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    HIGH PURITY TABLETED ALPHA-ALUMINA CATALYST SUPPORT
    1.
    发明公开
    HIGH PURITY TABLETED ALPHA-ALUMINA CATALYST SUPPORT 审中-公开

    公开(公告)号：US20240293802A1

    公开(公告)日：2024-09-05

    申请号：US18573474

    申请日：2021-11-26

    Applicant: BASF SE

    Inventor： Christian WALSDORFF ,  Sung Yeun CHOI ,  Andrey KARPOV ,  Kazuhiko AMAKAWA ,  Nicolas DUYCKAERTS

    IPC: B01J21/04 ,  B01J23/68 ,  B01J35/40 ,  B01J35/61 ,  B01J35/63 ,  B01J37/04 ,  B01J37/08 ,  C07D301/10

    CPC classification number: B01J21/04 ,  B01J23/688 ,  B01J35/40 ,  B01J35/612 ,  B01J35/633 ,  B01J37/04 ,  B01J37/08 ,  C07D301/10

    Abstract: A catalyst support comprising at least 85 wt.-% of alpha-alumina and having a pore volume of at least 0.40 mL/g, as determined by mercury porosimetry, and a BET surface area of 0.5 to 5.0 m2/g, wherein the catalyst support is a tableted catalyst support comprising, based on the total weight of the catalyst support, less than 500 ppmw of potassium. The invention moreover relates to a process for producing a tableted alpha-alumina catalyst support, which comprises i) forming a free-flowing feed mixture comprising i-a) at least one aluminum compound which is thermally convertible to alpha-alumina, the aluminum compound comprising a transition alumina and/or an alumina hydrate; and i-b) 30 to 120 wt.-%, relative to i-a), of a pore-forming material; ii) tableting the free-flowing feed mixture to obtain a compacted body; and iii) heat treating the compacted body at a temperature of at least 1100° C., to obtain the tableted alpha-alumina catalyst support. The invention further relates to a compacted body obtained by tableting a free-flowing feed mixture which comprises, relative to the total weight of the free-flowing feed mixture, a) at least one aluminum compound which is thermally convertible to alpha-alumina, the aluminum compound comprising a transition alumina and/or an alumina hydrate; and b) 30 to 120 wt.-%, relative to a), of a pore-forming material. The invention moreover relates to a shaped catalyst body for producing ethylene oxide by gas-phase oxidation of ethylene, comprising at least 12 wt.-% of silver, relative to the total weight of the catalyst, deposited on the tableted alpha-alumina catalyst support. The invention also relates to a process for producing ethylene oxide by gas-phase oxidation of ethylene, comprising reacting ethylene and oxygen in the presence of the shaped catalyst body. The invention allows for the use of specific pore-forming materials that are particularly suitable for obtaining an advantageous pore structure while allowing for a catalyst support having high purity.

    PROCESS FOR PRODUCING A POROUS ALPHA-ALUMINA CATALYST SUPPORT
    2.
    发明公开
    PROCESS FOR PRODUCING A POROUS ALPHA-ALUMINA CATALYST SUPPORT 审中-公开

    公开(公告)号：US20230256414A1

    公开(公告)日：2023-08-17

    申请号：US18011540

    申请日：2021-06-25

    Applicant: BASF SE

    Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Patrick HUBACH ,  Karl KHARAS

    IPC: B01J21/04 ,  B01J35/10 ,  B01J23/50 ,  B01J6/00 ,  B01J37/02 ,  C07C29/50

    CPC classification number: B01J21/04 ,  B01J35/1042 ,  B01J35/1047 ,  B01J23/50 ,  B01J6/001 ,  B01J37/0201 ,  C07C29/50

    Abstract: A process for producing a porous alpha-alumina catalyst support, comprising i) preparing a precursor material comprising, based on inorganic solids content, at least 50 wt.-% of a transition alumina having a loose bulk density of at most 600 g/L, a pore volume of at least 0.6 mL/g and a median pore diameter of at least 15 nm; and at most 30 wt.-% of an alumina hydrate; ii) forming the precursor material into shaped bodies; and iii) calcining the shaped bodies to obtain the porous alpha-alumina catalyst support. The catalyst support has a high overall pore volume, thus allowing for impregnation with a high amount of silver, while keeping its surface area sufficiently large so as to provide optimal dispersion of catalytically active species, in particular metal species. The invention further relates to a shaped catalyst body for producing ethylene oxide by gas-phase oxidation of ethylene, comprising at least 15 wt.-% of silver, relative to the total weight of the catalyst, deposited on a porous alpha-alumina catalyst support obtained in the process described above. The invention also relates to a process for preparing a shaped catalyst body as described above comprising impregnating a porous alpha-alumina catalyst support obtained in the process described above with a silver impregnation solution, preferably under reduced pressure; and optionally subjecting the impregnated porous alumina support to drying; and b) subjecting the impregnated porous alpha-alumina support to a heat treatment; wherein steps a) and b) are optionally repeated. The invention further relates to a process for producing ethylene oxide by gas-phase oxidation of ethylene, comprising reacting ethylene and oxygen in the presence of a shaped catalyst body as described above.

    POROUS CATALYST-SUPPORT SHAPED BODY
    3.
    发明公开
    POROUS CATALYST-SUPPORT SHAPED BODY 审中-公开

    公开(公告)号：US20230302432A1

    公开(公告)日：2023-09-28

    申请号：US18011855

    申请日：2021-06-25

    Applicant: BASF SE

    Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Patrick HUBACH ,  Hubert WAINDOK ,  Bernd HINRICHSEN ,  Gonzalo PRIETO GONZALEZ ,  Tania RODENAS TORRALBA ,  Karl C. KHARAS

    IPC: B01J21/04 ,  B01J35/04 ,  B01J35/10 ,  B01J35/00 ,  B01J37/08 ,  C07D301/10 ,  B01J37/02

    CPC classification number: B01J21/04 ,  B01J35/002 ,  B01J35/04 ,  B01J35/1009 ,  B01J35/1042 ,  B01J35/1061 ,  B01J37/0201 ,  B01J37/0236 ,  B01J37/088 ,  C07D301/10

    Abstract: A porous shaped catalyst support body comprising at least 85% by weight of alpha-alumina, wherein the support has a total pore volume in the range from 0.5 to 2.0 mL/g as determined by mercury porosimetry, and a pore structure characterized by a geometric tortuosity τ in the range from 1.0 to 2.0; and an effective diffusion parameter η in the range from 0.060 to 1.0; wherein geometric tortuosity τ and effective diffusion parameter η are determined by image analysis algorithms from computer-assisted 3D reconstructions of focused ion beam scanning electron microscope analyses. The structure of the support has a high total pore volume, such that impregnation with a large amount of silver is possible, while the surface area is kept sufficiently high in order to assure optimal dispersion of the catalytically active species, especially metal species. The support has a pore structure that leads to a maximum rate of mass transfer within the support. The invention also relates to a shaped catalyst body for preparation of ethylene oxide by gas phase oxidation of ethylene, comprising at least 15% by weight of silver, based on the total weight of the catalyst, deposited on a porous shaped catalyst support body as described above. The invention further relates to a process for producing the shaped catalyst body, in which a) a porous shaped catalyst support body as described above is impregnated with a silver impregnation solution, preferably under reduced pressure; and the impregnated porous shaped catalyst support body is optionally subjected to drying; and b) the impregnated porous shaped catalyst support body is subjected to a heat treatment; wherein steps a) and b) are optionally repeated. The invention also relates to a process for preparing ethylene oxide by gas phase oxidation of ethylene, comprising the reaction of ethylene and oxygen in the presence of a shaped catalyst body according to claim 11.

    SHAPED CATALYST BODY FOR THE PRODUCTION OF ETHYLENE OXIDE
    5.
    发明公开
    SHAPED CATALYST BODY FOR THE PRODUCTION OF ETHYLENE OXIDE 审中-公开

    公开(公告)号：US20230256420A1

    公开(公告)日：2023-08-17

    申请号：US18011542

    申请日：2021-06-24

    Applicant: BASF SE

    Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Patrick HUBACH

    IPC: B01J23/68 ,  B01J35/10 ,  B01J21/04 ,  B01J6/00 ,  C07C29/50

    CPC classification number: B01J23/688 ,  B01J35/1014 ,  B01J23/68 ,  B01J21/04 ,  B01J35/1009 ,  B01J6/001 ,  C07C29/50

    Abstract: A shaped catalyst body for producing ethylene oxide by gas-phase oxidation of ethylene, having a BET surface area in the range of 2 to 20 m2/g and comprising silver and a rhenium promotor deposited on a porous alpha-alumina catalyst support, characterized in that the support has a calcination history of at least 1460° C. The catalyst support has a high surface area and little ethylene oxide isomerization and/or decomposition activity. The invention further relates to a porous alpha-alumina catalyst support having a BET surface area of 1.7 to 10 m2/g, the porous alpha-alumina catalyst support being obtainable by a) preparing a precursor material comprising a transition alumina and/or an alumina hydrate; b) forming the precursor material into shaped bodies; and c) calcining the shaped bodies at a temperature of 1460° C. to 1700° C. to obtain the porous alpha-alumina support. The invention also relates to a process for producing ethylene oxide by gas-phase oxidation of ethylene, comprising reacting ethylene and oxygen in the presence of a shaped catalyst body as described above.

    PROCESS FOR PRODUCING A SILVER-BASED EPOXIDATION CATALYST
    7.
    发明申请
    PROCESS FOR PRODUCING A SILVER-BASED EPOXIDATION CATALYST 有权

    公开(公告)号：US20230114770A1

    公开(公告)日：2023-04-13

    申请号：US17914395

    申请日：2021-03-26

    Applicant: BASF SE

    Inventor： Andrey KARPOV ,  Christian WALSDORFF ,  Thorsten JOHANN ,  Christian ALMER ,  Daniela RIECK ,  Christian BARTOSCH ,  Mauricio GROBYS ,  Tobias WEINLAND ,  Holger BORCHERT

    IPC: B01J23/68 ,  B01J37/02 ,  B01J37/14 ,  B01J37/16 ,  C07D301/10

    Abstract: A process for producing a silver-based epoxidation catalyst, comprising i) impregnating a particulate porous refractory support with a first aqueous silver impregnation solution comprising silver ions and an aminic complexing agent selected from amines, alkanolamines and amino acids; ii) converting at least part of the silver ions impregnated on the refractory support to metallic silver by heating while directing a stream of a first gas over the impregnated refractory support to obtain an intermediate catalyst, wherein the first gas comprises at least 5 vol.-% oxygen; iii) impregnating the intermediate catalyst with a second aqueous silver impregnation solution comprising silver ions, an aminic complexing agent selected from amines, alkanolamines and amino acids, and one or more transition metal promoters, in particular rhenium; and iv) converting at least part of the silver ions impregnated on the intermediate catalyst to metallic silver by heating while directing a stream of a second gas over the impregnated intermediate catalyst to obtain the epoxidation catalyst, wherein the second gas comprises at most 2.0 vol.-% oxygen, wherein the impregnated refractory support and the impregnated intermediate catalyst are each heated to a temperature of 200 to 800° C. The process of the invention surprisingly allows for obtaining a catalyst with high selectivity in a cost-efficient manner. The invention also relates to a silver-based epoxidation catalyst obtainable by such a process, and to a process for producing an alkylene oxide by gas-phase oxidation of an alkylene, comprising reacting an alkylene and oxygen in the presence of a silver-based epoxidation catalyst obtainable by the above process.

    PROCESS FOR PRODUCING ETHYLENE OXIDE BY GAS-PHASE OXIDATION OF ETHYLENE
    8.
    发明申请
    PROCESS FOR PRODUCING ETHYLENE OXIDE BY GAS-PHASE OXIDATION OF ETHYLENE 有权

    公开(公告)号：US20210387958A1

    公开(公告)日：2021-12-16

    申请号：US17285780

    申请日：2019-09-19

    Applicant: BASF SE

    Inventor： Andrey KARPOV ,  Marco Oskar KENNEMA ,  Nicolas DUYCKAERTS ,  Christian WALSDORFF ,  Christian BARTOSCH ,  Juergen ZUEHLKE ,  Miguel Angel ROMERO VALLE

    IPC: C07D301/10 ,  B01J23/68 ,  B01J35/00 ,  B01J35/02 ,  B01J35/04 ,  B01J35/10 ,  B01J21/04

    Abstract: A process for producing ethylene oxide by gas-phase oxidation of ethylene, comprising: directing a feed comprising gaseous ethylene and gaseous oxygen through a packing of individual shaped catalyst bodies, under conditions conducive to obtain a reaction mixture containing at least 2.7 vol.-% of ethylene oxide, wherein each shaped catalyst body comprises silver deposited on a refractory support and is characterized by a content of at least 20 wt.-% of silver, relative to the total weight of the shaped catalyst body; a BET surface area in the range of 1.6 to 3.0 m2/g; a first face side surface, a second face side surface and a circumferential surface with a plurality of passageways extending from the first face side surface to the second face side surface; and a uniform multilobed cross-section; and a longest direct diffusion pathway d, with 2d being in the range of 0.7 to 2.4 mm, wherein the longest diffusion pathway d is defined as the shortest distance from the geometric surface of the shaped catalyst body to a point inside the structure of the shaped catalyst body for which point the shortest distance is the largest among all points. The process allows for increased activity and/or stability of the catalyst while maintaining or increasing selectivity at high productivity.

    FORMULATION AND USE THEREOF
    9.
    发明申请
    FORMULATION AND USE THEREOF 审中-公开
    配方及其用途

    公开(公告)号：US20150104487A1

    公开(公告)日：2015-04-16

    申请号：US14574837

    申请日：2014-12-18

    Applicant: BASF SE

    Inventor： Michael MAIER ,  Jörg HABICHT ,  Alexander KRAUS ,  Andrey KARPOV ,  Frank ROSOWSKI ,  Frank MÜLLER

    IPC: A01N59/20 ,  A01N25/04 ,  A01N43/653

    CPC classification number: A01N59/20 ,  A01N25/04 ,  A01N25/30 ,  A01N43/653 ,  B27K3/15 ,  C08K3/30 ,  C08L61/28 ,  C08L61/34 ,  C08L97/02 ,  Y10T428/662

    Abstract: A formulation is claimed, which contains at least one protective substance that is active with respect to cellulose-containing materials, such as wood-containing building materials in the form of solid wood or wood-based materials, and at least one specific compound with dispersing properties. The dispersants are branched comb-shaped polymers with polyether side chains, naphthalene-sulfonate-formaldehyde condensation products, melamine-sulfonate-formaldehyde condensation products and phosphatized polycondensation products. The formulations according to the invention are suitable in particular as plant protection agents and wood preservatives and are preferably used in the form of suspensions for pressure treatment of the respective building materials.

    Abstract translation: 要求保护的物质包含至少一种相对于含纤维素的材料具有活性的保护性物质，例如实木或木质材料形式的含木材建筑材料，以及至少一种具有分散性的特定化合物 属性。 分散剂是具有聚醚侧链的支链梳状聚合物，萘磺酸盐 - 甲醛缩合产物，三聚氰胺 - 磺酸 - 甲醛缩合产物和磷酸化缩聚产物。 根据本发明的制剂特别适用于植物保护剂和木材防腐剂，并且优选以用于各种建筑材料的压力处理的悬浮液的形式使用。

    EPOXIDATION CATALYST
    10.
    发明申请
    EPOXIDATION CATALYST 有权

    公开(公告)号：US20240408585A1

    公开(公告)日：2024-12-12

    申请号：US18274042

    申请日：2022-01-25

    Applicant: BASF SE

    Inventor： Andrey KARPOV ,  Christian ALMER ,  Christian WALSDORFF ,  Andreas LEHR ,  Michael NIKOLAY ,  Christian BARTOSCH ,  Mauricio GROBYS

    IPC: B01J27/055 ,  B01J21/04 ,  B01J23/68 ,  B01J35/61 ,  B01J35/63 ,  B01J37/02 ,  B01J37/08 ,  C07D301/10

    Abstract: An epoxidation catalyst comprising silver, cesium, rhenium and tungsten deposited on an alumina support, wherein the catalyst comprises 20 to 50 wt.-% of silver, relative to the weight of the catalyst, an amount of cesium Ccs of at least 7.5 mmol per kg of catalyst, and an amount of rhenium CR6 and an amount of tungsten Cw so as to meet the following requirements: CRe≥6.7 mmol per kg of catalyst; and CRe+(2χcw)≥13.2 mmol per kg of catalyst. The epoxidation catalyst allows for a more efficient conversion of ethylene oxide by gas-phase oxidation of ethylene, particularly displaying high selectivity and high activity. The invention also relates to a process for preparing an epoxidation catalyst as defined in above, comprising i) impregnating an alumina support with a silver impregnation solution; and ii) subjecting the impregnated refractory support to a calcination process; wherein steps i) and ii) are optionally repeated, and at least one silver impregnation solution comprises rhenium, tungsten and cesium. The invention moreover relates to a process for producing ethylene oxide by gas-phase oxidation of ethylene, comprising reacting ethylene and oxygen in the presence of an epoxidation catalyst according to any one of the preceding claims.

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