Silver-containing catalysts, the manufacture of such silver-containing catalysts, and the use thereof

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 small inside diameter compared to the outside 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.

That which is claimed is:  
     
         1 . A catalyst, comprising: 
 Silver at a high concentration level and at least one promoter compound, wherein said silver and said at least one promoter compound are supported on a support material having a high water absorption.    
     
     
         2 . A catalyst as recited in  claim 1 , wherein said support material is in the form of a shaped agglomerate having a hollow cylinder geometric configuration such that the L/D ratio of said shaped agglomerate is in the range of from about 0.3 to about 1.6 and the internal diameter is in the range upwardly to about 30 percent of the outer diameter of said shaped agglomerate.  
     
     
         3 . A catalyst as recited in  claim 2 , wherein said high concentration level of silver is in the range exceeding 15 weight percent of the total weight of the said catalyst.  
     
     
         4 . A catalyst as recited in  claim 3 , wherein said high water absorption is in the range of exceeding 42.5%.  
     
     
         5 . A catalyst as recited in  claim 4 , wherein said support material further has a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         6 . A catalyst as recited in  claim 1 , wherein said high concentration level of silver is in the range exceeding 15 weight percent of the total weight of the said catalyst.  
     
     
         7 . A catalyst as recited in claims  1  or  2 , wherein said high water absorption is in the range exceeding 42.5%.  
     
     
         8 . A catalyst as recited in claims  1 ,  2  or  3 , wherein said support material further has a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         9 . A catalyst as recited in  claim 1 , wherein said support material is in the form of a shaped agglomerate having a hollow cylinder geometric configuration such that the L/D ratio of said shaped agglomerate is in the range of from about 0.3 to about 1.6 and the ratio of internal diameter to outside diameter is in the range of from 0.01 to 0.25.  
     
     
         10 . A catalyst as recited in  claim 9 , wherein said high concentration level of silver is in the range exceeding 16 weight percent of the total weight of the said catalyst.  
     
     
         11 . A catalyst as recited in  claim 10 , wherein said high water absorption is in the range of exceeding 45%.  
     
     
         12 . A catalyst as recited in  claim 11 , wherein said support material further has a surface area in the range of from 0.05 m 2 /g to 5 m 2 /g.  
     
     
         13 . A catalyst as recited in  claim 1 , wherein said high concentration level of silver is in the range exceeding 16 weight percent of the total weight of the said catalyst.  
     
     
         14 . A catalyst as recited in claims  1  or  9 , wherein said high water absorption is in the range of exceeding 45%.  
     
     
         15 . A catalyst as recited in claims  1 ,  9  or  10 , wherein said support material further has a surface area in the range of from 0.05 m 2 /g to 5 m 2 /g.  
     
     
         16 . A catalyst as recited in  claim 1 , wherein said support material is in the form of a shaped agglomerate having a hollow cylinder geometric configuration such that the L/D ratio of said shaped agglomerate is in the range of from about 0.3 to about 1.6 and the ratio of inside diameter to outside diameter is in the range of from 0.02 to 0.25.  
     
     
         17 . A catalyst as recited in  claim 16 , wherein said high concentration level of silver is in the range exceeding 17 weight percent of the total weight of the said catalyst.  
     
     
         18 . A catalyst as recited in  claim 17 , wherein said high water absorption is in the range of exceeding 46%.  
     
     
         19 . A catalyst as recited in  claim 18 , wherein said support material further has a surface area in the range of from 0.1 m 2 /g to 3 m 2 /g.  
     
     
         20 . A catalyst as recited in  claim 1 , wherein said high concentration level of silver is in the range exceeding 17 weight percent of the total weight of the said catalyst.  
     
     
         21 . A catalyst as recited in claims  1  or  16 , wherein said high water absorption is in the range of exceeding 46%.  
     
     
         22 . A catalyst as recited in claims  1 ,  16  or  17 , wherein said support material further has a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         23 . A catalyst, comprising: 
 a shaped support material having a hollow cylinder geometric configuration such that the L/D ratio of said shaped support material is in the range of from about 0.3 to about 1.6 and the internal diameter is in the range upwardly to about 30 percent of the outer diameter of said shaped support material; and    a silver component, wherein the concentration of silver in said catalyst is in the range exceeding 15 weight percent of the total weight of said catalyst.    
     
     
         24 . A catalyst as recited in  claim 23 , wherein said shaped support material has a water absorption greater than 42.5%.  
     
     
         25 . A catalyst as recited in  claim 24 , wherein said shaped support material comprises an inorganic oxide having a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         26 . A catalyst as recited in  claim 25 , wherein the ratio of internal diameter to outside diameter of said shaped support material is in the range of from 0.01 to 0.25.  
     
     
         27 . A catalyst as recited in  claim 26 , wherein the concentration of silver in said catalyst exceeds 16 weight percent.  
     
     
         28 . A catalyst as recited in  claim 27 , wherein said catalyst further comprises a promoter component.  
     
     
         29 . A catalyst as recited in  claim 23 , wherein said shaped support material comprises an inorganic oxide having a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         30 . A catalyst as recited in claims  23  or  24 , wherein the ratio of internal diameter to outside of said shaped support material is in the range of from 0.01 to 0.25.  
     
     
         31 . A catalyst as recited in claims  23 , 24 or 25, 
 wherein the concentration of silver in said catalyst exceeds 16 weight percent of the total weight of said catalyst.    
     
     
         32 . A catalyst as recited in claims  23 ,  24 ,  25 , or  26  wherein said catalyst further comprises a promoter component.  
     
     
         33 . A method, comprising: 
 providing a shaped support material; and    impregnating said shaped support material with a silver-containing solution such that an amount of silver metal incorporated into said shaped support material exceeds 15 weight percent of the total weight of said shaped support material to thereby provide a silver impregnated shaped support material.    
     
     
         34 . A method as recited in  claim 33 , wherein said impregnating step is a single impregnation step by which said amount of silver metal is incorporated into said shaped support material.  
     
     
         35 . A method as recited in  claim 34 , wherein said shaped support material has a geometric configuration such that the L/D ratio is in the range of from about 0.3 to about 1.6 and the internal diameter is in the range upwardly to about 30 percent of the outer diameter of said shaped catalyst support.  
     
     
         36 . A method as recited in  claim 35 , wherein said shaped material has a water absorption in the range exceeding 42.5% and wherein said shaped material comprises an inorganic oxide having a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         37 . A method as recited in  claim 33 , wherein said shaped support material has a geometric configuration such that the L/D ratio is in the range of from about 0.3 to about 1.6 and the internal diameter is in the range upwardly to about 30 percent of the outer diameter of said shaped catalyst support.  
     
     
         38 . A method as recited in claims  33  or  34 , wherein said shaped material has a water absorption in the range exceeding 42.5% and wherein said shaped material comprises an inorganic oxide having a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         39 . A method as recited in  claim 33 , wherein said impregnating step is a single impregnation step by which said amount of silver metal that is incorporated into said shaped support material exceeds 16 weight percent.  
     
     
         40 . A method as recited in  claim 39 , wherein said shaped support material has a geometric configuration such that the L/D ratio is in the range of from about 0.3 to about 1.6 and the ratio of internal diameter to outside diameter is in the range of from 0.01 to 0.25.  
     
     
         41 . A method as recited in  claim 40 , wherein said shaped material has a water absorption in the range exceeding 42.5% and wherein said shaped material comprises an inorganic oxide having a surface area in the range of from 0.03 m 2 /g to 10 m 2 /g.  
     
     
         42 . A process for manufacturing ethylene oxide, said process comprises: 
 Contacting, under suitable epoxidation process conditions, a feed stream, comprising ethylene and oxygen, with the catalyst of  claim 1 .    
     
     
         43 . A catalyst composition made by the method of  claim 33.