Electrochemistry ushers in new opportunities for ethylene oxide and propylene oxide!

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Recently, in the latest issue of Science, Leow et al published the latest research results under the title "Chloride-mediated selective electrosynthesis of ethylene and propylene oxides at high current density", Electrochemical routes to ethylene oxide (EO) and propylene oxide (PO) were proposed to achieve a cleaner, more efficient, and more selective synthesis process.

In this research work, at industrial current densities, ethylene and propylene can be electrochemically oxidized to ethylene oxide and propylene oxide, respectively, with a Faradaic selection efficiency of about 70%. In response to this study, John L. Barton published an opinion piece "Electrification of the chemical industry" in the same issue, commenting on this work.

Leow et al. combined the flow battery with the ethylene oxide synthesis reaction to realize C2H2+H2O→C2H2O+H2 (see Figure 1). Two electrochemical reactions drive this reaction, the evolution of chlorine occurs at the anode 2Cl-→2e-+Cl2, and the evolution of hydrogen occurs at the cathode 2H2O+2e-→H2+2OH-. These reactions are not particularly novel and interesting, but the novelty lies in coupling these two simple reactions with three subsequent homogeneous chemical reactions.

Dissolved chlorine in the anode solution decomposes into hydrochloric acid and hypochlorous acid (HCl and HOCl, respectively). The latter reacts with ethylene to form 1-chloro-2-hydroxyethane (HOCH2CH2Cl), or ethylene chlorohydrin. The cathodic solution is enriched with hydroxide during the evolution of hydrogen. When the anode aqueous ethylene chloride solution is mixed with the alkaline cathode solution, ethylene oxide and chloride ions are produced. A similar route can also be used to produce propylene oxide from propylene.

Energy intensity can be reduced by cell design (e.g. changing flow rate or electrode thickness), but the pairing of electrochemical reactions (Cl2 and H2 generation) is unlikely to reduce energy intensity below the chlor-alkali process as it is related to cell voltage proportional. In order to significantly improve the energy demand, changes in the electrochemical process are required to reduce the battery voltage. Beyond the analysis in this article, there are more subtle advantages, such as reduced water usage.

While the particular process reported by Leow et al. is unlikely to be the next major production route for ethylene oxide and Renewable energy is necessary to achieve greener production.