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Chemical Engineering Journal 295 (2016) 370–375

Contents lists available at ScienceDirect

Chemical Engineering Journal


journal homepage: www.elsevier.com/locate/cej

Green and efficient epoxidation of propylene with hydrogen peroxide


(HPPO process) catalyzed by hollow TS-1 zeolite: A 1.0 kt/a pilot-scale
study
Min Lin a, Changjiu Xia a,b,⇑, Bin Zhu a, Hua Li c, Xingtian Shu a
a
State Key Laboratory of Catalytic Materials and Reaction Engineering, Research Institute of Petroleum Processing, SINOPEC, 100083 Beijing, PR China
b
Department of Material and Environmental Chemistry, Stockholm University, Stockholm SE 106 91, Sweden
c
Changling Petrochemical Co. Ltd., SINOPEC, Yueyang 414012, Hunan Province, PR China

h i g h l i g h t s

 Hollow TS-1 zeolite is an good catalyst for HPPO process at pilot scale.
 Increasing the solubility of propylene favors fast conversion rate.
 Shortening the residence time of H2O2 insider benefits high PO selectivity.
 The lifetime of hollow TS-1 zeolite in HPPO process is very long.

a r t i c l e i n f o a b s t r a c t

Article history: The propylene epoxidation catalyzed by hollow TS-1 zeolite with 30 wt% H2O2 solution as oxidant at
Received 4 September 2015 1.0 kt/a pilot plant has been examined. Rising reaction temperature is in favor of increasing TOF of
Received in revised form 3 February 2016 H2O2 but reduces the selectivity of PO, due to the promotion of major and side reactions at the same time.
Accepted 19 February 2016
Enhancing the CH3OH amount and the WHSV of H2O2 is preferential to improving the TOF of H2O2 and
Available online 26 February 2016
the selectivity of PO, but increase capital and energy consumption as well. Taking all into consideration,
the optimized epoxidation has been confirmed: T is 40–50 °C; molar ratio of CH3OH/H2O2 is 5–15, and the
Keywords:
WHSV of H2O2 is more than 1.2 h1. When the epoxidation of propylene carried out over 6000 h, the TOF
Epoxidation
Hollow TS-1
of H2O2 is 30.9–32.2 mmol g1 h1 and the PO selectivity is 96–99%, respectively. The final PO product
Zeolite from this plant is at 99.97% purity, which has been used as an intermediate to synthesize kinds of
Pilot scale chemicals.
Propylene oxide Ó 2016 Elsevier B.V. All rights reserved.

1. Introduction and hydrogen peroxide propene oxide (HPPO) process [4–9]. Com-
pared with other four routes, HPPO route is much more
Propylene oxide (PO) is one of key propylene based chemical environmental-friendly, without the generation of toxic by-
intermediates for producing fine chemicals, such as polyurethane products and wastes. HPPO process is based on titanium silicate
plastics, polyglycol esters, unsaturated resins and surfactants (TS-1) zeolite as catalyst, [10–13] low concentration (30–50 wt%)
[1–3]. As the fast development of material and environmental tech- aqueous H2O2 solution as oxidant under mild conditions (usually
nologies, the demand of PO is continuously growing in the world, lower than 70 °C) [14,15]. The first commercial HPPO propylene
for example, the global PO market is over 7.5 million tons in epoxidation plant at 100 kt/a capacity was launched by Evonik
2010. Several of synthetic methods have been exploited for produc- and SKC at Korea in 2008 [16]. Then, several more HPPO process
ing PO in academic and industrial sections, i.e. chlorohydrin pro- units were set up gradually in Belgium by BASF and DOW (300 kt/
cess, styrene monomer propene oxide (PO/SM) process, tert-butyl a, 2009), [17] in China by Evonik and Uhde (230 kt/a, 2013), [18]
alcohol (PO/TBA) process, cumene hydroperoxide (CHP) process and in Thailand by DOW (390 kt/a, 2012) [19]. In HPPO process,
PO is produced directly from propylene in a one-step reaction, as
⇑ Corresponding author at: State Key Laboratory of Catalytic Materials and illustrated in Fig. 1. However, epoxidation is a cascade reaction,
Reaction Engineering, Research Institute of Petroleum Processing, SINOPEC, 100083 and these side products lower the yield of PO via secondary reac-
Beijing, PR China. tion. Among them, propylene glycol monomethyl ethers (MME,
E-mail address: xiachangjiu@gmail.com (C. Xia).

http://dx.doi.org/10.1016/j.cej.2016.02.072
1385-8947/Ó 2016 Elsevier B.V. All rights reserved.
M. Lin et al. / Chemical Engineering Journal 295 (2016) 370–375 371

O hydroxide (TPAOH) was selected as organic structure directing


TS-1 zeolite
H3C CH CH2 + H2O2 H3C C CH2 + H2O agent (OSDA) for synthesis of the TS-1 zeolite, as described in
Methanol H (a)
30-70 oC ENI method. The molar ratio of SiO2:TiO2:TPAOH:H2O is
1:0.04:0.36:40, the hydrothermal synthesis temperature is
OH OH
170 °C, under the autogenous pressure. Firstly, the tetraethyl
H 3C C CH2
2O H
orthosilicate (TEOS) and tetrabutyl orthotitanate (TBOT) was dis-
O +H
solved in the aqueous TPAOH solution, and this mixture was
H 3C C CH2
heated at 80 °C for evaporating the ethanol and butanol molecules.
H +C CH3 CH3 (b)
H O OH OH O Then, the mixture was transferred to Teflon autoclave and
3 OH
H 3C C CH2 + H3C C CH2 hydrothermally synthesized at high temperature for 3 days. After
H H that, the as made TS-1 zeolite was calcined at 550 °C for 3 h. In sec-
ond step, the calcined TS-1 zeolite was post-synthesized at 170 °C
Fig. 1. Major and side reactions involved in the epoxidation of propylene catalyzed
for 1 day in the presence of OSDA under autogenous pressure, as
by TS-1 zeolite in mild conditions: (1) major reaction of propylene epoxidation; (b)
side ring-opening reactions of PO with CH3OH and H2O2. illustrated in the literatures [21]. In addition, the calcined hollow
TS-1 zeolite was characterized by multiple characterization meth-
ods, and sharped as catalyst for HPPO process.
with two isomers, as shown in Fig. 1) and 1,2-propylene glycol (PG)
are the two main byproducts, which are formed by ring-opening
reactions of PO with CH3OH and H2O. Thus, it is of ultra- 2.2. Characterization of hollow TS-1 zeolite
importance to optimize the operating parameters, such as reaction
temperature, CH3OH concentration, and weight hourly space veloc- X-ray powder diffraction patterns (XPRD) were collected on a
ity (WHSV) of H2O2, to avoid these side reactions occurred. Bruker (Siemens) D5005 diffractometer using nickel filtered Cu
However, the conversional TS-1 zeolite usually has poor cat- Ka radiation (k = 1.5418 Å) under ambient conditions in the 2h
alytic activity and reproducibility, due to the mismatch of hydrol- range of 5–35° with a step size of 0.02° and exposure time of 1 s
ysis and crystallization rates between Si and Ti species under per step. N2 adsorption/desorption isotherms were collected at
hydrothermal conditions [20]. To solve these problems, the hollow 77 K using a Micromeritics ASAP 2010 apparatus. Before the mea-
TS-1 zeolite was produced by post-synthesis method in the pres- surement, about 50 mg of the sample was dehydrated under vac-
ence of TPAOH solution at high temperature [21–23]. Compared uum (103 Torr) at 300 °C overnight. The specific surface areas
with conventional TS-1, hollow TS-1 zeolite is of abundant were determined from the linear part of the BET equation. Trans-
intracrystalline cavities and high framework Ti species content. mission electron microscopy (TEM) was carried out on a FEI G2
In our previous working, hollow TS-1 zeolite exhibits higher cat- F20S-TWIN electron microscope. Scanning electron microscopy
alytic performances and stability in several oxidation reactions (SEM) was operated on a FEI Quanta 200F instrument.
with aqueous H2O2 solution as oxidant, such as cyclohexanone
ammoxidation, aromatic oxidation, phenol hydroxylation at indus- 2.3. Catalytic testing at 1.0 kt/a scale
trial scale and propylene epoxidation in lab. Herein, the epoxida-
tion of propylene catalyzed by hollow TS-1 zeolite has been The pilot-scale propylene epoxidation reaction was carried out
carried out at 1.0 kt/a pilot scale. Thus the effects of several major on a fixed bed reactor, and the corresponding schematic diagram
important parameters on epoxidation reaction have been systemi- is illustrated in Fig. 2. In a typical procedure, hollow TS-1 zeolite
cally investigated, for obtaining the optimized reaction conditions was sharped into about £ 1–3 mm particles, and then they were
to support the even larger pilot scale test [24]. added into a stainless tube reactor. Then, the mixture of CH3OH,
H2O2 (30 wt%), H2O and propylene was injected into the bottom
2. Experimental of reactor, and the reaction temperature was 30–70 °C. After the
epoxidation of propylene with H2O2, the mixture of solvent, prod-
2.1. Synthesis of hollow TS-1 zeolite catalyst ucts and reagents went into the C@ 3 separation tower for evaporat-
ing the remainder propylene, which can be reused as starting
Hollow TS-1 zeolite was synthesized as previously published material for this process. Moreover, the mixture from the bottom
method [25,26]. In a general procedure, tetrapropylammonium of C@ 3 separation tower went into the PO separation tower, for

Fig. 2. Schematic process flow diagram of propylene epoxidation at 1.0 kt/a pilot scale.
372 M. Lin et al. / Chemical Engineering Journal 295 (2016) 370–375

Fig. 3. Multiple characterization results of hollow TS-1 zeolite catalyst: (a) TEM image; (b) SEM image; (c) PXRD pattern; (d) low temperature N2 adsorption–desorption
isotherm; (e) UV–Vis spectrum; and (f) FT-IR spectrum of hollow TS-1 zeolite.

separating raw PO from the aqueous CH3OH solution. After that, selectivity of PO, MME and PG were calculated as following equa-
the raw PO was refined in the PO purification tower, while the tions, respectively.
CH3OH was purified in the H2O/CH3OH separation tower. In the
n0H2 O2  nH2 O2
end, the H2O was removed from this process, and the purified X H2 O2 ¼  100%
CH3OH was recycled as solvent for this reaction. n0H2 O2
Propylene and epoxidation products were qualitatively ana-
lyzed by the ThermoFisher Trace ISQ mass spectroscopy (MS) WHSVH2 O2  X H2 O2
TOFH2 O2 ¼
equipment, and quantatified by the Agilent HP-6890 gas chro- MH2 O2
matography (GC) apparatus, with a hydrogen flame ionization
detector and a 30 m  0.25 mm  0.33 lm HP-5 weak polar GC nPO
SPO ¼  100%
column. Conversion and turnover frequency (TOF) of H2O2, the nPO þ nMME þ nPG
M. Lin et al. / Chemical Engineering Journal 295 (2016) 370–375 373

nMME
SMME ¼
nPO þ nMME þ nPG
 100% (a)
32.2

TOF of H2O2 molecules/(mmol.gCat .h )


-1
nPG

-1
SPG ¼  100% 32.0
nPO þ nMME þ nPG
31.8

3. Results and discussion


31.6

3.1. Characterization of hollow TS-1 zeolite


31.4

Multiple characterization results of hollow TS-1 zeolite are


31.2
illustrated in Fig. 3. From the result of XRD pattern, five diffraction
peaks between 22° and 25° are apparently detected, which indi-
31.0
cates that this material is of typical MFI topology and in high crys- 40 50 60 70
tallinity [27,28]. Meanwhile from high magnification SEM image, o
Reaction Temperature/ C
we can observe that the hollow TS-1 zeolite particle is of aggregate
morphology, and the crystal size ranges from 250 to 300 nm. AS 100 (b)
shown in TEM image, hollow TS-1 zeolite is of abundant intracrys- PO
MME
talline pores, which are in favor of mass diffusion inside zeolite

Selectivity of major and side product/%


PG
crystal. The size distribution of hollow cavities is not very uniform
(ranging from several to tens nanometers), which is favor of high 95
catalytic activity by enhancing the accessibility of reagent and pro-
duct molecules to active sites [29,30]. Moreover, the intracrys-
talline mesopores are confirmed by low temperature (77 K) N2
adsorption–desorption isotherm method. Obviously, there is a H4 90
10
hysteresis loop at P/P0 > 0.45 for hollow TS-1 zeolite, due to the
capillary condensation effects of blocked mesopores [31,32].
Furthermore, the pore parameters of hollow TS-1 zeolite are calcu-
lated by using Brunauer–Emmett–Teller (BET) model, which gives 5
a specific surface area of 437 m2 g1 and a micropore volume of
0.173 cm3 g1. It is noteworthy that the pore parameter of hollow
TS-1 zeolite is larger than that of common TS-1 zeolite in the liter- 0
atures. With respect to the chemical statue of Ti species, two 40 50 60 70
apparent bands at 210 nm and 330 nm are observed in the o
Reaction temperature/ C
UV–Vis spectrum, which are attributed to the tetrahedral frame-
work Ti species and anatase TiO2, respectively [33,34]. In addition, Fig. 4. Effect of reaction temperature on reaction rate (TOF) of H2O2 molecules (a)
there is a band near 960 cm1 appeared in the FT-IR spectrum, and the selectivity distribution of products (b) in propylene epoxidation reaction.
which is usually considered as the evidence of the TiAOASi bond’s Reaction conditions: P = 1.5 MPa, WHSV of H2O2 molecules is 1.1 h1, nCH3 OH =nH2 O2
is 6, nPropylene =nH2 O2 is 2.5.
stretching vibration [35]. Consequently, the incorporation of iso-
lated Ti species into the framework matrix in tetrahedral coordina-
tion has been confirmed. Thus, the high catalytic performance of hydrolyzed ring-opening and H2O2 decomposition reactions,
hollow TS-1 in propylene epoxidation reaction can be expected, producing much more MME and PG and reducing the utilization
due to the enhancement of mass diffusion property and much efficiency of H2O2. On the other hand, if propylene epoxidation
more active sites. carried out at very low temperature, the amount of remainder
H2O2 will be increased. It is related to safety issue and reduces
3.2. Effect of reaction temperature on propylene epoxidation the utilization efficiency of H2O2. Here, the optimized reaction
temperature is 40–50 °C, for achieving high PO selectivity.
It is widely accepted that the reaction temperature plays an
important role in the conversion rate of H2O2 molecules, which is 3.3. Effect of solvent methanol amount on propylene epoxidation
attributed to the propylene epoxidation is a strongly exothermic
reaction [4,36]. However, when reaction temperature increases, Due to epoxidation reaction is extremely exothermic, adding
some side reactions, such as ring-opening and hydrolysis, will be solvent amount is preferential to removing the heat from reaction
happened, causing the reducing of the selectivity of PO. In our system, to limit the adiabatic temperature rise inside reactor and
study, when reaction temperature passing from 40 to 70 °C as avoid safety problem. Moreover, it has been proposed that the sol-
shown in Fig. 4(a), the TOF of H2O2 molecule slightly increases vent CH3OH participate propylene epoxidation reaction via form-
from 31.16 to 32.20 mmol g1cat h
1
. However, the selectivity of PO ing five-membered rings between TiAOOH species and an
decreases from 98.9% to 95.6%, while the selectivity of MME and adsorbed CH3OH molecule, as described by Clerici and his cowork-
PG increases continuously as a function of the reaction tempera- ers [38,39]. Fig. 5(a) presents the effect of solvent amount on the
ture in this range, as shown in Fig. 4(b). Moreover, it is suggested propylene epoxidation catalyzed by hollow TS-1 zeolite. We
that increasing reaction temperature can accelerate the ring- observe that the TOF of H2O2 molecules increases dramatically
opening reactions of PO and H2O2 decomposition under the impact from 29.9 to 31.7 mmol g1 cat h
1
, along with the increasing of molar
of H2O, CH3OH molecules and catalyst. That is because raising tem- ratio of CH3OH/H2O2 between 5 and 21. Although adding large
perature can improve the self-ionization of H2O and CH3OH mole- amount of CH3OH reduces the concentrations of H2O2, much more
cules, with the increasing formation of H3O+ and OH ions [37]. propylene can be dissolved in the CH3OH solution [2.6  101 mol/
Then, these acidic and basic groups can serve as catalysts for (L atm), at 40 °C], [40,41] increasing the concentration of adsorbed
374 M. Lin et al. / Chemical Engineering Journal 295 (2016) 370–375

32.0 (a) 35 (a)

TOF of H2O2 molecules(mmol.gcat .h )


-1
TOF of H2O2 molecules(mmol.gCat .h )
-1

-1
31.6
30
-1

25
31.2
20
30.8
15

30.4 10

30.0 5

0
29.6 0.0 0.2 0.4 0.6 0.8 1.0 1.2
4 8 12 16 20 24 -1
WHSV of H2O2 molecules/(h )
CH3OH/H2O2 molar ratio

(b)
100 (b) 99.0

98.5
99

98.0

Selectivity of PO/%
Selectivity of PO/%

98
97.5

97 97.0

96 96.5

96.0
95
95.5
94
0 5 10 15 20 25 30 35
4 8 12 16 20 24
-1 -1
CH3OH/H2O2 molar ratio TOF of H2O2 molecules(mmol.g .h )

Fig. 5. Effect of molar ratio of CH3OH to H2O2 on epoxidation of propylene with Fig. 6. Effect of WHSV of H2O2 on epoxidation of propylene with H2O2 over hollow
H2O2 over hollow TS-1 zeolite catalyst. (a) TOF of H2O2 molecules as a function of TS-1 zeolite catalyst. (a) TOF of H2O2 molecules as a function of WHSV of H2O2; (b)
CH3OH/H2O2 molar ratio; (b) selectivity of PO along with CH3OH/H2O2 molar ratio. selectivity of PO along with WHSV of H2O2. Reaction conditions: T = 65 °C,
Reaction conditions: T = 35 °C, P = 2.0 MPa, WHSV of H2O2 molecules is 1.2 h1, P = 1.0 MPa, WHSV of H2O2 molecules is 1.2 h1, nCH3 OH =nH2 O2 is 7, nPropylene =nH2 O2
nPropylene =nH2 O2 is 2.0. is 1.4.

propylene molecules. Furthermore, high molar ratio of CH3OH/ molecules inside catalyst is preferential to avoiding the deep
H2O2 is favor of the formation of five-membered ring intermedi- epoxide-opening of major product PO. That is to say, these side
ates, which is one central step of epoxidation reaction mechanism. reactions can be catalyzed by hollow TS-1 zeolite and binders.
As a result, increasing solvent amount is useful for the high conver- However, when the WHSV of H2O2 molecules is too high, the
sion rate of H2O2 molecules. As shown in Fig. 5(b), high molar ratio corresponding residence time inside the channel of catalyst is too
of CH3OH/H2O2 also leads to the high selectivity of PO (the maxi- short to complete epoxidation of propylene. Thus, it is optimized
mum value is close to 100%), which is attributed to CH3OH of to select high WHSV of H2O2 (1.2 h1 under the conditions
weaker nucleophilic capability than H2O for reacting with PO ring. described in Fig. 6, or even higher than it) for achieving high selec-
However, from the viewpoint of application, high molar ratio of tivity of PO.
CH3OH/H2O2 means high energy consumed and large towers
needed for purifying the CH3OH as shown in the Fig. 2. Therefore, 3.5. The stability of hollow TS-1 zeolite at 1.0 kt/a scale
by taking all issues into account, we suggest that the optimized
molar ratio of CH3OH/H2O2 lines in 5–15. From the previous sections, it has been confirmed that hollow
TS-1 zeolite catalyst is of high catalytic activity and PO selectivity
3.4. Effect of WHSV of H2O2 molecules on epoxidation of propylene in the HPPO process. It is contributed to its hierarchical structure
and the incorporation of isolated tetrahedral Ti species into the
The TOF of H2O2 molecules and selectivity of PO at 65 °C as a framework matrix of MFI zeolite, which can act as effective Lewis
function of WHSV of H2O2 is illustrated in Fig. 6(a). It is observed acid catalyst. To verify the stability of this catalyst, the lifetime of
that the TOF of H2O2 molecules increases gradually from 2.94 to hollow TS-1 based catalyst was detected at pilot scale, working
34.27 mmol g1 cat h
1
as a function of WHSV of H2O2 from 0.12 to at T = 30–70 °C, P = 0.5–2.0 MPa, WHSV of H2O2 molecules is
1.2 h1, which is in good agreement with other research results 0.12–1.2 h1, nCH3 OH =nH2 O2 is 5–25, nPropylene =nH2 O2 is 1.2–2.5. In
in literatures. It is ascribed to abundant tetrahedral Ti active sites our previous work, hollow TS-1 zeolite presents even higher cat-
existed for propylene epoxidation reaction in the range of WHSV alytic activity and lifetime than conventional TS-1 zeolite in the
of H2O2 molecules described in Fig. 6. Furthermore, it is worth not- cyclohexanone ammoxidation process from lab to industrial scale.
ing that the selectivity of PO increases significantly from 95.6% to That is because much more TiAOASi and SiAOASi bonds formed
98.9% along with the increase TOF of H2O2 molecules, as shown after the recrystallization treatment, reducing the amount of
in Fig. 6(b). It suggests that low reactant residence time of H2O2 framework defects (SiAOH and TiAOH groups) and extraframe-
M. Lin et al. / Chemical Engineering Journal 295 (2016) 370–375 375

100 32 fully. And the purified PO from this process has been used as a use-
ful intermediate to produce a variety of chemicals.

TOF of H2O2 molecules/(mmol.g .h )


-1
98

-1
31
Acknowledgments
Selectivity of PO/%

96

30
This work was financially supported by the National Basic
Research Program of China (973 Program, 2006CB202508), China
94
Selectivity of PO Petrochemical Corporation (SINOPEC Group 20673054). Changjiu
TOF of H2O2 molecules 29 Xia thanks Swedish Research Council (VR) and Swedish Govern-
92
mental Agency for Innovation Systems (VINNOVA) and the
Göran-Gustafsson Foundation for Natural Sciences and Medical
90 28 Research.
0 1000 2000 3000 4000 5000 6000
Reaction time/h
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