18573474. HIGH PURITY TABLETED ALPHA-ALUMINA CATALYST SUPPORT simplified abstract (BASF SE)

HIGH PURITY TABLETED ALPHA-ALUMINA CATALYST SUPPORT

Organization Name

BASF SE

Inventor(s)

Christian Walsdorff of Ludwigshafen am Rhein (DE)

Sung Yeun Choi of Ludwigshafen am Rhein (DE)

Andrey Karpov of Ludwigshafen am Rhein (DE)

Kazuhiko Amakawa of Ludwigshafen am Rhein (DE)

Nicolas Duyckaerts of Ludwigshafen am Rhein (DE)

HIGH PURITY TABLETED ALPHA-ALUMINA CATALYST SUPPORT - A simplified explanation of the abstract

This abstract first appeared for US patent application 18573474 titled 'HIGH PURITY TABLETED ALPHA-ALUMINA CATALYST SUPPORT

The patent application describes a catalyst support made primarily of alpha-alumina with specific characteristics for use in gas-phase oxidation reactions.

• The catalyst support contains at least 85 wt.-% of alpha-alumina, with a pore volume of at least 0.40 mL/g and a BET surface area of 0.5 to 5.0 m/g.
• The support is in tablet form and contains less than 500 ppmw of potassium.
• The process for producing the catalyst support involves forming a mixture of aluminum compounds and pore-forming materials, tableting the mixture, and heat-treating it at high temperatures.

Potential Applications: - The catalyst support can be used in the production of ethylene oxide by gas-phase oxidation of ethylene. - It can also find applications in other gas-phase oxidation reactions where a high-purity, high-surface-area support is required.

Problems Solved: - The technology addresses the need for a catalyst support with specific characteristics suitable for gas-phase oxidation reactions. - It provides a method for producing such a catalyst support with high purity and controlled pore structure.

Benefits: - Improved catalytic performance in gas-phase oxidation reactions. - Enhanced durability and stability of the catalyst support. - Increased efficiency in ethylene oxide production processes.

Commercial Applications: Title: High-Purity Alpha-Alumina Catalyst Support for Gas-Phase Oxidation Reactions Description: The technology can be used in industrial processes for ethylene oxide production, as well as in other gas-phase oxidation reactions. It has implications for the chemical manufacturing industry, particularly in the production of specialty chemicals.

Questions about the Technology: 1. What are the specific advantages of using alpha-alumina as the primary component in the catalyst support? 2. How does the pore structure of the catalyst support impact its catalytic performance in gas-phase oxidation reactions?

Original Abstract Submitted

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 m/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.