Basf Se Corporation

Vito Nv

Marco Oskar Kennema

Christian Walsdorff

Miguel Angel Romero Valle

Juergen Zuehlke

Fred Borninkhof

Andrey Karpov

Jasper Lefevere

Christian Bartosch

Bart Michielsen

Florian Scharf

Nicolas Duyckaerts

Marcelo Daniel Kaufman Rechulski

Holger Borchert

Sabine Huber

Bernd Schube

Detlef Ruff

Matthias Johannes Wagner

Dirk Hensel

Jochen Roerig

Gerald Bastian

Monika Kus

Pieter Weltens

The invention relates to a die () for the extrusion of catalyst molding, catalyst support molding, or adsorbent molding () in flow direction () of an extrudable composition from an entry side () to a discharge side () of the die comprising a shell () and comprising one or more channel-formers () which are displacers of the extrudable composition and which extend in flow direction of the extrudable composition, wherein the channel-formers () have been metal-printed. It is preferable that this is free from cavities for receiving extrudable composition which extend at right angles to the flow direction () of the extrudable composition, and that this is free from connections running at right angles from channel-formers () to the interior side wall () of the die (). The invention further relates to a process for the production, by means of 3D metal printing, of a metal-printed die () for the extrusion of catalyst moldings/support moldings ().

Die comprising metal printed parts for the extrusion of moulded bodies

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 m/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 2being 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.

Process for producing ethylene oxide by gas-phase oxidation of ethylene

A three-dimensional porous catalyst, catalyst carrier or absorbent structure of stacked strands of catalyst, catalyst carrier or absorbent material, composed of layers of spaced-apart parallel strands, wherein parallel strands within a layer are arranged in groups of two or more closely spaced-apart, equidistant strands separated by a small distance, wherein the groups of equidistant strands are separated from adjacent strands or adjacent groups of strands by a larger distance.

Three-dimensional porous catalyst, catalyst carrier or absorbent structure of stacked strands

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 m/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 m/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.

Catalyst for producing ethylene oxide by gas-phase oxidation

A three-dimensional porous catalyst, catalyst carrier or absorbent monolith of stacked strands of catalyst, catalyst carrier or absorbent material, composed of alternating layers of linear spaced-apart parallel strands, wherein the strands in alternating layers are oriented at an angle to one another, wherein the distance between inner spaced-apart parallel strands is larger than the distance between outer spaced-apart parallel strands in at least a part of the layers of the monolith.

Catalyst, catalyst carrier or absorbent monolith of stacked strands

The invention relates to a shaped catalyst body in the form of a tetralobe having four circular through-passages, with the midpoints of the through-passages forming a square and the spacings between in each case two adjacent through-passages being from 0.8 to 1.2 times the thickness of the outer walls of the through-passages. The shaped catalyst body is used for the oxidation of S02 to S03.

Shaped catalyst body in the form of tetralobes of uniform wall thickness

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Ludwigshafen, Germany

Marco Oskar Kennema