Direct vapor phase propylene epoxidation over deposition-precipitation gold-titania catalysts in the presence of H2/O2:: Effects of support, neutralizing agent, and pretreatment

The effects of titanium connectivity, deposition solution neutralizing agent, and catalyst pretreatment were examined for a series of Au-on-titanium-containing supports for the direct gas-phase epoxidation of propylene using hydrogen and oxygen. The degree of titanium isolation was examined using pure titania, monolayer-titania on silica, submonolayer-titania on silica, and titanium silicalite-1 (TS-1) supports. Activity and selectivity were shown to increase as the degree of titanium isolation increased, with TS-1 and submonolayer-titania supports providing the best stability and yield. Isolation of the titanium was found to significantly reduce the cracking of propylene to ethanal and carbon dioxide. Sodium carbonate was found to be the best neutralizing agent for catalysts prepared using deposition-precipitation (DP). DP with ammonium hydroxide gave catalysts with reduced selectivity and activity. Titania-modified silica was found to produce better catalysts when the support was not calcined prior to gold deposition. Similarly, calcination was detrimental to catalysts prepared via deposition of a 2 nm gold colloid onto titania-modified supports even though the gold did not sinter. The beneficial effects of Ti site isolation and support acid/base control are best seen at higher temperatures, where only a few catalysts can maintain selectivity.