The current commercial production of propylene oxide is based on chlorohydrin or hydroperoxide processes. These processes are inefficient, energy intensive, involve multiple steps, have low selectivity, and are accompanied by huge volumes of effluent wastewater and by-products. An integrated one-step process to oxidize propylene by oxygen or peroxide is desired, but the development of such an integrated process has been hindered by low selectivity towards polyethylene oxide, due to the formation of a more thermodynamically stable by-product, CO2. Therefore, a catalyst is needed that not only is capable of converting propylene but also is highly selectively to propylene oxide. This project will develop a dual-function nanoparticle catalyst that will be able to provide two functional sites on the same catalyst surface. The first function site catalyzes the direct oxidation of hydrogen and oxygen to generate hydrogen peroxide at 100% selectivity. The second site, adjacent to the first, catalyzes the reaction of the surface hydrogen peroxide intermediate with propylene to form the polyethylene oxide product. Phase I will develop the dual-function nanoparticle catalyst by identifying the best combination of the two function sites and the one-step reaction conditions. Phase I will also provide data for a preliminary economic evaluation of the process. Commercial Applications And Other Benefits as described by awardee: The current value of products manufactured using derivatives of propylene oxide is estimated at $10 billion. This new technology should make the one-step direct process of producing polyethylene oxide competitive with the current multi-step commercial processes.
