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The effect of catalyst support and preparation method on silver-based catalysts for the direct vapor phase epoxidation of propylene to propylene oxide (PO) was studied. The shape of the CaCO 3 support is critical for optimum activity and selectivity of the catalyst. Among the CaCO 3 materials investigated as supports, the scalenohedral shape gives the best performance. A simplified method of catalyst preparation (referred to as ''slurry method'') was developed. With this method, it is not necessary to dissolve Ag 2 O into a solution as in the conventional incipient wetness method for preparing silver-based catalysts for propylene and ethylene epoxidation. The key to the slurry method is the addition of a small amount of an effective organic compound, such as ethanolamine, during the formation of the slurry.

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