Abstract: The invention pertains to a catalyst useful for the epoxidation of an olefin. More particularly, the invention pertains to an improved catalyst useful for the epoxidation of ethylene to ethylene oxide. The catalyst has improved selectivity in the epoxidation process. The catalyst comprises a solid support having a surface, which has a first mode of pores which have a diameter ranging from about 0.01 ?m to about 5 ?m and having a differential pore volume peak in the range of from about 0.01 ?m to about 5 ?m. The surface then has a second mode of pores, different from the first mode of pores, which second mode of pores have a diameter ranging from about 1 ?m to about 20 ?m and have a differential pore volume peak in the range of from about 1 ?m to about 20 ?m.

Abstract: This invention relates to catalyst carriers to be used as supports for metal and metal oxide catalyst components of use in a variety of chemical reactions. More specifically, the invention provides a process of formulating an alpha alumina carrier that is suitable as a support for silver and the use of such catalyst in chemical reactions, especially the epoxidation of ethylene to ethylene oxide. The composition comprises at least one hydrated precursor of alpha alumina; an optional alpha alumina; and a binder. The composition is substantially free of seeding particles.

Abstract: The invention relates to an improved process for producing a catalyst useful for the epoxidation of ethylene to ethylene oxide. In forming the catalyst, a silver-impregnated support is subjected to two calcinations. The support is subjected to a first calcination in a first atmosphere comprising air. Next the support is subjected to a second calcination in a second atmosphere which is substantially entirely comprised of inert gas, and which second atmosphere is substantially absent of hydrogen. This two-stage calcination produces an improved catalyst which contains fewer organics left over under standard conditions of air calcination alone, while costing less than calcination in an inert gas alone.

Abstract: This invention relates to catalyst carriers to be used as supports for metal and metal oxide catalyst components of use in a variety of chemical reactions. More specifically, the invention provides a process of formulating a low surface area alpha alumina carrier that is suitable as a support for silver and the use of such catalyst in chemical reactions, especially the epoxidation of ethylene to ethylene oxide. A precursor for a catalyst support comprises an admixture of an alpha alumina and/or a transition alumina; a binder; and either a solid blowing agent which expands, or propels a gas upon the application of sufficient heat, and optionally contains talc and/or water soluble titanium compound.

Abstract: This invention relates to catalyst carriers to be used as supports for metal and metal oxide catalyst components of use in a variety of chemical reactions. More specifically, the invention provides a process of formulating a low surface area alpha alumina carrier that is suitable as a support for silver and the use of such catalyst in chemical reactions, especially the epoxidation of ethylene to ethylene oxide. A precursor for a catalyst support comprises an admixture of an alpha alumina and/or a transition alumina; a binder; and either a solid blowing agent which expands, or propels a gas upon the application of sufficient heat, and optionally contains talc and/or water soluble titanium compound.

Abstract: The invention relates to an improved process for producing a catalyst useful for the epoxidation of ethylene to ethylene oxide. In forming the catalyst, a silver-impregnated support is subjected to two calcinations. The support is subjected to a first calcination in a first atmosphere comprising air. Next the support is subjected to a second calcination in a second atmosphere which is substantially entirely comprised of inert gas, and which second atmosphere is substantially absent of hydrogen. This two-stage calcination produces an improved catalyst which contains fewer organics left over under standard conditions of air calcination alone, while costing less than calcination in an inert gas alone.

Abstract: This invention relates to a process for reducing the corrosion rate of iron-containing vessels within an ethylene glycol distillation system. The inventive process includes the addition of an additive component of sodium nitrite and sodium hypophosphite into such iron-containing vessels, to thereby react with iron of the inside walls and form a protective coating thereon. This process reduces the corrosion rate in iron-containing vessels of the apparatus, and reduces the catalytic effects of iron corrosion products within the system. Thus, not only is the on-stream time of the vessels extended, but also product quality is improved by reducing the aldehyde content of the final ethylene glycol product.

Abstract: A solid (i.e., heterogeneous) catalyst useful for preparing an alkylene glycol from the corresponding alkylene oxide as well as a process for the catalytic hydration of an alkylene oxide to an alkylene glycol utilizing such a catalyst are provided. The catalyst of the present invention is based on an ion exchange resin including polystyrene crosslinked with from about 2 to about 10 weight (wt.) % divinyl benzene. The ion exchange resin further includes quaternary ammonium groups or quaternary phosphonium groups. The process includes reacting water and an alkylene oxide in at least one reactor under conditions to form an alkylene glycol, wherein the at least one reactor includes a catalyst based on an ion exchange resin that includes polystyrene crosslinked with from about 2 to about 10 weight (wt.) % divinyl benzene.

Abstract: The invention pertains to a catalyst useful for the epoxidation of an olefin. More particularly, the invention pertains to an improved catalyst useful for the epoxidation of ethylene to ethylene oxide. The catalyst has improved selectivity in the epoxidation process. The catalyst comprises a solid support having a surface, which has a first mode of pores which have a diameter ranging from about 0.01 ?m to about 5 ?m and having a differential pore volume peak in the range of from about 0.01 ?m to about 5 ?m. The surface then has a second mode of pores, different from the first mode of pores, which second mode of pores have a diameter ranging from about 1 ?m to about 20 ?m and have a differential pore volume peak in the range of from about 1 ?m to about 20 ?m.

Abstract: The invention pertains to a catalyst useful for the epoxidation of an olefin. More particularly, the invention pertains to an improved catalyst useful for the epoxidation of ethylene to ethylene oxide. The catalyst has improved selectivity in the epoxidation process. The catalyst comprises a solid support having a surface, which has a first mode of pores which have a diameter ranging from about 0.01 ?m to about 5 ?m and having a differential pore volume peak in the range of from about 0.01 ?m to about 5 ?m. The surface then has a second mode of pores, different from the first mode of pores, which second mode of pores have a diameter ranging from about 1 ?m to about 20 ?m and have a differential pore volume peak in the range of from about 1 ?m to about 20 ?m.

Abstract: A geometrically shaped solid carrier is provided that improves the performance and effectiveness of an olefin epoxidation catalyst for epoxidizing an olefin to an olefin oxide. In particular, improved performance and effectiveness of an olefin epoxidation catalyst is achieved by utilizing a geometrically shaped refractory solid carrier in which at least one wall thickness of said carrier is less than 2.5 mm.

Abstract: This invention relates to a process for reducing the corrosion rate of iron-containing vessels within an ethylene glycol distillation system. The inventive process includes the addition of an additive component of sodium nitrite and sodium hypophosphite into such iron-containing vessels, to thereby react with iron of the inside walls and form a protective coating thereon. This process reduces the corrosion rate in iron-containing vessels of the apparatus, and reduces the catalytic effects of iron corrosion products within the system. Thus, not only is the on-stream time of the vessels extended, but also product quality is improved by reducing the aldehyde content of the final ethylene glycol product.

Abstract: A method for controlling ethylene oxidation uses ethylene and oxygen, in conjunction with a silver based catalyst, a moderator and a co-moderator, to form ethylene oxide. When controlling the ethylene oxidation reaction, the moderator concentration is maintained constant within a comparatively narrow operative concentration range and the co-moderator concentration is varied within a comparatively wider operative concentration range, to optimize a catalyst property such as the catalyst activity and/or the catalyst selectivity.

Abstract: This invention relates to a process for reducing the corrosion rate of iron-containing vessels within an ethylene glycol distillation system. The inventive process includes the addition of an additive component of sodium nitrite and sodium hypophosphite into such iron-containing vessels, to thereby react with iron of the inside walls and form a protective coating thereon. This process reduces the corrosion rate in iron-containing vessels of the apparatus, and reduces the catalytic effects of iron corrosion products within the system. Thus, not only is the on-stream time of the vessels extended, but also product quality is improved by reducing the aldehyde content of the final ethylene glycol product.

Abstract: The present invention relates to a method for recovering rhenium from an ethylene oxide catalyst containing rhenium and at least silver on a solid support, wherein at least a substantial portion of the rhenium present in the catalyst is extracted by intimate contact of the catalyst with one or more polar non-acidic organic solvents substantially free of water such that a rhenium-containing solution is formed containing the polar non-acidic organic solvent and extracted rhenium, the polar non-acidic organic solvent containing one or more oxygen, nitrogen, and/or halogen atoms in its molecular structure.

Abstract: A carrier for a catalyst useful for the epoxidation of an olefin which comprises an inert, refractory solid carrier is provided. The carrier has no or little absolute volume from small pores, of less than 1 micrometer, and large pores, of above 5 micrometer. By “no or little absolute volume from small pores of less than 1 micron” it is meant that the pore volume of such pores is less than 0.20 ml/g. By “no or little absolute volume from large pores of above 5 micron” it is meant that the pore volume of such pores is less than 0.20 ml/g. The invention further provides a catalyst useful for the epoxidation of an olefin supported on such a carrier and a process for the oxidation of an olefin, especially ethylene, to an olefin oxide, especially ethylene oxide.

Abstract: A carrier for a catalyst useful for the epoxidation of an olefin which comprises an inert, refractory solid carrier is provided. The carrier has no or little absolute volume from small pores, of less than 1 micrometer, and large pores, of above 5 micrometer. By “no or little absolute volume from small pores of less than 1 micron” it is meant that the pore volume of such pores is less than 0.20 ml/g. By “no or little absolute volume from large pores of above 5 micron” it is meant that the pore volume of such pores is less than 0.20 ml/g. The invention further provides a catalyst useful for the epoxidation of an olefin supported on such a carrier and a process for the oxidation of an olefin, especially ethylene, to an olefin oxide, especially ethylene oxide.

Abstract: A reactor and heat exchanger assembly is provided with the heat exchanger integrally affixed to the reactor exit head and adapted to immediately cool reactor gases from the reactor.

Abstract: A method to achieve a controlled start-up temperature of an expoxidation process which exceeds the maximum achievable temperature of the epoxidation reactor relative to using an external heat source. The method of the present invention employs an oxidation reaction within the reactor to bring the temperature of the reactor to a temperature that is suitable for conditioning a high selectivity catalyst. The method of the present invention includes first bringing a reactor including a high selectivity catalyst to a first temperature using the external heat source to the reactor, while staying within the reactor design limitations and maintaining a gas flow to the reactor that is within 25 to 100% of the design rates. Once the reactor has achieved the first temperature, at least an olefin, e.g., ethylene, and then oxygen are introduced to the reactor feed gas.

Abstract: A catalytic process for preparing a monoalkylene glycol from a corresponding alkylene oxide utilizing an ion exchange resin and a reactor in which an upflow process is used is provided. In particular, the process includes reacting water and an alkylene oxide in at least one reactor under conditions to form an alkylene glycol, wherein the at least one reactor includes an ion exchange resin and the reactor is operating in an upflow direction.