Multi-lobed porous ceramic body and process for making the same

Patent metadata

Field	Value
Publication number	US-9968923-B2
Application number	US-201715638887-A
Country	US
Kind code	B2
Filing date	Jun 30, 2017
Priority date	Dec 29, 2010
Publication date	May 15, 2018
Grant date	May 15, 2018

Abstract

A carrier having at least three lobes, a first end, a second end, a wall between the ends and a non-uniform radius of transition at the intersection of an end and the wall is disclosed. A catalyst comprising the carrier, silver and promoters deposited on the carrier and useful for the epoxidation of olefins is also disclosed. A method for making the carrier, a method for making the catalyst and a process for epoxidation of an olefin with the catalyst are also disclosed.

First claim

What is claimed is:

1. A process for making a catalyst useful for the epoxidation of olefins, comprising:
a. providing a porous ceramic body comprising a first end, a second end, and a wall disposed between and intersecting said ends, said wall comprising at least three lobes and three valleys formed in the length of the wall, said lobes rounded at the intersection of said first end and said wall and said valleys not rounded at the intersection of said first end and said wall, each valley located between two of said lobes;
b. impregnating said porous ceramic body with a silver containing solution; and
c. heating said impregnated porous ceramic body in a temperature range between 100° C. and 500° C.

2. The process of claim 1 wherein said solution comprises at least 8 weight percent silver based on the weight of said catalyst.

3. The process of claim 2 wherein said silver is between 10 and 30 weight percent based on the total weight of said catalyst.

4. The process of claim 1 wherein said impregnation comprises two or more impregnation steps.

5. The process of claim 1 wherein said impregnation further includes one or more promoters.

6. The process of claim 5 wherein one or more promoters is selected from the group consisting of rare earth metals, magnesium, rhenium, and alkali metals.

7. The process of claim 6 wherein the quantity of said rhenium promoter is at least 1.25 mmole/kg relative to the total weight of the catalyst.

Assignees

• Saint Gobain Ceramics

Inventors

• Richard Michael A
• Covey John David

Classifications

• C07C213/04 Primary

  by reaction of ammonia or amines with olefin oxides or halohydrins · CPC title

• C07D301/04

  with air or molecular oxygen · CPC title

• B01J37/024

  Multiple impregnation or coating · CPC title

• B01J37/0201

  Impregnation · CPC title

• B01J23/688 Primary

  with manganese, technetium or rhenium · CPC title