Silver catalysts, ethylene epoxidation over

For many years ethylene chlorohydrin was manufactured on a large iadustrial scale as a precursor to ethylene oxide, but this process has been almost completely displaced by the direct oxidation of ethylene to ethylene oxide over silver catalysts. However, siace other commercially important epoxides such as propylene oxide and epichlorohydrin cannot be made by direct oxidation of the parent olefin, chlorohydrin iatermediates are stiU important ia the manufacture of these products. 

The gas phase oxidation of ethylene to ethylene oxide over silver catalysts has been studied extensively.49 la-c It has been suggested that epoxide formation involves transfer of oxygen from a silver-oxygen complex to the olefin on the catalyst surface.4913 Silver-on-silica also catalyzes the liquid phase oxidation of cumene to cumene hydroperoxide. A mechanism that involved insertion of coordinated oxygen into a C—H bond was proposed630 ... 

J. T. Jankowiak, M. A. Barteau, Ethylene epoxidation over silver and copper-silver bimetallic catalysts 1. Kinetics and selectivity, /. Catal. 236 (2005) 366. 

Dehydrochlorination to Epoxides. The most useful chemical reaction of chlorohydrins is dehydrochlotination to form epoxides (oxkanes). This reaction was first described by Wurtz in 1859 (12) in which ethylene chlorohydria and propylene chlorohydria were treated with aqueous potassium hydroxide [1310-58-3] to form ethylene oxide and propylene oxide, respectively. For many years both of these epoxides were produced industrially by the dehydrochlotination reaction. In the past 40 years, the ethylene oxide process based on chlorohydria has been replaced by the dkect oxidation of ethylene over silver catalysts. However, such epoxides as propylene oxide (qv) and epichl orohydrin are stiU manufactured by processes that involve chlorohydria intermediates. 

While chlorine is a poison for the ammonia synthesis over iron, it serves as a promoter in the epoxidation of ethylene over silver catalysts, where it increases the selectivity to ethylene oxide at the cost of the undesired total combustion to C02. In this case an interesting correlation was observed between the AgCl27Cl ratio from SIMS, which reflects the extent to which silver is chlorinated, and the selectivity towards ethylene oxide [16]. In both examples, the molecular clusters reveal which elements are in contact in the surface region of the catalyst. 

Propene epoxidation. Stoukides and Vayenas have studied the epoxi-dation of propene over silver catalysts.71 73 A Langmuir-Hishelwood type model was used to explain the results of work performed between 290 and 400°C.71 As with the work on ethylene oxidation, two types of oxygen were proposed to be involved, molecular and atomic oxygen responsible for partial and total oxidation respectively. 

Whereas such applications of catalytic clean-up technology are of obvious importance, it is even more desirable to develop new catalytic processes that produce less or no waste products. Many conventional routes consume acids or bases and produce salts which cause waste problems. The production of ethylene epoxide from ethylene by direct oxidation over silver catalysts forms an example for a clean, catalytic process which has replaced traditional routes involving the... 

The gas-phase oxidation of ethylene to ethylene oxide over a supported silver catalyst was discovered in 1933 and is a commercially important industrial process. Using either air or oxygen, the ethylene oxide is produced with 75% selectivity at elevated temperatures (ca. 250 °C). Low yields of epoxides are obtained with propylene and higher alkenes so that other metal-based catalysts are used. A silver-dioxygen complex of ethylene has been implicated as the active reagent.222... 

The cooxidation at 199 °C of C2H4 together with [l,2-14C]ethylene oxide and the cooxidation at 215 °C of C3H6 with [2-14C]propylene oxide over a silver catalyst showed no oxygen exchange between olefin and epoxide, but a certain portion of C02 was produced by destruction of the product epoxide (2% of C02 was produced from oxidation of propylene oxide and about 10% from ethylene oxide). 

Olefin epoxidation is not only important in the manufacture of bulk chemicals, e. g. ethylene and propylene oxides, but is also a widely used transformation in the fine-chemicals industry [1], Ethylene oxide is manufactured by vapor-phase oxidation of ethylene, with air or oxygen, over a supported silver catalyst [2], This method is not generally applicable as olefins containing allylic or other reactive C-H bonds give complex mixtures of products with low epoxide selectivity. The method has recently been extended to some other olefins that do not contain reactive allylic C-H bonds, e. g. butadiene, styrene, norbornene, and tert-butyl ethylene [3]. Some of these products, e. g. butadiene monoepoxide and styrene oxide, have potential applications as fine chemicals/intermediates. 

It is interesting that for the epoxidation of ethylene over silver it is the single-crystal surface that gives the highest TOF. At 217°C, Campbell (328, 329) has found that TOF = 2 s for the Ag (110) surface and about 1 s for the Ag (111) surface (330). The activity and selectivity of the single-crystal surfaces is modified by chlorine (330) and by cesium (331), for example, in much the same way as are those of supported silver catalysts. 

Ethylene oxide, one of the few epoxides manufactured on an industrial scale, is prepared by passing a mixture of ethylene and air (or oxygen) over a silver catalyst ... 

The chemical reactivity of the catalyst support may make important contributions to the catalytic chemistry of the material. We noted earlier that the catalyst support contains acidic and basic hydroxyls. The chemical nature of these hydroxyls will be described in detail in Chapter 5. Whereas the number of basic hydroxyls dominates in alumina, the few highly acidic hydroxyl groups also present on the alumina surface can also dramatically affect catalytic reactions. An example is the selective oxidation of ethylene catalyzed by silver supported by alumina. The epoxide, which is produced by the catalytic reaction of oxygen and ethylene over Ag, can be isomerized to acetaldehyde via the acidic protons present on the surface of the alumina support. The acetaldehyde can then be rapidly oxidized over Ag to COg and H2O. This total combustion reaction system is an example of bifunctional catalysis. This example provides an opportunity to describe the role of promoting compounds added in small amounts to a catalyst to enhance its selectivity or activity by altering the properties of the catalyst support. To suppress the total combustion reaction of ethylene, alkali metal ions such as Cs+ or K+ are typically added to the catalyst support. The alkali metal ions can exchange with the acidic support protons, thus suppressing the isomerization reaction of epoxide to acetaldehyde. This decreases the total combustion and improves the overall catalytic selectivity. 

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