Preparation of hierarchical TS-1 zeolites from ordered macroporous-mesoporous carbon templates for efficient chloropropene epoxidation

The combination of Titanium silicalite-1 zeolite and H2O2 oxidant provides an excellent alternative to many highly toxic and polluting olefin oxidation processes due to the by-product being water-only and without deep oxidation. However, the diffusion of bulky reactants and products suffers from the inherent micropores of conventional TS-1 zeolites. Herein, we designed a reticulated ordered macroporous carbon material with uniform and coherent mesopores, and successfully synthesized ordered hierarchical TS-1 zeolites containing intracrystalline macroporous-mesoporous-microporous by dry gel method. The fully interconnected intracrystalline macroporous-mesoporous-microporous hierarchical TS-1 improves the accessibility of the active site and the diffusion efficiency of bulky compounds. It showed excellent catalytic performance during the epoxidation reaction of chloropropene, and its epichlorohydrin yield and H2O2 effective utilization were 70.11% and 77.05%, which were 2.2 and 1.9 times of the catalytic performance of commercial TS-1 zeolites, respectively, and significantly better than the ultrafine TS-1 synthesized by conventional methods. The high catalytic performance was maintained after three cycles of use. This offers a good opportunity for the design and synthesis of efficient zeolite catalysts in the future.