Ethylene oxide synthesis has been chosen as a benchmark case to evaluate the performance of a microreaction system in comparison to an existing industrial process. This reaction was selected because microreaction technology provides equipment with very good mass-and heat-transfer conditions, which avoids hot spots inside the reactor channels that are known problems for the partial oxidation of ethylene. Furthermore, because the microstructured reactors are inherently safe with respect to explosions, gas compositions within the explosion limits are attainable and can be handled safely. For example, 15% ethylene in pure oxygen, which is in the middle of the explosive regime and far away from typical compositions for industrial processes, could be used. Space time yields of 0.14-0.78 tons h -1 m -3 calculated on the basis of the channel volume, in comparison to the values of 0.13-0.26 tons h -1 m -3 for an industrial reactor calculated on the basis of the reactor volume, have been achieved by using the microreactor.
Direct epoxidation of propene with hydrogen peroxide vapor was conducted in a microstructured reactor
containing TS-1 catalyst coatings. At 140 °C, 1 bar, 5 vol % hydrogen peroxide, and 15 vol % propene,
productivities of more than 1 kg of propene oxide per kg of catalyst and hour are obtained in lab scale, which
is in an industrially highly relevant range. Excellent selectivities to propene oxide based on propene of >90%
were reached. Potential and need for improvement lie in the propylene oxide selectivity based on hydrogen
peroxide, which was observed to be about 25%. By increasing the molar excess of propene to about 6.6,
propylene oxide selectivities related to hydrogen peroxide of up to 60% have been observed in the pilot
plant.
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