Epoxidation processes and catalysts for use therein

Abstract

Epoxidation methods and catalyst are described herein. The epoxidation catalysts generally include a metal component including silver and a support material including kaolinite, wherein the epoxidation catalyst includes less than 55 wt. % metal component.

What is claimed is: 
     
         1 . A catalyst comprising:
 (a) silver having an oxidation state of zero; and   (b) a phyllosilicate solid component;   
       wherein the silver is deposited on the phyllosilicate solid component. 
     
     
         2 . The catalyst of  claim 1 , wherein the phyllosilicate solid component is a clay mineral group phyllosilicate. 
     
     
         3 . The catalyst of  claim 1 , wherein the catalyst further comprises a Group 1 metal salt. 
     
     
         4 . The catalyst of  claim 3 , wherein the Group 1 metal salt is KNO 3 . 
     
     
         5 . The catalyst of  claim 1 , wherein the catalyst further comprises a promoter metal selected from: rhenium, tungsten, zinc, nickel, gold, copper, sodium, potassium, lithium, rubidium, cesium, or molybdenum. 
     
     
         6 . The catalyst of  claim 1 , wherein the catalyst comprises from about 10 wt. % to about 70 wt. % of silver. 
     
     
         7 . The catalyst of  claim 3 , wherein the catalyst comprises from about 0.05 wt. % to about 10 wt. % of the Group 1 metal nitrate salt. 
     
     
         8 . The catalyst of  claim 5 , wherein the catalyst comprises from about 0.0 wt. % to about 5.0 wt. % of the promoter metal. 
     
     
         9 . A method comprising:
 (a) obtaining a phyllosilicate solid component; and   (b) depositing silver having an oxidation state of zero on the phyllosilicate solid component to form a silver catalyst.   
     
     
         10 . The method of  claim 9  further comprising calcinating the silver catalyst at a temperature from about 250° C. to about 800° C. to form a calcinated silver catalyst. 
     
     
         11 . The method of  claim 9  further comprising depositing a promoter metal onto the silver catalyst to form a promoter deposited silver catalyst. 
     
     
         12 . The method of  claim 9  further comprising depositing a Group 1 nitrate salt onto the silver catalyst to form a Group 1 nitrate deposited silver catalyst. 
     
     
         13 . The method of  claim 10  further comprising drying the calcinated silver catalyst at a temperature from about 100° C. to about 200° C. to form a dried calcinated silver catalyst. 
     
     
         14 . A method comprising:
 (a) obtaining a catalyst of  claim 1 ; and   (b) contacting the catalyst with molecular oxygen and an α-olefin(C 2-12 ) to form an epoxide(C 2-12 ).   
     
     
         15 . An epoxidation catalyst comprising:
 a metal component comprising silver; and   a support material comprising kaolinite;   
       wherein the epoxidation catalyst comprises less than 55 wt. % metal component. 
     
     
         16 . The catalyst of  claim 15  further comprising a Group 1 metal salt. 
     
     
         17 . The catalyst of  claim 15  further comprising a promoter metal selected from rhenium, tungsten, zinc, nickel, gold, copper, sodium, potassium, lithium, rubidium, cesium, molybdenum or combinations thereof. 
     
     
         18 . A method of forming an epoxide comprising:
 contacting an olefin with an oxidizing agent in the presence of the catalyst of  claim 15  to form the epoxide.   
     
     
         19 . The method of  claim 18  exhibiting a conversion that is increased by at least 10% over an identical process but with a metal content greater than 55 wt. %. 
     
     
         20 . The method of  claim 18  exhibiting a selectivity that is increased by at least 5% over an identical process but with a metal content greater than the 55 wt. %.