Abstract: The present invention relates to methods for qualifying material for using in the cleaning of alkylene oxide equipment. Qualified material is not expected to contribute to the formation of determinable amounts of alkylene oxide by-products. Methods of cleaning alkylene oxide equipment, and alkylene oxide processes incorporating these methods are also provided.

Abstract: Control of an in-series, multiple, e.g., two, reaction zone, hydroformylation process for producing normal (N) and iso (I) aldehydes at a N:I ratio, the process comprising contacting an olefinically unsaturated compound, e.g., propylene, with carbon monoxide, hydrogen and a catalyst comprising (A) a transition metal, e.g., rhodium, (B) an organobisphosphite, and (C) an organomonophosphite ligand, the contacting conducted in first and subsequent reaction zones and at hydroformylation conditions comprising an olefinically unsaturated compound partial pressure in each zone, the control exercised by decreasing the olefinically unsaturated compound partial pressure in the first reaction zone to decrease the N:I ratio or increasing the olefinically unsaturated compound partial pressure in the first reaction zone to increase the N:I ratio.

Abstract: A method for starting-up a high efficiency alkylene oxide catalyst is described. A feed gas comprising an alkylene, oxygen, and at least one organic chloride is introduced to the catalyst. The molar ratio of oxygen to alkylene, reaction temperature, and overall chloriding effectiveness are adjusted to specified ranges of values within a specified catalyst aging period.

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

Abstract: A process for conditioning a high efficiency silver catalyst used to manufacture ethylene oxide from ethylene, oxygen, and at least one organic chloride is described. A non-reactive conditioning gas comprising at least one of ethylene, oxygen, and a ballast gas is introduced to the catalyst at a conditioning temperature ranging from 150° C. to 180° C. for a selected period of at least 4 hours.

Abstract: A method of controlling an in-series, multiple, e.g., two, reaction zone, hydroformylation process for producing normal (N) and iso (I) aldehydes at a N:I ratio, the process comprising contacting an olefinically unsaturated compound with synthesis gas and a catalyst comprising (A) a transition metal, e.g., rhodium, (B) an organobisphosphite ligand, and (C) an organomonophosphite ligand, the contacting conducted in first and subsequent reaction zone(s) and at hydroformylation conditions comprising a transition metal concentration in each zone, the method comprising decreasing the transition metal concentration in the first reaction zone to decrease the N:I ratio or increasing the transition metal concentration in the first reaction zone to increase the N:I ratio.

Abstract: A system and process for removing an inorganic salt from a catalyst roaster belt is disclosed. The system includes an apparatus with a drying vessel having a catalyst roaster belt inlet, a catalyst roaster belt outlet, a heating medium inlet, and a heating medium outlet, wherein the catalyst roaster belt inlet and the catalyst roaster belt outlet are spaced apart along a first direction, the heating medium inlet and the heating medium outlet are spaced apart along a second direction, the heating medium inlet is spaced apart from the catalyst roaster belt inlet in the second direction, and the catalyst roaster belt inlet is between the heating medium inlet and the heating medium outlet along the second direction. The system includes an acid bath and a moveable catalyst roaster belt extending from the acid bath through the catalyst roaster belt inlet and through the catalyst roaster belt outlet.

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

Abstract: Methods of reducing the value of an alkylene oxide production parameter (such as alkylene oxide production rate) in a process of making an alkylene oxide by reacting an alkylene and oxygen over a high efficiency catalyst are shown and described. One method comprises reducing the concentration of oxygen in the reactor feed gas to reduce the value of the alkylene oxide production parameter.

Abstract: The present invention provides porous body precursors and shaped porous bodies. Also included are catalysts and other end-use products based upon the shaped porous bodies and thus the porous body precursors. Finally, processes for making these are provided. The porous body precursors, comprise one or more topography-enhancing additives, i.e., additives that are capable of at least marginally enhancing one or more of surface area, aspect ratio, pore volume, median pore diameter, surface morphology, etc. Downstream products need not necessarily comprise the topography-enhancing additives in order to exhibit the benefits of their inclusion in the porous body precursors.

Abstract: A hydrocarbon-containing gas is mixed with an oxygen-containing gas in a gas mixer in the presence of a water mist. The water mist surrounds and contacts entrained particles in either the oxygen-containing gas stream or the hydrocarbon-containing gas stream. The water acts to suppress and prevent ignition of the hydrocarbon gas in the mixer by serving as a sink for heat created by energetic collisions between such particles and structures within the gas mixer. The water mist also acts to quench ignition caused by such collisions. The water mist can be introduced into the gas mixer in a number of different configurations, including via nozzles injecting a mist into a hydrocarbon gas manifold or an oxygen gas manifold, nozzles placed within the gas mixer adjacent to ends of the oxygen supply pipes, and nozzles placed coaxially within the oxygen supply pipes in the gas mixer.

Abstract: A combination of calixarene bisphosphite ligand and an organophosphine ligand. The combination can be employed with a catalytic metal to form a complex catalyst. The catalyst can be employed in a hydroforaiylation process for producing a mixture of aldehydes.

Abstract: A method of mixing an oxygen gas with a hydrocarbon-containing gas includes the steps of wet scrubbing the oxygen gas in a wet scrubber, supplying oxygen gas from the wet scrubber to a gas mixer and mixing the oxygen gas with the hydrocarbon-containing gas in the gas mixer. Wet scrubbers for use in the method may take various forms, including packed-tower, bubble cap, and sparger-type wet scrubbers. The removal of the particulate matter reduces the risk of ignition of the hydrocarbon-containing gas in the gas mixer. The use of a wet scrubber in the oxygen supply line overcomes many problems currently faced with screen and filters, as per current practice.

Abstract: A gas mixer (10) for mixing a first gas stream with a second gas stream includes an impact labyrinth (24) in the first gas stream having structures (25), e.g., corrugated walls, forming a tortuous path through which the first gas stream must pass en route to a mixing point (20) in the gas mixer. The labyrinth fosters ignition of particles entrained in the first gas stream. Elongate, straight pipes (30) receive the first gas stream from the impact labyrinth (24) and carrying the first gas stream to the mixing point (20) the pipes (30) are positioned with a vessel (12) carrying the second gas stream. The pipes (30) have openings which are substantially aligned with the flow direction of the second gas stream at the mixing point (20) thereby introducing the first gas stream into the second gas stream in a low shear manner.

Abstract: Embodiments of the present disclosure provide processes, columns, and systems for removing acetaldehyde from alkylene oxide in a feed stream and for providing an alkylene oxide-water stream that can be directly transferred to a glycol reaction process. The alkylene oxide purification column includes a first section to convert a feed stream into a gas phase portion and a liquid phase portion and a second section located in the column above the first section to separate alkylene oxide from the acetaldehyde, water, and other impurities that enter the second section from the first section.

Abstract: A process of controlling heavies in a recycle catalyst stream, particularly, for use in a continuous hydroformylation process of converting an olefin with synthesis gas in the presence of a hydroformylation catalyst to form an aldehyde product stream with subsequent separation of the catalyst for recycle to the hydroformylation step. Heavies are controlled, and preferably reduced, by means of feeding a recycle gas stream, taken as a portion of an over-head stream from a condenser, back to a vaporizer wherein the aldehyde product stream is separated.

Abstract: A gas mixer is disclosed which includes a vessel (10) (e.g., pipe) containing a stream (12) of a first hydrocarbon-containing gas. The mixer includes a hollow pipe (14) located internal to the vessel containing a stream of a second gas, e.g., an oxygen-containing gas stream such as a stream of pure oxygen gas or air enriched with oxygen. The internal pipe further includes a mixer tip (30) at the peripheral end thereof. The mixer tip includes a body having an internal passage for conducting the second gas out of the pipe and an opening introducing the second gas stream into the first gas stream in a radial plane at an acute angle relative to the longitudinal axis of the pipe. The pipe further includes a deflector (20) on its external surface in longitudinal alignment with the opening of the mixer tip. The deflector serves to deflect any entrained particles within the first gas stream away from the mixing zone where the two streams mix, minimizing the risk of ignition of the hydrocarbon-containing gas.

Abstract: A hydrocarbon-containing gas is mixed with an oxygen-containing gas in a gas mixer in the presence of a water mist. The water mist surrounds and contacts entrained particles in either the oxygen-containing gas stream or the hydrocarbon-containing gas stream. The water acts to suppress and prevent ignition of the hydrocarbon gas in the mixer by serving as a sink for heat created by energetic collisions between such particles and structures within the gas mixer. The water mist also acts to quench ignition caused by such collisions. The water mist can be introduced into the gas mixer in a number of different configurations, including via nozzles injecting a mist into a hydrocarbon gas manifold or an oxygen gas manifold, nozzles placed within the gas mixer adjacent to ends of the oxygen supply pipes, and nozzles placed coaxially within the oxygen supply pipes in the gas mixer.

Abstract: A simplified method of operating an alkylene oxide production process that utilizes a high efficiency silver catalyst is shown and described. The method accounts for declining catalyst activity that occurs as the catalyst ages by making alternating changes to the reaction temperature and an overall chloriding effectiveness parameter.

Abstract: An improved method of operating an alkylene oxide production process to achieve and maintain a desired alkylene oxide production parameter is shown and described. The method comprises adjusting one of an overall catalyst chloriding effectiveness parameter or reaction temperature to obtain the desired alkylene oxide production parameter.