Single-site catalysts and cleaner production processes, the case of TS-1

Abstract

The synthesis of Titanium Silicalite-1 (TS-1) made possible the development of new oxidation processes, environmentally clean and economically convenient. First industrial application, in 1986, was the hydroxylation of phenol to hydroquinone and catechol (10,000 t/a). In 2003, the production of cyclohexanone oxime became operative within an integrated process for the manufacture of ∈-caprolactam by an entirely new technology (60,000 t/a). The overall process is salt-free and with minimal gaseous emissions. In 2006, the construction of a 300,000 t/a plant for propylene oxide started in Belgium and others have been planned in the world. All three processes utilize hydrogen peroxide produced by the conventional anthraquinone process. Parallel to this, however, an intense research is in progress on the direct synthesis of the oxidant from the elements, to simplify the process and reduce the H2O2 production costs. Other means to achieve the same objectives are process integration, in the short term, andin situ generation, in the longer one. TS-1, on the other hand, will likely remain unrivalled catalyst for many years to come. The metal substituted zeolites, that in last two decades have been prepared in a large number, are catalytically inferior and inadequate to possible industrial applications.