Toward a CO2-free ethylene oxide process: Homogeneous ethylene oxide in gas-expanded liquids

Among industrial chemical processes, ethylene oxide manufacture emits the largest amount of CO₂ (∼2-3 million tons/yr), as byproduct from the burning of both the ethylene (feed) and ethylene oxide. Further, the conventional silver-based catalytic process presents safety challenges due to the formation of explosive ethylene oxide/O₂ mixtures in the gas phase. By judicious choice of the catalyst (methyltrioxorhenium), oxidant (H₂O₂) and reaction medium (methanol/water), a homogeneous liquid phase catalytic system has been demonstrated that eliminates CO₂ formation while producing ethylene oxide at >90% selectivity at near-ambient temperatures. Given its high volatility, the ethylene oxide is easily recovered from the reaction phase by distillation. The vicinity of the gaseous ethylene feed to its critical temperature (9 °C) is exploited to significantly increase its solubility in the liquid reaction phase by facile compression beyond the critical pressure of ethylene (∼50 bar). Since H₂O₂ is stable at typical reaction temperatures (40 °C or less), potentially explosive ethylene oxide/O₂ mixtures are avoided in the gas phase. In addition to the potential of arresting the carbon footprint of a large-scale industrial process, the demonstrated process concept shows how gas-expanded liquids can be generally exploited in homogeneous catalysis to enhance productivity.