Communications
DOI: 10.1002/anie.200903011
Heterogeneous Catalysis
Propene Epoxidation with Dioxygen Catalyzed by Gold Clusters**
Jiahui Huang, Tomoki Akita, Jꢀrꢀmy Faye, Tadahiro Fujitani, Takashi Takei, and
Masatake Haruta*
There are two major shifts that the chemical industry is going
to take in the 21st century: a gradual shift to renewable
biomass resources and a shift to reactions which produce little
waste. After polymerization, the oxidation of hydrocarbons
represents the second largest contributor to the total product
value in the chemical industry (18%).[1] The products, func-
tional organic compounds containing oxygen, such as epox-
ides, ketones, aldehydes, alcohols, and acids, are used for
producing polymers, surfactants, detergents, cosmetics, and
other products. If the selective oxidation of hydrocarbons
could be efficiently carried out by using dioxygen (O2) or air
alone instead of using oxidants, such as hazardous chlorine or
costly organic peroxides, it would contribute to the conversion
of current chemical production into a green and sustainable
industry.
In particular, if the selective oxidation of propene (C3H6)
with O2 to propene epoxide (PO) was realized, it might spark
considerable technological innovation in the chemical indus-
try. Indeed, this reaction has been regarded as the Holy Grail
in catalysis research[2] because a huge energy of 497 kJmolÀ1
is needed to dissociate O2 (Figure S1 in the Supporting
Information)[3] and, once atomically dissociated, oxygen tends
to be negatively charged (OÀ), and preferentially attacks the
propylene glycol. Its annual worldwide production has grown
at a rate above 4.0% and amounted to approximately
7.5 million tons in 2007.[4] Propene epoxide is currently
produced by the chlorohydrin process and several organic
peroxide processes.[5] The chlorohydrin process is accompa-
nied by the by-production of CaCl2 (2.2 tons per 1.0 ton of
propene epoxide) together with toxic chlorinated organic
compounds (several hundreds grams per 1.0 ton propene
epoxide), whereas the organic peroxide processes usually
suffer from the mismatch of market demand for the products,
because the demand for the co-products, such as tert-butyl
alcohol and styrene, is less than for propene epoxide.
Recently two new processes have been developed:
a
cumene hydroperoxide process in 2003[6] in Japan where the
co-product, cumyl alcohol, is recycled by reduction with
hydrogen (H2); and a hydrogen peroxide (H2O2) epoxidation
process in 2008[7] in Belgium using methanol as a solvent.
However, these new industrial processes are still based on
multi-staged liquid-phase reactions and require hydrogen.
In contrast to the simple industrial process for the gas-
phase epoxidation of symmetrical ethene (C2H4) with dioxy-
gen over a silver (Ag) catalyst, the use of silver catalysts in
propene epoxidation with O2 usually resulted in propene
epoxide selectivities of less than 50%,[8,9] while gold (Au)
sponge or Au/SiO2 was reported to yield acrolein as a main
product but no propene epoxide.[10] An alternative route
which needs no substantial energy is the reductive activation
of O2 with H2 (5.9 kJmolÀ1, Figure S1 in the Supporting
Information) under milder conditions. This process can be
regarded as an in situ H2O2 synthesis process. One of us
reported in 1998 the gas-phase C3H6 epoxidation with O2 and
H2 mixture over gold nanoparticles (NPs, 2.0–5.0 nm) depos-
ited on anatase TiO2.[11] Since then, the catalytic performances
have been appreciably improved by optimizing catalyst
formulations.[12–14] For example, gold nanoparticles deposited
on mesoporous titanium-silicate present a propene epoxide
selectivity of 91% at a C3H6 conversion of 8.5%.[12]
À
weakly bound allylic hydrogen atoms ( CH3) in propene
resulting in the production of acrolein (Figure S2 in the
Supporting Information).
Propene epoxide is an important bulk chemical which is
used for producing mainly polyurethane foams and resins, and
[*] Dr. J. Huang, Prof. Dr. T. Takei, Prof. Dr. M. Haruta
Graduate School of Urban Environmental Sciences
Tokyo Metropolitan University (TMU)
1-1 Minami-osawa, Hachioji, Tokyo 192-0397 (Japan)
Fax: (+81)42-677-2851
E-mail: haruta-masatake@center.tmu.ac.jp
Dr. T. Akita
Research Institute for Ubiquitous Energy Devices, National Institute
of Advanced Industrial Science and Technology (AIST)
1-8-31 Midorigaoka, Ikeda, Osaka 563-8577 (Japan)
Herein, gold clusters with diameters below 2.0 nm were
deposited on alkaline-treated titanosilicalite-1 (TS-1) by solid
grinding (SG) with dimethyl gold(III) acetylacetonate.[15]
These gold-cluster catalysts exhibited, without any promoters,
high stability (for more than 24 h) as well as high catalytic
activity (C3H6 conversion about 8.8%) and propene epoxide
selectivities (about 82%) in C3H6 epoxidation with an O2 +
H2 mixture. Over 0.19 wt% Au/TS-1-K1 (herein alkaline-
treated TS-1 is denoted as TS-1-K1, where K stands for KOH
and 1 stands for 1.0 h, see Experimental Section for the
preparation of TS-1-K1) with a mean gold diameter of 1.8 nm,
a small amount of propene epoxide is produced even from a
mixture of C3H6 and O2 (Table S1 in the Supporting
Dr. J. Faye, Dr. T. Fujitani
Research Institute for Innovation in Sustainable Chemistry, AIST
16-1 Onogawa, Tsukuba, Ibaraki 305-8569 (Japan)
Dr. J. Huang, Dr. T. Akita, Dr. T. Fujitani, Prof. Dr. T. Takei,
Prof. Dr. M. Haruta
Japan Science and Technology Agency (JST), CREST
4-1-8 Hon-cho, Kawaguchi, Saitama 332-0012 (Japan)
[**] We are grateful to Prof. S. T. Oyama of Virginia Polytechnic Institute
and State University for his continuous cooperation, critical and
constructive discussion, and manuscript refinement.
Supporting information for this article is available on the WWW
7862
ꢀ 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim
Angew. Chem. Int. Ed. 2009, 48, 7862 –7866