A Perspective on the Role and Development of Supports for Maximizing the Efficiency of Catalytic Gas-Phase Ethylene Epoxidation

Ethylene oxide (EO) is a vital ethylene derivative utilized in various products such as antifreeze, household cleaners, plastics, and sterilizers for medical equipment. The main components of modern commercial EO catalysts include silver and solid-phase promoters supported on a low surface area α-alumina carrier, with the aim of maximizing EO selectivity and minimizing the formation of combustion byproducts in the gas-phase ethylene epoxidation reaction. Achieving higher selectivities toward EO formation results in the reduction of greenhouse gas emissions, improvement in plant efficiency, and overall economic gains. The role of catalyst support is crucial for achieving high-performance silver-based EO catalysts with high selectivities. This article summarizes the work reported in the literature on the feasibility of using various types of catalyst supports, including alumina-based and non-alumina-based, for the gas-phase ethylene epoxidation reaction. It emphasizes the importance of optimization of the physicochemical properties of the catalyst support to improve catalyst efficiency. Additionally, it includes heat and mass transfer calculations for industrial and laboratory reactors, demonstrating the significance of support properties in achieving successful EO catalysis on an industrial scale.