110th Anniversary: Near-Total Epoxidation Selectivity and Hydrogen Peroxide Utilization with Nb-EISA Catalysts for Propylene Epoxidation

The Nb-EISA catalyst with relatively low Nb loadings (∼2 wt %) shows exceptional propylene epoxidation performance with H₂O₂ as oxidant at 30–40 °C, 5–9 bar propylene pressure with nearly total propylene oxide (PO) selectivity (>99%), H₂O₂ utilization (>99%) toward PO formation, high productivity (∼3200 mg/h/g), and mild Nb leaching (3–6%). The predominantly Lewis acidic nature of the Nb-EISA catalysts favors epoxidation while their relatively low Brønsted acidity inhibits H₂O₂ decomposition and Nb leaching. At higher Nb loadings (8–17 wt %), the catalytic performance deteriorates. However, significant performance improvements were achieved when the Nb-EISA materials are calcined in N₂ (instead of air) during synthesis, depositing a carbon layer in the pores. The resulting pore hydrophobicity not only inhibits epoxide ring opening but also increases propylene concentration inside the pores resulting in higher EO productivity and lower H₂O₂ decomposition. The carbonized Nb-EISA materials also show improved stability to leaching.