at most 0.5 μm, such as at most 0.4 μm, at most 0.3 μm; and / or the D10 particle size is from 0.1 to 0.5 μm, such as from 0.2 to 0.4 μm, or about 0.3 μm; and / or

[0211] wherein the D90 particle size of particle size fraction Y is at least 1.5 μm, e.g. at least 1.75 μm, or at least 2 μm; and / or the D90 particle size is at most 3 μm, e.g. at most 2.5 μm, or at most 2 μm; and / or the D90 particle size is from 1.5 to 3 μm, e.g. from 1.75 to 2.5 μm, or about 2 μm.

[0212] 13. A support for a catalyst according to any of the preceding clauses, wherein the particle size fraction Z has a D50 particle size of at least 10 μm, such as at least 15 μm, at least 18 μm or at least 20 μm; and / or a D50 particle size of at most 50 μm, such as at most 40 μm or at most 30 μm; and / or a D50 particle size of from 10 to 50 μm, such as from 15 to 40 μm, from 18 to 30 μm or from 20 to 30 μm; and / or

[0213] wherein the D10 particle size of particle size fraction Z is at least 4 μm, for example at least 6 μm, or at least 8 μm, or at least 10 μm; and / or the D10 particle size is at most 30 μm, for example at most 20 μm or at most 15 μm; and / or the D10 particle size is from 4 to 30 μm, for example from 6 to 20 μm, from 8 to 15 μm or from 10 to 15 μm; and / or

[0214] wherein the D90 particle size of particle size fraction Z is at least 20 μm, e.g., at least 25 μm, at least 30 μm or at least 35 μm; and / or the D90 particle size is at most 100 μm, e.g., at most 80 μm, at most 75 μm; or at most 65 μm; and / or the D90 particle size is from 20 to 100 μm, e.g., from 25 to 80 μm, from 30 to 75 μm or from 35 to 65 μm.

[0215] 14. A support for a catalyst according to any preceding clause, wherein when size fraction Y is present, size fraction Y comprises ceramic particles having a D50 size of ≤40% of the D50 size of size fraction X, for example ≤30%, ≤20%, ≤10% or ≤8%; and / or

[0216] Wherein when size fraction Z is present, size fraction Z comprises ceramic particles having a D50 size of ≥300% of the D50 size of size fraction X, e.g., ≥300%, ≥500%, ≥750%, ≥1000%, ≥1250% or ≥1500%.

[0217] 15. A support for a catalyst according to any of the preceding clauses, wherein the support is obtainable from a composition, wherein the composition comprises a ceramic material and a pore-forming material.

[0218] 16. A support for a catalyst according to clause 15, wherein the D50 particle size of the pore-forming material is at least 150 μm, for example at least 200 μm, at least 250 μm, at least 300 μm, at least 350 μm, at least 400 μm; and / or the D50 particle size is 150 to 425 μm, for example 150 to 400 μm, 200 to 350 μm.

[0219] 17. A support for a catalyst according to clause 15, wherein the pore-forming material comprises a first pore-forming particle size fraction and a second pore-forming particle size fraction,

[0220] wherein the D50 particle size of the first pore-forming particle size fraction is at least 50 μm, for example at least 60 μm, at least 70 μm, at least 80 μm or at least 90 μm; and / or the D50 particle size is from 50 to 150 μm, for example from 60 to 140 μm, from 70 to 130 μm, from 80 to 120 μm or from 90 to 110 μm,

[0221] And wherein the D50 particle size of the second pore forming particle size fraction is at least 150 μm, for example at least 200 μm, at least 250 μm, at least 300 μm, at least 350 μm, at least 400 μm; and / or the D50 particle size is 150 to 425 μm, for example 150 to 400 μm, 200 to 350 μm.

[0222] 18. A support for a catalyst according to any one of clauses 15 to 17, wherein the support is obtainable from a composition, and

[0223] wherein the composition comprises at least 6 wt % of the pore-forming material, such as at least 7 wt %, at least 8 wt % or at least 9 wt %, based on the total weight of the composition; and / or

[0224] wherein the composition comprises at least 5 wt% of the first pore-forming particle size fraction, based on the total weight of the composition, e.g., at least 6 wt%, at least 7 wt% or at least 8 wt%; and wherein the composition comprises at least 0.2 wt% of the second pore-forming particle size fraction, based on the total weight of the composition, e.g., at least 0.4 wt%, at least 0.6 wt% or at least 0.7 wt%.

[0225] 19. A support for a catalyst according to any of the preceding clauses, wherein the support is obtainable from a composition, and

[0226] wherein the composition comprises at least 10 wt% of particle size fraction X, e.g., at least 15 wt%, at least 20 wt%, at least 25 wt% or at least 30 wt% by weight of the total weight of the composition; and / or up to 50 wt% of particle size fraction X, e.g., up to 45 wt%, up to 42 wt% or up to 40 wt% by weight of the total weight of the composition; and / or from 10 to 50 wt% of particle size fraction X, e.g., from 15 to 45 wt%, from 20 to 42 wt%, from 25 to 40 wt% or from 30 to 40 wt% by weight of the total weight of the composition; and / or

[0227] wherein the composition comprises at least 0.1 wt% of particle size fraction Y, e.g. at least 0.2 wt% or at least 0.3 wt% by weight of the total weight of the composition; and / or at most 3 wt% of particle size fraction Y, e.g. at most 2.5 wt%, at most 2 wt% or at most 1.7 wt% by weight of the total weight of the composition; and / or from 0.1 to 3 wt% of particle size fraction Y, e.g. from 0.2 to 2.5 wt%, from 0.3 to 2 wt% or from 0.3 to 1.7 wt% by weight of the total weight of the composition; and / or

[0228] Wherein the composition comprises at least 10 wt% of the particle size fraction Z, based on the total weight of the composition, e.g., at least 14 wt%, at least 15 wt% or at least 16 wt%; and / or at most 35 wt% of the particle size fraction Z, based on the total weight of the composition, e.g., at most 30 wt%, at most 28 wt% or at most 27 wt%; and / or from 10 to 35 wt% of the particle size fraction Z, based on the total weight of the composition, e.g., from 14 to 30 wt%, from 15 to 28 wt% or from 16 to 27 wt%.

[0229] 20. A supported catalyst for use in a packed bed reactor for producing alkylene oxide, comprising a carrier according to any preceding clause; and / or

[0230] wherein the supported / supported catalyst is used in a packed bed reactor for the production of ethylene oxide, 1,9-decadiene oxide, 1,3-butadiene oxide, 2-butylene oxide, isobutylene oxide, 1-butylene oxide and / or propylene oxide; and / or

[0231] Among them, the supported / supported catalyst is used in a packed bed reactor for the production of ethylene oxide.

[0232] 21. A support or supported catalyst according to any preceding clause, wherein the support has a drop test result of at least 75% survival, such as at least 80%, at least 85% or at least 90%, wherein the drop test is measured in accordance with the instructions.

[0233] 22. A support or supported catalyst according to any of the preceding clauses, wherein the macroscopic structure of the support / supported catalyst is essentially in the form of spheres; and / or

[0234] wherein the support / supported catalyst does not include a fluidly connected intra-particle channel extending through the support / supported catalyst from a first orifice on a first side of the support / supported catalyst to a second orifice on a substantially opposite second side of the support / supported catalyst; and / or

[0235] wherein the carrier / supported catalyst comprises a plurality of repeating surface structures having substantially the same shape; and / or

[0236] wherein the support / supported catalyst comprises at least 5 repeating surface structures, more preferably at least 10, such as at least 15, or at least 20, most preferably at least 25; and / or wherein the support / supported catalyst comprises a surface structure extending over ≥20% of the outer surface of the support / supported catalyst, such as over ≥30%, ≥40%, ≥60% or ≥80% of the outer surface; and / or wherein the surface structure comprises ridges, grooves, protuberances and / or depressions; and / or

[0237] wherein the surface structure in the form of ridges or grooves is in the form of annular ridges / grooves, wherein optionally the annular ridges / grooves are in the form of substantially circular or regular convex polygons, such as triangles, squares, pentagons, hexagons, heptagons, octagons, enneagons or decagons; and / or

[0238] The surface structure in the form of protrusions or depressions may be curved, pyramidal and / or stepped protrusions / depressions.

[0239] 23. A support or supported catalyst according to any of the preceding clauses, wherein the geometric surface area per unit volume (GSA) of the support / supported catalyst (e.g. a support / supported catalyst having a diameter or maximum dimension ≥ 8 mm, or > 9 mm, e.g. ≤ 17 mm to ≥ 8 mm) or the packed bed is ≥ 0.7 cm 2 / cm 3 , for example, GSA ≥ 1 cm 2 / cm 3 , preferably GSA ≥ 1.2cm 2 / cm 3 , preferably GSA ≥ 1.3 cm 2 / cm 3 , the most preferred GSA ≥ 1.4cm 2 / cm 3 ; and / or the lateral crushing strength of the carrier / supported catalyst is ≥5kgf, for example ≥6kgf, preferably ≥7kgf, more preferably ≥8kgf, most preferably ≥10kgf, for example ≥50kgf, for example ≥60kgf, preferably ≥70kgf, more preferably ≥80kgf, most preferably ≥85kgf; and / or

[0240] Wherein, the GSA of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤ 9 mm, e.g., ≤ 9 mm to ≥ 7 mm) or the packed bed is ≥ 1.3 cm 2 / cm 3 , for example ≥1.4cm 2 / cm 3 , preferably GSA ≥ 1.5 cm 2 / cm 3 , preferably GSA ≥ 1.6 cm 2 / cm3 , the most preferred GSA ≥ 1.7 cm 2 / cm 3 and / or the lateral crushing strength of the carrier / supported catalyst is ≥3kgf, preferably ≥4kgf, more preferably ≥5kgf, most preferably ≥6kgf or ≥7kgf, for example ≥30kgf, preferably ≥50kgf, more preferably ≥60kgf, most preferably ≥70kgf or ≥80kgf; and / or

[0241] Wherein, the GSA of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension ≤7 mm, e.g., ≤7 mm to ≥5 mm) or the packed bed is ≥1.7 cm 2 / cm 3 , e.g. ≥1.8cm 2 / cm 3 , preferably GSA ≥ 1.9cm 2 / cm 3 , preferably GSA ≥ 2.0 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 and / or the lateral crushing strength of the carrier / supported catalyst is ≥3kgf, preferably ≥4kgf, more preferably ≥5kgf, most preferably ≥6kgf or ≥7kgf, for example ≥30kgf, preferably ≥40kgf, more preferably ≥50kgf, most preferably ≥60kgf or ≥70kgf; and / or

[0242] Wherein, the GSA of the support / supported catalyst (e.g., a support / supported catalyst having a diameter or maximum dimension of ≤10 mm to ≥5 mm) or the packed bed is ≥1.2 cm 2 / cm 3 , e.g. ≥1.5cm 2 / cm 3 , preferably GSA ≥ 1.7 cm 2 / cm 3 , preferably GSA ≥ 1.9 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 and / or the side crushing strength of the carrier / supported catalyst may be ≥3kgf, preferably ≥5kgf, more preferably ≥7kgf, most preferably ≥8kgf or ≥9kgf, for example ≥30kgf, preferably ≥50kgf, more preferably ≥70kgf, most preferably ≥80kgf or ≥90kgf.

[0243] 24. A support or supported catalyst according to any of the preceding clauses, wherein the support / supported catalyst is a cast support / supported catalyst (e.g. a gel cast supported catalyst), and / or wherein the support / supported catalyst is obtainable by gel casting a composition comprising a ceramic material, an organic binder component and optionally a pore-forming material; optionally, wherein the organic binder component comprises a polymerisable component, which suitably comprises a polymerisable monomer and a cross-linking component, wherein the binder component is operable to polymerise to form a (co)polymer; and / or

[0244] wherein the organic binder component is formed by 40 to 95 wt % of polymerizable monomers and 60 to 5 wt % of crosslinking ingredients, such as 50 to 90 wt % of polymerizable monomers and 50 to 10 wt % of crosslinking ingredients, or 55 to 85 wt % of polymerizable monomers and 45 to 15 wt % of crosslinking ingredients, or 60 to 80 wt % of polymerizable monomers and 40 to 20 wt % of crosslinking ingredients, such as 65 to 75 wt % of polymerizable monomers and 35 to 25 wt % of crosslinking ingredients; and / or

[0245] wherein the ceramic material comprises alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silica, titanate, carbon and / or magnesium oxide, or a precursor thereof; and / or wherein the ceramic material comprises alumina, calcium aluminate, zirconium oxide, or a precursor thereof; and / or wherein the composition or carrier / supported catalyst comprises a promoter, such as a promoter selected from oxides of lanthanum, copper, magnesium, manganese, potassium, calcium, zirconium, barium, cerium, sodium, lithium, molybdenum, yttrium, cobalt and / or chromium; and / or a promoter, such as a promoter selected from one or more oxides of lanthanum, copper, magnesium, calcium, zirconium, rhenium, tungsten, molybdenum; and and / or wherein the composition or the carrier / supported catalyst comprises a promoter, for example a promoter selected from the oxides of manganese, calcium, zirconium, molybdenum, rhenium, yttrium; and / or wherein the composition comprises 0.1 to 10% polymerizable monomer, preferably 0.5 to 8 wt%, more preferably 1 to 6 wt%, for example 1.5 to 5 wt%, most preferably 2 to 4 wt%, based on the dry weight of the composition; and / or wherein the composition comprises 50 to 95% ceramic material, preferably 50 to 90 wt%, more preferably 55 to 85 wt%, most preferably 60 to 80 wt%, based on the dry weight of the composition.

[0246] 25. A supported catalyst according to any one of clauses 20 to 24, wherein the catalytic material comprises a metal, such as a noble metal, for example gold, platinum, rhodium, palladium, ruthenium, rhenium and / or silver; and / or a base metal, for example copper, chromium, iron, cobalt, nickel, zinc, manganese, vanadium, titanium and / or scandium; and / or

[0247] The catalytic material includes silver.

[0248] 26. A method of producing a supported or supported catalyst, suitably a supported or supported catalyst according to any one of clauses 1 to 25, comprising the steps of:

[0249] a. contacting a composition for producing a support / supported catalyst with an initiator and an optional polymerization accelerator, the composition being suitably a composition as defined in any of the preceding clauses, such as a gel casting composition;

[0250] b. placing the resulting composition of step (a) in a mold;

[0251] c. demolding the composition to produce a green body;

[0252] d. Optionally, drying the green body at room temperature or baking the green body at a high temperature;

[0253] e. calcining the green body;

[0254] f. Optionally, contacting the support with a catalytic material.

[0255] 27. A reactor for the production of alkylene oxide, comprising a catalyst bed, wherein the catalyst bed comprises a support or supported catalyst according to any one of clauses 1 to 25, optionally wherein the reactor comprises a plurality of reactor tubes comprising a support or supported catalyst according to any one of clauses 1 to 25, suitably ≥ 500 reactor tubes, for example ≥ 1000 reactor tubes.

[0256] 28. A reactor tube for the production of alkylene oxide comprising a catalyst bed, wherein the catalyst bed comprises a support or supported catalyst according to any one of clauses 1 to 25.

[0257] 29. A reaction medium for the production of an alkylene oxide comprising a catalyst bed, wherein the catalyst bed comprises a support or supported catalyst according to any one of clauses 1 to 25.

[0258] 30. A process for producing an alkylene oxide comprising producing an alkylene oxide using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a support or supported catalyst according to any one of clauses 1 to 25.

[0259] 31. An apparatus for producing alkylene glycol, comprising a reactor for producing alkylene oxide according to clause 27 or 28 and a reactor for producing alkylene glycol configured to receive the alkylene oxide produced by the alkylene oxide reactor.

[0260] 32. A method for producing an alkylene glycol, which comprises producing an alkylene oxide according to clause 30, and then using the produced alkylene oxide to produce an alkylene glycol.

[0261] All features contained herein may be combined with any of the above aspects in any combination.

[0262] In order to better understand the present invention and to show how to implement the embodiments of the present invention, reference will now be made to the following experimental data and drawings by way of example.

[0263] Supported Catalyst Example 1 according to the present invention was produced using the following method from a molding composition formed by mixing the components provided below (Table 1).

[0264] An aqueous monomer solution containing chain forming monomers, chain connecting monomers and water is formed. A dispersant is added thereto. A pore former is then introduced and mixed until fully dispersed. Alumina powder is then mixed to form an aqueous slurry. A catalyst and an initiator are then added to the aqueous slurry. The amounts of the components in the resulting slurry are:

[0265] Components wt% Alumina powder 1(X) 34 Alumina powder 2(Y) 1 Alumina powder 3(Z) 21.4 Pore ​​former 1 8.4 Pore ​​former 2 0.7 Dispersants 1.1 polymer 3 Crosslinking agent 1.5 catalyst 0.7 Initiator 1.3 water 27

[0266] Table 1 - Summary of Composition Components Used to Prepare Supported Catalyst Example 1

[0267] Table 2 below provides the particle sizes of Alumina Powder 1, Alumina Powder 2, and Alumina Powder 3.

[0268] Alumina powder 1(X) Alumina powder 2(Y) Alumina powder 3(Z) D10 0.4-0.9 0.1-0.4 14-18 D50 2.0-3.5 0.5-0.8 28-34 D90 5.0-9.0 1.5-3.0 50-59

[0269] Table 2 - D10, D50 and D90 particle sizes of alumina powders 1, 2 and 3.

[0270] The resulting aqueous slurry is then cast into a mold with negative pressure, which is operable to form a surface structure on the molded support. Once the slurry gels into a solid green body after 5 to 6 minutes, it is demolded. The green body support now has a rubbery, jelly-like consistency. The green body is then dried at 110°C for at least 24 hours. The dried green body is then fired to 1450°C, at which time the binder, dispersant and pore former are burned off, leaving a solid porous supported catalyst - Supported Catalyst Example 1.

[0271] The total pore volume of supported catalyst Example 1 is 0.45 to 0.55 cm 3 / g, with a specific surface area of ​​1.8 to 2.1 m 2 / g, the average side crushing strength is 10kgf, and the pore size distribution is: <1% of the pores have a pore size of 0.1μm or less, and <15% of the pores have a pore size of 10μm or more.

[0272] The formed support / catalyst was subjected to a drop test to determine the material brittleness, which is related to the material wear of the support / catalyst. The drop test was completed as follows:

[0273] Each sample was dropped vertically from a height of 12 meters onto a flat steel plate in a single pass. An operator in a cherry-picker dropped each sample one by one into a vertically oriented tube. The samples contacted the steel plate at the bottom, visible through a Perspex window, and recorded whether each sample survived or broke upon contact with the steel plate. Each sample was repeated 100 times in total. A trap door was used to clear the dropped samples every 5 samples. The number of surviving samples was used to calculate the percentage survival rate. Samples with a survival rate of at least 90% were considered to have passed.

[0274] The supported catalyst Example 1 according to the invention passed the drop test with a score of >90% survival.

[0275] Supported catalyst Example 1 was used in a packed bed reactor for the production of alkylene oxides. Compared to commercial supported catalysts not according to the invention, supported catalyst Example 1 had a 30% lower pressure drop in use and showed increased activity, selectivity, attrition and catalyst life. BRIEF DESCRIPTION OF THE DRAWINGS

[0276] Figure 1 A perspective view of a first comparative supported catalyst is shown.

[0277] Figure 2 A perspective view of a second comparative supported catalyst is shown.

[0278] Figure 3 A perspective view showing a first embodiment of a supported catalyst according to the present invention is shown.

[0279] Figure 4 A perspective view showing a second embodiment of a supported catalyst according to the present invention is shown.

[0280] Figure 5 Flow results for a first comparative supported catalyst are shown with a cross section of the side of the column along the transverse X axis.

[0281] Figure 6 Flow results for a first comparative supported catalyst are shown, with a cross section from the top of the column along the longitudinal Z axis.

[0282] Figure 7 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are aligned with the flow direction, with a cross section from the side of the column along the transverse X-axis.

[0283] Figure 8 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are aligned with the flow direction, with a cross section from the side of the column along the transverse Y axis.

[0284] Fig. 9 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are aligned with the flow direction, with a cross section from the top of the column along the longitudinal Z axis.

[0285] Fig.10 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are at 90° to the flow direction, with a cross section from the side of the column along the transverse X axis.

[0286] Fig.11 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are at 90° to the flow direction, with a cross section from the side of the column along the transverse Y axis.

[0287] Fig.12 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are at 90° to the flow direction, with a cross section from the top of the column along the longitudinal Z axis.

[0288] Fig.13 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are at 45° to the flow direction, with a cross section from the side of the column along the transverse X axis.

[0289] Fig.14 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are at 45° to the flow direction, with a cross section from the side of the column along the transverse Y axis.

[0290] Fig.15 Flow results for a second comparative supported catalyst are shown when the intra-particle flow channels are at 45° to the flow direction, with a cross section from the top of the column along the longitudinal Z axis.

[0291] Fig.16 Flow results for a first embodiment of a supported catalyst according to the invention are shown, with a cross section from the side of the column along the horizontal axis X.

[0292] Fig.17 Flow results for a first embodiment of a supported catalyst according to the invention are shown, with a cross section from the top of the column along the longitudinal axis Z.

[0293] Fig.18 Flow results for a second embodiment of a supported catalyst according to the invention are shown, with a cross section from the side of the column along the horizontal axis X.

[0294] Fig.19 Flow results for a second embodiment of a supported catalyst according to the invention are shown, with a cross section from the top of the column along the longitudinal axis Z. DETAILED DESCRIPTION

[0295] Computational fluid dynamics (CFD) compared the performance of two comparative supported catalysts with the supported catalyst according to the present invention.

[0296] like Figure 1 As shown, the first comparative supported catalyst 100 has a grooved spherical macrostructure with a diameter of 16 mm, wherein there are four equidistant parallel fluid-connected intra-particle channels in the form of holes 102 extending between orifices on opposite sides of the outer surface of the supported catalyst. The grooves 104 of the supported catalyst 100 are in the form of four equidistant parallel linear grooves having a curved cross-section on the outer surface of the supported catalyst. The outer surface of the supported catalyst 100 has the expected smooth continuous curvature of a spherical macrostructure.

[0297] like Figure 2 The second comparative supported catalyst 200 shown is called a Rashig ring, which is in the form of a cylinder of 8 mm by 8 mm with a central linear intra-particle fluid channel extending from an orifice on the upper surface to an orifice on the lower surface. The outer surface of the supported catalyst 200 has the expected smooth continuous curvature of a cylindrical macrostructure.

[0298] like Figure 3 The first embodiment of a supported catalyst 300 according to the present invention shown is identical to the first comparative supported catalyst in having holes 302 and grooves 304, but in addition the outer surface of the supported catalyst 300 includes a surface structure in the form of a plurality of interconnected hexagonal annular ridge-like surface structures 306 extending over substantially the entire outer surface except for the orifices of the holes 302 and the surfaces of the grooves 304. The portion of the outer surface extending between the inner edges of the annular ridges is formed by an inverted hexagonal pyramid with open ends.

[0299] like Figure 4 As shown, the second embodiment of a supported catalyst 400 according to the present invention is identical to the second comparative supported catalyst, having grooves 402 and surface structures 404, except that supported catalyst 400 does not have fluidly connected intra-particle channels extending through the body of the supported catalyst.

[0300] CFD was used to test the flow around the supported catalysts described above.

[0301] The test conditions are as follows:

[0302] Choose a large pipe diameter to avoid disturbing the flow around the pellets (50mm ID)

[0303] Analog resolution 0.125mm / pixel

[0304] Flow rate: 0.4m 3 / min

[0305] Holes / side channels are oriented in the same direction as the flow

[0306] The results of the flow test were:

[0307]

[0308] As shown in the table above and Figures 5 to 19 As shown in the results of , the supported catalyst according to the present invention provides a higher gas velocity in contact with the supported catalyst than the comparative supported catalyst. Figures 5 to 19 In the darker areas (such as Figure 5 The "A" in the figure indicates lower / static gas velocities, and the brighter areas (e.g. Figure 5 In addition, the supported catalyst according to the present invention provides a higher amount of gas turbulence above the supported catalyst and also provides a smaller velocity static zone below the supported catalyst.

[0309] Additionally, for the second comparative example, it can be seen that pellet orientation has a significant effect on the size of the dead zone (see the darkest shade below the pellet). When the pellet is 45° to the flow direction, the dead zone volume increases from about 50% of the total pellet volume (when flow aligned) to about 75% of the pellet volume. The dead zone height is affected even more dramatically, from 43% of the pellet diameter (when flow aligned) to about 123% (45°). This will have a significant impact on the pellets located directly below the pellets at this angle in the packed bed, reducing catalyst contact with the gas.

[0310] Attention is paid to all papers and documents which are filed concurrently with or prior to this application and which are open to public inspection with this specification, and the contents of all these papers and documents are incorporated herein by reference.

[0311] All features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all steps of any method or process so disclosed, may be combined in any combination, unless at least some of such features and / or steps in the combination are mutually exclusive.

[0312] Unless expressly stated otherwise, each feature disclosed in this specification (including any accompanying claims, abstracts and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose. Therefore, unless expressly stated otherwise, each feature disclosed is only an example of a series of equivalent or similar features.

[0313] The invention is not limited to the details of the foregoing embodiments. The invention extends to any novel feature or any novel combination of features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel step or any novel combination of steps of any method or process disclosed herein.

Claims

1. A carrier for a catalyst, wherein the carrier comprises a surface structure, wherein the carrier comprises a ceramic material; and wherein the pore size distribution of the carrier is: ≤2% of the pores have a pore size of ≤0.1 μm, and / or the carrier has a pore size of at least 1.5 μm. 2 / g, and / or the carrier has a specific surface area of ​​≥0.4cm 3 / g total pore volume.

2. A carrier for a catalyst, wherein the carrier comprises a surface structure, and wherein the carrier comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of: Particle size fraction Y; and / or Particle size fraction Z; and / or remainder; in, When particle size fraction Y is present, particle size fraction Y comprises ceramic particles having a D50 particle size of ≤ 40% of the D50 particle size of particle size fraction X, Wherein, when particle size fraction Z is present, particle size fraction Z comprises ceramic particles having a D50 particle size of ≥ 300% of the D50 particle size of particle size fraction X.

3. A carrier for a catalyst, wherein the carrier comprises a surface structure, and wherein the carrier comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of: a particle size fraction Y comprising ceramic particles having a D50 particle size of at most 1 μm; and / or a particle size fraction Z comprising ceramic particles having a D50 particle size of at least 15 μm; and / or remainder; in, When particle size fraction Y is present, the D50 particle size of particle size fraction Y is smaller than the D50 particle size of particle size fraction X, Wherein, when particle size fraction Z exists, the D50 particle size of particle size fraction Z is greater than the D50 particle size of particle size fraction X.

4. A support for a catalyst according to any one of the preceding claims, wherein the support is a gel cast support.

5. The support for a catalyst according to any one of the preceding claims, wherein the support has a substantially spherical and / or elliptical macrostructure.

6. A support for a catalyst according to any one of the preceding claims, wherein the support has a pore size distribution such that ≤2% of the pores have a pore size ≤0.1 μm, such as ≤1.5%, ≤1%, ≤0.75% or ≤0.5%.

7. A support for a catalyst according to any one of the preceding claims, wherein the support has a pore size distribution such that ≤25% of the pores have a pore size ≥10 μm, such as ≤20%, ≤15%, ≤10% or ≤5%.

8. A support for a catalyst according to any one of the preceding claims, wherein the support has a diameter of at least 1.5 m 2 / g specific surface area, for example at least 1.6 m 2 / g, at least 1.7m 2 / g or at least 1.8m 2 / g.

9. A support for a catalyst according to any one of the preceding claims, wherein the support has a maximum of 3 m 2 / g specific surface area, for example, up to 2.75m 2 / g, up to 2.5m 2 / g, up to 2.25m 2 / g or up to 2.1m 2 / g.

10. A support for a catalyst according to any one of the preceding claims, wherein the support has a molecular weight of 1.5 to 3 μm. 2 / g specific surface area, for example, 1.6 to 2.75 m 2 / g, 1.7 to 2.5m 2 / g, 1.8 to 2.25m 2 / g, or 1.8 to 2.1 m 2 / g.

11. A support for a catalyst according to any one of the preceding claims, wherein the support has a diameter of ≥ 0.4 cm 3 / g total pore volume, e.g. ≥0.45 cm 3 / g, ≥0.5cm 3 / g or ≥0.55cm 3 / g.

12. A support for a catalyst according to any one of the preceding claims, wherein the ceramic material comprises a particle size fraction X and at least one of: Particle size fraction Y; and / or Particle size fraction Z; and / or the remainder, and wherein the D50 particle size of particle size fraction Y (when present) < the D50 particle size of particle size fraction X < the D50 particle size of particle size fraction Z (when present).

13. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, wherein the composition comprises a ceramic material, wherein the ceramic material comprises a particle size fraction X and at least one of: a particle size fraction Y and / or a particle size fraction Z.

14. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of particle size fraction X is at least 1 μm, such as at least 1.5 μm, at least 1.75 μm or at least 2 μm.

15. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of particle size fraction X is at most 10 μm, such as at most 8 μm, at most 6 μm; or at most 4 μm.

16. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of particle size fraction X is from 1 to 10 μm, such as from 1.5 to 8 μm, from 1.75 to 6 μm, or from 2 to 4 μm.

17. A support for a catalyst according to any one of the preceding claims, wherein the D10 particle size of the particle size fraction X is at least 0.3 μm, such as at least 0.4 μm, or at least 0.5 μm; and / or the D10 particle size is at most 5 μm, such as at most 3 μm, at most 2.8 μm; and / or the D10 particle size is from 0.3 to 5 μm, such as from 0.4 to 3 μm, or from 0.5 to 2.8 μm.

18. A support for a catalyst according to any one of the preceding claims, wherein the D90 particle size of the particle size fraction X is at least 3 μm, such as at least 4 μm, or at least 5 μm; and / or the D90 particle size is at most 25 μm, such as at most 20 μm, or at most 15 μm; and / or the D90 particle size is from 3 to 25 μm, such as from 4 to 20 μm, or from 5 to 15 μm.

19. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of particle size fraction Y is at least 0.2 μm, such as at least 0.3 μm, at least 0.4 μm, or at least 0.5 μm.

20. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of particle size fraction Y is at most 1 μm, such as at most 0.9 μm, or at most 0.8 μm.

21. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of particle size fraction Y is from 0.2 to 1 μm, such as from 0.3 to 0.9 μm, from 0.4 to 0.8 μm, or from 0.5 to 0.8 μm.

22. A support for a catalyst according to any one of the preceding claims, wherein the D10 particle size of the particle size fraction Y is at least 0.1 μm, such as at least 0.2 μm, or at least 0.3 μm; and / or the D10 particle size is at most 0.5 μm, such as at most 0.4 μm, at most 0.3 μm; and / or the D10 particle size is from 0.1 to 0.5 μm, such as from 0.2 to 0.4 μm, or about 0.3 μm.

23. A support for a catalyst according to any one of the preceding claims, wherein the D90 particle size of the particle size fraction Y is at least 1.5 μm, such as at least 1.75 μm, or at least 2 μm; and / or the D90 particle size is at most 3 μm, such as at most 2.5 μm, or at most 2 μm; and / or the D90 particle size is from 1.5 to 3 μm, such as from 1.75 to 2.5 μm, or about 2 μm.

24. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of the particle size fraction Z is at least 10 μm, such as at least 15 μm, at least 18 μm or at least 20 μm.

25. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of the particle size fraction Z is at most 50 μm, such as at most 40 μm or at most 30 μm.

26. A support for a catalyst according to any one of the preceding claims, wherein the D50 particle size of the particle size fraction Z is from 10 to 50 μm, such as from 15 to 40 μm, from 18 to 30 μm, or from 20 to 30 μm.

27. A support for a catalyst according to any one of the preceding claims, wherein the D10 particle size of the particle size fraction Z is at least 4 μm, such as at least 6 μm, or at least 8 μm, or at least 10 μm; and / or the D10 particle size is at most 30 μm, such as at most 20 μm or at most 15 μm; and / or the D10 particle size is from 4 to 30 μm, such as from 6 to 20 μm, from 8 to 15 μm, or from 10 to 15 μm.

28. A support for a catalyst according to any one of the preceding claims, wherein the D90 particle size of the particle size fraction Z is at least 20 μm, such as at least 25 μm, at least 30 μm or at least 35 μm; and / or the D90 particle size is at most 100 μm, such as at most 80 μm, at most 75 μm; or at most 65 μm; and / or the D90 particle size is from 20 to 100 μm, such as from 25 to 80 μm, from 30 to 75 μm, or from 35 to 65 μm.

29. A support for a catalyst according to any one of the preceding claims, wherein when size fraction Y is present, size fraction Y comprises ceramic particles having a D50 size of ≤40% of the D50 size of size fraction X, e.g. ≤30%, ≤20%, ≤10% or ≤8%.

30. A support for a catalyst according to any one of the preceding claims, wherein when a particle size fraction Z is present, it comprises ceramic particles having a D50 particle size of ≥300%, such as ≥300%, ≥500%, ≥750%, ≥1000%, ≥1250% or ≥1500% of the D50 particle size of particle size fraction X.

31. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, wherein the composition comprises a ceramic material and a pore-forming material.

32. The support for catalyst according to claim 31, wherein the D50 particle size of the pore-forming material is at least 150 μm, such as at least 200 μm, at least 250 μm, at least 300 μm, at least 350 μm, or at least 400 μm.

33. The support for catalyst according to claim 31 or 32, wherein the D50 particle size of the pore-forming material is 150 to 425 μm, for example 150 to 400 μm, or 200 to 350 μm.

34. The support for catalyst according to claim 31, wherein the pore-forming material comprises a first pore-forming particle size fraction and a second pore-forming particle size fraction, wherein the D50 particle size of the first pore-forming particle size fraction is at least 50 μm, for example at least 60 μm, at least 70 μm, at least 80 μm or at least 90 μm; and / or the D50 particle size is from 50 to 150 μm, for example from 60 to 140 μm, from 70 to 130 μm, from 80 to 120 μm or from 90 to 110 μm, And wherein the D50 particle size of the second pore forming particle size fraction is at least 150 μm, for example at least 200 μm, at least 250 μm, at least 300 μm, at least 350 μm, at least 400 μm; and / or the D50 particle size is 150 to 425 μm, for example 150 to 400 μm, 200 to 350 μm.

35. A support for a catalyst according to any one of claims 31 to 34, wherein the support is obtainable from a composition and wherein the composition comprises at least 6 wt% of pore-forming material, such as at least 7 wt%, at least 8 wt% or at least 9 wt%, based on the total weight of the composition.

36. A carrier for a catalyst according to any one of claims 31 to 35, wherein the composition comprises at least 5 wt% of the first pore-forming particle size fraction, such as at least 6 wt%, at least 7 wt% or at least 8 wt%, based on the total weight of the composition; and wherein the composition comprises at least 0.2 wt% of the second pore-forming particle size fraction, such as at least 0.4 wt%, at least 0.6 wt% or at least 0.7 wt%, based on the total weight of the composition.

37. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises at least 10 wt% of particle size fraction X, such as at least 15 wt%, at least 20 wt%, at least 25 wt% or at least 30 wt%, based on the total weight of the composition.

38. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises at most 50 wt% of particle size fraction X, such as at most 45 wt%, at most 42 wt% or at most 40 wt%, based on the total weight of the composition.

39. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises 10 to 50 wt% of particle size fraction X, such as 15 to 45 wt%, 20 to 42 wt%, 25 to 40 wt%, or 30 to 40 wt%, based on the total weight of the composition.

40. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises at least 0.1 wt% of particle size fraction Y, such as at least 0.2 wt% or at least 0.3 wt%, based on the total weight of the composition.

41. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises at most 3 wt% of particle size fraction Y, such as at most 2.5 wt%, at most 2 wt% or at most 1.7 wt%, based on the total weight of the composition.

42. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises 0.1 to 3 wt% of particle size fraction Y, such as 0.2 to 2.5 wt%, 0.3 to 2 wt%, or 0.3 to 1.7 wt%, based on the total weight of the composition.

43. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises at least 10 wt% of a particle size fraction Z, such as at least 14 wt%, at least 15 wt% or at least 16 wt%, based on the total weight of the composition.

44. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises at most 35 wt% of particle size fraction Z, such as at most 30 wt%, at most 28 wt% or at most 27 wt%, based on the total weight of the composition.

45. A support for a catalyst according to any one of the preceding claims, wherein the support is obtainable from a composition, and wherein the composition comprises 10 to 35 wt% of a particle size fraction Z, such as 14 to 30 wt%, 15 to 28 wt%, or 16 to 27 wt%, based on the total weight of the composition.

46. ​​A supported catalyst for use in a packed bed reactor for the production of alkylene oxides comprising a support according to any one of the preceding claims.

47. The supported catalyst of claim 46, wherein the support / supported catalyst is used in a packed bed reactor for the production of ethylene oxide, 1,9-decadiene oxide, 1,3-butadiene oxide, 2-butylene oxide, isobutylene oxide, 1-butylene oxide and / or propylene oxide.

48. A supported catalyst according to claim 46 or 47, wherein the carrier / supported catalyst is used in a packed bed reactor for the production of ethylene oxide.

49. A support or supported catalyst according to any preceding claim, wherein the support has a drop test result of at least 75% survival, such as at least 80%, at least 85% or at least 90%, wherein the drop test is measured according to the instructions.

50. A support or supported catalyst according to any one of the preceding claims, wherein the macroscopic structure of the support / supported catalyst is substantially in the form of a sphere.

51. A support or supported catalyst according to any of the preceding claims, wherein the support / supported catalyst does not include a fluidly connected intra-particle channel extending from a first orifice on a first side of the support / supported catalyst through the support / supported catalyst to a second orifice on a substantially opposite second side of the support / supported catalyst.

52. A support or supported catalyst according to any one of the preceding claims, wherein the support / supported catalyst comprises a plurality of repeating surface structures having substantially the same shape.

53. A support or supported catalyst according to any one of the preceding claims, wherein the support / supported catalyst comprises at least 5 repeating surface structures, more preferably at least 10, such as at least 15, or at least 20, most preferably at least 25.

54. A support or supported catalyst according to any of the preceding claims, wherein the support / supported catalyst comprises a surface structure extending over ≥20% of the outer surface of the support / supported catalyst, for example over ≥30%, ≥40%, ≥60% or ≥80% of the outer surface.

55. A support or supported catalyst according to any preceding claim, wherein the surface structure comprises ridges, grooves, protrusions and / or depressions.

56. A support or supported catalyst according to any of the preceding claims, wherein the surface structure in the form of ridges or grooves is in the form of annular ridges / grooves, wherein optionally, the annular ridges / grooves are essentially circular or in the form of regular convex polygons, such as triangles, squares, pentagons, hexagons, heptagons, octagons, nonagons or decagons.

57. A support or supported catalyst according to any one of the preceding claims, wherein the surface structure in the form of elevations or depressions is curved, pyramidal and / or stepped elevations / depressions.

58. A support or supported catalyst according to any one of the preceding claims, wherein the support / supported catalyst, for example a support / supported catalyst having a diameter or maximum dimension ≥ 8 mm, or > 9 mm, for example ≤ 17 mm to ≥ 8 mm, or a packed bed having a geometric surface area per unit volume (GSA) ≥ 0.7 cm 2 / cm 3 , for example, GSA ≥ 1 cm 2 / cm 3 , preferably GSA ≥ 1.2cm 2 / cm 3 , preferably GSA ≥ 1.3 cm 2 / cm 3 , the most preferred GSA ≥ 1.4 cm 2 / cm 3 and / or the lateral crushing strength of the carrier / supported catalyst is ≥5kgf, for example ≥6kgf, preferably ≥7kgf, more preferably ≥8kgf, most preferably ≥10kgf, for example ≥50kgf, for example ≥60kgf, preferably ≥70kgf, more preferably ≥80kgf, most preferably ≥85kgf.

59. A support or supported catalyst according to any one of the preceding claims, wherein the support / supported catalyst, for example a support / supported catalyst having a diameter or maximum dimension of ≤9 mm, for example ≤9 mm to ≥7 mm, or a packed bed having a GSA of ≥1.3 cm 2 / cm 3 , for example ≥1.4cm 2 / cm 3 , preferably GSA ≥ 1.5 cm 2 / cm 3 , preferably GSA ≥ 1.6 cm 2 / cm 3 , the most preferred GSA ≥ 1.7 cm 2 / cm 3 and / or the side crushing strength of the carrier / supported catalyst is ≥3kgf, preferably ≥4kgf, more preferably ≥5kgf, most preferably ≥6kgf or ≥7kgf, for example ≥30kgf, preferably ≥50kgf, more preferably ≥60kgf, most preferably ≥70kgf or ≥80kgf.

60. A support or supported catalyst according to any one of the preceding claims, wherein the support / supported catalyst, e.g. a support / supported catalyst having a diameter or maximum dimension ≤ 7 mm, e.g. ≤ 7 mm to ≥ 5 mm, or a packed bed having a GSA ≥ 1.7 cm 2 / cm 3 , e.g. ≥1.8cm 2 / cm 3 , preferably GSA ≥ 1.9cm 2 / cm 3 , preferably GSA ≥ 2.0 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 and / or the lateral crushing strength of the carrier / supported catalyst is ≥3kgf, preferably ≥4kgf, more preferably ≥5kgf, most preferably ≥6kgf or ≥7kgf, for example ≥30kgf, preferably ≥40kgf, more preferably ≥50kgf, most preferably ≥60kgf or ≥70kgf.

61. A support or supported catalyst according to any one of the preceding claims, wherein the support / supported catalyst, for example a support / supported catalyst having a diameter or maximum dimension of ≤10 mm to ≥5 mm, or a packed bed having a GSA of ≥1.2 cm 2 / cm 3 , e.g. ≥1.5cm 2 / cm 3 , preferably GSA ≥ 1.7 cm 2 / cm 3 , preferably GSA ≥ 1.9 cm 2 / cm 3 , the most preferred GSA ≥ 2.1cm 2 / cm 3 and / or the side crushing strength of the carrier / supported catalyst is ≥3kgf, preferably ≥5kgf, more preferably ≥7kgf, most preferably ≥8kgf or ≥9kgf, for example ≥30kgf, preferably ≥50kgf, more preferably ≥70kgf, most preferably ≥80kgf or ≥90kgf.

62. A support or supported catalyst according to any preceding claim, wherein the support / supported catalyst is a cast support / supported catalyst, such as a gel cast supported catalyst.

63. A carrier or supported catalyst according to any of the preceding claims, wherein the carrier / supported catalyst is obtainable by gel casting a composition comprising a ceramic material, an organic binder component and an optional pore-forming material; optionally, wherein the organic binder component comprises a polymerizable component, the polymerizable component suitably comprising a polymerizable monomer and a cross-linking component, wherein the binder component is operable to polymerize to form a (co)polymer.

64. A carrier or supported catalyst according to claim 64, wherein the organic binder component is formed by 40 to 95 wt% of polymerizable monomers and 60 to 5 wt% of cross-linking ingredients, such as 50 to 90 wt% of polymerizable monomers and 50 to 10 wt% of cross-linking ingredients, or 55 to 85 wt% of polymerizable monomers and 45 to 15 wt% of cross-linking ingredients, or 60 to 80 wt% of polymerizable monomers and 40 to 20 wt% of cross-linking ingredients, such as 65 to 75 wt% of polymerizable monomers and 35 to 25 wt% of cross-linking ingredients.

65. A support or supported catalyst according to any one of the preceding claims, wherein the ceramic material comprises alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silica, titanate, carbon and / or magnesium oxide, or a precursor thereof.

66. A support or supported catalyst according to any preceding claim, wherein the ceramic material comprises alumina, calcium aluminate, zirconium oxide, or a precursor thereof.

67. A support or supported catalyst according to any of the preceding claims, wherein the composition or support / supported catalyst comprises a promoter, for example a promoter selected from oxides of lanthanum, copper, magnesium, manganese, potassium, calcium, zirconium, barium, cerium, sodium, lithium, molybdenum, yttrium, cobalt and / or chromium.

68. A support or supported catalyst according to any one of the preceding claims, wherein the composition or support / supported catalyst comprises a promoter, such as a promoter selected from one or more of the oxides of lanthanum, copper, magnesium, calcium, zirconium, rhenium, tungsten, molybdenum.

69. A support or supported catalyst according to any one of the preceding claims, wherein the composition or support / supported catalyst comprises a promoter, for example a promoter selected from oxides of manganese, calcium, zirconium, molybdenum, rhenium, yttrium.

70. A support or supported catalyst according to any preceding claim, wherein the composition comprises 0.1 to 10% polymerisable monomer, preferably 0.5 to 8 wt%, more preferably 1 to 6 wt%, for example 1.5 to 5 wt%, most preferably 2 to 4 wt%, based on the dry weight of the composition.

71. A support or supported catalyst according to any preceding claim, wherein the composition comprises 50 to 95% ceramic material, preferably 50 to 90 wt%, more preferably 55 to 85 wt%, most preferably 60 to 80 wt%, based on the dry weight of the composition.

72. A supported catalyst according to any one of claims 46 to 71, wherein the catalytic material comprises a metal, such as a precious metal, for example gold, platinum, rhodium, palladium, ruthenium, rhenium and / or silver; and / or a base metal, for example copper, chromium, iron, cobalt, nickel, zinc, manganese, vanadium, titanium and / or scandium.

73. The supported catalyst of any one of claims 46 to 71, wherein the catalytic material comprises silver.

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