Process for producing a silver-based epoxidation catalyst

Abstract

A process for producing a silver-based epoxidation catalyst, comprising i) impregnating a particulate porous refractory support with a first aqueous silver impregnation solution comprising silver ions and an aminic complexing agent selected from amines, alkanolamines and amino acids; ii) converting at least part of the silver ions impregnated on the refractory support to metallic silver by heating while directing a stream of a first gas over the impregnated refractory support to obtain an intermediate catalyst, wherein the first gas comprises at least 5 vol.-% oxygen; iii) impregnating the intermediate catalyst with a second aqueous silver impregnation solution comprising silver ions, an aminic complexing agent selected from amines, alkanolamines and amino acids, and one or more transition metal promoters, in particular rhenium; and iv) converting at least part of the silver ions impregnated on the intermediate catalyst to metallic silver by heating while directing a stream of a second gas over the impregnated intermediate catalyst to obtain the epoxidation catalyst, wherein the second gas comprises at most 2.0 vol.-% oxygen, wherein the impregnated refractory support and the impregnated intermediate catalyst are each heated to a temperature of 200 to 800° C. The process of the invention surprisingly allows for obtaining a catalyst with high selectivity in a cost-efficient manner. The invention also relates to a silver-based epoxidation catalyst obtainable by such a process, and to a process for producing an alkylene oxide by gas-phase oxidation of an alkylene, comprising reacting an alkylene and oxygen in the presence of a silver-based epoxidation catalyst obtainable by the above process.