Abstract: A method of producing an alkylene oxide includes passing a reaction mixture comprising alkylene, oxygen and a gaseous chlorine-containing promoter species over a supported catalyst containing silver and a promoting amount of rhenium to undergo an epoxidation reaction at a first operating condition. The method further includes subsequently performing the epoxidation reaction at a preferred operating condition. The preferred operating condition is characterized by an efficiency of the epoxidation reaction toward the alkylene oxide where the efficiency is lower than that of a maximum efficiency achievable at an operating temperature corresponding to the preferred operating condition.

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: A two-stage, gas phase process for manufacturing alkylene glycol (e.g., ethylene glycol) from an alkene (e.g., ethylene), oxygen and water, the process comprising the steps of: (A) Contacting under gas phase, oxidation conditions gaseous alkene and oxygen over a heterogeneous oxidation catalyst to produce a gaseous oxidation product comprising alkylene oxide, water and unreacted alkene; (B) Contacting under gas phase, hydrolysis conditions the gaseous oxidation product of (A) with added water over a heterogeneous hydrolysis catalyst to produce a gaseous alkylene glycol and unreacted alkene; and (C) Recycling the unreacted alkene of (B) to (A). The hydrolysis catalyst is selected from the group consisting of hydrotalcites, metal-loaded zeolites, phosphates, and metal-loaded ion-exchanged molecular sieves.

Abstract: A plant and process for producing alkylene oxides to control the production of silver chloride on a high efficiency silver catalyst is disclosed and described. The process involves reacting an alkylene and an organic chloride gas phase promoter with oxygen over the high efficiency silver catalyst. The sulfur concentration in the alkylene oxide reactor feed is controlled to reduce the production of silver chloride which acts as a catalyst poison.

Abstract: An improved carrier useful for preparing a catalyst having excellent catalytic performance when used in the production of alkylene oxide, such as ethylene oxide. The carrier is obtained by a) impregnating a preformed alpha-alumina carrier with at least one modifier selected from among alkali metal silicates and alkaline earth metal silicates, b) drying the impregnated carrier; and c) calcining dried carrier. The carrier may optionally be washed, prior to being impregnated by conventional catalytic material and/or promoter material.

Abstract: A catalyst for the manufacture of alkylene oxide, for example ethylene oxide, by the vapor-phase epoxidation of alkene containing impregnated silver and at least one efficiency-enhancing promoter on an inert, refractory solid support, said support incorporating a sufficient amount of zirconium component (present and remaining substantially as zirconium silicate) as to enhance at least one of catalyst activity, efficiency and stability as compared to a similar catalyst which does not contain the zirconium component.

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: A method of producing an alkylene oxide includes passing a reaction mixture comprising alkylene, oxygen and a gaseous chlorine-containing promoter species over a supported catalyst containing silver and a promoting amount of rhenium to undergo an epoxidation reaction at a first operating condition. The method further includes subsequently performing the epoxidation reaction at a preferred operating condition. The preferred operating condition is characterized by an efficiency of the epoxidation reaction toward the alkylene oxide where the efficiency is lower than that of a maximum efficiency achievable at an operating temperature corresponding to the preferred operating condition.

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 catalyst for the manufacture of alkylene oxide, for example ethylene oxide, by the vapor-phase epoxidation of alkene containing impregnated silver and at least one efficiency-enhancing promoter on an inert, refractory solid support, said support incorporating a sufficient amount of zirconium component (present and remaining substantially as zirconium silicate) as to enhance at least one of catalyst activity, efficiency and stability as compared to a similar catalyst which does not contain the zirconium component.

Abstract: A two-stage, gas phase process for manufacturing alkylene glycol (e.g., ethylene glycol) from an alkene (e.g., ethylene), oxygen and water, the process comprising the steps of: (A) Contacting under gas phase, oxidation conditions gaseous alkene and oxygen over a heterogeneous oxidation catalyst to produce a gaseous oxidation product comprising alkylene oxide, water and unreacted alkene; (B) Contacting under gas phase, hydrolysis conditions the gaseous oxidation product of (A) with added water over a heterogeneous hydrolysis catalyst to produce a gaseous alkylene glycol and unreacted alkene; and (C) Recycling the unreacted alkene of (B) to (A). The hydrolysis catalyst is selected from the group consisting of hydrotalcites, metal-loaded zeolites, phosphates, and metal-loaded ion-exchanged molecular sieves.

Abstract: A catalyst for the manufacture of alkylene oxide, for example ethylene oxide, by the vapor-phase epoxidation of alkene containing impregnated silver and at least one efficiency-enhancing promoter on an inert, refractory solid support, said support incorporating a sufficient amount of zirconium component (present and remaining substantially as zirconium silicate) as to enhance at least one of catalyst activity, efficiency and stability as compared to a similar catalyst which does not contain the zirconium component.

Abstract: An improved process for the manufacture of ethylene oxide through the epoxidation of ethylene using a catalyst comprising silver and at least one efficiency-enhancing salt of a member of a redox-half reaction pair. Added to the epoxidation reaction is a two-component gas-phase promoter system comprising a chlorine-containing component (for example ethyl chloride, methyl chloride, vinyl chloride and ethylene dichloride), and a nitrogen-containing component of nitric oxide and other compounds capable of generating under reaction conditions at least one gaseous efficiency-enhancing member of a redox-half reaction pair comprising NO, NO2, N2O3 or N2O4. The amount of each component of said gaseous promoter is adjusted to maintain the ration of N* to Z* less than or equal to 1 wherein, N* is the nitric oxide equivalent in ppmv, ranging from 1 to 20 ppmv and Z*=ethyl chloride equivalent (ppmv)*100 percent/ethane equivalent (mol percent)*100 ranging from 5 to 40 ppmv.

Abstract: A catalyst for the manufacture of alkylene oxide, for example ethylene oxide, by the vapor-phase epoxidation of alkene containing impregnated silver and at least one efficiency-enhancing promoter on an inert, refractory solid support, said support incorporating a sufficient amount of zirconium component (present and remaining substantially as zirconium silicate) as to enhance at least one of catalyst activity, efficiency and stability as compared to a similar catalyst which does not contain the zirconium component.

Abstract: A supported silver catalyst and use thereof in a process for producing an alkylene oxide, such as ethylene oxide, by the direct oxidation of an alkylene with oxygen or an oxygen-containing gas, wherein the catalyst provides improved stability and improved resilience to reactor upsets and timely recovery to substantially pre-upset levels of catalyst activity and/or efficiency. In some embodiments, the catalyst also exhibits improved activity. A catalyst capable of producing ethylene oxide at a selectivity of at least 87 percent while achieving a work rate of at least 184 kg/h/m3 at a temperature of no greater than 235° C. when operated in a process where the inlet feed to a reactor containing the catalyst comprises ethylene, oxygen, and carbon dioxide, wherein the concentration of carbon dioxide in the inlet feed is greater than or equal to 2 mole percent.

Abstract: A catalyst for the manufacture of alkylene oxide, for example ethylene oxide, by the vapor-phase epoxidation of alkene containing impregnated silver and at least one efficiency-enhancing promoter on an inert, refractory solid support, said support incorporating a sufficient amount of zirconium component (present and remaining substantially as zirconium silicate) as to enhance at least one of catalyst activity, efficiency and stability as compared to a similar catalyst which does not contain the zirconium component.

Abstract: An improved process for the manufacture of ethylene oxide through the epoxidation of ethylene using a catalyst comprising silver and at least one efficiency-enhancing salt of a member of a redox-half reaction pair. Added to the epoxidation reaction is a two-component gas-phase promoter system comprising a chlorine-containing component (for example ethyl chloride, methyl chloride, vinyl chloride and ethylene dichloride), and a nitrogen-containing component of nitric oxide and other compounds capable of generating under reaction conditions at least one gaseous efficiency-enhancing member of a redox-half reaction pair comprising NO, NO2, N2O3 or N2O4. The amount of each component of said gaseous promoter is adjusted to maintain the ration of N* to Z* less than or equal to 1 wherein, N* is the nitric oxide equivalent in ppmv, ranging from 1 to 20 ppmv and Z*=ethyl chloride equivalent (ppmv)*100 percent/ethane equivalent (mol percent)*100 ranging from 5 to 40 ppmv.

Abstract: An improved carrier useful for preparing a catalyst having excellent catalytic performance when used in the production of alkylene oxide, such as ethylene oxide. The carrier is obtained by a) impregnating a preformed alpha-alumina carrier with at least one modifier selected from among alkali metal silicates and alkaline earth metal silicates, b) drying said impregnated carrier; and c) calcining said dried carrier. The carrier may optionally be washed, prior to being impregnated by conventional catalytic material and/or promoter material.

Abstract: Catalysts for the production of alkylene oxide by the epoxidation of alkene with oxygen comprise a silver-containing support, and a sufficient amount of cobalt component to enhance at least one of activity and/or efficiency and/or stability as compared to a similar catalyst which does not contain cobalt component.

Abstract: Catalysts for the production of alkylene oxide by the epoxidation of alkene with oxygen comprise a silver impregnated support containing a sufficient amount of manganese component to enhance at least one of activity and/or efficiency and/or stability as compared to a similar catalyst which does not contain manganese component.