Novel Catalytic Technology for Propylene Epoxidation

72310S03-I Propylene oxide is a valuable commodity chemical intermediate that is used for the production of urethane polyether polyols, propylene glycol, glycol ethers, allyl alcohols, and isopropanolamines. The worldwide production capacity of propylene oxide exceeds 8 billion lbm per year, and has grown at an average rate of 2% per annum since 1988. However, the multiple-step processes currently used by industry to manufacture propylene oxide are extremely energy intensive. The development and implementation of a new catalytic technology for the direct production of propylene oxide in the United States could save up to 16 trillion BTUs per annum. This project will develop a novel catalytic technology for the direct epoxidation of propylene in a three-phase reactor containing a slurry of a highly dispersed nanoparticle catalyst in a unique fluid medium. Phase I will prepare, evaluate, and conduct an initial optimization of several nanoparticle catalysts and fluids in a bench-scale reactor for propylene epoxidation. In addition, a preliminary process engineering and economic model of a commercial-scale process will be developed in order to evaluate economic viability and energy efficiency. Commercial Applications and Other Benefits as described by awardee: A catalyst process for the direct manufacture of propylene oxide should be less energy intensive than currently practiced technologies and could save up to 16 trillion BTUs per annum.