The B. F. Goodrich Company

Jamal S Eden

Joseph A Cowfer

Angelo J Magistro

A fluidizable catalyst composition is provided containing about 2% to about 8% by weight of copper (about 4% to about 17% by weight of copper salt), from about 1.0% to about 10% by weight of a rare earth metal salt(s), preferably the chloride salt(s), and from about 0.25% to about 2.3% by weight of an alkali metal salt(s), preferably the chloride salt(s), all weight percents based upon the total weight of the catalyst composition. The metals are codeposited on a fluidizable, high surface area alumina support. The weight of the alkali metal employed is not over 2.5% by weight (as the chloride) and the weight ratio of the rare earth metal salt(s) to the alkali metal salt(s) must be at least 1:1. Such catalyst compositions are extremely useful as fluid bed catalysts in the vapor phase oxychlorination reaction of ethylene, oxygen and hydrogen chloride to produce 1,2-dichloroethane (EDC). The use of the catalysts results in improved, high percent ethylene efficiencies and high percent HCl conversions, and avoids operating problems caused by stickiness of the catalyst in the fluid bed. A combination of copper chloride, potassium chloride and one or more of the rare earth chlorides on a fluidizable gamma alumina support, produces an excellent catalyst for a fluid bed ethylene oxychlorination process.

Catalyst and process for the fluid-bed oxychlorination of ethylene to EDC

A fluidizable catalyst composition is provided containing about 2% to about 8% by weight of copper (about 4% to about 17% by weight of copper salt), from about 0.2% to about 10% by weight of a rare earth metal salt(s), preferably the chloride salt(s), and from about 0.25% to about 2.3% by weight of an alkali metal salt(s), preferably the chloride salt(s), all weight percents based upon the total weight of the catalyst composition. The metals are codeposited on a fluidizable, high surface area alumina support. The weight of the alkali metal employed is not over 2.5% by weight (as the chloride) and the weight ratio of the rare earth metal salt(s) to the alkali metal salt(s) must be at least 0.8:1. Such catalyst compositions are extremely useful as fluid bed catalysts in the vapor phase oxychlorination reaction of ethylene, oxygen and hydrogen chloride to produce 1,2-dichloroethane (EDC). The use of the catalysts results in improved, high percent ethylene efficiencies and high percent HCl conversions, and avoids operating problems caused by stickiness of the catalyst in the fluid bed. A combination of copper chloride, potassium chloride and one or more of the rare earth chlorides on a fluidizable gamma alumina support, produces an excellent catalyst for a fluid bed ethylene oxychlorination process.

A fluidizable catalyst composition is provided having cupric chloride deposited on a fluidizable, modified gamma alumina support in which the support has incorporated, prior to the deposit of copper, from 0.5% to 3.0% by weight based on the weight of the support of at least one metal selected from the group consisting of potassium, lithium, rubidium, cesium, alkaline earth metals, rare earth metals, or combinations thereof. Such catalyst compositions are extremely useful as the fluid bed catalyst in the vapor phase oxyhydrochlorination reaction of ethylene, oxygen and hydrogen chloride to produce 1,2-dichloroethane. The use of the catalysts results in improved EDC efficiency based on ethylene and avoids operating problems caused by stickiness of the catalyst in the fluid bed. Incorporation of a combination of potassium and barium in the fluidizable gamma alumina support, prior to deposit of the copper, produces an excellent catalyst for a fluid bed ethylene oxyhydrochlorination process in which the vent gases from the process are recycled.

Copper catalyst compositions for fluid-bed oxyhydrochlorination of

There is disclosed a method and composition for improving the fluidization characteristics and alleviating or inhibiting stickiness in a supported cupric chloride catalyst used as fluid bed catalyst in oxyhydrochlorinations reactions. The method involves the in situ preparation of the supported cupric chloride catalyst by addition of bare support on which no cupric chloride is deposited to the supported cupric chloride catalyst in the fluidized bed, or the use in the bed as the initial charge or as addition to the bed as makeup, of a composition which is a mixture of supported cupric chloride catalyst and bare support. In either event, as the oxyhydrochlorination proceeds, a portion of the cupric chloride on the supported catalyst becomes released therefrom and deposited in situ on the bare support, and stickiness of the cupric chloride containing catalyst particles to one another in the fluid bed is alleviated or inhibited.

Copper-catalyzed fluid-bed ethylene oxhydrochlorination process

Process for the selective catalytic oxidation of carbon monoxide in the presence of olefin monomers without appreciable oxidation of such monomers. According to this process, a gaseous waste stream containing carbon monoxide, olefin monomers, and a variety of other agents, is contacted with a catalytically effective amount of copper chromite, preferably in an oxygen enriched environment, at temperatures in the range from about 200.degree. C. to about 325.degree. C. The contact time of the stream with the catalyst bed can vary within broad limits, and the duration of which will vary inversely with the temperature of the catalyst bed.

Selective catalytic oxidation of carbon monoxide in the presence of

There is disclosed an improved method of making chlorinated derivatives of ethylene wherein chlorine-containing by-products are burned in a catalytic combustion reactor to produce primarily a hydrogen halide which is recycled to the chlorinated derivative reaction and the heat of combustion from said reactor is utilized to preheat the materials used in said chlorinated derivative reaction. The catalyst employed is one containing 0.01% to 0.50% of platinum or palladium on 99.99% to 99.50% Al.sub.2 O.sub.3, SiO.sub.2 or a combination of Al.sub.2 O.sub.3 and SiO.sub.2 as a support and having a surface area of at least 50 square meters per gram. The catalytic combustion reaction is carried out at temperatures in the range of about 300.degree. C. to about 450.degree. C. to produce a mixture of gases containing essentially hydrogen chloride and being substantially free of elemental chlorine and chlorohydrocarbon compounds, said gases being then mixed with ethylene and reacted to form ethylene dichloride (EDC).

Low temperature catalytic combustion of chlorohydrocarbons

There is disclosed an improved method of making chlorinated derivatives of ethylene wherein chlorine-containing by-products are burned in a catalytic combustion reactor to produce primarily a hydrogen halide which is recycled to the chlorinated derivative reaction and the heat of combustion from said reactor is utilized to preheat the materials used in said chlorinated derivative reaction. The catalyst employed is one containing 5% to 20% of UO.sub.3 (uranium trioxide) on 80% to 95% Al.sub.2 O.sub.3, SiO.sub.2 or a combination of Al.sub.2 O.sub.3 and SiO.sub.2 as a support and having a surface area of at least 50 square meters per gram. The catalytic combustion reaction is carried out at temperatures in the range of about 350.degree. C. to about 450.degree. C. to produce a mixture of gases containing essentially hydrogen chloride and being substantially free of elemental chlorine and chlorohydrocarbon compounds, said gases being then mixed with ethylene and reacted to form ethylene dichloride (EDC).

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Akron, OH, United States of America

Jamal S Eden