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.

公开(公告)号：US20220008884A1

公开(公告)日：2022-01-13

申请号：US17293647

申请日：2019-11-12

Applicant: BASF SE

Inventor： Nicolas DUYCKAERTS ,  Martin KAMASZ ,  Christian WALSDORFF

IPC: B01J8/06 ,  C07C45/38 ,  B01J35/02 ,  B01J23/50 ,  B01J35/10 ,  B01J35/08

Abstract: The present invention relates to a catalyst bed comprising silver catalyst bodies and a reactor comprising such a catalyst bed. Further, the invention relates to the use of the catalyst bed and the reactor for gas phase reactions, in particular for the oxidative dehydrogenation of organic compounds under exothermic conditions. In a preferred embodiment, the present invention relates to the preparation of olefinically unsaturated carbonyl compounds from olefinically unsaturated alcohols by oxidative dehydrogenation utilizing a catalyst bed comprising metallic silver catalyst bodies.

公开(公告)号：US20230234030A1

公开(公告)日：2023-07-27

申请号：US18011857

申请日：2021-06-25

Applicant: BASF SE

Inventor： Sung Yeun CHOI ,  Andrey KARPOV ,  Christian WALSDORFF ,  Nicolas DUYCKAERTS ,  Kazuhiko AMAKAWA ,  Patrick HUBACH ,  Karl C. KHARAS

IPC: B01J21/04 ,  B01J23/50 ,  B01J23/36 ,  B01J35/02 ,  B01J35/10 ,  B01J35/00 ,  B01J37/04 ,  B01J37/00 ,  B01J37/08 ,  C07D301/10

CPC classification number: B01J21/04 ,  B01J23/50 ,  B01J23/36 ,  B01J35/026 ,  B01J35/1038 ,  B01J35/1042 ,  B01J35/1009 ,  B01J35/1066 ,  B01J35/1061 ,  B01J35/0026 ,  B01J37/04 ,  B01J37/0063 ,  B01J37/0018 ,  B01J37/08 ,  C07D301/10

Abstract: A tableted catalyst support, characterized by an alpha-alumina content of at least 85 wt.-%, 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. The tableted catalyst support is an alpha-alumina catalyst support obtained with high geometrical precision and displaying a high overall pore volume, thus allowing for impregnation with a high amount of silver, while exhibiting a surface area sufficiently large so as to provide optimal dispersion of catalytically active species, in particular metal species. The invention further provides a process for producing a tableted alpha-alumina catalyst support, which comprises i) forming a free-flowing feed mixture comprising, based on inorganic solids content, at least 50 wt.-% of a transition alumina; 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., preferably at least 1300° C., more preferably at least 1400° C., in particular at least 1450° C., to obtain the tableted alpha-alumina catalyst support. The invention moreover relates to a compacted body obtained by tableting a free-flowing feed mixture which comprises, 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, as determined, and a median pore diameter of at least 15 nm. The invention moreover 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 the tableted alpha-alumina catalyst support. 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 the shaped catalyst body.

公开(公告)号：US20210379569A1

公开(公告)日：2021-12-09

申请号：US17285799

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

IPC: B01J23/68 ,  B01J21/04 ,  B01J37/02 ,  B01J35/10 ,  B01J37/08 ,  B01J35/04 ,  B01J35/02 ,  C07D301/04

Abstract: A shaped catalyst body for producing ethylene oxide by gas-phase oxidation of ethylene, comprising silver deposited on a porous refractory support, the shaped catalyst body having a first face side surface, a second face side surface and a circumferential surface, characterized by a content of at least 20 wt.-% of silver, relative to the total weight of the shaped catalyst body; a multilobe structure; a plurality of passageways extending from the first face side surface to the second face side surface, outer passageways being arranged around a central passageway with one outer passageway being assigned to each lobe, wherein neighboring outer passageways are arranged essentially equidistantly to each other and the outer passageways are arranged essentially equidistantly to the central passageway; a minimum wall thickness A between two neighboring passageways in the range of 0.6 to 1.3 mm; a minimum wall thickness B between each outer passageway and the circumferential surface in the range of 1.1 to 1.8 mm; and a BET surface area in the range of 1.6 to 3.0 m2/g. The shaped catalyst bodies allow for a favorable balance between mechanical stability, pressure drop and selectivity. 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 defined above. The invention further relates to a process for preparing a shaped catalyst body as above, comprising i) impregnating a refractory support having a BET surface area in the range of 1.4 to 2.5 m2/g with a silver impregnation solution; and ii) subjecting the impregnated refractory support to a calcination process; wherein steps i) and ii) are optionally repeated.

公开(公告)号：US20250019333A1

公开(公告)日：2025-01-16

申请号：US18714615

申请日：2022-12-02

Applicant: BASF SE

Inventor： Nicolas DUYCKAERTS ,  Rupert WAGNER ,  Martin KAMASZ ,  Andreas KELLER ,  Christian WALSDORFF

IPC: C07C45/38 ,  B01D3/14 ,  B01J23/50

Abstract: In a process for preparing isoprenal and/or prenal by bringing a gaseous reactant stream comprising isoprenol into contact with a silver-containing heterogeneous catalyst in the presence of molecular oxygen to obtain an isoprenal and/or prenal-containing product stream, a weight ratio of formaldehyde to isoprenol of less than 0.04 is maintained in the reactant stream. The process maintains high conversion and selectivity over time and avoids catalyst clogging and pressure drop.

公开(公告)号：US20240278222A1

公开(公告)日：2024-08-22

申请号：US17927373

申请日：2021-05-17

Applicant: BASF SE

Inventor： Nicolas DUYCKAERTS ,  Kazuhiko AMAKAWA ,  Jens WEIGUNY ,  Christian WALSDORFF ,  Miguel Angel ROMERO VALLE ,  Gerald MEYER ,  Rouven WEILER

IPC: B01J27/198 ,  B01J8/02 ,  B01J35/40 ,  B01J35/55 ,  C07C51/25 ,  C07D307/60

CPC classification number: B01J27/198 ,  B01J8/02 ,  B01J35/40 ,  B01J35/55 ,  C07C51/252 ,  C07D307/60

Abstract: A shaped catalyst body for heterogeneously catalyzed reactions of organic compounds in the gas-phase in fixed-bed reactors, containing an element from group 3 to 12 of the Periodic Table of the Elements, and having a three-lobed structure with a lateral surface around the lobes, a top cover and a bottom cover, as well as three continuous holes running from one cover side to the other cover side, wherein each hole is assigned to one lobe and wherein the cover sides have outwardly shaped arches, its production and a process for its use in the heterogeneously catalyzed reaction of an organic compound in the gas phase.

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.