Abstract: A process for initiating a highly selective ethylene oxide catalyst is provided in which the highly selective ethylene oxide catalyst is operated first as a ‘standard’ Ag-based catalyst (e.g., a catalyst that contains only silver and alkali metal, especially cesium). Moreover, the inventive initiation procedure is more efficient when the concentration of carbon dioxide in the feed is higher than 6 vol. %, and even more efficient when the concentration of carbon dioxide in the feed is higher than 10 vol. %, of the feed mixture during the initiation period.

Abstract: The invention describes a process for producing a catalyst useful for the epoxidation of an olefin. More particularly, the invention pertains to a catalyst useful for the oxidation of ethylene to ethylene oxide. The catalyst comprises a solid support such as alpha-alumina, which has a catalytically effective amount of silver or a silver-containing compound, and a promoting amount of rhenium or a rhenium-containing compound, and a promoting amount of one or more alkali metals or alkali metal-containing compounds on the surface of the support. To produce a catalyst precursor. The catalyst precursor is contacted with an atmosphere comprising oxygen and steam, which atmosphere is substantially absent of an olefin, to hasten the attainment of peak selectivity in the process of oxidation of ethylene to ethylene oxide.

Abstract: A high activity and high selectivity silver catalyst comprising silver and, optionally, one or more promoters supported on a suitable support material having the form of a shaped agglomerate. The structure of the shaped agglomerate is that of a hollow cylinder having a relatively small inside (bore) diameter. The catalyst is made by providing the shaped material of a particular geometry and incorporating the catalytic components therein. The catalyst is useful in the epoxidation of ethylene.

Abstract: A process for preparing an epoxidation catalyst comprising silver and a high-selectivity dopant on a support, which process comprises depositing a base having a pKb of at most 3.5 when measured in water at 25° C., on the support prior to depositing silver on the support, and depositing silver and a high-selectivity dopant on the support; the epoxidation catalyst; and a process for preparing an olefin oxide by reacting an olefin with oxygen in the presence of the epoxidation catalyst.

Abstract: A process is provided for the epoxidation of an olefin comprising the steps of: contacting a feed comprising an olefin and oxygen with a catalyst comprising a silver component and a high-selectivity dopant deposited on a fluoride-mineralized carrier; and producing a product mix comprising an olefin oxide, wherein the concentration of carbon dioxide in the feed is less than about 2 mole-%, relative to the total feed.

Abstract: The invention relates to a process for the epoxidation of an olefin, wherein the concentration of the olefin oxide in the outlet is greater than about 2.2% by volume. More particularly, the invention relates to a process for the epoxidation of ethylene by contacting a feed including at least ethylene and oxygen with an improved epoxidation catalyst. The catalyst which has improved selectivity in the epoxidation process at high productivities, includes a solid support having a surface, which has a first mode of pores that have a diameter ranging from about 0.01 ?m to about 5 ?m and having a differential pore volume peak in the range from about 0.01 ?m to about 5 ?m. The surface also has a second mode of pores, which is different from the first mode of pores, having a diameter ranging from about 1 ?m to about 20 ?m and have a differential pore volume peak in the range from about 1 ?m to about 20 ?m.

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: The invention relates to a process for the epoxidation of an olefin, wherein the concentration of the olefin oxide in the outlet is greater than about 2.2% by volume. More particularly, the invention relates to a process for the epoxidation of ethylene by contacting a feed including at least ethylene and oxygen with an improved epoxidation catalyst. The catalyst which has improved selectivity in the epoxidation process at high productivities, includes a solid support having a surface, which has a first mode of pores that have a diameter ranging from about 0.01 ?m to about 5 ?m and having a differential pore volume peak in the range from about 0.01 ?m to about 5 ?m. The surface also has a second mode of pores, which is different from the first mode of pores, having a diameter ranging from about 1 ?m to about 20 ?m and have a differential pore volume peak in the range from about 1 ?m to about 20 ?m.

Abstract: A process is provided for the epoxidation of an olefin comprising the steps of: contacting a feed comprising an olefin and oxygen with a catalyst comprising a silver component deposited on a fluoride-mineralized carrier; and producing a product mix comprising an olefin oxide, wherein the partial pressure of olefin oxide in the product mix is greater than about 60 kPa. A process is provided for the epoxidation of an olefin comprising the steps of: contacting a feed comprising an olefin and oxygen with a catalyst comprising a silver component and a high-selectivity dopant deposited on a fluoride-mineralized carrier; and producing a product mix comprising an olefin oxide, wherein the partial pressure of olefin oxide in the product mix is greater than about 20 kPa.

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: The present invention relates to an improved epoxidation process and an improved epoxidation reactor. The present invention makes use of a reactor which comprises a plurality of microchannels. Such process microchannels may be adapted such that the epoxidation and optionally other processes can take place in the microchannels and that they are in a heat exchange relation with channels adapted to contain a heat exchange fluid. A reactor comprising such process microchannels is referred to as a “microchannel reactor”. The invention also provides a method of installing an epoxidation catalyst in a microchannel reactor. The invention also provides a method of preparing an epoxidation catalyst. The invention also provides an epoxidation catalyst. The invention also provides a certain process for the epoxidation of an olefin and a process for the preparation of a chemical derivable from an olefin oxide. The invention also provides a microchannel reactor.

Abstract: The present invention relates to an improved epoxidation process and an improved epoxidation reactor. The present invention makes use of a reactor which comprises a plurality of microchannels. Such process microchannels may be adapted such that the epoxidation and optionally other processes can take place in the microchannels and that they are in a heat exchange relation with channels adapted to contain a heat exchange fluid. A reactor comprising such process microchannels is referred to as a “microchannel reactor”. The invention also provides a method of installing an epoxidation catalyst in a microchannel reactor. The invention also provides a method of preparing an epoxidation catalyst. The invention also provides an epoxidation catalyst. The invention also provides a certain process for the epoxidation of an olefin and a process for the preparation of a chemical derivable from an olefin oxide. The invention also provides a microchannel reactor.

Abstract: A catalyst comprising a noble metal supported on a diatomaceous earth and a transition metal zeolite is disclosed. The catalyst is used in an epoxidation process comprising reacting an olefin, hydrogen, and oxygen. The diatomaceous earth is readily available and may be used in a slurry process without further particle size enlargement.

Abstract: A process for the production of an olefin oxide, which process comprises reacting a feed comprising an olefin and oxygen in the presence of a silver-containing catalyst, wherein before the catalyst has reached an advanced stage of ageing the reaction temperature is above 255° C. and the olefin content of the feed is above 25 mole-%, relative to the total feed.

Abstract: There is disclosed a process for producing an olefin oxide, which is characterized by reacting an olefin with oxygen in the presence of a silver catalyst and 0.2 mole or more of water per mol of the olefin.

Abstract: Described is a method of improving the process and operation of an existing system for manufacturing ethylene oxide. The ethylene oxide manufacturing system includes an epoxidation reactor system containing a volume of high activity epoxidation catalyst. The method includes replacing a portion of the volume of high activity epoxidation catalyst with a volume of high selectivity catalyst, and modifying the operation of the process system so as to provide for a feed to the epoxidation reactor system having a reduced carbon dioxide concentration.

Abstract: There is provided a catalyst carrier comprising a refractory inorganic material having a sodium solubilization rate no greater than 5 ppmw/5 minutes. There is further a catalyst comprising a refractory inorganic material carrier having a sodium solubilization rate no greater than 5 ppmw/5 minutes; and one or more catalytically reactive metals deposited on said carrier. There is also provided a catalyst suitable for the vapor phase production of alkylene oxide from olefins and oxygen comprising an alumina-based carrier having a sodium solubilization rate no greater than 5 ppmw/5 minutes; and catalytically reactive silver deposited on said carrier.

Abstract: A process for the epoxidation of an olefin, which process comprises reacting a feed comprising the olefin, oxygen and a reaction modifier in the presence of a highly selective silver-based catalyst at a reaction temperature T, and with the reaction modifier being present in a relative quantity Q which is the ratio of an effective molar quantity of active species of the reaction modifier present in the feed to an effective molar quantity of hydrocarbons present in the feed, and which process comprises the steps of: operating at a first operating phase wherein the value of T is T1 and the value of Q is Q1, and subsequently operating at a second operating phase at a reaction temperature which is different from the reaction temperature employed in the first operating phase, such that the value of T is T2 and the value of Q is substantially Q2, whereby Q2 is determined by calculation and Q2 is defined by the formula Q2=Q1+B(T2?T1), wherein B denotes a constant factor which is greater than 0; a reaction system

Abstract: A method of increasing the lifetime of a hydro-oxidation catalyst comprising, preferably, gold, silver, or mixtures thereof, and optionally one or more promoters, on a titanium-containing support, such as a titanosilicate or titanium dispersed on silica. The method of the invention involves contacting the catalyst support with a hydroxy-functionalized organosilicon compound, a carboxy-functionalized organosilicon compound, or a mixture of hydroxy- and carboxy-functionalized organosilicon compounds, such as, sodium methyl siliconate or (2-carboxypropyl)tetramethyldisiloxane. The contacting is preferably conducted during deposition of the catalytic metal(s) and optional promoters(s) onto the support. A catalyst composition and hydro-oxidation process utilizing the silicon-treated catalyst support are also claimed.

Abstract: A method for the start-up of a process for the epoxidation of an olefin, which method comprises contacting a catalyst bed comprising a silver-based highly selective epoxidation catalyst, or a precursor of the catalyst comprising the silver in cationic form, with a feed comprising oxygen at a temperature of the catalyst bed above 260° C. for a period of at most 150 hours, and subsequently decreasing the temperature of the catalyst bed to a value of at most 260° C., and a process for the epoxidation of an olefin, which process, comprises contacting a catalyst bed comprising a silver-based highly selective epoxidation catalyst, or a precursor of the catalyst comprising the silver in cationic form, with a feed comprising oxygen at a temperature of the catalyst bed above 260° C. for a period of at most 150 hours, and subsequently decreasing the-temperature of the catalyst bed to a value of at most 260° C. and contacting the catalyst with the feed comprising the olefin and oxygen.

Abstract: A carrier for use in the catalyst for the production of an epoxide is obtained by preparing a carrier precursor containing (a) ?-alumina, (b) silicon or a compound thereof, and (c) at least one element selected from the class consisting of germanium, tin, lead, phosphorus, antimony, and bismuth or a compound thereof and subsequently heat-treating the precursor in non-oxidative gas. The catalyst for the production of the epoxide is obtained by having silver deposited on this carrier and the epoxide is obtained from a corresponding unsaturated hydrocarbon of 2–4 carbon atoms with a high selectivity by using the catalyst.

Abstract: The invention is a process for epoxidizing an olefin with hydrogen and oxygen in the presence of a noble metal-containing titanium or vanadium zeolite and a modifier selected from the group consisting of carbon monoxide, methylacetylene, and propadiene. The process results in significantly reduced alkane by-product formed by the hydrogenation of olefin compared to processes that do not use the carbon monoxide, methylacetylene, and/or propadiene modifier.

Abstract: A material especially useful for the selective oxidation of hydrocarbons and other organic compounds includes a non-crystalline, porous inorganic oxide having at least 97 volume percent mesopores based on micropores and mesopores, and at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal.

Abstract: The present invention provides an improved oxidation catalyst composition containing a catalytically effective amount of silver and a rubidium promoter deposited on a carrier, which rubidium metal promoter provides a quantity of rubidium at least 5 &mgr;mole and less than 60 &mgr;mole per gram of catalyst composition. The catalysts of the invention are deposited on carriers such as &agr;-alumina and silver-bonded calcium carbonate. The invention is also directed to a process for the oxidation of olefins, which process involves reacting the olefin with oxygen in the presence of a catalyst composition having a catalytically effective amount of silver and a rubidium promoter deposited on a carrier, wherein said rubidium metal promoter provides a quantity of rubidium of at least 5 &mgr;mole and less than 60 &mgr;mole per gram of catalyst composition.

Abstract: A silver catalyst for ethylene oxidation to ethylene oxide is provided containing a promoter combination consisting of critical amounts of an alkali metal component and a sulfur component, the catalyst being essentially free of rhenium and transition metal components; optionally the catalyst contains a fluorine component.

Abstract: The invention relates to an ethylene oxide catalyst comprised of silver deposited on an alumina carrier which has been treated to remove at least 25% of the surface sodium ions and replace the removed sodium ions with up to 10 ppm of lithium ions and to the preparation thereof.

Abstract: A process for the vapor phase oxidation of ethylene to ethylene oxide, which process involves reacting a reaction mixture having ethylene and oxygen in the presence of a supported highly selective silver-based catalyst by: operating at an initial operation phase wherein fresh catalyst is used, and operating at a further operation phase when a cumulative ethylene oxide production exceeds 0.01 kT ethylene oxide per m3 of catalyst, wherein in said further operation phase the concentration of ethylene in the reaction mixture is increased; and a method of using ethylene oxide into the 1.2-ethanediol or the 1,2-ethanediol ether wherein the ethylene oxide has been obtained by the process for the production of ethylene oxide.

Abstract: A method for improving the selectivity of a supported highly selective epoxidation catalyst comprising silver in a quantity of at most 0.

Abstract: A process and catalysts for the direct oxidation of an olefin having three or more carbon atoms, such as propylene, by oxygen to an olefin oxide, such as prbpylene oxide. The process involves contacting the olefin under reaction conditions with oxygen in the presence of hydrogen and a catalyst. The catalyst contains silver and titanium, optionally gold, and optionally, at least one promoter element selected from Group 1, Group 2, zinc, cadmium, the platinum group metals, the lanthanide rare earths, the actinide elements, and combinations thereof. In preferred embodiments, the catalyst is calcined prior to use, rather than reduced prior to use. Suitable titanium-containing supports include titanium dioxide, titanium dioxide on silica, titanosilicates, promoter metal titanates, titanium dispersed on silica and promoter metal silicates.

Abstract: The present invention relates to a process for the reaction of at least one organic compound with one oxygen-delivering substance, for example a hydroperoxide, in the presence of at least one catalyst containing a metal-organic framework material comprising pores and a metal ion and an at least bidentate organic compound, said bidentate organic compound being coordinately bound to the metal ion. Further, the present invention is directed to the products being obtainable by the process according to the invention.

Abstract: The invention relates to a method for oxidizing hydrocarbons with a hydrogen/oxygen mixture in the presence of a catalyst. The catalyst contains a) a support material which contains titanium and b) silver particles having an average particle size ranging from 0.3 to 100 nm.

Abstract: It provide a catalyst for the production of epoxides by a vapor-phase oxidation of an unsaturated hydrocarbon having a chain length of 4-20 carbon atoms and containing no allylic hydrogen atom, characterized by having a catalytic component containing silver and at least one element selected from the group consisting of alkali metals and thallium deposited onto a carrier obtained by mixing &agr;-alumina having a sodium content in the range of 1-70 mmol (as reduced to Na) per kg of &agr;-alumina with an aluminium compound, a silicon compound, and a sodium compound and calcining the resultant mixture, the carrier having a silicon content (as reduced to SiO2) in the range of 0.3 -11.5 mass % based on the mass of the carrier and a sodium content (as reduced to Na2O) in the range of 0.11-2.5 mass % based on the mass of the carrier.

Abstract: The present invention provides hydro-oxidation catalysts for the oxidation of hydrocarbons, containing an organic-inorganic hybrid material as well as gold particles and/or silver particles, a process for the production thereof, and the use thereof as a catalyst.

Abstract: Disclosed is a process of recovering 3,4-epoxy-1-butene (epoxybutene) from an epoxybutene-laden reaction product gas by absorption into a high-boiling solvent. Also disclosed is a process for the purification of the epoxybutene by separating epoxybutene from the solvent and other reaction by-products by a novel combination of distillation and decantation steps.

Abstract: An olefin oxidation catalyst comprising a carrier, and silver and an alkali metal supported thereon, wherein the content of organic substances is less than 0.1 wt %.

Abstract: A process and catalysts for the direct oxidation of an olefin having three or more carbon atoms, such as propylene, by oxygen to an olefin oxide, such as propylene oxide. The process involves contacting the olefin under reaction conditions with oxygen in the presence of hydrogen and a catalyst. The catalyst contains silver and titanium, optionally gold, and optionally, at least one promoter element selected from Group 1, Group 2, zinc, cadmium, the lanthanide rare earths, and the actinide elements. Suitable supports include titanium dioxide, titanium dioxide on silica, titanosilicates, promoter metal titanates, titanium dispersed on silica and promoter metal silicates.

Abstract: A method for restoring lost activity and selectivity of fresh cesium-promoted catalysts which comprises heating the catalyst at an elevated temperature in the presence of a sweep gas immediately prior to using the catalyst. The catalysts are particularly useful for the selective epoxidation of olefins to their corresponding olefin epoxides. Also described is a method for inhibiting or preventing deactivation of fresh Cs-promoted catalysts.

Abstract: Disclosed is a method of recovering and purifying 3,4-epoxy-1-butene (epoxybutene) from a reaction product gas, obtained by the vapor phase catalytic partial oxidation of 1,3-butadiene with oxygen over a silver catalyst. The recovery and purification comprises absorption of the epoxybutene into a water-miscible solvent followed by separation of the absorbed epoxybutene from the absorbent by extraction into a water-immiscible solvent. A method of recovering and purifying epoxybutene from the extraction solvent and other reaction by-products by a novel combination of distillation and decantation steps also is disclosed.

Abstract: A process is provided for use in the epoxidation of olefins, having particular utility in the epoxidation of propylene to form propylene oxide, using a lanthanide-promoted, supported, silver catalyst prepared via precipitation. A preferred embodiment uses silver nitrate and lanthanum nitrate to form the catalyst on a BaCO3 support.

Abstract: Disclosed is a process for the preparation of mono-epoxides of certain diolefins wherein a conjugated diolefin, or polyolefin, that contains allylic carbon-hydrogen bonds, is contacted with molecular oxygen in the presence of a modified silver catalyst.

Abstract: There is provided a process for the vapor phase oxidation of ethylene to ethylene oxide in the presence of a supported highly selective silver-based catalyst, the process comprising operating fresh catalyst for an initial operation phase, then operating at a further operation phase when the catalyst has reached an advanced aged defined by a cumulative ethylene oxide production exceeding 1.5 kT EO per m3 of catalyst. In the further operation phase the composition of the reaction mixture is changed to contain from 1.1 to 4 times the concentration of ethylene used in the initial operation phase and the corresponding optimised and safe concentration of oxygen.

Abstract: A process for the direct oxidation of an olefin by oxygen to the corresponding olefin oxide in the presence of a reducing agent and a catalyst. The catalyst comprises a metal component, such as a transition metal oxide, dispersed on a metal ion-exchanged metallosilicates, such as a Group 1 or Group 2 ion-exchanged porous aluminosilicate. Selectivity to the olefin oxide is high and the catalyst is readily regenerated.

Abstract: In a process for oxidizing an organic compound containing at least one C—C double bond, or a mixture of two or more thereof, which comprises the step (II) below: (II) reaction of the organic compound or the mixture of two or more thereof with a medium comprising molecular oxygen in the presence of a heterogeneous catalyst, the medium further comprises carbon monoxide (CO).

Abstract: A process and catalysts for the direct oxidation of an olefin having three or more carbon atoms, such as propylene, by oxygen to an olefin oxide, such as propylene oxide. The process involves contacting the olefin under reaction conditions with oxygen in the presence of hydrogen and a catalyst. The catalyst contains silver and titanium, optionally gold, and optionally, at least one promoter element selected from Group 1, Group 2, zinc, cadmium, the lanthanide rare earths, and the actinide elements. Suitable supports include titanium dioxide, titanium dioxide on silica, titanosilicates, promoter metal titanates, titanium dispersed on silica and promoter metal silicates.

Abstract: In manufacturing ethylene oxide by catalytic vapor phase oxidation of ethylene, a process comprising adding, as liquid, an organic halide as a reaction inhibitor into the ethylene raw material gas flow is provided. According to this process, ethylene oxide can be manufactured stably and in high selectivity.

Abstract: A catalyst for the production of ethylene oxide is formed by causing a carrier having &agr;-alumina as a main component thereof to incorporate therein silica and a metal or a compound of at least one element selected from the elements of the groups Ib and IIb in the periodic table of the elements such as, for example, silver oxide and depositing silver on the carrier. The carrier is obtained by mixing at least &agr;-alumina, a silicon compound, an organic binder, and a compound of at least one element selected from the elements of the groups Ib and IIb in the periodical table of the elements and then calcining the resultant mixture at a temperature in the range of 1,000°-1,800° C.

Abstract: Disclosed herein is an improved gas phase process for the selective epoxidation of non-allylic olefins wherein the epoxidation is carried out in the presence of one or more volatile, nitrogen-containing, basic compounds. The presence of a nitrogen-containing basic compound in the olefin-containing reaction gas or vapor suppresses the formation of an organic resinous material which coats the catalyst, thereby decreasing catalyst activity and life and also increases substantially the activity of the epoxidation catalyst. The disclosed process is particularly useful for the continuous manufacture of 3,4-epoxy-1-butene from 1,3-butadiene.

Abstract: A silver catalyst excelling in catalytic performance and permitting production of ethylene oxide with a high selectivity for a long time, a method for the production of ethylene oxide by the use of the silver catalyst, and a method for ideal manufacture of the silver catalyst are disclosed. The silver catalyst is formed by depositing silver on a carrier having .alpha.-alumina as a main component and used for the production of ethylene oxide, which carrier of the silver catalyst has undergone the following treatment capable of yielding a wash exhibiting a resistivity index of not less than 10,000 .OMEGA..multidot.cm (25.degree. C.):(Method of treatment)In a conical beaker having an inner volume of 500 ml, 300 ml of the carrier is placed, dried therein at 120.degree. C. for two hours, and boiled in conjunction with (water absorption +220) ml of pure water added thereto under normal pressure at 90.degree. C.

Abstract: The present invention is directed to a process for the selective epoxidation of non-allylic olefins. The process includes the step of contacting a gas mixture comprising a non-allylic olefin, oxygen, and a fluorinated hydrocarbon with a silver epoxidation catalyst at conditions effective to epoxidize the non-allylic olefin. The fluorinated hydrocarbon has a C--F bond dissociation energy of 110 kcal/mole or greater, and sufficiently non-acidic C--H bonds, if present, so as to avoid abstraction of HF from the fluorinated hydrocarbon under reaction conditions.

Abstract: A silver catalyst for ethylene oxidation to ethylene oxide is provided containing a promoter combination consisting of an alkali metal component, a sulfur component, a germanium or tin component, and a fluorine component the catalyst being essentially free of rhenium and transition metal compounds.