Beruflich Dokumente
Kultur Dokumente
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
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
-1
SPG ¼ 100% 32.0
nPO þ nMME þ nPG
31.8
-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.
-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
References
Fig. 7. The TOF of H2O2 molecules and the selectivity of PO in propylene
epoxidation catalyzed by hollow TS-1 zeolite as a function of reaction time at [1] T.A. Nijhuis, M. Makkee, J.A. Moulijn, B.M. Weckhuysen, Ind. Eng. Chem. Res. 45
1.0 kt/a polite scale. Reaction conditions: T = 30–70 °C, P = 0.5–2.0 MPa, WHSV of (2006) 3447–3459.
H2O2 molecules is 0.12–1.2 h1, nCH3 OH =nH2 O2 is 5–25, nPropylene =nH2 O2 is 1.2–2.5. [2] M.J. Climent, A. Corma, S. Iborra, Chem. Rev. 111 (2) (2011) 1072–1133.
[3] T. Hayashi, K. Tanaka, M. Haruta, J. Catal. 178 (2) (1998) 566–575.
[4] G. Wu, Y. Wang, L. Wang, W. Feng, H. Shi, Y. Lin, T. Zhang, X. Jin, S. Wang, X.
work Ti species. As shown in Fig. 7, the HPPO process catalyzed by Wu, P. Yao, Chem. Eng. J. 215 (2013) 306–314.
[5] V. Russo, R. Tesser, E. Santacesaria, M. Di Serio, Ind. Eng. Chem. Res. 52 (3)
hollow TS-1 zeolite runs very smoothly far than 6000 h at pilot (2013) 1168–1178.
plant, with almost the same catalytic performance as the initial [6] C. Wang, B. Wang, X. Meng, Z. Mi, Catal. Today 74 (2002) 15.
catalytic activity. Under the wide operation conditions, the TOF [7] Z. Xi, N. Zhou, Y. Sun, K. Li, Science 292 (5519) (2001) 1139–1141.
[8] G.F. Thiele, E. Roland, J. Mol. Catal. A: Chem. 117 (1) (1997) 351–356.
of H2O2 is around 31–32 mmol g1 h1 (X H2 O2 is 96–99%) and selec- [9] W. Song, Y. Zuo, G. Xiong, X. Zhang, F. Jin, L. Liu, X. Wang, Chem. Eng. J. 253
tivity of PO is 96–99%, which is much better than that reported by (2014) 464–471.
BASF and DOW (the selectivity of PO is 93.2%) [15]. [10] M. Taramasso, G. Perego, B. Notari. US 4410501, 1983.
[11] B. Notari, Catal. Today 18 (1993) 163.
Furthermore, the raw propylene oxide produced in the fixed-
[12] X. Liu, C. Yang, Y. Wang, Y. Guo, Y. Guo, G. Lu, Chem. Eng. J. 243 (2014) 192–
bed reactor is purified in the PO purification column, obtaining 196.
the final PO product at 99.97% purity. And then, the purified PO [13] X. Wang, X. Zhang, Y. Wang, H. Liu, J. Wang, J. Qiu, H.L. Ho, W. Han, K.L. Yeung,
Chem. Eng. J. 175 (2011) 408–416.
has been used as chemical intermediates to manufacture 1,2-
[14] Gema Blanco-Brieva, M. Carmen Capel-Sanchez, M. Pilar de Frutos, Ana
ethyl glycerol, oilfield demulsifier, propylene carbonate, triiso- Padilla-Polo, Jose M. Campos-Martin, Jose L.G. Fierro, Ind. Eng. Chem. Res. 47
propanolamine, hydroxypropyl, dimethyl carbonate in China. By (21) (2008) 8011–8015.
using these result obtained at 1.0 kt/a pilot plant, one 100 kt/a [15] P. Bassler, M. Weidenbach, H. Goebbel, Chem. Eng. Trans. 21 (2010) 571–576.
[16] http://corporate.evonik.com/en/company/locations/location-asia/pages/skc-
industrial demonstration propylene epoxidation unit at SINOPEC evonik-peroxide-korea-co-ltd.aspx.
has already been set up and run for a long period smoothly [19]. [17] http://www.chemicals-technology.com/projects/basf-hppo/.
[18] http://corporate.evonik.com/en/media/press_releases/Pages/news-details.
aspx?newsid=45021.
4. Conclusion [19] http://newsroom.dow.com/press-release/company-news/scg-dow-group-
achieves-successful-thailand-hppo-plant-start.
[20] C. Shen, Y.J. Wang, J.H. Xu, G.S. Luo, Chem. Eng. J. 259 (2015) 552–561.
The epoxidation of propylene catalyzed by hollow TS-1 zeolite
[21] Y. Wang, M. Lin, A. Tuel, Microporous Mesoporous Mater. 102 (2007) 80.
based catalyst at 1.0 kt/a pilot scale, operating in a fixed-bed reac- [22] A. Zheng, C. Xia, Y. Xiang, M. Xin, B. Zhu, M. Lin, G. Xu, X. Shu, Catal. Commun.
tor and under mild conditions, has been investigated. Hollow TS-1 45 (2014) 34.
zeolite, which is of abundant intracrystalline mesopores and high [23] S. Li, A. Tuel, D. Laprune, F. Meunier, D. Farrusseng, Chem. Mater. 27 (1) (2015)
276–282.
framework Ti species, presents high catalytic activity and long life- [24] http://urethaneblog.typepad.com/my_weblog/2014/01/sinopec-hppo-plant.
time (over 6000 h) in this process. Rising reaction temperature html.
accelerates the major epoxidation, H2O2 decomposition and ring- [25] Y. Wang, A. Tuel, Microporous Mesoporous Mater. 113 (2008) 286.
[26] M. Lin, X. Shu, X. Wang, B. Zhu. US 6475465[P], 2002.
opening reactions at the same time, enhancing the TOF of H2O2 [27] A. Carati, C. Flego, D. Berti, R. Millini, B. Stocchi, C. Perego, Stud. Surf. Sci. Catal.
and the selectivity of side-products (such as MME and PG). Increas- 125 (1999) 45–52.
ing CH3OH solvent amount is of ultra-importance to improve the [28] G. Bellussi, A. Carati, M.G. Clerici, G. Maddinelli, R. Millini, J. Catal. 133 (1992)
220.
TOF of H2O2 and PO selectivity, due to adding CH3OH is in favor [29] X. Mu, D. Wang, Y. Wang, M. Lin, S. Cheng, X. Shu, Chin. J. Catal. 34 (2013) 69–
of the solubility of propylene and removing the reaction heat to 79.
avoid H2O2 decomposition and epoxide-opening reactions. How- [30] C. Xia, L. Ju, Y. Zhao, H. Xu, B. Zhu, F. Gao, M. Lin, Z. Dai, X. Zou, X. Shu, Chin. J.
Catal. 36 (6) (2015) 845–854.
ever, increasing molar ratio of CH3OH/H2O2 causes the high cost [31] J. Mielby, J.O. Abildstrøm, F. Wang, T. Kasama, C. Weidenthaler, S. Kegnæs,
and energy consumption. Moreover, it is confirmed that hollow Angew. Chem. 126 (2014) 12721–12724.
TS-1 based catalyst is of high transformation capacity for epoxida- [32] J. Zečević, C.J. Gommes, H. Friedrich, P.E. de Jongh, K.P. de Jong, Angew. Chem.
Int. Ed. 51 (2012) 4213–4217.
tion reaction (WSHV of H2O2 P 1.2 h1). And reducing the resi-
[33] C. Li, G. Xiong, Q. Xin, J. Liu, P. Ying, Z. Feng, J. Li, W. Yang, Y. Wang, G. Wang, X.
dence time of H2O2 and PO inside catalyst is useful to obtain Liu, M. Lin, X. Wang, E. Min, Angew. Chem. Int. Ed. 38 (1999) 2220–2222.
high H2O2 TOF and PO selectivity, but reducing H2O2 conversion. [34] S. Bordiga, A. Damin, F. Bonino, G. Ricchiardi, C. Lamberti, A. Zecchina, Angew.
Therefore, taking all factors into consideration, when the reaction Chem. 114 (24) (2002) 4928–4931.
[35] W. Lin, H. Frei, J. Am. Chem. Soc. 124 (31) (2002) 9292–9298.
pressure and molar ratio of propylene/H2O2 are fixed at [36] R. Sanz, D.P. Serrano, P. Pizarro, I. Moreno, Chem. Eng. J. 171 (3) (2011) 1428–
0.5–2 MPa and 1.2–2.5, respectively, other optimized reaction con- 1438.
ditions at 1.0 kt/a pilot scale have been confirmed: T is 40–50 °C; [37] H. Lawrence Clever, J. Chem. Educ. 45 (1968) 231.
[38] M.G. Clerici, P. Ingallina, J. Catal. 140 (1993) 71–83.
molar ratio of CH3OH/H2O2 is 5–15, and the WHSV of H2O2 is no [39] M. Neurock, L.E. Manzer, Chem. Commun. (1996) 1133–1134.
less than 1.2 h1. According to these optimized parameters, an [40] Y. Miyano, K. Fukuchi, Fluid Phase Equilib. 226 (2004) 183–187.
even larger demonstration unit has been designed and run success- [41] X. Liu, X. Wang, X. Guo, G. Li, Catal. Today 93 (2004) 505–509.