U.S. patent application number 10/692685 was filed with the patent office on 2004-05-13 for crystalline mww-type titanosilicate catalyst for producing oxidized compound, production process for the catalyst, and process for producing oxidized compound by using the catalyst.
This patent application is currently assigned to SHOWA DENKO K.K.. Invention is credited to Oguchi, Wataru, Tatsumi, Takashi, Tsuji, Katsuyuki, Wu, Peng.
Application Number | 20040092757 10/692685 |
Document ID | / |
Family ID | 18780139 |
Filed Date | 2004-05-13 |
United States Patent
Application |
20040092757 |
Kind Code |
A1 |
Oguchi, Wataru ; et
al. |
May 13, 2004 |
Crystalline MWW-type titanosilicate catalyst for producing oxidized
compound, production process for the catalyst, and process for
producing oxidized compound by using the catalyst
Abstract
A crystalline titanosilicate catalyst which is usable as a
catalyst in the oxidation reaction of a compound having a
carbon-carbon double bond and at least one other functional group,
a process for producing the catalyst, and a process for producing
an oxidized compound by an oxidation reaction using the catalyst.
It has been found that a crystalline titanosilicate having a
structural code of MWW effectively functions as a catalyst in an
oxidation reaction of a compound having a carbon-carbon double bond
and at least one other functional group wherein the carbon-carbon
double bond of the compound is oxidized by using a peroxide as an
oxidizing agent, thereby to highly selectively provide an intended
oxidized compound.
Inventors: |
Oguchi, Wataru; (Oita-shi,
JP) ; Tsuji, Katsuyuki; (Kawasaki-shi, JP) ;
Tatsumi, Takashi; (Kawasaki-shi, JP) ; Wu, Peng;
(Yokohama-shi, JP) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
SUITE 800
WASHINGTON
DC
20037
US
|
Assignee: |
SHOWA DENKO K.K.
|
Family ID: |
18780139 |
Appl. No.: |
10/692685 |
Filed: |
October 27, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10692685 |
Oct 27, 2003 |
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09959937 |
Nov 13, 2001 |
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09959937 |
Nov 13, 2001 |
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PCT/JP01/08469 |
Sep 27, 2001 |
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60247963 |
Nov 14, 2000 |
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Current U.S.
Class: |
549/533 ;
502/242 |
Current CPC
Class: |
B01J 29/89 20130101;
C07D 301/12 20130101; B01J 29/70 20130101; C07C 29/03 20130101;
C01B 37/005 20130101; C07C 29/03 20130101; C07C 31/225
20130101 |
Class at
Publication: |
549/533 ;
502/242 |
International
Class: |
C07D 301/06; B01J
021/08; B01J 021/12; B01J 021/14 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 29, 2000 |
JP |
2000-298133 |
Claims
1. A crystalline MWW-type titanosilicate catalyst for producing an
oxidized compound, which is usable in producing an oxidized
compound by an oxidation reaction of a compound having a
carbon-carbon double bond and at least one other functional group
wherein the carbon-carbon double bond of the compound is oxidized
by using a peroxide as an oxidizing agent; the catalyst having an
MWW structure and being represented by the following composition
formula (1): xTiO.sub.2.(1-x)SiO.sub.2 Composition formula (1)
wherein x is a number of 0.0001 to 0.2:
2. A crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound according to claim 1, wherein x is a number of
0.005 to 0.2.
3. A crystalline MWW-type titanosilicate catalyst for producing an
oxidized compound, which is usable in producing an oxidized
compound by an oxidation reaction of a compound having a
carbon-carbon double bond and at least one other functional group
wherein the carbon-carbon double bond of the compound is oxidized
by using a peroxide as an oxidizing agent; the catalyst having an
MWW structure and being represented by the following composition
formula (2): xTiO.sub.2.yM.sub.2O.sub.3.(1-x-2y)SiO- .sub.2
Composition formula (2) wherein M represents at least one element
selected from the group consisting of aluminum, boron, chromium,
gallium and iron, x is a number of 0.0001 to 0.2 and y is a number
of 0.0001 to 0.1.
4. A crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound according to claim 3, wherein M in the
composition formula (2) is boron.
5. A crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound according to claim 3, wherein x is a number from
0.005 to 0.2.
6. A crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound according to claim 3, wherein y is a number from
0.0001 to 0.05.
7. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 1,
said production process comprising: a first step of heating a
mixture comprising a template compound, a titanium-containing
compound, a boron-containing compound, a silicon-containing
compound and water, to thereby obtain a precursor; and a second
step of calcining the precursor obtained in the first step, to
thereby obtain a crystalline titanosilicate.
8. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the template compound is a nitrogen-containing
compound.
9. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 8,
wherein the nitrogen-containing compound is at least one compound
selected from the group consisting of piperidine,
hexamethyleneimine and a mixture thereof.
10. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the titanium-containing compound is at least one compound
selected from the group consisting of titanium oxide, titanium
halide and tetraalkyl orthotitanates.
11. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the boron-containing compound is at least one compound
selected from the group consisting of boric acid, boric acid salt,
boron oxide, boron halide and trialkylborons.
12. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the silicon-containing compound is at least one compound
selected from the group consisting of silicic acid, silicic acid
salt, silicon oxide, silicon halide, fumed silicas,
tetraalkylorthosilicates and colloidal silica.
13. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the ratio between titanium and silicon in the mixture to be
used in the first step is 0.001 to 0.3:1 (titanium:silicon) in
terms of the molar ratio therebetween.
14. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the ratio between boron and silicon in the mixture to be
used in the first step is 0.3 to 10:1 (boron:silicon) in terms of
the molar ratio therebetween.
15. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the ratio between water and silicon in the mixture to be
used in the first step is 5 to 200:1 (water:silicon) in terms of
the molar ratio therebetween.
16. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the ratio between the template compound and silicon in the
mixture to be used in the first step is 0.1 to 5:1 (template
compound:silicon) in terms of the molar ratio therebetween.
17. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the heating temperature in the first step is in the range
from 110 to 200.degree. C.
18. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the calcining temperature in the second step is in the
range from 200 to 700.degree. C.
19. A process for producing a crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound according to claim 7,
wherein the precursor obtained in the first step is contacted with
an acid, and thereafter the second step is performed.
Description
[0001] This application is a continuation application of U.S.
application Ser. No. 09/959,937 filed on Nov. 13, 2001, which was
the National State of International Application No. PCT/JP01/08469,
filed on Sep. 27, 2001, which claims the benefit of an application
based on U.S. application Ser. No. 60/247,963 (filed on Nov. 14,
2000), the above-noted applications hereby incorporated by
reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to crystalline titanosilicate
catalyst having a structural (or framework type) code of MWW, which
is usable as a)catalyst in an oxidation reaction of the
carbon-carbon double bond of a compound having a carbon-carbon
double bond and at least one other functional group. The present
invention also relates to a process for producing such a catalyst
and a process for producing an oxidized compound using this
catalyst.
[0003] More specifically, the present invention relates to a
crystalline titanosilicate catalyst having a structural code of
MWW, which is usable as a catalyst in an oxidation reaction of the
carbon-carbon double bond of a compound having a carbon-carbon
double bond and at least one other functional group using a
peroxide as an oxidizing agent; a process for producing such a
catalyst; and a process for producing an oxidized compound
(particularly, an epoxy compound) comprising performing an
oxidation reaction of the carbon-carbon double bond of a compound
having a carbon-carbon double bond and at least one other
functional group in the presence of the catalyst.
BACKGROUND ART
[0004] In general, "zeolite" is a generic term for crystalline and
porous aluminosilicates for, and the basic unit of the structure of
a zeolite is (SiO.sub.4).sup.4- or (AlO.sub.4).sup.5- having a
tetrahedral structure. However, it has recently been clarified that
a structure peculiar to or analogous to such a zeolite is also
present in many other oxides such as aluminophosphate.
[0005] In addition, according to the International Zeolite
Association (hereinafter, simply referred to as "IZA") who defines
the zeolite in W. Meier, D. H. Meier, D. H. Olxon and Ch.
Baerlocher, Atlas of Zeolite Structure Types, 4.sup.th Edition,
Elsevier (1996) (hereinafter, simply referred to as "Atlas"),
substances having the same structure, other than aluminosilicate,
are described as an object substance in prescribing the structure,
and these substances are called "zeolite-like materials" in the
Atlas.
[0006] The history of this definition is described in detail in
Yoshio Ono and Takeaki Yajima, Zeolite no Kagaku to Kogaku (Science
and Engineering of Zeolites), pp. 1-2, published by Kodansha (Jul.
10, 2000).
[0007] In the present specification, the definition of "zeolite"
follows the above definition as described in Yoshio Ono and Takeaki
Yajima, Zeolite no Kagaku to Kogaku (Science and Engineering of
Zeolite), published by Kodansha (Jul. 10, 2000), where the term
"zeolite" may include not only aluminosilicates but also substances
(such as titanosilicate) having a structure analogous to
aluminosilicate.
[0008] In the present specification, the structures of zeolite and
zeolite-like materials are denoted by a structural code, using
three alphabetic capital letters, approved by IZA and originated in
the standard substance which had first been used for the
clarification of the structure thereof. The structural codes
includes those contained in Atlas and those approved in the
4.sup.th edition, et seq. In the present specification, the terms
"aluminosilicate" and "titanosilicate" are not limited at all by
the properties and/or states thereof (such as crystalline or
amorphous, or porous or not porous). Therefore, in the present
specification, these terms denote "aluminosilicates" and
"titanosilicates" of all properties, unless specifically indicated
otherwise.
[0009] In the present specification, the term "molecular sieve"
means an activity or operation for classifying molecules by the
size thereof, and the term also means a substance having such a
function. Zeolite is also included in the definition of a molecular
sieve. The details thereon are described in the portion relating to
"molecular sieve,, in Hyojun Kagaku Yogo Jiten (Standard Chemical
Glossary), edited by the Chemical Society of Japan, published by
Maruzen (Mar. 30, 1991).
[0010] In recent years, various studies have been made on the
oxidation reactions of organic compounds by using a titanosilicate
which is a zeolite, as a catalyst, and using a peroxide as an
oxidizing agent. Among these, a catalyst named :TI-1", which is a
crystalline titanosilicate, has been found to show an activity in
an oxidation reaction using various peroxides, after the process
for synthesizing the same was disclosed in U.S. Pat. No. 4,410,501,
and TS-1 has been applied to various reactions. Specific examples
thereof include the method disclosed in JP-B-4-5028 ("JP-B" as used
herein means an "examined Japanese Patent publication"), where TS-1
is used as a catalyst in the epoxidation of an olefin compound
using hydrogen peroxide or an organic peroxide as an oxidizing
agent.
[0011] The structural code of the titanosilicate TS-1 is "MFI",
which is the same code as the structural code of a representative
synthetic zeolite ZSM-5, and TS-1 contains a ring structure
containing ten (10) oxygen atoms (as described in Yoshio Ono and
Takeaki Yajima, Zeolite no Kagaku to Kogaku, p. 4, published by
Kodansha). As TS-1 has a relatively small pore size of 0.51 nm to
0.56 nm in terms of a calculated value therefor, the scope of
olefin compounds which can be epoxidized by using TS-1 is limited.
Further, both of the rate of the diffusion of an olefin compound as
a reaction starting material into the inside of a pore and the rate
of the effusion of an epoxy compound as a reaction product from the
pore are low, so that a reaction activity which is sufficiently
high, in view of the industrial use of TS-1, cannot be achieved in
many cases. Furthermore, there is a problem such that a
ring-opening reaction of the epoxy group of an epoxy compound as a
reaction product is liable to occur, and the resultant selectivity
is disadvantageously decreased.
[0012] On the other hand, JP-A-7-242649 ("JP-A" as used herein
means "unexamined Japanese Patent publication") discloses a method
of performing an epoxidation reaction of an olefin compound by
using a crystalline titanium-containing molecular sieve having a
structure similar to aluminum-free zeolite Beta (structural code:
*BEA) as a catalyst and by using hydrogen peroxide or an organic
peroxide as an oxidizing agent.
[0013] Since the *BEA has a large pore diameter as compared with
that of the structural code of MFI for the titanosilicate TS-1, an
effect of enabling a reaction of a sterically bulky compound or an
effect of elevating the diffusion rate to thereby improve the
resultant reaction rate was expected. In some examples of the
above-mentioned Patent publication, a compound which does not react
even in the case using the titanosilicate TS-1 can be actually
oxidized. However, there are caused problems that the conversion of
an oxidizing agent is low when hydrogen peroxide is used as the
oxidizing agent for the epoxidation reaction, and that a
ring-opening reaction of the epoxide is caused to produce a
corresponding glycol, and as a result, the resultant selectivity is
decreased. Further, in the case of the molecular sieve as described
in this Patent publication, the decreasing rate of activity is
rather high. That is, the catalyst life is short, and therefore it
is necessary to repeat the regeneration of the catalyst frequently,
whereby this point seriously hinders the implementation of such a
molecular sieve on an industrial scale.
[0014] On the other hand, in recent years, synthetic zeolites
having a structural code of MWW, which is different from those of
MFI or *BEA, are attracting attention. The process for producing
the same is disclosed, for example, in JP-A-63-297210.
[0015] Further, according to Peng Wu, Takashi Tatsumi and Takayuki
Komatsu, Chemistry Letters, 774 (2000), it has been reported that
when a crystalline titanosilicate having the structural code of MWW
and containing a titanium atom in the crystal structure thereof is
produced, and cyclohexene is oxidized by using this crystalline
titanosilicate as a catalyst and by using hydrogen peroxide,
cyclohexene oxide can be produced.
[0016] However, the yield of the intended product is rather low,
while both of the resultant epoxide and diol are produced in a
considerably large amount, whereby a tendency of selectively
providing any of these compounds is not observed. Therefore, there
is a caused problem when this method is intended to be utilized
industrially.
[0017] As described hereinabove, various proposals have been made
for conducting the oxidation reaction of an olefin compound by
using a titanosilicate as a catalyst and by using a peroxide as an
oxidizing agent. However, industrially practicable techniques are
rather limited, and further, in any of the above-mentioned cases,
only an oxidation reaction of a simple compound having a
carbon-carbon double bond is disclosed. There has not yet been
reported a titanosilicate which is usable as a catalyst in the
oxidation reaction of a compound not only having a carbon-carbon
double bond and but also having at least one other functional
group.
DISCLOSURE OF INVENTION
[0018] An object of the present invention is to provide a
crystalline titanosilicate catalyst which is usable as a catalyst
in a selective oxidation reaction of the carbon-carbon double bond
of a compound having a carbon-carbon double bond and at least one
other functional group.
[0019] Another object of the present invention is to provide a
process for producing such a titanosilicate catalyst, and to
provide a process for producing an oxidized compound by an
oxidation reaction using the catalyst.
[0020] As a result of earnest-study for solving the above-mentioned
problems, the present inventors have found that a crystalline
titanosilicate catalyst having a structural code of MWW can
effectively function as a catalyst for a reaction wherein the
carbon-carbon double bond of a compound having a carbon-carbon
double bond and at least one other functional group is oxidized by
using a peroxide, so as to provide an intended oxidized compound
highly selectively. The present invention has been accomplished
based on this discovery.
[0021] More specifically, the present invention, in an aspect, is a
crystalline MWW-type titanosilicate catalyst, for producing an
oxidized compound, which is usable in producing an oxidized
compound by an oxidation reaction of a compound having a
carbon-carbon double bond and at least one other functional group
wherein the carbon-carbon double bond of the compound is oxidized
by using a peroxide as an oxidizing agent. The catalyst has an MWW
structure and is represented by the following (chemical)
composition formula (1):
xTiO.sub.2.(1-x)SiO.sub.2 Composition formula (1)
[0022] (wherein x is a number of 0.0001 to 0.2).
[0023] The present invention, in a second aspect, is a crystalline
MWW-type titanosilicate catalyst for producing an oxidized
compound, which is usable in producing an oxidized compound by an
oxidation reaction of a compound having a carbon-carbon double bond
and at least one other functional group wherein the carbon-carbon
double bond of the compound is oxidized by using a peroxide as an
oxidizing agent. The catalyst has an MWW structure and is
represented by the following composition formula (2):
xTiO.sub.2.yM.sub.2O.sub.3.(1-x-2y)SiO.sub.2 Composition formula
(2)
[0024] (wherein M represents at least one element selected from the
group consisting of aluminum, boron, chromium, gallium and iron, x
is a number of 0.0001 to 0.2 and y is a number of 0.0001 to
0.1).
[0025] The present invention in a third aspect is a process for
producing the crystalline MWW-type titanosilicate catalyst for
producing an oxidized compound according to the present invention
in the above-mentioned first or second aspect thereof.
[0026] The present invention in a fourth aspect is a process for
producing an oxidized compound, comprising: performing an oxidation
reaction of a compound having a carbon-carbon double bond and at
least one other functional group wherein the carbon-carbon double
bond of the compound is oxidized by-using a peroxide as an
oxidizing agent in the presence of the crystalline MWW-type
titanosilicate catalyst for producing an oxidized compound
according to the present invention in the first or second
aspect.
BEST MODE FOR CARRYING OUT THE INVENTION
[0027] Hereinbelow, the present invention will be described in
detail with reference to the accompanying drawings as desired. In
the following description, "%" and "part(s)" representing a
quantitative proportion or a ratio are based on mass, unless
otherwise noted specifically.
[0028] At first, the present invention in the first aspect and the
present invention in the second aspect will be described.
[0029] The present invention in the first aspect is a crystalline
MWW-type titanosilicate catalyst for producing an oxidized
compound, which is usable in producing an oxidized compound by an
oxidation reaction of a compound having a carbon-carbon double bond
and at least one other functional group wherein the carbon-carbon
double bond of the compound is oxidized by using a peroxide as an
oxidizing agent. The catalyst has an MWW structure and is
represented by the following composition formula (1):
xTiO.sub.2.(1-x)SiO.sub.2 Composition formula (1)
[0030] (wherein x is a number of 0.0001 to 0.2).
[0031] The present invention in a second aspect is a crystalline
MWW-type titanosilicate catalyst for producing an oxidized
compound, which is usable in producing an oxidized compound by an
oxidation reaction of a compound having a carbon-carbon double bond
and at least one other functional group wherein the carbon-carbon
double bond of the compound is oxidized by using a peroxide as an
oxidizing agent. The catalyst has an MWW structure and is
represented by the following composition formula (2):
xTiO.sub.2.yM.sub.2O.sub.3.(1-x-2y)SiO.sub.2 Composition formula
(2)
[0032] (wherein M represents at least one element selected from the
group consisting of aluminum, boron, chromium, gallium and iron, x
is a number of 0.0001 to 0.2 and y is a number of 0.0001 to
0.1).
[0033] In the crystalline MWW-type titanosilicate catalyst for
producing an oxidized compound according to the present invention
in the first aspect, the ratio of constituent units TiO.sub.2 and
SiO.sub.2 present in the catalyst can be specified by the molar
ratio therebetween. Therefore, "x" means the molar ratio of
TiO.sub.2 present in the titanosilicate, and (1-x) means the molar
ratio of SiO.sub.2 also present in the titanosilicate. In the other
words, the ratio x/(1-x) merely shows the molar ratio of
titanium/silicon, and this ratio does not exclude the presence of
at least one other element in the above-mentioned crystalline
MWW-type titanosilicate for producing an oxidized compound.
[0034] In the composition formula (1), the range of x is from
0.0001 to 0.2, preferably from 0.005 to 0.2, more preferably from
0.01 to 0.1. In addition to the titanium species which have been
introduced into the framework by substituting with silicon, a
titanium species may be present at a site outside the crystal
framework (or skeleton). For example, a 6-coordination titanium
species or an anatase-like titanium oxide may be present together
with the above-mentioned titanium species. However, such a titanium
species outside the framework generally has a tendency such that it
promotes a side reaction or narrows the pores in the titanosilicate
so as to inhibit the diffusion of a substance relating to the
reaction. Therefore, the titanium species present at a site outside
the crystal framework, if present, may preferably be present in a
smaller amount.
[0035] In general, the x specified in the composition formula (1)
shows an estimated ratio of titanium contained within the
framework. In practice, when titanium is present outside the
framework in addition to titanium within the framework, it is
difficult to precisely quantitate the titanium contained within the
framework. In general, for example, in the ultraviolet-visible
absorption spectrum of a titanosilicate, the absorption in the
vicinity of 210 nm is assigned to titanium within the framework,
the absorption in the vicinity of 260 nm is assigned to a
6-coordination titanium species outside the framework, and the
absorption in the vicinity of 330 nm is assigned to an anatase-like
titanium species. Therefore, if an absorption is present in the
vicinity of 210 nm, this absorption reveals that the titanosilicate
corresponding to the spectrum contains titanium within the
framework. Actually, the titanosilicate catalyst according to the
present invention in the first aspect has an absorption in the
vicinity of 220 nm, and this absorption reveals the presence of
titanium within the framework. However, when another absorption is
present at other wavelengths, it is difficult to quantitatively
discuss the ratio of these titanium species present in the
titanosilicate, even in a case where other means such as nuclear
magnetic resonance method or infrared absorption method is combined
with the above ultraviolet-visible absorption spectrum.
[0036] Only one clear fact is that the value of the molar ratio of
titanium to silicon calculated from the ratio between titanium and
silicon determined by the component analysis such as elemental
analysis, is the maximum value of the amount of titanium contained
within the framework. As described above, it is difficult to
directly determine the molar ratio of titanium contained within the
framework. Therefore, in the present invention, the molar ratio of
titanium to silicon calculated by the component analysis as x in
the composition formula (1) is for convenience used as the molar
ratio of titanium contained within the framework.
[0037] The crystalline titanosilicate catalyst according to the
present invention in the first aspect having a structural code of
MWW wherein silicon is partially substituted with titanium may
contain an element other than titanium, silicon and oxygen, as long
as such an element does not greatly cause an adverse effect on the
reactivity of the catalyst. In a case where the catalyst according
to the present invention in the first aspect is produced by a
production process using boron as a structure supporting agent, as
described hereinafter, a slight amount of boron may remain in the
catalyst in many cases, even if an operation for removing boron is
performed. However, boron in a small amount does not have any
serious effect on the reactivity of the catalyst, and therefore,
boron can be present in the catalyst in a substantial amount. In
principle, other trivalent metals such as aluminum, gallium, iron
and chromium may also be used as a structure supporting agent in
place of boron, and in such a case, these elements may sometimes
remain within and outside the framework.
[0038] In this case, there is formed a crystalline MWW-type
titanosilicate catalyst for producing an oxidized compound
according to the present invention in the second aspect. That is,
the present invention in the second aspect is a crystalline
MWW-type titanosilicate catalyst for producing an oxidized
compound, which is usable in producing an oxidized compound by an
oxidation reaction of a compound having a carbon-carbon double bond
and at least one other functional group wherein the carbon-carbon
double bond of the compound is oxidized by using a peroxide as an
oxidizing agent. The catalyst has an MWW structure and is
represented by the following composition formula (2):
xTiO.sub.2.yM.sub.2O.sub.3.(1-x-2y)SiO.sub.2 Composition formula
(2)
[0039] (wherein M represents at least one element selected from the
group consisting of aluminum, boron, chromium, gallium and iron, x
is a number of 0.0001 to 0.2 and y is a number of 0.0001 to
0.1).
[0040] In the above composition formula (2), the number "x" has the
same meaning as in the composition formula (1) and the number "y"
is also a molar ratio of constituent unit M.sub.2O.sub.3 present in
the catalyst. Similarly to the composition formula (1), the ratio
of x/(1-x-2y) represents merely a molar ratio of
"titanium"/"silicon" and the ratio of y/(1-x-2y) represents merely
a ratio of "at least one element in total selected from the group
consisting of aluminum, boron, chromium, gallium and
iron"/"silicon". Accordingly, these ratios do not exclude the
presence of other elements in the catalyst according to the present
invention in the second aspect. In the composition formula (2), y
is a number of 0.0001 to 0.1, preferably 0.0001 to 0.05, more
preferably 0.0001 to 0.03.
[0041] In the composition formula (2) according to the present
invention in the second aspect, the number y can be determined from
the component analysis values in a similar manner as in the case of
the number x in the composition formula (1) according to the
present invention in the first aspect. The form or state of the
presence of M.sub.2O.sub.3 may be either within the framework or
outside the framework. M is at least one element selected from the
group consisting of aluminum, chromium, gallium and iron, and has a
valence number of 3.
[0042] As used in the synthesis of MCM-22, an alkali metal such as
sodium and potassium can be generally expected to function as a
mineralizing agent, and therefore, the alkali metal may be used in
the production of the catalyst according to the present invention
in the first or second aspect for the purpose of accelerating the
crystallization. However, in general, the alkali metal has a
possibility of inhibiting the catalytic function of the crystalline
titanosilicate, and therefore, it is preferred to remove the alkali
metal from the crystalline titanosilicate by ion exchange or the
like.
[0043] The MWW structure, which is one known structure of molecular
sieves, is characterized in that it has a pore comprising a ring
structure containing 10 oxygen atoms and has a super cage
(0.7.times.0.7.times.1.8 nm). This structure has been approved by
IZA after the publication of the above-mentioned Atlas. The details
of the structure can be inspected, for example, on the homepage
(http://www.iza-structure.org/) of the IZA Structure Commission (as
of September, 2000). Examples of known molecular sieves having this
structure may include MCM-22 (Science, Vol. 264, 1910 (1994)),
SSZ-25 (European Patent No. No. 231860), ITQ-1 (Chem. Mater., Vol.
8, 2415 (1996) and J. Phys. Chem. B. Vol. 102, 44 (1998)), ERB-1
(European Patent No. No. 203032) and PSH-3 (U.S. Pat. No. 449409).
The molecular sieve having structural code of MWW can be identified
by the pattern of its characteristic X-ray diffraction
(hereinafter, simply referred to as "XRD"). The XRD pattern may
also be available as a simulation pattern of ITQ-1, for example, on
the above-mentioned homepage. Representative examples of the
diffraction line may include those shown in Table 1 below.
1TABLE 1 Diffraction Line Given by MWW Structure Relative Strength
d/.ANG. .+-. 0.1 (s: strong, m: moderate, w: weak) 12.3 .+-. 0.6 s
11.0 .+-. 0.6 s 8.8 .+-. 0.5 s 6.2 .+-. 0.4 m 5.5 .+-. 0.3 w 3.9
.+-. 0.2 m 3.7 .+-. 0.2 w 3.4 .+-. 0.2 s
[0044] The present invention in the third aspect will be described
below. The present invention in the third aspect is a process for
producing a crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound, comprising the following first and
second steps:
First Step
[0045] a step of heating a mixture comprising a template compound,
a titanium-containing compound, a boron-containing compound, a
silicon-containing compound and water, to thereby obtain a
precursor;
Second Step
[0046] a step of calcining the precursor obtained in the first
step, to thereby obtain a crystalline titanosilicate.
[0047] The crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound according to the present invention
can also be synthesized by a conventionally known direct synthesis
method or a post-synthesis method such as an atom-planting method
(with respect to the details of the atom-planting method, Yoshio
Ono & Tastuaki Yashima "Science and Engineering of Zeolites"
(Jul. 10, 2000), p 142, Kodansha; and Peng Wu, Takayuki Komatsu,
Tatsuaki Yashima, Shin-ichi Nakata, and Hiroshi Shouji,
"Modification of mordenite acidity by isomorphous substitution of
trivalent cations in the framework sites using the atom-planting
method" Microporous Materials 12 (1997) 25-37 may be referred to.).
In the case of the atom-planting method, the catalyst may be
synthesized, for example, by preparing a molecular sieve having a
MWW structure containing boron or aluminum, removing at least a
part of boron or aluminum through a water vapor treatment or the
like, and then contacting the resultant residue with a titanium
compound such as titanium trichloride.
[0048] A more efficient production process for the MWW-type
titanosilicate catalyst may include a production process according
to the present invention in the third aspect. That is, the process
for producing a crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound according to the present invention
in the third aspect is a production process for a crystalline
MWW-type titanosilicate catalyst for providing an oxidized
compound, characterized in that the production process comprises
two steps, i.e., a step of heating a mixture comprising a template
compound, a titanium-containing compound, a boron-containing
compound, a silicon-containing compound and water, to thereby
obtain a precursor; and a step of calcining the resultant
precursor, to thereby obtain a crystalline MWW-type titanosilicate
for producing an oxidized compound.
[0049] At first, the above first step is described below. The first
step in the process for producing the crystalline titanosilicate of
the present invention in the third aspect is a step of heating a
mixture comprising a template compound, a titanium-containing
compound, a boron-containing compound, a silicon-containing
compound and water, to thereby obtain a precursor.
[0050] The "template compound" as used herein is a compound having
a function of, in the synthesis of zeolite having an MWW structure,
determining the structure thereof and, particularly, of determining
the shape of the pore. The template compound is not particularly
limited, as long as it can be removed later by calcining. Examples
thereof may generally include nitrogen-containing compounds.
Specific examples of such a nitrogen-containing compound may
include piperidine, hexamethyleneimine and/or a mixture thereof,
but the template compound usable in the present invention is not
limited to these specific compounds.
[0051] The titanium-containing compound which is usable in the
first step is not particularly limited, as long as the
titanium-containing compound can provide a gel-type product.
Specific examples of the titanium-containing compound may include
titanium oxide, titanium halide and tetraalkyl orthotitanates, but
the titanium-containing compound usable in the present invention is
not limited to these specific compounds. Among these, in view of
easiness in the handling thereof, titanium halide and tetraalkyl
orthotitanates are preferred. More specifically, titanium
tetrafluoride, tetraethyl orthotitanate, tetrapropyl orthotitanate
and tetrabutyl orthotitanate may suitably be used.
[0052] The boron-containing compound which is usable in the first
step is not particularly limited. Preferred specific examples
thereof may include boric acid, which can also be used in the form
of a borate such as sodium borate.
[0053] The silicon-containing compound which is usable in the first
step is not particularly limited. Specific examples thereof may
include silicic acid, silicic acid salt, silicon oxide, silicon
halide, fumed silicas, tetraalkyl orthosilicates and colloidal
silica. In any of these cases, a silicon-containing compound having
a high purity is preferred. More specifically, the
silicon-containing compound may preferably have an alkali metal
content such that the total moles of the alkali metal components is
smaller than the moles of titanium, preferably 1/10 times or less
the moles of titanium, more preferably 1/100 times or less the
moles of titanium. Among these, in the case of colloidal silica,
one having a smaller alkali content is preferred.
[0054] The ratio between titanium and silicon in the mixture to be
used in the first step may preferably be 0.001 to 0.3:1
(titanium:silicon), more preferably 0.005 to 0.2:1
(titanium:silicon), particularly preferably 0.01 to 0.2:1
(titanium:silicon), in terms of the molar ratio therebetween.
[0055] The ratio between boron and silicon in the mixture to be
used in the first step may preferably be 0.3 to 10:1
(boron:silicon), more preferably 0.5 to 5:1 (boron:silicon),
particularly preferably 1 to 2:1 (boron:silicon), in terms of the
molar ratio therebetween.
[0056] The ratio between water and silicon in the mixture to be
used in the first step may preferably be 5 to 200:1
(water:silicon), more preferably 15 to 50:1 (water silicon), in
terms of the molar ratio therebetween.
[0057] The ratio between the template compound and silicon in the
mixture to be used in the first step may preferably be 0.1 to 5:1
(template compound:silicon), more preferably 0.3 to 3:1 (template
compound: silicon), particularly preferably 0.5 to 2:1 (template
compound:silicon), in terms of the molar ratio therebetween.
[0058] These ratios of the mixture to be used in the first step are
not particularly limited. However, in view of efficient provision
of a high-activity crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound, each of the above-mentioned ranges
is preferred. An element other than the elements described above
can also be present together in the mixture to be used in the first
step. However, if an alkali metal or an alkaline earth metal is
present in a somewhat large amount, titanium may be prevented from
entering into the framework. Therefore, the amount of an alkali
metal or an alkaline earth metal may preferably be smaller. More
specifically, for example, the total moles of an alkali metal and
an alkaline earth metal may preferably be smaller than the moles of
titanium. The total moles of an alkali metal and an alkaline earth
metal may preferably be 1/10 times or less the moles of titanium,
more preferably 1/100 times or less the moles of titanium.
[0059] The heating temperature to be used in the first step is not
particularly limited. However, in the case of synthesizing a
precursor, the heating may preferably be performed under
hydrothermal reaction conditions. The term "hydrothermal reaction"
as used herein means, as described in Hyojun Kagaku Yogo Jiten
(Standard Chemical Glossary), Item "Hydrothermal Reaction", edited
by the Chemical Society of Japan, published by Maruzen (Mar. 30,
1991), a synthesis or a modification reaction of a substance to be
performed in the presence of water at high temperature,
particularly to be performed in the presence of water at high
temperature and high pressure. A synthesis reaction utilizing the
hydrothermal reaction is called "hydrothermal synthesis".
Therefore, in the first step, the heating may preferably be
performed under hydrothermal synthesis conditions such that a
mixture comprising a template compound, a titanium-containing
compound, a boron-containing compound, a silicon-containing
compound and water is charged into a closed container such as
autoclave and is pressurized under heating. The heating temperature
may preferably be in the range of from 110 to 200.degree. C., more
preferably from 120 to 190.degree. C.
[0060] If the temperature in the hydrothermal synthesis is below
this range, the intended product may not be obtained, or even if
obtained, the heating may take a long period of time, and such a
procedure is not suitable for a practical purpose. On the other
hand, if the temperature exceeds this range, the yield of the
intended product is disadvantageously decreased in the oxidation
reaction using the resultant catalyst which is finally been
obtained in this manner.
[0061] The hydrothermal synthesis may usually be performed for 2
hours to 30 days, preferably for 3 hours to 10 days. If the
hydrothermal synthesis time is less than this range, the
crystallization can be insufficient so that a high-performance
catalyst may not be obtained. On the other hand, even if the
hydrothermal synthesis is performed for a time period exceeding
this range, the resultant catalytic activity is not substantially
enhanced. In this case, an adverse effect such as conversion of the
materials into another phase or an increase in the particle size
can be caused disadvantageously.
[0062] Next, the second step is described below. The second step is
a step of calcining the precursor obtained in the first step, to
thereby obtain a crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound.
[0063] The method of calcining the precursor is not particularly
limited and may be performed under known conditions in the usual
calcination of a catalyst. The calcination may be performed in the
closed system or in the flow system, and if desired, the
calcination may be performed in an inert gas stream, such as
nitrogen gas stream. The calcination temperature may preferably be
in the range of from 200 to 700.degree. C., more preferably from
300 to 650.degree. C., particularly preferably from 400 to
600.degree. C. If the calcination temperature is less than
200.degree. C., the template compound may not be satisfactorily
removed. On the other hand, if the calcination temperature exceeds
700.degree. C., the MWW-type crystal structure may be destroyed,
and as a result, this destruction may adversely affect the
resultant catalytic performance.
[0064] The process for producing a crystalline MWW-type
titanosilicate catalyst for providing an oxidized compound
according to the present invention in the third aspect is described
in detail below. The process for producing a catalyst according to
the present invention in the third aspect is a process of
converting a titanosilicate in an amorphous state into a precursor
having a lamella phase called MCM-22(P) by using piperidine or
hexamethyleneimine as a template, and using boron (boric acid) as a
structure supporting agent (first step); and then calcining the
precursor (second step), to thereby obtain a crystalline MWW-type
titanosilicate catalyst for providing an oxidized compound.
[0065] There is described a more specific embodiment of the process
for producing a crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound. For example, an aqueous solution of
piperidine or hexamethyleneimine (template) is divided into two
portions, tetraalkyl orthotitanate is added to one of the two
portions and dissolved therein, a boron compound is added to the
other of the two portions and dissolved therein, and silica is
further added to each of the two portions, and then the resultant
mixture are stirred, to prepare two kinds of homogenous gels
containing titanium or boron.
[0066] These two kinds of gels are mixed with each other and
thoroughly stirred, and thereafter the mixture is transferred to a
closed container such as autoclave and subjected to a hydrothermal
synthesis. The thus obtained solid product is separated from the
mother liquor by filtration or the like, thoroughly washed with
water and then dried. By calcining the thus obtained precursor, a
crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound can be obtained.
[0067] The catalyst which is obtainable by the production process
according to the present invention in the third aspect may be used
as a catalyst for an oxidation reaction as it is. The boron which
has been introduced inside or outside the framework present in the
titanosilicate obtained by this production process, or the anatase
phase which has resulted from the condensation of titanium itself
which does not participate in an oxidation reaction may be removed
at least partially by contacting the catalyst with an acid. By the
contact of the catalyst with the acid, the thus obtained
crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound can have a higher performance.
[0068] A certain effect may be obtained, when the catalyst is
contacted with an acid before or after the calcination, or both
before and after the calcination in the process for producing a
crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound. However, a particularly enhanced effect can be
obtained, when the catalyst in the precursor state is contacted
with an acid before the calcination. In the latter case, the
by-product anatase phase due to the calcination can be strongly
suppressed.
[0069] The "contact with an acid" as used herein specifically means
an operation such that a solution containing an acid or an acid
itself is contacted with the precursor which has been obtained
after the first step, or with the titanosilicate which has been
obtained after the second step. The contacting method is not
particularly limited. The contacting method may be a method of
spraying or applying an acid or an acid solution to the precursor
or titanosilicate, or a method of dipping the precursor or
titanosilicate in an acid or an acid solution. The method of
dipping the precursor or titanosilicate in an acid or an acid
solution is simple and easy, and therefore this method is
preferred.
[0070] The acid to be used for the above-mentioned acid contact may
be an inorganic acid, an organic acid or a salt of these acids.
Specific examples of preferred inorganic acids may include
hydrochloric acid, sulfuric acid, nitric acid and phosphoric acid.
Specific examples of preferred organic acids may include formic
acid, acetic acid, propionic acid and tartaric acid. Examples of
the salt of these acids may include sodium salt, potassium salt,
calcium salt, magnesium salt and ammonium salt of these acids.
[0071] The contact with an acid may be performed either before or
after the calcination as described above, but may preferably be
performed before the calcination so as to attain an enhanced
effect. A solid substance such as precursor is dipped in an acid
solution in an amount of approximately from 5 to 100 ml per one
gram of the solid substance, and kept therein for a predetermined
time. Thereafter, the solid is recovered from the acid solution by
filtration or the like, and then thoroughly washed with a solvent.
Stirring is not always necessary but may be performed.
[0072] In the case of using the acid in the form of a solution, the
solvent is not particularly limited. Specific examples thereof may
include water, alcohols, ethers, esters and ketones. Among these,
water is preferred.
[0073] The acid concentration is not particularly limited but may
suitably be on the order of 0.1 to 10 mol/l. The temperature may be
in the range of from 0 to 200.degree. C., but may preferably be
from 50 to 180.degree. C., more preferably from 60 to 150.degree.
C. The treatment time may be from 0.1 hour to 3 day, but may
suitably be from 2 hours to 1 day.
[0074] The present invention in a fourth aspect is described below.
The present invention in the fourth aspect is a process for
producing an oxidized compound comprising:performing an oxidation
reaction of a compound having a carbon-carbon double bond and at
least one of other functional group wherein the carbon-carbon
double bond of the compound is oxidized by using a peroxide as an
oxidizing agent in the presence of the crystalline MWW-type
titanosilicate catalyst for providing an oxidized compound
according to the present invention in the first or second aspect.
According to the production process for an oxidized compound
according to the present invention in the fourth aspect, the
oxidation reaction of a carbon-carbon double bond only can be
selectively performed substantially without affecting other
functional groups of the compound having a carbon-carbon double
bond and at least one of other functional group. Needless to say,
other functional groups may be simultaneously reacted, to thereby
obtain an entirely different product. Such a case, of course, may
be included in the scope of the present invention in the fourth
aspect.
[0075] Specific examples of the peroxide which is usable in the
present invention in the fourth aspect may include hydrogen
peroxide and organic peroxides. Examples of the organic peroxide
may include tert-butyl hydroperoxide, tert-amyl hydroperoxide,
cumene hydroperoxide, ethylbenzene hydroperoxide, cyclohexyl
hydroperoxide, methylcyclohexyl hydroperoxide, tetralin (i.e.,
tetrahydronaphtalene) hydroperoxide, isobutylbenzene hydroperoxide,
ethylnaphthalene hydroperoxide and peracetic acid. However, the
peroxides usable in the present invention are not limited to these
specific compounds. These peroxides may also be used in combination
of two or more species thereof.
[0076] The peroxide to be used for such a purpose may particularly
preferably be hydrogen peroxide. An aqueous hydrogen peroxide
solution having any of various concentrations may be used. Examples
of such concentrations may include, e.g., 30 mass %, 60 mass %, 90
mass % or the like. The amount of peroxide to be added to the
reactant is not particularly limited, and the amount may be
equivalent or more to the carbon-carbon double bond of the compound
having a carbon-carbon double bond and at least one of other
functional group, which is a raw material to be subjected to an
oxidation reaction, or the amount may be equivalent or less,
depending on the conditions.
[0077] The compound having a carbon-carbon double bond and at least
one of other functional group for use in the process for producing
an oxidized compound according to the present invention in the
fourth aspect is not particularly limited, and may be any compound
as long as it has a carbon-carbon double bond and at least one
other functional group within one molecule thereof. In this case, a
compound containing two or more carbon-carbon double bonds, of
course, may be included within the definition of the above
"compound having a carbon-carbon double bond and at least one of
other functional group".
[0078] Specific examples of the other functional group may include
an alkenyl group, an alkynyl group, an aryl group, an arene group,
an alcohol group, a phenol group, an ether group, an epoxide group,
a halogen group, an aldehyde group, a ketone group, a carbonyl
group, an ester group, an amide group, a cyanate group, an
isocyanate group, a thiocyanate group, an amine group, a. diazo
group, a nitro group, a nitrile group, a nitroso group, a sulfide
group, a sulfoxide group, a sulfone group, a thiol group, an
orthoester group, a urea group and imine group. However, the "other
functional group" usable in the present invention is not limited to
these specific compounds. Two or more of the same functional group
may be contained in one molecule, and/or two or more kinds of
functional groups may be contained in one molecule.
[0079] More specific examples of the compound having a
carbon-carbon double bond and at least one other functional group
may include allyl ethers, compounds having from 3 to 10 carbon
atoms, ethers of polyhydric alcohol, and carboxylic acid esters. Of
course, these compounds may also be used in combination of two or
more species thereof.
[0080] More specifically,-examples of the allyl ethers may include
allyl methyl ether, allyl ethyl ether, allyl propyl ether, allyl
butyl ether, allyl vinyl ether and diallyl ether.
[0081] Examples of the compounds having from 3 to 10 carbon atoms
may include allyl alcohol, allyl bromide, allyl chloride, acrolein,
methacrolein and acrylic acid.
[0082] Examples of the ethers of polyhydric alcohol may include
ethylene glycol monoalkenyl ether, ethylene glycol dialkenyl ether,
1,2-propanediol monoalkenyl ether, 1,2-propanediol dialkenyl ether,
1,3-propanediol monoalkenyl ether, 1,3-propanediol dialkenyl ether,
1,2-butanediol monoalkenyl ether, 1,2-butanediol dialkenyl ether,
1,3-butanediol monoalkenyl ether, 1,3-butanediol dialkenyl ether,
1,4-butanediol monoalkenyl ether, 1,4-butanediol dialkenyl ether,
and pentaerythritol monoalkenyl ether, pentaerythritol dialkenyl
ether, pentaerythritol trialkenyl ether and pentaerythritol
tetraalkenyl ether, trimethylolpropane monoalkenyl ether,
trimethylolpropane dialkenyl ether, and trimethylolpropane
trialkenyl ether.
[0083] Examples of the carboxyllic acid esters may include allyl
formate, allyl acetate, allyl tartrate, allyl propionate and allyl
methacrylate.
[0084] Examples of particularly preferred combination may include a
combination such that the compound having a carbon-carbon double
bond and at least one of other functional group is diallyl ether,
allyl acetate, allyl methacrylate or allyl alcohol and the
oxidizing agent is hydrogen peroxide.
[0085] The amount of the crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound used in the process for
producing an oxidized compound according to the present invention
in the fourth aspect is not particularly limited. The preferred
range thereof may vary depending on the kind of oxidation reaction,
the reaction temperature, the reactivity and temperature of the
substrate or reactant, the concentration of peroxide, the kind and
concentration of solvent, and the reaction form or type (e.g.,
batch system, continuous system). In a case where the catalyst is
used in a slurry system, the amount of the catalyst may usually be
in the range of from 0.1 to 20 mass %, more preferably from 0.5 to
10 mass %, in terms of the concentration of the catalyst in the
reactant mixture. In the case of a fixed-bed flow reaction system,
the apparent amount of the catalyst may preferably be larger than
the above-mentioned range.
[0086] The shape or form of the crystalline MWW-type titanosilicate
catalyst for providing an oxidized compound is not particularly
limited. The form may be a powder, microspheres, pellets or
extrusion-molded articles, or the catalyst may also be in a form
such that it is supported on a support or carrier. In the molding
of the catalyst, a binder may be used. The binder or support for
such a purpose may preferably be a substance which is substantially
non-acidic or weakly acidic, and which does not accelerate the
decomposition reaction of the peroxide or the decomposition
reaction of the intended oxidized compound.
[0087] The oxidation reaction in the process for producing an
oxidized compound according to the present invention in the fourth
aspect may be performed without using a solvent or in the presence
of an appropriate solvent. Examples of the appropriate solvent may
include alcohols, ketones, nitrites and water. Specific examples of
alcohols may include methanol, ethanol, 1-propanol, 2-propanol,
1-butanol, 2-butanol, tert-butanol, amyl alcohol, ethylene glycol,
propylene glycol and 1,2-butanediol. Specific examples of ketones
may include acetone, methyl ethyl ketone and diethyl ketone.
Specific examples of nitrites may include acetonitrile,
propionitrile and benzonitrile. These may be used singly or as a
mixture thereof. Among these solvents, preferred are acetone,
acetonitrile and water, and more preferred is acetonitrile.
[0088] In the process for producing an oxidized compound according
to the present invention in the fourth aspect, the reaction
temperature at the oxidation reaction, which is not particularly
limited, may preferably be from 0 to 150.degree. C., more
preferably from 10 to 100.degree. C. If the reaction temperature is
less than 0.degree. C., the reaction rate is low and this
temperature is not suitable for practical purposes. On the other
hand, if the temperature exceeds 150.degree. C., a decomposition
reaction of the peroxide may seriously proceed and, further, a
decomposition reaction of the intended product may
disadvantageously be accelerated.
[0089] The oxidation reaction is generally an exothermic reaction,
and therefore, the heat of reaction may preferably be removed by a
suitable method so as to control the reaction temperature to a
constant range. The reaction pressure is not particularly
limited.
[0090] The oxidation reaction in the process for producing an
oxidized compound according to the present invention in the fourth
aspect may be performed by any method in a batch system, a
continuous system or a semi-continuous system, e.g., by using a
suitable reactor or reaction apparatus such as fixed bed reactor,
fludized-bed reactor, moving-bed reactor, tank reactor, stirring
slurry-type reactor, continuous stirred tank reactor (CSTR). With
respect to the mixture containing a crystalline MWW-type
titanosilicate catalyst for providing an oxidized compound, a
compound having a carbon-carbon double bond and at least one other
functional group and a peroxide, these components constituting the
mixture may be mixed partially or all at once or may be mixed in
sequence or in order. It is also possible to mix the two species
selected from the three species of these components (i.e., the
catalyst, the compound having a carbon-carbon double bond and at
least one of other functional group, and the peroxide), and then
mix the remaining one species of these components into such a
mixture.
[0091] In this reaction, the intended oxidized compound (reaction
product) may be separated by a separation/purification method used
in an ordinary purification procedure. More specifically, for
example, when the reaction is performed in a batch system, when the
amount of the oxidized compound which has been produced reaches a
value in the desired region, the oxidized compound may be separated
and recovered from the reaction mixture by-using any known method
such as fractional distillation, extract distillation or
liquid-liquid extraction.
[0092] In the case of a slurry-type reactor, the crystalline
MWW-type titanosilicate catalyst for providing an oxidized compound
can be recovered by a suitable method such as filtration or
centrifugation, and the thus recovered catalyst can be reused as a
catalyst for oxidation reaction.
[0093] In the case of a fixed bed-type reactor, the crystalline
MWW-type titanosilicate catalyst for providing an oxidized compound
can be easily separated from the product (oxidized compound), the
solvent, the unreacted compound having a carbon-carbon double bond
and at least one of other functional group and the peroxide, while
the catalyst remains being held in the reactor.
[0094] In the process for producing an oxidized compound according
to the present invention in the fourth aspect, at least one of the
recovered crystalline MWW-type titanosilicate catalyst for
providing an oxidized compound, the unreacted compound having a
carbon-carbon double bond and at least one of other functional
group and the peroxide can be reused, after purification by an
appropriate method or without purification thereof.
[0095] In the present invention in the fourth aspect, the recovered
crystalline MWW-type titanosilicate catalyst for providing an
oxidized compound generally has a tendency such that the activity
thereof is decreased each time it is used repeatedly, and the
catalyst after the repeated use cannot exhibit its initial
activity. In such a case, the recovered catalyst may be regenerated
or reproduced. The recovered catalyst may be regenerated by a
conventionally known method. More specifically, the catalyst may be
regenerated so that it has an initial activity, for example, by
calcining the catalyst in air at a temperature of 100 to
600.degree. C.
EXAMPLE
[0096] Hereinbelow, the present invention will be described in
further detail by referring to the Examples. However, these
Examples are set forth only to show the outline of the present
invention and the present invention should not be construed as
being limited to these specific Examples.
DESCRIPTION OF TERMS IN EXAMPLES AND COMPARATIVE EXAMPLES
Method of Calculating Conversion of Allyl Alcohol
[0097]
[0098] The molar ratio of allyl alcohol which has been consumed in
the reaction, based on the allyl alcohol which has been charged
prior to the reaction. The allyl alcohol consumed in the reaction
was calculated from the increase and decrease of allyl alcohol
between the amounts thereof before and after the reaction.
Method of Calculating Selectivity for Glycidol
[0099] The molar ratio between glycidol and glycerin which has been
calculated from the results of analysis of a filtrate after the
reaction.
Method of Calculating Conversion of Hydrogen Peroxide
[0100] The ratio of hydrogen peroxide which has been consumed in
the reaction based on the hydrogen peroxide which has been charged
prior to the reaction. The hydrogen peroxide consumed in the
reaction was calculated from the increase and decrease of hydrogen
peroxide between the amounts thereof before and after reaction.
Calculation of Effective Ratio of Hydrogen Peroxide
[0101] The effective ratio of hydrogen peroxide indicates a ratio
of hydrogen peroxide which has been obtained by subtracting the
amount of the hydrogen peroxide consumed in the decomposition into
oxygen, from the amount of the hydrogen peroxide consumed in the
reaction. That is, the effective ratio of hydrogen peroxide is the
ratio of hydrogen peroxide consumed in the epoxidation reaction,
based on the total amount of the consumed hydrogen peroxide.
Yield of Epoxide
[0102] The yield of the epoxide compound (intended oxidized
product) based on hydrogen peroxide after the completion of the
oxidation reaction using the hydrogen peroxide. This yield
indicates a molar ratio of the amount of epoxide compound produced
to the amount of the hydrogen peroxide charged into the
reaction.
Reduction Ratio of Catalytic Activity
[0103] This ratio indicates a decrement in the molar amount of the
epoxide compound which has been produced by using a repeatedly used
catalyst, based on the molar amount of the epoxide compound which
has been produced by using an unused catalyst.
Apparatuses for Analysis in Examples and Comparative Examples
Method of Elemental Analysis for Titanosilicate
[0104] A sample of titanosilicate was accurately weighed in a
Teflon (polytetrafluoroethylene) beaker, and 1 ml of hydrofluoric
acid (concentration:50% by mass) was added to the beaker so as to
dissolve the titanosilicate therein. Then, pure water was added to
the beaker until the concentrations of the respective elements to
be measured were in the range of 0-10 ppm. The thus obtained
solution was subjected to a component analysis for titanium,
silicon and boron by using a desktop-type plasma emission analysis
apparatus (SPS 1700, mfd. by Seiko Denshi Kogyo K. K.). In this
analysis, the titanium concentration was measured by using a
wavelength of 334.9410 nm, the silicon concentration was measured
by using a wavelength of 251.611 nm, and the boron concentration
was measured by using a wavelength of 249.7730 nm.
Analysis of Organic Compound Concentration in Filtrate of Reaction
Mixture
[0105] The organic compound concentration was measured by using the
following gas chromatography analyzing apparatus under the
following analyzing conditions.
[0106] In this analysis, an internal standard method was used. More
specifically, 1 ml of 1,4-dioxane as an internal standard was added
to 10 ml of a reaction solution to prepare a solution to be
analyzed and 0.4 .mu.l of the resultant analysis solution was
injected into the gas chromatograph.
Gas Chromatograph
[0107] Column: GC-14B mfd. by Shimadzu Seisakusho capillary column
TC-WAX (length:30 m, internal diameter:0.25 mm, column wall
thickness:0.25 .mu.m)
[0108] Carrier gas: nitrogen (split ratio:20, column flow rate: 2
ml/min)
[0109] Temperature condition: The temperatures of the detector and
the vaporization chamber were 200.degree. C. The column temperature
was kept at 50.degree. C. for 5 minutes from the initiation of
analysis, then was elevated to 150.degree. C. at a
temperature-rising rate of 10.degree. C./min, kept at 150.degree.
C. for 10 minutes, thereafter elevated to 200.degree. C. at a
temperature-rising rate of 10.degree. C./min and kept at this
temperature for 25 minutes.
[0110] Detector: FID (H.sub.2 pressure:70 kPa, air pressure:100
kPa)
Analysis of Hydrogen Peroxide Concentration in Filtrate of Reaction
Mixture
[0111] A potentiometric titration was performed by using an
automatic potentiometric titrating apparatus AT-012 (mfd. by Kyoto
Denshi Kagaku Kogyosha) and by using an aqueous solution containing
Ce(IV) as a titration reagent, to thereby measure the hydrogen
peroxide concentration in the filtrate of a reaction mixture. More
specifically, 40 ml of ion-exchanged water was added to a 100
ml-glass beaker, and then about 0.3 g of a sample of the filtrate
of the reaction mixture to be measured was accurately weighed out
in the beaker. Thereafter, potentiometric titration was performed
by means of the above automatic potentiometric titrating apparatus
by slowly adding to the beaker a 0.1 mol/l-aqueous solution which
had been prepared by using tetraammonium cerium sulfate dihydrate
(produced by Wako Pure Chemical Industries, Ltd.). The hydrogen
peroxide concentration was calculated from the amount of the above
0.1 mol/l-aqueous tetraammonium cerium sulfate solution which had
been required for the potentiometric titration until the end point
thereof, and the weight of the filtrate of the reaction mixture
which had been used for the analysis.
Example 1
Production of Catalyst 1
[0112] 182.5 g of piperidine (purity:98%, produced by Wako Pure
Chemical Industries, Ltd.) (hereinafter, piperidine is simply
referred to as "PI" in some cases) was dissolved in 513 g of
ion-exchanged water at 25.degree. C. to prepare an aqueous
piperidine solution. This aqueous piperidine solution was divided
into two equal portions. Under vigorous stirring, 18.0 g of
tetrabutyl orthotitanate (purity: 95%, produced by Wako Pure
Chemical Industries, Ltd.) was added to one of the two portions,
and 124.2 g of boric acid (purity:99.5%, produced by Wako Pure
Chemical Industries, Ltd.) was added to the other of the two
portions. The hydrolysis reaction of tetrabutyl orthotitanate was
caused to completely proceed under stirring for 30 minutes, and
thereafter, 45 g of fumed silica (trade name: Cab-o-sil M7D, mfd.
by Cabot Co.) was added to each of the two resultant solutions
containing titanium or boron. After the addition of silica, the
solutions were stirred for 1 hour, to thereby obtain two kinds of
homogenous gel-like products. These two kinds of gels were mixed
with each other and the resultant mixed gel was continuously
stirred for 1 hour and 30 minutes, to thereby obtain a mixture
having a molar ratio of
1.SiO.sub.2:0.033.TiO.sub.2:0.67.B.sub.2O.sub.3:1.4.PI:19.H.sub.2O.
[0113] This gel was transferred to 2-liter autoclave equipped with
a Teflon-made inner cylinder disposed in the autoclave, stirred
therein at a temperature of 130.degree. C. and a revolution number
of 100 rpm for 24 hours, subsequently stirred at a temperature of
150.degree. C. and at 100 rpm for 24 hours, and further stirred at
a temperature of 170.degree. C. and at 100 rpm for 120 hours. After
the completion of the stirring, the content in the autoclave was
cooled to 25.degree. C., a solid product was separated from the
content by filtration, and the resultant solid product was washed
by using ion-exchanged water. The washing was repeated until the pH
of washing water became 9 or less. The thus obtained solid product
was dried at a temperature of 50.degree. C. To 1 g of the resultant
solid product, 20 ml of 6 mol/1-nitric acid was added to perform an
acid treatment at a temperature of 100.degree. C. for 20 hours.
After the completion of the acid treatment, the solid was collected
by filtration and calcined in an atmosphere of air at a temperature
of 530.degree. C. for 10 hours, to thereby obtain final intended
product of MWW-type titanosilicate Catalyst 1.
[0114] The molar ratio of titanium/silicon and the molar ratio of
boron/silicon of Catalyst 1 were measured in the above-mentioned
manner. The results are shown in Table 2 appearing hereinbelow.
Example 2
Production of Catalyst 2
[0115] MWW-type titanosilicate Catalyst 2 was obtained in the same
manner as in Example 1 except for using 1.0 mol/l-sulfuric acid in
place of 6 mol/1-nitric acid in the acid treatment.
[0116] The molar ratio of titanium/silicon and the molar ratio of
boron/silicon of Catalyst 2 were measured. The results are shown in
Table 2 appearing hereinbelow.
Example 3
Production of Catalyst 3
[0117] MWW-type titanosilicate Catalyst 3 was obtained in the same
manner as in Example 1 except for using 2.0 mol/l-sulfuric acid in
place of 6 mol/1-nitric acid in the acid treatment.
[0118] The molar ratio of titanium/silicon and the molar ratio of
boron/silicon in Catalyst 3 were measured. The results obtained are
shown in Table 2 appearing hereinbelow.
Example 4
Production of Catalyst 4
[0119] 182.5 g of PI (purity: 98%, produced by Wako Pure Chemical
Industries, Ltd.) was dissolved in 513 g of ion-exchanged water at
25.degree. C. to prepare an aqueous piperidine solution. This
aqueous piperidine water was divided into two equal portions. Under
vigorous stirring, 18.0 g of tetrabutyl orthotitanate (purity: 95%,
produced by Wako Pure Chemical Industries, Ltd.) was added to one
of the two portions and 124.2 g of boric acid (purity: 99.5%,
produced by Wako Pure Chemical Industries, Ltd.) was added to the
other of the two portions. The hydrolysis reaction of tetrabutyl
orthotitanate was caused to completely proceed under stirring for
30 minutes, and thereafter 45 g of fumed silica (Cab-o-sil M7D) was
added to each of the two solutions containing titanium or boron.
After the addition of silica, the solutions were stirred for 1
hour, to thereby obtain two kinds of homogenous gel-like products.
These two gels were mixed with each other and the resultant mixed
gel was continuously stirred for 1 hour and 30 minutes, to thereby
obtain a mixture having a molar ratio of
1SiO.sub.2:0.033.TiO.sub.2:0.67.B.sub.2O.sub.3:1.4.PI:19.H.sub.2O.
[0120] This gel was transferred to a 2-liter autoclave equipped
with a Teflon inner cylinder disposed therein, stirred at a
temperature of 130.degree. C. and at 100 rpm for 24 hours,
subsequently stirred at a temperature of 150.degree. C. and a
revolution number of 100 rpm for 24 hours, and further stirred at a
temperature of 170.degree. C. and at 100 rpm for 120 hours. After
the completion of the stirring, the content in the autoclave was
cooled to 25.degree. C., a solid product was separated from the
content by filtration, and the solid product was washed by using
ion-exchanged water. The washing was repeated until the pH of
washing water became 9 or less. The thus obtained solid product was
calcined at a temperature of 530.degree. C. for 10 hours, to
thereby obtain final intended product of MWW-type titanosilicate
Catalyst 4.
[0121] The molar ratio of titanium/silicon and the molar ratio of
boron/silicon of Catalyst 4 were measured. The results are shown in
Table 2 appearing hereinbelow.
Example 5
Production of Catalyst 5
[0122] 182.5 g of PI (purity: 98%, produced by Wako Pure Chemical
Industries, Ltd.) was dissolved in 513 g of ion-exchanged water at
25.degree. C. to prepare an aqueous piperidine solution. This
aqueous piperidine water was divided into two equal portions. Under
vigorous stirring, 18.0 g of tetrabutyl orthotitanate (purity: 95%,
produced by Wako Pure Chemical Industries, Ltd.) was added to one
of the two portions and 124.2 g of boric acid (purity: 99.5%,
produced by Wako Pure Chemical Industries, Ltd.) was added to the
other of the two portions. The hydrolysis reaction of tetrabutyl
orthotitanate was caused to completely proceed under stirring for
30 minutes, 45 g of fumed silica (Cab-o-sil M7D) was added to each
of the two solutions containing titanium or boron. After the
addition of silica, the solutions were stirred for 1 hour, to
thereby obtain two kinds of homogenous gel-like products. These two
gels were mixed with each other and the resultant mixed gel was
continuously stirred for 1 hour and 30 minutes, to thereby obtain a
mixture having a molar ratio of
1-SiO.sub.2:0.033.TiO.sub.2:0.67.B.sub.2O.sub.3:1.4.PI:19.H.sub.2O.
[0123] This gel was transferred to 2-liter autoclave equipped with
a Teflon inner cylinder disposed therein, stirred at a temperature
of 130.degree. C. and at 100 rpm for 24 hours, then stirred at a
temperature of 150.degree. C. and at 100 rpm for 24 hours, further
stirred at a temperature of 170.degree. C. and at 100 rpm for 120
hours. After the completion of the stirring, the content in the
autoclave was cooled to 25.degree. C., a solid product was
separated from the content by filtration, and the solid product was
washed by using ion-exchanged water. The washing was repeated until
the pH of the washing water became 9 or less. The thus obtained
solid product was dried at a temperature of 50.degree. C. To 1 g of
the resultant solid product, 20 ml of 6 mol/1-nitric acid was added
to perform an acid treatment at a temperature of 100.degree. C. for
20 hours. After the completion of the acid treatment, the solid was
collected by filtration. To 1 g of the resultant solid product, 20
ml of 2 mol/1-nitric acid was further added to perform an acid
treatment at a temperature of 100.degree. C. for 20 hours. The thus
treated solid was calcined at a temperature of 530.degree. C. for
10 hours, to thereby obtain final intended product of MWW-type
titanosilicate Catalyst 5.
[0124] The molar ratio of titanium/silicon and the molar ratio of
boron/silicon of Catalyst 5 were measured. The results are shown in
Table 2 appearing hereinbelow.
[0125] The molar ratio of titanium/silicon and the molar ratio of
boron/silicon of Catalysts 1 to 5 obtained in Examples 1 to 5 are
shown in Table 2 appearing hereinbelow.
2 TABLE 2 Molar Ratio of Molar Ratio of No. Titanium/Silicon
Boron/Silicon Example 1 Catalyst 1 0.0217 0.0204 Example 2 Catalyst
2 0.0132 0.0244 Example 3 Catalyst 3 0.0068 0.0294 Example 4
Catalyst 4 0.0323 0.0910 Example 5 Catalyst 5 0.0074 0.0016
Example 6
Production of Oxidized Compound using MWW-Type Titanosilicate
Catalyst 1
[0126] To a 20 ml-volume three-neck flask equipped with a
thermometer, a reflux condenser and a magnetic stirrer, 0.58 g (10
mmol) of allyl alcohol and 3.9 g (5 ml) of acetonitrile were added,
and MWW-type titanosilicate Catalyst 1 (70 mg) obtained in Example
1 was charged into the flask. The flask was heated in a water bath
at 60.degree. C. and the mixture was vigorously stirred.
Immediately after the temperature of the reaction mixture reacted
57.degree. C., 1.1 g (10 mmol as hydrogen peroxide) of an aqueous
30 mass %-hydrogen peroxide solution was added to the reaction
system. This point was taken as the reaction initiation time, and
the stirring was continued, until 30 minutes was counted from the
reaction initiation. After 30 minutes from the reaction initiation,
the reaction mixture was immediately cooled with ice to stop the
reaction. Thereafter, the reaction mixture was filtered to separate
unreacted allyl alcohol, unreacted hydrogen peroxide, water,
product and solvent from the catalyst. At this time, the
concentration of organic substances in the filtrate was analyzed by
gas chromatography and the concentration of unreacted hydrogen
peroxide was determined by potentiometric titration using Ce(Iv).
The results of the reaction are shown in Table 3 appearing
hereinbelow. The conversion of allyl alcohol was 87.0% and the
selectivity for glycidol as the product epoxide compound was 99.9%.
Further, the conversion of hydrogen peroxide was 87.9% and the
effective ratio of hydrogen peroxide was 99.0%.
3 TABLE 3 Kind of Catalyst Effective Molar Molar Ratio of Ratio of
Ratio of Conversion (%) Hydrogen Titanium/ Boron/ Solvent Used
Allyl Hydrogen Selectivity (mol %)*.sup.3 Peroxide No.
Silicon*.sup.5 Silicon*.sup.5 in Reaction Alcohol*.sup.1
Peroxide*.sup.2 Glycidol Glycerin (%) Example 6 Catalyst 1 0.0217
0.0204 Acetonitrile 87.0 87.9 99.9 0.1 99.0 Example 7 Catalyst 2
0.0132 0.0244 Acetonitrile 42.6 45.3 98.1 1.9 94.1 Example 8
Catalyst 3 0.0068 0.0294 Acetonitrile 16.2 17.2 92.1 7.9 94.2
Example 9 Catalyst 4 0.0323 0.0910 Acetonitrile 3.1 4.9 32.0 68.0
63.5 Example 10 Catalyst 5 0.0074 0.0016 Acetonitrile 12.4 13.4
94.5 5.5 92.3 Example 11 Catalyst 1 0.0217 0.0204 Water 82.3 97.6
99.9 0.1 84.3 Example 12 Catalyst 1 0.0217 0.0204 Ethanol 32.5 33.0
91.0 9.0 98.5 Comparative MFI-type 0.0222 -- Acetonitrile 26.4 28.9
87.9 12.1 91.3 Example 1 *.sup.1Conversion of allyl alcohol:
consumed allyl alcohol (mol)/raw material allyl alcohol (mol)
.times. 100 (%) *.sup.2conversion of hydrogen peroxide: consumed
hydrogen peroxide (mol)/raw material hydrogen peroxide (mol)
.times. 100 (%) *.sup.3Selectivity for glycidol: glycidol
(mol)/[glycidol (mol) + glycerin (mol)] .times. 100 (mol %)
Selectivity for glycerin: glycerin (mol)/[glycidol (mol) + glycerin
(mol)] .times. 100 (mol %) *.sup.4Effective ratio of hydrogen
peroxide: [glycidol (mol) + glycerin (mol)]/consumed hydrogen
peroxide (mol) .times. 100 (%) *.sup.5Molar ratio (calculated by
ICP emission spectroscopic analysis)
Example 7
Production of Oxidized Compound using MWW-Type Titanosilicate
Catalyst 2
[0127] The same operation as in Example 6 was performed except for
using the Catalyst 2 obtained in Example 2 instead of the Catalyst
1 obtained in Example 1. The results of the reaction are shown in
Table 3 appearing hereinabove.
Example 8
Production of Oxidized Compound using MWW-Type Titanosilicate
Catalyst 3
[0128] The same operation as in Example 6 was performed except for
using the Catalyst 3 obtained in Example 3 instead of the Catalyst
1 obtained in Example 1. The results of the reaction are shown in
Table 3 appearing hereinabove.
Example 9
Production of Oxidized Compound using MWW-Type Titanosilicate
Catalyst 4
[0129] The same operation as in Example 6 was performed except for
using the Catalyst 4 prepared in Example 4. The results of the
reaction are shown in Table 3 appearing hereinabove.
Example 10
Production of Oxidized Compound using MWW-Type Titanosilicate
Catalyst 5
[0130] The same operation as in Example 6 was performed except for
using the Catalyst 5 prepared in Example 5. The results of the
reaction are shown in Table 3 appearing hereinabove.
Example 11
Examination of Reaction Solvent
[0131] The same operation as in Example 6 was performed except for
adding 5 g (5 ml) of water as a solvent in place of using
acetonitrile as a solvent used in Example 6. The results of the
reaction are shown in Table 3 appearing hereinabove.
Example 12
[0132] The same operation as in Example 6 was performed except for
adding 3.9 g (5 ml) of ethanol as a solvent in place of using
acetonitrile as a solvent used in Example 6. The results of the
reaction are shown in Table 3 appearing hereinabove.
Comparative Example 1
Production of MFI-Type Titanosilicate Catalyst and Production of
Oxidized Compound
[0133] To 500 ml-volume beaker equipped with a magnetic stirrer,
62.5 g of tetraethyl orthosilicate (produced by Wako Pure Chemical
Industries, Ltd.) was added and subsequently, 107 g of an aqueous
20 mass % tetrapropyl ammonium hydroxide solution (produced by
Tokyo Kasei Kogyo Co., Ltd.) was added at a temperature of
30.degree. C. over 10 minutes. The resultant mixture was stirred
for 1.0 hour and, thereafter, a mixture containing 38 g of
isopropyl alcohol (produced by Wako Pure Chemical Industries, Ltd.)
and 14 g of tetra orthotitanate (produced by Tokyo Kasei Kogyo Co.,
Ltd.) was added over 30 minutes. The resultant mixture was stirred
at 30.degree. C. for 30 minutes, and thereafter the mixture was
heated by using a water bath at 80.degree. C. and was continuously
stirred for 2 hours. To the thus obtained mixture, 230 g of water
was added and the resulting solution was transferred to a autoclave
equipped with a Teflon inner cylinder disposed therein and
subjected to hydrothermal synthesis at 175.degree. C. for 48 hours.
After the completion of hydrothermal synthesis, the contents of the
autoclave were taken out therefrom and centrifuged to separate the
solid product. The thus obtained solid product was washed with
distilled water in the content. After the completion of the
washing, the product was calcined at 500.degree. C. for 8 hours in
the presence of air to remove organic substances. The product after
the calcination was further washed for 12 hours by using 20 ml of
an. aqueous 1.0 mol/1 nitric acid solution per 1 g of the solid and
after the completion of acid washing, the solid product was
separated by filtration. Subsequently, this solid product was
calcined at 500.degree. C. for 12 hours in the presence of air, to
thereby obtain an intended MFI-type titanosilicate catalyst having
a molar ratio of titanium/silicon of 0.0222.
[0134] The same operation as in Example 6 was performed except for
using this MFI-type titanosilicate catalyst instead of the Catalyst
1 obtained in Example 1. The results of the reaction are shown in
Table 3 appearing hereinabove.
Example 13
Repeated Use
[0135] To a 20 ml-volume three-neck flask equipped with a
thermometer, a reflux condenser and a magnetic stirrer, 0.23 g (4
mmol) of allyl alcohol and 7.9 g (10 ml) of acetonitrile were
added, and MWW-type titanosilicate Catalyst 1 (100 mg) obtained in
Example 1 was charged into the flask. The resulting mixture was
heated in a water bath at 60.degree. C. under vigorous stirring.
Immediately after the temperature of the reaction-mixture reached
57.degree. C., 0.14 g (4 mmol as hydrogen peroxide) of 30 mass
%hydrogen peroxide was added to the reaction system. This point was
taken as the reaction initiation time, and the stirring was
continued until 0.5 hours was counted from the reaction initiation.
After 0.5 hours from the reaction initiation, the reaction mixture
was immediately cooled with ice to stop the reaction. Thereafter,
the reaction mixture was filtered to separate unreacted allyl
alcohol, unreacted hydrogen peroxide, water, product and solvent
from the catalyst. At this time, the concentration of organic
substances in the thus obtained filtrate was analyzed by gas
chromatography and the concentration of unreacted hydrogen peroxide
was determined by potentiometric titration using Ce(IV).
[0136] After the catalyst recovered by filtration was dried in a
dryer at 80.degree. C. for 6 hours in an atmosphere of air, a
second-time reaction was performed under the same conditions as in
the first-time reaction described above. After the completion of
reaction, the mixture was filtered in the same manner as in the
first-time reaction to separate the filtrate from the catalyst.
Then, the filtrate was analyzed and the catalyst was recovered in
the same manner as in the first-time reaction.
[0137] Again, the catalyst recovered after the second-time reaction
was dried, a third-time reaction was performed under the same
conditions as in the first and second-time reactions, and after the
completion of reaction, the mixture was separated and analyzed in
the same manner as in the first and second-time reactions. In such
a manner, the reaction was performed three times in total. The
results of the reaction are shown in the following Table 4. The
reduction ratio of activity, indicating the deterioration of
catalyst, was 2% in the second-time reaction and 10% in the
third-time reaction.
4 TABLE 4 Reduction Yield of Ratio of Kind of Number of Glycidol
Activity Catalyst Use (%)*.sup.1 (%)*.sup.3 Example 13 Catalyst 1
1st time 88.3 0 2nd time 86.7 2 3rd time 79.5 10 Comparative
MFI-type*.sup.2 1st time 28.4 0 Example 2 2nd time 20.5 28 3rd time
19.8 31 *.sup.1Yield of glycidol: amount of glycidol produced
(mol)/amount of raw material hydrogen peroxide (mol) .times. 100
(%) *.sup.2MFI-type titanosilicate: molar ratio of titanium/silicon
= 0.0222 *.sup.3Reduction ratio of activity: [(yield of glycidol at
first-time) - (yield of glycidol at second or third-time)/(yield of
glycidol at first-time) .times. 100 (%)
Comparative Example 2
[0138] The same operation as in Example 11 was performed except for
using the MFI-structure titanosilicate catalyst having a molar
ratio of titanium/silicon of 0.0222 obtained in Comparative Example
1 instead of the Catalyst 1 obtained in Example 1. The results of
the reaction are shown in Table 4 appearing hereinabove. The
reduction ratio of activity, indicating the deterioration of
catalyst, was 28% at the second-time reaction and 31% at the
third-time reaction.
Example 14
Examination of Reaction Substrate
[0139] To a 20 ml-volume three-neck flask equipped with a
thermometer, a reflux condenser and a magnetic stirrer, 0.98 g (10
mmol) of diallyl ether and 3.9 g (5 ml) of acetonitrile were added,
and MWW-type titanosilicate Catalyst 1 (70 mg) obtained in Example
1 was charged into the flask. The resulting mixture was heated in a
water bath at 60.degree. C. under vigorous stirring. Immediately
after the temperature of the reaction mixture reached 57.degree.
C., 1.1 g (10 mmol as hydrogen peroxide) of 30 mass %-hydrogen
peroxide was added to the reaction system. This point was taken as
the reaction initiation time, the stirring was continued until 1
hour after the reaction initiation. After 1 hour from the reaction
initiation, the reaction mixture was immediately cooled with ice to
stop the reaction. Thereafter, the reaction mixture was filtered to
separate unreacted diallyl ether, unreacted hydrogen peroxide,
water, product and solvent from the catalyst. At this time, the
concentration of organic substances in the thus obtained filtrate
was analyzed by gas chromatography and the-concentration of
unreacted hydrogen peroxide was determined by potentiometric
titration using Ce(IV). The results of the reaction are shown in
the following Table 5. The yield of allyl glycidyl ether as an
intended epoxide compound was 24.4%.
5 TABLE 5 Yield of Epoxide Substrate Epoxide Product (%)*.sup.1
Example 14 diallyl ether allyl glycidyl 24.4 ether Example 15 allyl
propyl glycidyl propyl 42.6 ether ether Example 16 allyl chloride
epichlorohydrin 53.1 Example 17 styrene styrene oxide 1.6
Comparative diallyl ether allyl glycidyl 16.7 Example 3 ether
Comparative allyl propyl glycidyl propyl 17.9 Example 4 ether ether
Comparative allyl chloride epichlorohydrin 20.1 Example 5
Comparative styrene styrene oxide 1.1 Example 6 *.sup.1Yield of
epoxide: Amount of epoxide produced (mol)/amount of raw material
hydrogen peroxide (mol) .times. 100 (%)
Example 15
[0140] The same operation as in Example 12 was performed 25 except
for using 1.00 g (10 mmol) of allyl propyl ether instead of allyl
alcohol used in Example 12. The results of the reaction are shown
in Table 5 appearing hereinabove. The yield of glycidyl propyl
ether as an intended epoxide compound was 42.6%.
Example 16
[0141] The same operation as in Example 12 was performed except for
using 0.77 g (10 mmol) of allyl chloride instead of allyl alcohol
used in Example 12. The results of the reaction are shown in Table
5 appearing hereinabove. The yield of epichlorohydrin as an
intended epoxide compound was 53.1%.
Example 17
[0142] The same operation as in Example 12 was performed except
for-using 1.04 g (10 mmol) of styrene instead of allyl alcohol used
in Example 12. The results of the reaction are shown in Table 5
appearing hereinabove. The yield of styrene oxide as an intended
epoxide compound was 1.6%.
Comparative Examples 3 to 6
[0143] The same operation as in Examples 14 to 17 was performed
except for using the MFI structure titanosilicate catalyst obtained
in Comparative Example 1 instead of the Catalyst 1 obtained in
Example 1. The results of the reaction are shown in Table 5
appearing hereinabove. The yield of allyl glycidyl ether was 16.7%,
the yield of glycidyl propyl ether was 17.9%, the yield of
epichlorohydrin was 20.1%, and the yield of styrene oxide was 1.1%,
which were intended epoxide compounds.
Industrial Applicability
[0144] As described hereinabove, it is apparent that, as compared
with conventionally known titanosilicate catalysts, the crystalline
titanosilicate catalyst represented by the following the
composition formula (1) or (2) and having a structural code of MWW
as described above may function as a very useful catalyst in the
production of an oxidized compound from a compound having a
carbon-carbon double bond and at least one other functional group
by an oxidation reaction using a peroxide as an oxidizing
agent:
xTiO.sub.2.(1-x)SiO.sub.2 Composition formula (1)
[0145] (wherein x is a number of 0.0001 to 0.2).
xTi.sub.2.yM.sub.2O.sub.3.(1-x-2y)SiO.sub.2 Composition formula
(2)
[0146] (wherein M represents at least one element selected from the
group consisting of aluminum, boron, chromium, gallium and iron, x
is a number of 0.0001 to 0.2 and y is a number of 0.0001 to
0.1).
[0147] It is also clear that according to the process for producing
the above-mentioned titanosilicate catalyst using hydrothermal
synthesis described above, a high-performance crystalline MWW-type
titanosilicate catalyst for providing an oxidized compound can be
obtained with good efficiency.
* * * * *
References