Process for epoxidation and catalyst to be used therein

Abstract

The present invention relates to a process for treating a solid material containing at least one zeolite and being at least partly crystalline or treating a shaped body obtained from said solid material wherein said solid material or shaped body is brought in contact with a composition containing water after at least one of the following steps of an integrated process for producing a solid material or a shaped body containing at least one zeolite: (i) after step (II) of separating the at least partly crystalline solid material from its mother liquor or (ii) after step (S) of shaping said solid material into a shaped body or (iii) after a step (C) of calcining said solid material or said shaped body. The present invention furthermore relates to the solid material obtainable by the inventive process and the shaped body obtainable by the inventive process. The present invention finally relates to the use of the solid material or the shaped body as mentioned above as a catalyst in chemical reactions, in particular in reactions of compounds containing at least one C—C double bond with at least one hydroperoxide.

We claim  
     
         1 . Process for treating a solid material or a shaped body containing at least one zeolite and being at least partly crystalline characterized in that said solid material or the shaped body is brought in contact with a composition containing water after at least one of the following steps of an integrated process for producing a solid material or a shaped body: (i) after step (II) of separating the at least partly crystalline solid material from its mother liquor or (ii) after step (S) of shaping said solid material into a shaped body or (iii) after a step (C) of calcining said solid material or said shaped body.  
     
     
         2 . Process according to  claim 1 , characterized in that the solid material is brought in contact with a composition containing water at temperatures elevated with respect to room temperature.  
     
     
         3 . Process according to  claim 1 , characterized in that the composition containing water is selected from the following group comprising: deionized water, water vapor, steam, steam at pressures elevated relative to ambient pressure, supercritical water, aqueous solutions, ammonia water.  
     
     
         4 . Process according to any of  claims 1  to  3 , characterized in that the at least one zeolite contains Ti.  
     
     
         5 . Process according to  claim 4 , characterized in that the at least one zeolite containing Ti is selected from materials of the structure classes MFI, MEL, MWW, BEA or any mixed structures thereof.  
     
     
         6 . Process according to  claim 1 , characterized in that the step of bringing the solid material or the shaped body in contact with a composition containing water is performed in a reactor that is used for the synthesis or treatment of the solid material or in a reactor in which the solid material or the shaped bodies made form the solid material are used as catalysts in a chemical reaction.  
     
     
         7 . Integrated process for the production of a solid material containing at least one zeolite, comprising at least the following steps: 
 (I) at least partial crystallization of at least one solid material containing at least one zeolite out of a synthesis mixture, resulting in mixture (I) containing at least said solid material and a mother liquor;    (II) separating and/or concentrating of the solid material in mixture (I);    (W) bringing the solid material from step (II) in contact with a composition containing water;    (III) agglomerating or granulating or agglomerating and granulating of the solid material from step (W);    wherein step (m) is optional.    
     
     
         8 . Integrated process according to  claim 7 , characterized in that after step (W), the solid material is separated from at least parts of the composition containing water, i.e. a repetition of step (II) is performed.  
     
     
         9 . Integrated process according to  claim 7 , characterized in that the method of separating and/or concentrating in step (II) is selected from the following group consisting of: ultrafiltration, spray-drying, spray granulating, bringing inert support bodies in contact with the synthesis solution from (I).  
     
     
         10 . Integrated process for the production of a shaped body containing at least one zeolite, comprising at least the following steps: 
 (I) at least, partial crystallization of at least one solid material containing at least one zeolite out of a synthesis mixture, resulting in mixture (I) containing at least said solid material and a mother liquor;    (II) separating and/or concentrating of the solid material in mixture (I);    (W) bringing the solid material from step (II) in contact with a composition containing water;    (III) agglomerating or granulating or agglomerating and granulating of the solid material from step (W);    wherein step (III) is optional and wherein, after step (W) or after step (III), at least one step (S) of shaping the solid material into a shaped body is performed.    
     
     
         11 . Integrated process according to  claim 10 , characterized in that the at least one step of shaping the solid material is selected from the following group comprising: pelletizing, pressing, extruding, sintering, roasting, briquetting.  
     
     
         12 . Integrated process according to  claim 10 , characterized in that the step (W) is performed after the step (S) of shaping the solid material is performed, wherein said step (W) either replaces the step (W) performed after step (II) or is performed in addition to the step (W) performed after step (II).  
     
     
         13 . Integrated Process according to any of the  claims 7  to  12 , characterized in that after at least one of the steps (II), (W) or (III), a step (C) of calcining the solid material and/or the shaped body is performed.  
     
     
         14 . Integrated process according to  claim 13 , characterized in that said step of calcining is performed at temperatures higher than 400° C.  
     
     
         15 . Solid material obtainable by a process of treating a solid material containing at least one zeolite and being at least partly crystalline, wherein said solid material is brought in contact with a composition containing water after at least one of the following steps of an integrated process for producing said solid material: (i) after step (II) of separating the at least partly crystalline material from its mother liquor or (ii) after a step (C) of calcining said solid material or said shaped body.  
     
     
         16 . Solid material according to  claim 15 , characterized in that it contains Ti.  
     
     
         17 . Solid material according to  claim 15 , characterized in that it displays a discernible hump, i.e. an increased UV/VIS absorption, over materials that have not been brought in contact with a composition containing water, in the region from 250 to 350 nm.  
     
     
         18 . Solid material according to any of the  claims 15  to  17 , characterized in that it is shaped into a shaped body in a step (S) and that in addition to the step of bringing the solid material in contact with a composition containing water or instead of said step, the shaped body is brought in contact with a composition containing water, either directly after the step (S) of shaping the solid material into a shaped body or after a subsequent step (C) of calcining said shaped body.  
     
     
         19 . Use of the solid material or the shaped body according to any of the  claims 15  to  18  or of the solid material or the shaped body obtained according to any of the  claims 1  to  14  as a catalyst or a co-catalyst in the reaction of at least one compound with at least one C—C-double bond with at least one hydroperoxide.