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Direct epoxidation process using improved catalyst composition

a technology of catalyst composition and epoxidation process, which is applied in the field of direct epoxidation process using improved catalyst composition, can solve the problems of prone to produce non-selective byproducts, and achieve the effect of reducing alkane byproducts

Active Publication Date: 2009-04-30
LYONDELL CHEM TECH LP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0007]The invention is a catalyst comprising a noble metal, lead, bismuth, and a titanium or vanadium zeolite. In one embodiment, the catalyst is a mixture comprising a titanium or vanadium zeolite and a supported catalyst comprising a noble metal, lead, bismuth, and a carrier. The catalyst is useful in olefin epoxidation. Thus, the invention also includes an olefin epoxidation process that comprises reacting olefin, oxygen, and hydrogen in the presence of a catalyst comprising a titanium or vanadium zeolite, a noble metal, lead, and bismuth. This process surprisingly gives significantly reduced alkane byproduct formed by the hydrogenation of olefin compared to the process using catalyst systems that do not contain bismuth and lead.

Problems solved by technology

One disadvantage of the described direct epoxidation catalysts is that they are prone to produce non-selective byproducts such as glycols or glycol ethers formed by the ring-opening of the epoxide product or alkane byproduct formed by the hydrogenation of olefin.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

PREPARATION OF Pd-Bi-Pb / TiO2, Pd-Bi / TiO2, and Pd-Au / TiO2 CATALYSTS

[0034]Catalyst 1A (Pd-Bi-Pb / TiO2):

[0035]Lead nitrate (0.69 g) and an aqueous solution of disodium palladium tetrachloride (1.11 g, 19.7 wt. % Pd) are added to a solution of bismuth nitrate (0.3 g Bi(NO3)3 dissolved in 15 mL, 2.56 M solution of nitric acid, 16.6% by volume of 70% HNO3) with mixing. The Pd-Bi-Pb solution is then added by incipient wetness to spray dried titania (20 g, 30 micron size, 40 m2 / g, calcined in air at 700° C.). The solids are calcined in air in a muffle furnace by heating at 10° C. / min to 110° C. for 4 hours and then at 2° C. / min to 300° C. for 4 hours. These calcined solids are then washed with an aqueous sodium bicarbonate solution (40 mL, containing 2.25 g NaHCO3), followed by deionized water (40 mL, four times). The washed solids are vacuum dried (20 torr) at 50° C. for 16 hours and then calcined in a muffle furnace by heating at 10° C. / min to 110° C. for 4 hours and then heating at 2° C. / ...

example 2

EPOXIDATION REACTION USING CATALYSTS FROM EXAMPLE 1

[0040]A 300 cc stainless steel reactor is charged with the supported noble metal catalyst (0.07 g of 1A, 1B, or 1C), TS-1 powder (0.63 g), methanol (˜100 g), and a buffer solution (13 g of 0.1 M aqueous ammonium phosphate, pH=6). The reactor is then charged to 300 psig with a feed consisting of 2% hydrogen, 4% oxygen, 5% propylene, 0.5% methane and the balance nitrogen (volume %) for runs utilizing a 2:1 O2:H2 ratio or a feed consisting of 4% hydrogen, 4% oxygen, 5% propylene, 0.5% methane and the balance nitrogen (volume %) for runs utilizing a 1:1 O2:H2 ratio. The pressure in the reactor is maintained at 300 psig via a backpressure regulator with the feed gases passed continuously through the reactor at 1600 cc / min (measured at 23° C. and one atmosphere pressure). In order to maintain a constant solvent level in the reactor during the run, the oxygen, nitrogen and propylene feeds are passed through a two-liter stainless steel vess...

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PUM

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Abstract

Catalysts useful for the direct epoxidation of olefins are disclosed. The catalysts comprise a noble metal, lead, bismuth, and a titanium or vanadium zeolite. The noble metal, lead, and bismuth may be supported on the titanium or vanadium zeolite. The catalyst may also be a mixture comprising the titanium or vanadium zeolite and a supported catalyst comprising the noble metal, lead, bismuth, and a carrier. The invention includes a process for producing an epoxide comprising reacting an olefin, hydrogen and oxygen in the presence of the catalyst. The process results in significantly reduced alkane byproduct formed by the hydrogenation of olefin.

Description

FIELD OF THE INVENTION[0001]This invention relates to a catalyst and its use in the production of epoxides from hydrogen, oxygen, and olefins.BACKGROUND OF THE INVENTION[0002]Many different methods for the preparation of epoxides have been developed. Generally, epoxides are formed by the reaction of an olefin with an oxidizing agent in the presence of a catalyst. Ethylene oxide is commercially produced by the reaction of ethylene with oxygen over a silver catalyst. Propylene oxide is commercially produced by reacting propylene with an organic hydroperoxide oxidizing agent, such as ethylbenzene hydroperoxide or tert-butyl hydroperoxide. This process is performed in the presence of a solubilized molybdenum catalyst, see U.S. Pat. No. 3,351,635, or a heterogeneous titania on silica catalyst, see U.S. Pat. No. 4,367,342.[0003]Besides oxygen and alkyl hydroperoxides, hydrogen peroxide is also a useful oxidizing agent for epoxide formation. U.S. Pat. Nos. 4,833,260, 4,859,785, and 4,937,2...

Claims

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Application Information

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IPC IPC(8): C07D301/04B01J29/068
CPCC07D301/10C07D301/08
Inventor GREY, ROGER A.
Owner LYONDELL CHEM TECH LP