Increased Silver Activity for Direct Propylene Epoxidation via Subnanometer Size Effects

Silver Cluster Catalysts for Propylene Oxide The formation of ethylene oxide—in which an oxygen atom bridges the double bond of ethylene—can be made directly and efficiently from ethylene and oxygen with the aid of silver catalysts (typically comprising a small silver cluster on aluminum oxide). Similar approaches are not so successful for making propylene oxide—an important starting material for polyurethane plastics, which are made from chlorinated intermediates. Lei et al. (p. 224) report that silver trimers, Ag3, deposited on alumina are active for direct propylene oxide formation at low temperatures with only a low level of formation of CO2 by-product, unlike larger particles that form from these clusters at higher temperatures. Density functional calculations suggest that the open-shell nature of the clusters accounts for the improved reactivity. Clusters of three silver atoms deposited on alumina are active for the low-temperature direct formation of propylene oxide. Production of the industrial chemical propylene oxide is energy-intensive and environmentally unfriendly. Catalysts based on bulk silver surfaces with direct propylene epoxidation by molecular oxygen have not resolved these problems because of substantial formation of carbon dioxide. We found that unpromoted, size-selected Ag3 clusters and ~3.5-nanometer Ag nanoparticles on alumina supports can catalyze this reaction with only a negligible amount of carbon dioxide formation and with high activity at low temperatures. Density functional calculations show that, relative to extended silver surfaces, oxidized silver trimers are more active and selective for epoxidation because of the open-shell nature of their electronic structure. The results suggest that new architectures based on ultrasmall silver particles may provide highly efficient catalysts for propylene epoxidation.