Catalyst for epoxidation reactions

Abstract

The present invention relates to the manufacture of solid materials or shaped bodies containing at least one zeolite and being at least partly crystalline. Furthermore, the present invention relates to the solid materials or shaped bodies as such and to the use of these materials for reactions of compounds having at least one C—C double bond with at least one hydroperoxide. Specifically, the present invention relates to a process for the manufacture of a solid material containing at least one zeolite and being at least partly crystalline, wherein the synthesis of the said solid material involves at least one partial step of contacting at least one transition metal oxide source with at least one epoxide or hydrolysate thereof prior to or during the at least partial crystallization of said solid material.

1 - 19 . (canceled)  
   
   
       20 . A process for preparing a solid material for use as catalytic material in an epoxidation reaction, the solid material comprising at least one zeolite and being at least partially crystalline, wherein a step (I) of an at least partial crystallization of at least one solid material comprising at least one zeolite out of a synthesis mixture involves at least one partial step of contacting at least one transition metal oxide source with at least one epoxide or hydrolysate thereof prior to or, during the at least partial crystallization of said synthesis mixture into said solid material, and wherein the at least one epoxide is the product of said epoxidation reaction.  
   
   
       21 . The process according to  claim 20 , wherein step (I) comprises at least the following partial steps 
 (Ia) mixing at least one hydrolyzable silicon source with a mineralizing and/or structuring agent and water;    (Ib) mixing at least one transition metal oxide source with an epoxide or a hydrolysate thereof;    (Ic) mixing the mixtures from (Ia) and (Ib) so that at least a part of the hydrolyzable compounds hydrolyzes;    (Id) distilling at least part of the alcohol that has been formed as a result of the at least partial hydrolisation of at least part of the hydrolyzable compounds;    (Ie) adding water to the bottom of (Id);    (If) reacting the synthesis mixture resulting from (Ie) at a temperature elevated with respect to room temperature.    
   
   
       22 . The process according to  claim 21 , wherein the hydrolyzable silicon source comprises at least one silicon oxide, the mineralizing and/or structuring agent comprises at least one tetraalkylammonium hydroxide, and the transition metal oxide source comprises at least one titanate.  
   
   
       23 . The process according to  claim 22 , wherein the hydrolyzable silicon source comprises at least tetraethoxy silicate, the mineralizing and/or structuring agent comprises at least tetrapropylammonium hydroxide, the transition metal oxide source comprises at least tetrabutylorthotitanate and the epoxide or the hydrolysate thereof comprises at least propylene oxide or propylene glycol.  
   
   
       24 . The process according to  claim 20 , wherein the at least one zeolite belongs to at least one of the following structure classes: MFI, MEL, MWW, BEA or any mixed structure thereof.  
   
   
       25 . The process according to  claim 21 , wherein the at least one zeolite belongs to at least one of the following structure classes: MFI, MEL, MWW, BEA or any mixed structure thereof.  
   
   
       26 . The process according to  claim 20 , step ( 1 ) of the at least partial crystallization resulting in a mixture (I) comprising at least said solid material and a mother liquor, said process further comprising the step 
 (II) separating and/or concentrating the solid material in mixture (I).    
   
   
       27 . The process according to  claim 21 , step (I) of the at least partial crystallization resulting in a mixture (I) comprising at least said solid material and a mother liquor, said process further comprising the step 
 (II) separating and/or concentrating the solid material in mixture (I).    
   
   
       28 . The process according to  claim 26 , wherein, after step (II), at least one of the following two additional steps is performed: 
 (W) bringing the solid material from step (II) in contact with a composition containing water;    (III) agglomerating or granulating or agglomerating and granulating the solid material from step (W) or from step (II).    
   
   
       29 . The process according to  claim 27 , wherein, after step (II), at least one of the following two additional steps is performed: 
 (W) bringing the solid material from step (II) in contact with a composition containing water;    (III) agglomerating or granulating or agglomerating and granulating the solid material from step (W) or from step (II).    
   
   
       30 . The process according to  claim 28 , wherein, after step (W), the solid material is separated from at least part of the composition containing water.  
   
   
       31 . The process according to  claim 26 , optionally comprising the step 
 (III) agglomerating, or granulating, or agglomerating and granulating the solid material from step (II);    said process further comprising the step    (S) shaping the solid material from step (II) or (III) obtaining a shaped body.    
   
   
       32 . The process according to  claim 31 , wherein the following step (W) is performed after step (II), or after step (S), or after step (II) and after step (S) 
 (W) bringing the solid material from step (II) or the shaped body from step (S) in contact with a composition containing water.    
   
   
       33 . The process according to  claim 31 , wherein step (S) is selected from the group consisting of pelletizing, pressing, extruding, sintering, roasting, and briquetting.  
   
   
       34 . Process according to  claim 32 , wherein step (S) is selected from the group consisting of pelletizing, pressing, extruding, sintering, roasting, and briquetting.  
   
   
       35 . Process according to  claim 33 , wherein before, or during, or before and during the step (S), a binding material is added to said solid material.  
   
   
       36 . Process according to  claim 26 , wherein after at least one of the steps (II), (W), (III) or (S), a step (C) of calcining the solid material, or the shaped body, or the solid material or the shaped body is performed.  
   
   
       37 . Process according to  claim 36 , wherein step (C) is performed at temperatures higher than 400° C.  
   
   
       38 . Process according to  claim 26 , wherein the process is an integrated process.  
   
   
       39 . A solid material comprising at least one zeolite for use as catalytic material in an epoxidation reaction, the solid material being obtainable by a process of treating a synthesis mixture, wherein a step (I) of an at least partial crystallization of at least one solid material comprising at least one zeolite out of a synthesis mixture involves at least one partial step of contacting at least one transition metal oxide source with at least one epoxide or hydrolysate thereof prior to or during the at least partial crystallization of said synthesis mixture into said solid material, and wherein the at least one epoxide is the product of said epoxidation reaction, said step (I) comprising at least the following partial steps 
 (Ia) mixing at least one hydrolyzable silicon source with a mineralizing and/or structuring agent and water;    (Ib) mixing at least one transition metal oxide source with an epoxide or a hydrolysate thereof;    (Ic) mixing the mixtures from (Ia) and (Ib) so that at least a part of the hydrolyzable compounds hydrolyzes;    (Id) distilling at least part of the alcohol that has been formed as a result of the at least partial hydrolisation of at least part of the hydrolyzable compounds;    (Ie) adding water to the bottom of (Id);    (If) reacting the synthesis mixture resulting from (Ie) at a temperature elevated with respect to room temperature.    
   
   
       40 . The solid material according to  claim 39 , wherein the solid material contains Ti.  
   
   
       41 . The solid material according to  claim 39 , wherein the solid material is shaped into a shaped body.  
   
   
       42 . A process for preparing a solid material for use as catalytic material in an epoxidation reaction, the solid material comprising at least one zeolite and being at least partially crystalline, wherein a step (I) of an at least partial crystallization of at least one solid material comprising at least one zeolite out of a synthesis mixture involves at least one partial step of contacting at least one transition metal oxide source with at least one epoxide or hydrolysate thereof prior to or during the at least partial crystallization of said synthesis mixture into said solid material, and wherein the at least one epoxide is the product of said epoxidation reaction, wherein 
 step (I) comprises at least the following partial steps    (Ia) mixing at least one hydrolyzable silicon source with a mineralizing and/or structuring agent and water;    (Ib) mixing at least one transition metal oxide source with an epoxide or a hydrolysate thereof;    (Ic) mixing the mixtures from (Ia) and (Ib) so that at least a part of the hydrolyzable compounds hydrolyzes;    (Id) distilling at least part of the alcohol that has been formed as a result of the at least partial hydrolisation of at least part of the hydrolyzable compounds;    (Ie) adding water to the bottom of (Id);    (If) reacting the synthesis mixture resulting from (Ie) at a temperature elevated with respect to room temperature;    wherein step (I) of the at least partial crystallization resulting in a mixture (I) comprising at least said solid material and a mother liquor, said process further comprising the step    (II) separating and/or concentrating the solid material in mixture (I); optionally comprising the step    (III) agglomerating, or granulating, or agglomerating and granulating the solid material from step (II);    said process further comprising the step    (S) shaping the solid material from step (II) or (III) obtaining a shaped body.    
   
   
       43 . A process for preparing a solid material for use as catalytic material in an epoxidation reaction, the solid material comprising at least one zeolite and being at least partially crystalline, wherein a step ( 1 ) of an at least partial crystallization of at least one solid material comprising at least one zeolite out of a synthesis mixture involves at least one partial step of contacting at least one transition metal oxide source with at least one epoxide or hydrolysate thereof prior to or during the at least partial crystallization of said synthesis mixture into said solid material, and wherein the at least one epoxide is the product of said epoxidation reaction, wherein 
 step (I) comprises at least the following partial steps    (Ia) mixing at least one hydrolyzable silicon source with a mineralizing and/or structuring agent and water;    (Ib) mixing at least one transition metal oxide source with an epoxide or a hydrolysate thereof;    (Ic) mixing the mixtures from (Ia) and (Ib) so that at least a part of the hydrolyzable compounds hydrolyzes;    (Id) distilling at least part of the alcohol that has been formed as a result of the at least partial hydrolisation of at least part of the hydrolyzable compounds;    (Ie) adding water to the bottom of (Id);    (If) reacting the synthesis mixture resulting from (Ie) at a temperature elevated with respect to room temperature;    wherein step ( 1 ) of the at least partial crystallization resulting in a mixture (I) comprising at least said solid material and a mother liquor, said process further comprising the step    (II) separating and/or concentrating the solid material in mixture (I); optionally comprising the step    (III) agglomerating, or granulating, or agglomerating and granulating the solid material from step (II);    said process further comprising the step    (S) shaping the solid material from step (II) or (III) obtaining a shaped body; and wherein    the following step (W) is performed after step (II), or after step (S), or after step (II) and after step (S)    (W) bringing the solid material from step (II) or the shaped body from step (S) in contact with a composition containing water.