Carrier for ethylene oxide catalysts
AssigneeScientific Design Company, Inc.
InventorsNabil Rizkalla, Andrzej Rokicki
Life of this patent
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Abstract
A carrier for an ethylene epoxidation catalyst is provided that includes an alumina first component and a mixed metal oxide of alumina second component. The mixed metal oxide of alumina second component comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn). A catalyst containing the carrier, as well as a process for the epoxidation of ethylene using the catalyst are also disclosed.
Claims43
A carrier for an ethylene epoxidation catalyst, the carrier comprising an alumina first component, and a mixed metal oxide of alumina second component, wherein said mixed metal oxide of alumina second component comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn).
An ethylene epoxidation catalyst comprising:
- a carrier comprising an alumina first component and a mixed metal oxide of alumina second component, wherein said mixed metal oxide of alumina second component comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn);
- a catalytic amount of silver deposited on and/or in said carrier;
- and
- a promoting amount of one or more promoters deposited on and/or in said carrier.
A method for the vapor phase conversion of ethylene to ethylene oxide in the presence of oxygen, the method comprising reacting a reaction mixture comprising ethylene and oxygen in the presence of a catalyst, said catalyst comprising:
- a carrier comprising an alumina first component and a mixed metal oxide of alumina second component, wherein said mixed metal oxide of alumina second component comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn);
- a catalytic amount of silver deposited on and/or in said carrier;
- and
- a promoting amount of one or more promoters deposited on and/or in said carrier.
A method of making a carrier, said method comprising:
- admixing an alumina precursor with a mixed metal oxide of alumina precursor;
- and
- calcining the admixture at a temperature to form alumina particles which are coated with a mixed metal oxide of alumina, wherein said mixed metal oxide of alumina comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn).
A method of making a carrier, said method comprising:
- providing a preformed alumina carrier;
- soaking said preformed alumina carrier in a solution comprising a mixed metal oxide of alumina precursor;
- drying the soaked preformed alumina carrier;
- and
- calcining the dried and soaked preformed alumina carrier at a temperature to form a alumina carrier comprising a mixed metal oxide of alumina component, wherein said mixed metal oxide of alumina component comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn).
A method of making a carrier, said method comprising:
- combining a mixed metal oxide of alumina precursor with at least an alumina powder and a solvent to form a paste;
- forming said paste into a desired shape;
- and
- calcining the shaped paste at a temperature to form a carrier containing a mixed metal oxide of alumina component, wherein said mixed metal oxide of alumina component comprises a corundum lattice structure having a plurality of O—Al—O bonds, wherein an Al atom of at least one O—Al—O bond of the plurality of O—Al—O bonds, but not all of the plurality of O—Al—O bonds, is replaced with a divalent or trivalent transition metal selected from the group consisting of scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni) copper (Cu), and zinc (Zn).
Dependencies are inferred from the claim text.