1-Pentene epoxidation in catalytic microfabricated reactors

Silicon-glass microreactors with TS-1 catalyst wall coatings were fabricated and used for 1-pentene epoxidation with hydrogen peroxide in continuous flow. Seeding of the microchannels before zeolite growth was necessary to obtain a small crystal size and a sufficient zeolite film thickness. Crystal size was further reduced by adjusting synthesis conditions and utilizing triethoxymethylsilane (TEMS) as a crystal growth inhibitor. Zeolite film morphology and crystal orientation did not show any significant effect on reactor performance. However, reaction rate was found to increase with decreasing TS-1 crystal size in the zeolite films and with increasing amount of tetrahedrally coordinated Ti(IV). Catalyst deactivation was observed, caused by the presence of organic compounds and Ti leaching from the microporous framework.