Methods for conditioning an ethylene epoxidation catalyst are provided. The conditioning methods comprise contacting an ethylene epoxidation catalyst comprising a carrier, having silver and a rhenium promoter deposited thereon, with a conditioning feed gas comprising oxygen for a period of time of at least 2 hours at a temperature that is above 180° C. and at most 250° C., wherein the contacting of the ethylene epoxidation catalyst with the conditioning feed gas occurs in an epoxidation reactor and in the absence of ethylene. Associated methods for the epoxidation of ethylene are also provided.

A method of preparing epoxypropane by direct epoxidation of propylene includes the steps of contacting a mixed gas consisting of a reaction feed gas and a diluent gas with a catalyst to carry out reaction under reaction conditions of propylene epoxidation to prepare epoxypropane. The reaction feed gas contains propylene, oxygen gas and hydrogen gas while at least a portion of the diluent gas is a gaseous olefin. Using gaseous olefin as at least a portion of the diluent gas to perform propylene epoxidation that can significantly extend service life of the catalyst, effectively reduce the used amount of diluent gas, and improve the reaction selectivity and propylene conversion rate.

A method of preparing epoxypropane by direct epoxidation of propylene includes the steps of contacting a mixed gas consisting of a reaction feed gas and a diluent gas with a catalyst to carry out reaction under reaction conditions of propylene epoxidation to prepare epoxypropane. The reaction feed gas contains propylene, oxygen gas and hydrogen gas while at least a portion of the diluent gas is a gaseous olefin. Using gaseous olefin as at least a portion of the diluent gas to perform propylene epoxidation that can significantly extend service life of the catalyst, effectively reduce the used amount of diluent gas, and improve the reaction selectivity and propylene conversion rate.

An ethylene oxide (EO) reactor is provided in which a removable impingement basket is configured to be inserted into the reactor inlet pipe of the EO reactor. The removable impingement basket provides protection for the silver-based catalyst filled tubes and other components that are present inside the EO reactor as well as providing another access point into the EO reactor. The removable impingement basket also can provide better distribution of the inlet gas as compared to an EO reactor containing a non-removable impingement plate.

An ethylene oxide (EO) reactor is provided in which a removable impingement basket is configured to be inserted into the reactor inlet pipe of the EO reactor. The removable impingement basket provides protection for the silver-based catalyst filled tubes and other components that are present inside the EO reactor as well as providing another access point into the EO reactor. The removable impingement basket also can provide better distribution of the inlet gas as compared to an EO reactor containing a non-removable impingement plate.

A precursor mixture for producing a porous body, wherein the precursor mixture comprises: (i) at least one milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) non-silicate powder that functions as a binder of the alpha alumina powders, and (iii) at least one burnout material having a particle size of 1-10 microns and a decomposition temperature of less than 550° C., with the proviso that a burnout material having a decomposition temperature of 550° C. or greater is excluded from the precursor mixture.

A precursor mixture for producing a porous body, wherein the precursor mixture comprises: (i) at least one milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) non-silicate powder that functions as a binder of the alpha alumina powders, and (iii) at least one burnout material having a particle size of 1-10 microns and a decomposition temperature of less than 550° C., with the proviso that a burnout material having a decomposition temperature of 550° C. or greater is excluded from the precursor mixture.

The present invention is directed to a shaped catalyst body for preparing ethylene oxide, which comprises at least silver, cesium and rhenium applied to an alumina support, wherein the alumina support comprises Si, Ca, and Mg in a defined amount. Furthermore, the present invention is directed to a process for preparing the catalyst according to the present invention and process for preparing ethylene oxide by gas-phase oxidation of ethylene by means of oxygen in the presence of a shaped catalyst body according to the present invention.

The present invention is directed to a shaped catalyst body for preparing ethylene oxide, which comprises at least silver, cesium and rhenium applied to an alumina support, wherein the alumina support comprises Si, Ca, and Mg in a defined amount. Furthermore, the present invention is directed to a process for preparing the catalyst according to the present invention and process for preparing ethylene oxide by gas-phase oxidation of ethylene by means of oxygen in the presence of a shaped catalyst body according to the present invention.

A carrier for an ethylene epoxidation catalyst, the carrier comprising a porous alumina body formed of sintered particles of alumina in a substantial absence of inorganic binder species other than alumina, wherein the substantial absence of inorganic binder species corresponds to an amount of less than 0.6 wt % inorganic binder species other than alumina and comprises at least a substantial absence of silicon-containing species.