公开(公告)号：US20230302432A1

公开(公告)日：2023-09-28

申请号：US18011855

申请日：2021-06-25

Applicant: BASF SE

Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Patrick HUBACH ,  Hubert WAINDOK ,  Bernd HINRICHSEN ,  Gonzalo PRIETO GONZALEZ ,  Tania RODENAS TORRALBA ,  Karl C. KHARAS

IPC: B01J21/04 ,  B01J35/04 ,  B01J35/10 ,  B01J35/00 ,  B01J37/08 ,  C07D301/10 ,  B01J37/02

CPC classification number: B01J21/04 ,  B01J35/002 ,  B01J35/04 ,  B01J35/1009 ,  B01J35/1042 ,  B01J35/1061 ,  B01J37/0201 ,  B01J37/0236 ,  B01J37/088 ,  C07D301/10

Abstract: A porous shaped catalyst support body comprising at least 85% by weight of alpha-alumina, wherein the support has a total pore volume in the range from 0.5 to 2.0 mL/g as determined by mercury porosimetry, and a pore structure characterized by a geometric tortuosity τ in the range from 1.0 to 2.0; and an effective diffusion parameter η in the range from 0.060 to 1.0; wherein geometric tortuosity τ and effective diffusion parameter η are determined by image analysis algorithms from computer-assisted 3D reconstructions of focused ion beam scanning electron microscope analyses. The structure of the support has a high total pore volume, such that impregnation with a large amount of silver is possible, while the surface area is kept sufficiently high in order to assure optimal dispersion of the catalytically active species, especially metal species. The support has a pore structure that leads to a maximum rate of mass transfer within the support. The invention also relates to a shaped catalyst body for preparation of ethylene oxide by gas phase oxidation of ethylene, comprising at least 15% by weight of silver, based on the total weight of the catalyst, deposited on a porous shaped catalyst support body as described above. The invention further relates to a process for producing the shaped catalyst body, in which a) a porous shaped catalyst support body as described above is impregnated with a silver impregnation solution, preferably under reduced pressure; and the impregnated porous shaped catalyst support body is optionally subjected to drying; and b) the impregnated porous shaped catalyst support body is subjected to a heat treatment; wherein steps a) and b) are optionally repeated. The invention also relates to a process for preparing ethylene oxide by gas phase oxidation of ethylene, comprising the reaction of ethylene and oxygen in the presence of a shaped catalyst body according to claim 11.

公开(公告)号：US20230234030A1

公开(公告)日：2023-07-27

申请号：US18011857

申请日：2021-06-25

Applicant: BASF SE

Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Nicolas DUYCKAERTS ,  Kazuhiko AMAKAWA ,  Patrick HUBACH ,  Karl C. KHARAS

IPC: B01J21/04 ,  B01J23/50 ,  B01J23/36 ,  B01J35/02 ,  B01J35/10 ,  B01J35/00 ,  B01J37/04 ,  B01J37/00 ,  B01J37/08 ,  C07D301/10

CPC classification number: B01J21/04 ,  B01J23/50 ,  B01J23/36 ,  B01J35/026 ,  B01J35/1038 ,  B01J35/1042 ,  B01J35/1009 ,  B01J35/1066 ,  B01J35/1061 ,  B01J35/0026 ,  B01J37/04 ,  B01J37/0063 ,  B01J37/0018 ,  B01J37/08 ,  C07D301/10

Abstract: A tableted catalyst support, characterized by an alpha-alumina content of at least 85 wt.-%, a pore volume of at least 0.40 mL/g, as determined by mercury porosimetry, and a BET surface area of 0.5 to 5.0 m2/g. The tableted catalyst support is an alpha-alumina catalyst support obtained with high geometrical precision and displaying a high overall pore volume, thus allowing for impregnation with a high amount of silver, while exhibiting a surface area sufficiently large so as to provide optimal dispersion of catalytically active species, in particular metal species. The invention further provides a process for producing a tableted alpha-alumina catalyst support, which comprises i) forming a free-flowing feed mixture comprising, based on inorganic solids content, at least 50 wt.-% of a transition alumina; ii) tableting the free-flowing feed mixture to obtain a compacted body; and iii) heat treating the compacted body at a temperature of at least 1100° C., preferably at least 1300° C., more preferably at least 1400° C., in particular at least 1450° C., to obtain the tableted alpha-alumina catalyst support. The invention moreover relates to a compacted body obtained by tableting a free-flowing feed mixture which comprises, based on inorganic solids content, at least 50 wt.-% of a transition alumina having a loose bulk density of at most 600 g/L, a pore volume of at least 0.6 mL/g, as determined, and a median pore diameter of at least 15 nm. The invention moreover relates to a shaped catalyst body for producing ethylene oxide by gas-phase oxidation of ethylene, comprising at least 15 wt.-% of silver, relative to the total weight of the catalyst, deposited on the tableted alpha-alumina catalyst support. The invention moreover relates to a process for producing ethylene oxide by gas-phase oxidation of ethylene, comprising reacting ethylene and oxygen in the presence of the shaped catalyst body.

公开(公告)号：US20230256415A1

公开(公告)日：2023-08-17

申请号：US18011543

申请日：2021-06-24

Applicant: BASF SE

Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Karl C. KHARAS

IPC: B01J21/04 ,  B01J23/50 ,  B01J35/10 ,  B01J35/02 ,  B01J35/00 ,  B01J37/08 ,  B01J37/00 ,  B01J37/02 ,  C07D301/10

CPC classification number: B01J21/04 ,  B01J23/50 ,  B01J35/1042 ,  B01J35/1047 ,  B01J35/026 ,  B01J35/0026 ,  B01J37/088 ,  B01J37/0009 ,  B01J37/0207 ,  C07D301/10

Abstract: A porous alpha-alumina catalyst support is prepared by (i) preparing a precursor material comprising a boehmitic-derived alumina having a pore volume of at least 0.6 mL/g, wherein the boehmitic-derived alumina is obtained by thermal decomposition of a boehmitic starting material and the boehmitic starting material consists predominantly of block-shaped crystals, and optionally an inorganic bond material; (ii) forming the precursor material into shaped bodies; (iii) calcining the shaped bodies to obtain the porous alpha-alumina catalyst support. The support structure has a high overall pore volume, while keeping its surface area sufficiently large so as to provide optimal dispersion of catalytically active species, in particular metal species. The support is useful for a catalyst for producing ethylene oxide by gas-phase oxidation of ethylene.