A convenient and easily large-scale production strategy for the synthesis of interparticle porosity dominated hierarchical porous TS-1 (IPD-mesoTS-1) based on sufficiently small TS-1 nanosized crystals was designed and Co nanoparticles were in situ dispersed and deposited on the as-prepared IPD-mesoTS-1 (Co/IPD-mesoTS-1). The catalytic performances for epoxidation of styrene were systematically evaluated. Outstanding catalytic activity has been obtained owing to the highly dispersed Co nanoparticles and the hierarchical porous structure of IPD-mesoTS-1. In addition, the Co concentration, temperature, solvents, oxidants and reaction time also play the important roles in the epoxidation.