Unravelling the key factors in the chlorine-promoted epoxidation of ethylene over a silver-copper oxide nanocatalyst

Ethylene oxide is one of the most important raw materials in the chemical industry, with an annual production close to 35 million metric tons. Despite its importance, to date, no metal has been found that can compete with the original silver bulk material catalyst discovered in 1931. Recently, a few copper and copper-silver based nanostructures have demonstrated remarkable selectivity and activity, especially when coupled with an industrial chlorine promoter. The present work evaluates the mechanistic role of chlorine as an active promoter of the selective oxidation of ethylene to ethylene oxide in the presence of a silver-copper oxide hybrid nanocatalyst (AgCuO). Experimental kinetic studies combined with density functional theory (DFT) calculations provide insight into the influence that Ag/CuO-supported chlorine atoms have over the ethylene epoxidation reaction. Remarkably, the typically described indirect route via the formation of an oxametallacycle (OMC) is also accompanied by a direct route. Furthermore, the presence of chlorine seems to facilitate a more favorable adsorption energy for ethylene oxide (EO) than for acetaldehyde (AA), the main reaction by-product. As a result, complete oxidation of EO can be further prevented in the presence of this AgCuO hybrid heteronanostructure.

Formation of a 2D Meta-stable Oxide by Differential Oxidation of AgCu Alloys

Metal alloy catalysts can develop complex surface structures when exposed to reactive atmospheres. The structures of the resulting surfaces have intricate relationships with a myriad of factors, such as the affinity of the individual alloying elements to the components of the gas atmosphere and the bond strengths of the multitude of low-energy surface compounds that can be formed. Identifying the atomic structure of such surfaces is a prerequisite for establishing structure-property relationships, as well as for modeling such catalysts in ab initio calculations. Here, we show that an alloy, consisting of an oxophilic metal (Cu) diluted into a noble metal (Ag), forms a meta-stable two-dimensional oxide monolayer, when the alloy is subjected to oxidative reaction conditions. The presence of this oxide is correlated with selectivity in the corresponding test reaction of ethylene epoxidation. In the present study, using a combination of in situ, ex situ, and theoretical methods (NAP-XPS, XPEEM, LEED, and DFT), we determine the structure to be a two-dimensional analogue of Cu₂O, resembling a single lattice plane of Cu₂O. The overlayer holds a pseudo-epitaxial relationship with the underlying noble metal. Spectroscopic evidence shows that the oxide's electronic structure is qualitatively distinct from its three-dimensional counterpart, and because of weak electronic coupling with the underlying noble metal, it exhibits metallic properties. These findings provide precise details of this peculiar structure and valuable insights into how alloying can enhance catalytic properties.

Anisotropic Reactivity of CaAg under Ethylene Epoxidation Conditions

The chemical behavior of CaAg as catalyst for ethylene epoxidation was studied using a combination of experimental (X-ray powder diffraction, scanning electron microscopy, thermal analysis and infrared spectroscopy), and quantum chemical techniques as well as real-space chemical bonding analysis. Under oxidative ethylene epoxidation conditions, the CaAg (010) surface possesses an outstanding stability during long-term experiments. It is caused by the formation of an ordered, stable and dense CaO passivation layer with a small amount of embedded Ag atoms. On this way, the (010) surface constitutes a kinetic barrier for further incorporation of oxygen into the subsurface region and thereby prevents  further oxidative decomposition of CaAg. The calculated adsorption energies of the reaction species show strong adsorption of the reaction products that may explain the observed low conversion of ethylene toward ethylene oxide using CaAg as catalyst.

Significant enhancement of the selectivity of propylene epoxidation for propylene oxide: a molecular oxygen mechanism

As an attractive and environmentally friendly process for propylene oxide (PO) production, direct epoxidation of propylene (DEP) with molecular oxygen catalyzed by metal-based catalysts such as Ag and Cu has drawn much attention, but remains one of the biggest challenges in chemistry.

A Nanoarchitecture Based on Silver and Copper Oxide with an Exceptional Response in the Chlorine-Promoted Epoxidation of Ethylene

The selective oxidation of ethylene to ethylene epoxide is highly challenging as a result of competing reaction pathways leading to the deep oxidation of both ethylene and ethylene oxide. Herein we present a novel catalyst based on silver and copper oxide with an excellent response in the selective oxidation pathway towards ethylene epoxide. The catalyst is composed of different silver nanostructures dispersed on a tubular copper oxide matrix. This type of hybrid nanoarchitecture seems to facilitate the accommodation of chlorine promoters, leading to high yields at low reaction temperatures. The stability after the addition of chlorine promoters implies a substantial improvement over the industrial practice: a single pretreatment step at ambient pressure suffices in contrast with the common practice of continuously feeding organochlorinated precursors during the reaction.

Defect stabilized gold atoms on graphene as potential catalysts for ethylene epoxidation: a first-principles investigation

The defects on graphene make Au atoms active while being monodisperse and superior for ethylene epoxidation.

Ag-Cu catalysts for ethylene epoxidation: selectivity and activity descriptors

Ag-Cu alloy catalysts for ethylene epoxidation have been shown to yield higher selectivity towards ethylene oxide compared to pure Ag, the unique catalyst employed in the industrial process. Previous studies showed that under oxidizing conditions Cu forms oxide layers on top of Ag. Using first-principles atomistic simulations based on density functional theory, we investigate the reaction mechanism on the thin oxide layer structures and establish the reasons for the improved selectivity. We extend the range of applicability of the selectivity descriptor proposed by Kokalj et al. [J. Catal. 254, 304 (2008)], based on binding energies of reactants, intermediates, and products, by refitting its parameters so as to include thin oxide layer catalysts. We show that the selectivity is mainly controlled by the relative strength of the metal-carbon vs. metal-oxygen bonds, while the height of the reaction barriers mostly depend on the binding energy of the common oxametallacycle intermediate.