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Integrated process and dual-function catalyst for olefin epoxidation

United States Patent

March 18, 2003
View the Complete Patent at the US Patent & Trademark Office
The invention discloses a dual-functional catalyst composition and an integrated process for production of olefin epoxides including propylene oxide by catalytic reaction of hydrogen peroxide from hydrogen and oxygen with olefin feeds such as propylene. The epoxides and hydrogen peroxide are preferably produced simultaneously in situ. The dual-functional catalyst comprises noble metal crystallites with dimensions on the nanometer scale (on the order of <1 nm to 10 nm), specially dispersed on titanium silicalite substrate particles. The dual functional catalyst catalyzes both the direct reaction of hydrogen and oxygen to generate hydrogen peroxide intermediate on the noble metal catalyst surface and the reaction of the hydrogen peroxide intermediate with the propylene feed to generate propylene oxide product. Combining both these functions in a single catalyst provides a very efficient integrated process operable below the flammability limits of hydrogen and highly selective for the production of hydrogen peroxide to produce olefin oxides such as propylene oxide without formation of undesired co-products.
Zhou; Bing (Cranbury, NJ), Rueter; Michael (Plymouth Meeting, PA)
Hydrocarbon Technologies, Inc. (Lawrenceville, NJ)
09/ 996,920
November 30, 2001
This invention was made with support under Contract No. DE-FG02-01ER83350 awarded by the Department of Energy, and the Government has certain rights in this invention.