Patents by Inventor Nabil Rizkalla
Nabil Rizkalla has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
-
Patent number: 10669247Abstract: A method for lowering the sodium content of different carriers which may have different physical properties as well as varying degrees of sodium is provided. The method, which lowers the sodium content from the surface, subsurface as well as the binding layer of the carrier, includes contacting a carrier with water. A rinse solution is recovered from the contacting. The rinse solution includes leached sodium from the carrier. The sodium content in the rinse solution is then determined. The contacting, recovering and determining are repeated until a steady state in the sodium content is achieved.Type: GrantFiled: September 11, 2017Date of Patent: June 2, 2020Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 10040773Abstract: A silver-based ethylene epoxidation catalyst is provided that exhibits improved performance, i.e., selectivity and activity decline. The catalyst that exhibits the improved performance includes greater than about 20% by weight of silver disposed on an alpha-alumina carrier, and a promoting amount of one or more promoters disposed on the alpha-alumina carrier. The silver is present on the alpha-alumina carrier as silver particles having a diameter of greater than about 150 nm and a distribution density of about 20 particles per 1 square micron or less.Type: GrantFiled: February 26, 2016Date of Patent: August 7, 2018Assignee: Scientific Design Company, Inc.Inventors: Wojciech L. Suchanek, Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20170369460Abstract: A method for lowering the sodium content of different carriers which may have different physical properties as well as varying degrees of sodium is provided. The method, which lowers the sodium content from the surface, subsurface as well as the binding layer of the carrier, includes contacting a carrier with water. A rinse solution is recovered from the contacting. The rinse solution includes leached sodium from the carrier. The sodium content in the rinse solution is then determined. The contacting, recovering and determining are repeated until a steady state in the sodium content is achieved.Type: ApplicationFiled: September 11, 2017Publication date: December 28, 2017Applicant: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 9758498Abstract: A method for lowering the sodium content of different carriers which may have different physical properties as well as varying degrees of sodium is provided. The method, which lowers the sodium content from the surface, subsurface as well as the binding layer of the carrier, includes contacting a carrier with water. A rinse solution is recovered from the contacting. The rinse solution includes leached sodium from the carrier. The sodium content in the rinse solution is then determined. The contacting, recovering and determining are repeated until a steady state in the sodium content is achieved.Type: GrantFiled: July 28, 2015Date of Patent: September 12, 2017Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 9452419Abstract: 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.Type: GrantFiled: May 16, 2014Date of Patent: September 27, 2016Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20160251326Abstract: A silver-based ethylene epoxidation catalyst is provided that exhibits improved performance, i.e., selectivity and activity decline. The catalyst that exhibits the improved performance includes greater than about 20% by weight of silver disposed on an alpha-alumina carrier, and a promoting amount of one or more promoters disposed on the alpha-alumina carrier. The silver is present on the alpha-alumina carrier as silver particles having a diameter of greater than about 150 nm and a distribution density of about 20 particles per 1 square micron or less.Type: ApplicationFiled: February 26, 2016Publication date: September 1, 2016Applicant: Scientific Design Company, Inc.Inventors: Wojciech L. Suchanek, Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 9427729Abstract: A silver-based ethylene oxide catalyst that can be used in the vapor phase conversion of ethylene to ethylene oxide in the presence of oxygen is provided that includes a carrier; a catalytic effective amount of silver; and a promoting amount of at least one promoter, wherein the catalyst has a surface sodium content of 100 ppm or less.Type: GrantFiled: May 16, 2014Date of Patent: August 30, 2016Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20150329510Abstract: A method for lowering the sodium content of different carriers which may have different physical properties as well as varying degrees of sodium is provided. The method, which lowers the sodium content from the surface, subsurface as well as the binding layer of the carrier, includes contacting a carrier with water. A rinse solution is recovered from the contacting. The rinse solution includes leached sodium from the carrier. The sodium content in the rinse solution is then determined. The contacting, recovering and determining are repeated until a steady state in the sodium content is achieved.Type: ApplicationFiled: July 28, 2015Publication date: November 19, 2015Applicant: SCIENTIFIC DESIGN COMPANY, INC.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 9095843Abstract: A method for lowering the sodium content of different carriers which may have different physical properties as well as varying degrees of sodium is provided. The method, which lowers the sodium content from the surface, subsurface as well as the binding layer of the carrier, includes contacting a carrier with water. A rinse solution is recovered from the contacting. The rinse solution includes leached sodium from the carrier. The sodium content in the rinse solution is then determined. The contacting, recovering and determining are repeated until a steady state in the sodium content is achieved.Type: GrantFiled: May 16, 2014Date of Patent: August 4, 2015Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20150057150Abstract: A process for the preparation of a catalyst useful for the vapor phase production of ethylene oxide from ethylene and oxygen comprising providing a catalyst precursor comprising an inert support having a catalytically effective amount of a silver containing compound, a promoting amount of an alkali metal containing compound, and a promoting amount of a transition metal containing compound disposed thereon; calcining the catalyst precursor to convert the silver in the silver containing compound to metallic silver by heating the catalyst precursor to form a catalyst; and curing the catalyst in an inert gas atmosphere at temperatures of about 250° C. to about 600° C. for a period of about 1 hour to 200 hours.Type: ApplicationFiled: November 10, 2014Publication date: February 26, 2015Applicant: SCIENTIFIC DESIGN COMPANY, INC.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20140343308Abstract: A silver-based ethylene oxide catalyst that can be used in the vapor phase conversion of ethylene to ethylene oxide in the presence of oxygen is provided that includes a carrier; a catalytic effective amount of silver; and a promoting amount of at least one promoter, wherein the catalyst has a surface sodium content of 100 ppm or less.Type: ApplicationFiled: May 16, 2014Publication date: November 20, 2014Applicant: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20140343306Abstract: A method for lowering the sodium content of different carriers which may have different physical properties as well as varying degrees of sodium is provided. The method, which lowers the sodium content from the surface, subsurface as well as the binding layer of the carrier, includes contacting a carrier with water. A rinse solution is recovered from the contacting. The rinse solution includes leached sodium from the carrier. The sodium content in the rinse solution is then determined. The contacting, recovering and determining are repeated until a steady state in the sodium content is achieved.Type: ApplicationFiled: May 16, 2014Publication date: November 20, 2014Applicant: SCIENTIFIC DESIGN COMPANY, INC.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20140343307Abstract: 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.Type: ApplicationFiled: May 16, 2014Publication date: November 20, 2014Applicant: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 8883675Abstract: A process for the preparation of a catalyst useful for the vapor phase production of ethylene oxide from ethylene and oxygen comprising providing a catalyst precursor comprising an inert support having a catalytically effective amount of a silver containing compound, a promoting amount of an alkali metal containing compound, and a promoting amount of a transition metal containing compound disposed thereon; calcining the catalyst precursor to convert the silver in the silver containing compound to metallic silver by heating the catalyst precursor to form a catalyst; and curing the catalyst in an inert gas atmosphere at temperatures of about 250° C. to about 600° C. for a period of about 1 hour to 200 hours.Type: GrantFiled: May 17, 2011Date of Patent: November 11, 2014Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Patent number: 8791280Abstract: 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.Type: GrantFiled: August 10, 2005Date of Patent: July 29, 2014Assignee: SD Lizenzverwertungsgesellschaft mbH & Co. KGInventor: Nabil Rizkalla
-
Patent number: 8487123Abstract: A start-up process for epoxidation of ethylene is provided. The process includes initiating an epoxidation reaction by reacting a feed gas composition in the presence of an epoxidation catalyst at a first temperature of about 180° C. to about 210° C. The first temperature is increased to a second temperature of about 230° C. to about 290° C., over a time period of about 6 hours to about 50 hours, while simultaneously adding a sufficient concentration of moderator so that the amount of moderator adsorbed on the catalyst after achieving the second temperature is from about 10 to about 50 g/m3 of catalyst. The second temperature is maintained for about 50 hours to about 350 hours, while regulating the feed gas composition to contain about 0.5% to about 25% CO2. The second temperature is decreased to a third temperature, while simultaneously increasing moderator concentration to a level greater than the sufficient concentration.Type: GrantFiled: December 23, 2010Date of Patent: July 16, 2013Assignee: Scientific Design Company, Inc.Inventors: Nabil Rizkalla, Norma B. Castagnola, Girish Desai
-
Publication number: 20130006002Abstract: 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.Type: ApplicationFiled: September 12, 2012Publication date: January 3, 2013Applicant: SD LIZENZVERWERTUNGSGESELLSCHAFT MBH & CO. KGInventor: Nabil Rizkalla
-
Patent number: 8318627Abstract: 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.Type: GrantFiled: August 10, 2005Date of Patent: November 27, 2012Assignee: SD Lizenzverwertungsgesellschaft mbH & Co. KGInventor: Nabil Rizkalla
-
Publication number: 20110281724Abstract: A process for the preparation of a catalyst useful for the vapor phase production of ethylene oxide from ethylene and oxygen comprising providing a catalyst precursor comprising an inert support having a catalytically effective amount of a silver containing compound, a promoting amount of an alkali metal containing compound, and a promoting amount of a transition metal containing compound disposed thereon; calcining the catalyst precursor to convert the silver in the silver containing compound to metallic silver by heating the catalyst precursor to form a catalyst; and curing the catalyst in an inert gas atmosphere at temperatures of about 250° C. to about 600° C. for a period of about 1 hour to 200 hours.Type: ApplicationFiled: May 17, 2011Publication date: November 17, 2011Applicant: SCIENTIFIC DESIGN COMPANY, INC.Inventors: Nabil Rizkalla, Andrzej Rokicki
-
Publication number: 20110152549Abstract: A start-up process for epoxidation of ethylene is provided. The process includes initiating an epoxidation reaction by reacting a feed gas composition in the presence of an epoxidation catalyst at a first temperature of about 180° C. to about 210° C. The first temperature is increased to a second temperature of about 230° C. to about 290° C., over a time period of about 6 hours to about 50 hours, while simultaneously adding a sufficient concentration of moderator so that the amount of moderator adsorbed on the catalyst after achieving the second temperature is from about 10 to about 50 g/m3 of catalyst. The second temperature is maintained for about 50 hours to about 350 hours, while regulating the feed gas composition to contain about 0.5% to about 25% CO2. The second temperature is decreased to a third temperature, while simultaneously increasing moderator concentration to a level greater than the sufficient concentration.Type: ApplicationFiled: December 23, 2010Publication date: June 23, 2011Applicant: SCIENTIFIC DESIGN COMPANY, INC.Inventors: Nabil Rizkalla, Norma B. Castagnola, Girish Desai