Alkene Epoxidation Catalyst Selectivity and Wastewater Reduction
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Solution Overview
Problem
Current processes for producing alkylene oxides, such as propylene oxide, face challenges including high wastewater pollution, carbon footprint, and market risks due to co-product formation and complex logistics.
Innovation Solution
A process involving the reaction of an alkene with an arene oxide, pyridine N-oxide, or pyrimidine N-oxide in the presence of a catalyst comprising copper, silver, or gold, and metal salts like chromium, iron, or cobalt, without oxygen or oxygen-containing gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the chlorohydrin process is used for propylene oxide production, then industrial scalability is achieved, but wastewater pollution and carbon footprint increase significantly
Solution Approach 1:
The invention extracts and eliminates the harmful chlorohydrin intermediate and calcium chloride byproduct from the process, replacing them with a direct oxidation system using hydrogen peroxide that produces only water as a byproduct, thereby removing the source of wastewater pollution while maintaining industrial scalability
Solution Approach 2:
The invention changes the chemical parameters of the oxidation process by using hydrogen peroxide instead of chlorine-based reagents, and employs specific catalysts (钛硅分子筛TS-1, tungsten heteropoly acids, or metal complexes) to achieve selective oxidation at lower temperatures, fundamentally altering the reaction pathway to eliminate harmful emissions
2Productivity
If co-product-based processes are used, then propylene oxide production is achieved, but market risks and logistical complexity increase due to co-product separation and processing
Solution Approach 1:
The invention converts the previously harmful or unwanted co-products into the desired product by using a catalytic system that selectively transforms both propylene and the co-product (styrene or isobutene) into propylene oxide through sequential oxidation, thereby eliminating the need for separate co-product processing facilities and reducing market risks
3Manufacturing precision
If direct oxidation of propene is attempted, then propylene oxide selectivity can be improved, but temperature control and by-product formation remain unsolved challenges
Solution Approach 1:
The invention introduces specific catalysts as intermediaries (钛硅分子筛TS-1, tungsten heteropoly acids, or metal complexes with ligands) that mediate the oxidation reaction between propylene and hydrogen peroxide, enabling the reaction to proceed at lower temperatures (0-100°C) with high selectivity while suppressing unwanted by-product formation through controlled activation of the oxidant
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process improves epoxide conversion and selectivity, reducing undesirable by-products and achieving higher activation energies for oxygen transfer, thus enhancing the efficiency and environmental sustainability of alkylene oxide production.
Implementation Method 1
the catalyst comprises a metal and/or a metal salt, wherein the metal is copper, silver and/or gold, wherein the metal salt comprises chromium, iron, cobalt and/or copper cation(s)
Data Source
AI summary
The invention relates to a method for producing alkylene oxides by reacting an alkene with an arene oxide, pyridine-N-oxide, and/or pyrimidine-N-oxide, preferably an arene oxide and/or pyridine-N-oxide, in the presence of a catalyst in a first reactor, wherein the catalyst comprises a metal and/or a metal salt, and the metal is copper, silver, and/or gold. The metal salt comprises chrome, iron, cobalt, and/or copper cation(s), and the reaction is carried out in the absence of oxygen or an oxygen-containing gas mixture.