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An overview of ordered mesoporous material SBA-15: synthesis, functionalization and application in oxidation reactions
Article in Journal of Porous Materials · June 2017
DOI: 10.1007/s10934-016-0311-z
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An overview of ordered mesoporous material SBA-15: synthesis, functionalization and application in oxidation reactions
Vasu Chaudhary1• Sweta Sharma1
Published online: 8 November 2016
ÓSpringer Science+Business Media New York 2016
Abstract Ordered mesoporous materials are attracting wide concern because of their applications in the field of catalysis, adsorption, separations, drug delivery systems and gas sensors owing of their extremely high surface area combined with well-defined pore structures with narrow pore size distributions. Various mesoporous materials such as MCM-41, MCM-48, SBA-15 and SBA-16 have been reported in past two decades. Synthesis of mesoporous materials involves the concept of aggregation of surfactants as structure directing agents under acidic or basic condi- tions. The dimensions of these mesopores can be obtained by type of surfactant, auxiliary chemicals and synthesis conditions. At present, SBA-15 has attracted more atten- tion among different mesoporous silica structures due to their desirable properties such as thick pore wall and hexagonal mesopores (4–12 nm), high surface area, ease of synthesis and functionalization and high thermal and mechanical stability. In last few years, great effort has been made on the development of various methods for the synthesis of mesoporous materials as support for oxidation reactions. The aim of this review article is to focus mainly on mesoporous SBA-15 together with its application as support for various oxidation reactions.
Keywords Mesoporous materialsSBA-15Catalytic activityOxidation reactions
1 Introduction
Porous materials are of great interest due to their many advantages such as large surface area combined with large and uniform pore size, well defined pores, enhanced accessibility and their ability to anchor diverse chemical functionalities on their surface. Porous materials are clas- sified into three categories according to IUPAC nomen- clature; microporous (pore size \2 nm), mesoporous (2–50 nm) and macroporous ([50 nm) materials as shown in Fig.1[1–3]. In past two decades, porous materials have undergone remarkable growth and several microporous and mesoporous materials have been introduced successfully.
There are variety of porous materials varying in composi- tion, pore size and degree of crystallinity. These materials have been explored as promising candidates in various fields such as adsorption, catalysis, chromatography and gas storage [4–11].
Zeolites and in general, microporous molecular sieves are the most recognized member from the family of microporous materials which have excellent properties by virtue of their narrow pore size distribution and possess good stability, high selectivity and activity due to their crystallinity [12–14]. Crystalline zeolites have well defined micropores with excellent shape selectivity due to which they have become exceptionally successful as catalysts for oil refining and petrochemistry and organic synthesis in the production of fine and specialty chemicals. In spite of large application of zeolites in the field of catalysis, pore size (0.4–1.2 nm) remains a strong limitation in conversion processes involving bulky molecules. Therefore in order to improve the diffusion of reactants into the catalytic site, zeolite pore size must be increased and crystal size must be decreased [15–18]. Recent research has been focused on the enlargement of the pore sizes into the mesopore range,
& Sweta Sharma
1 Department of Chemical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, India DOI 10.1007/s10934-016-0311-z
allowing larger molecules to enter the pore system. Thus mesoporous materials came into the picture when some restrictions have been found using zeolites as catalysts in industrial applications [19,20].
In recent years, much attention has been paid to explore the potential catalytic applications of mesoporous materi- als. Several reactions such as Knoevenagel condensation, biomass transformations, selective oxidation reactions in the conversion of hydrocarbons and hydrodesulphurization have been performed by using mesoporous materials as support [21–27]. In this review article we focus our attention on the application of SBA-15 mesoporous mate- rial as support for catalytic oxidation of various reactions.
2 Need for new mesoporous materials
In 1992, Mobil Corporation scientists discovered a new family of silicate/aluminosilicate materials known as M41S phase, with ordered mesoporosity, tunable pore diameter (2–30 nm) and high specific surface area ([800 m2/g). The most well-known members of this class include the MCM- 41 (with a hexagonal arrangement of the mesopores), MCM-48 (with a cubic arrangement of the mesopores) and MCM-50 (with a lamellar structure) [1, 4, 12, 28–30].
Since the discovery of M41S series, there has been much interest and research into mesoporous silicate materials in various fields of application such as catalysts, separation, drug delivery and sensors [9–11,31,32].
These mesoporous materials are synthesized by the hydrolysis and condensation of inorganic precursor (sol gel process) by templating (surfactant) mechanism [33]. The type of phase that results from the synthesis is dependent on type of surfactant, pH, temperature and additives.
MCM-41 has one dimensional pore in the range of
2–10 nm depending on templates used and it is the most investigated mesoporous material because other members in this family are either thermally unstable or difficult to synthesize. Tanev and Pinnavaia [34], reported the use of non charged amine as surfactant to produce hexagonal mesoporous silica (HMS) whose framework walls were thicker compared to MCM-41.
In 1998, Stucky and group synthesized another type of hexagonal array of pores; Santa Barbara Amorphous (SBA) which has attracted the interest of many researchers due to their well-defined pore structure, large pore size (4.6–30 nm), inert framework, thick pore wall and high thermal and hydrothermal stability, which makes them suitable candidates for many applications in catalysis, adsorption, immobilization, drug delivery and chromato- graphic techniques [35–38]. A wide variety of SBA materials has been reported in the literature such as SBA-1 (Pm3n, cubic), SBA-15 (P6mm, hexagonal) and SBA-16 (Im3m, cubic) [35,39–42].
The synthesis of all these mesoporous materials is based on the supramolecular self-assembly of the surfactants (template). These are prepared under mild conditions in the presence of anionic or cationic surfactants in either basic or acidic conditions. Under typical reaction conditions, these surfactants exist in solution as micelles and formation of mesoporous silica is initiated by adding a silica precursor in template solution. There are different ways to influence the interactions between mesophase and polycondensation reaction of the silica source. These are alkaline routes (S?I-), acidic routes (S?X-I?), non-ionic (S0I0) and neu- tral routes (N0I0), where S indicates surfactant molecule, I silica source, X halides and N nonionic surfactant [28, 43–46]. Table1 summarized the different type of mesoporous materials with their properties and synthesis conditions.
<2 nm
2-50 nm
> 50nm
Microporous
(Zeolite based materials, pillared clays)
Mesoporous
(Mesoporous materials ,MCM-41, MCM-48, MCM- 50, SBA-15,SBA-16)
Macroporous
(Ceramic based materials,porous gels, porous glasses)
Fig. 1 IUPAC classification of porous materials
742 J Porous Mater (2017) 24:741–749
3 Mesoporous SBA-15
SBA-15 is one of the most intensely studied materials due to its remarkable features such as high surface area, thick framework walls and straight cylindrical pores amongst all mesoporous silica [47,48]. The pore size of SBA-15 varied from 4 to 12 nm and can be increased up to 30 nm with the addition of organic additives such as trimethylbenzene.
SBA-15 is synthesized in a cooperative self-assembly process with the use of a nonionic triblock copolymer consisting of ethylene oxide and propylene oxide units (EO20PO70EO20) as template, also known as Pluronic P123 and tetraethoxysilane (TEOS) or tetramethoxysilane (TMOS) as silica sources which results in a 2-D array with long 1-D channel [49–51]. The propylene oxide unit forms the hydrophobic part while ethylene oxide units form the hydrophilic part [41,52,53].
Synthesis of SBA-15 involves dissolving of template in acidic solution followed by addition of silica source. The mixed solution is heated at 30–40°C for 20–24 h and then aged for 24–48 h at 80–120°C. A white solid is obtained after aging. The obtained solid is filtered, washed thor- oughly with distilled water; air dried first at room tem- perature for overnight and after that, sample is dried in oven at 80°C for 5–6 h. Finally the sample is calcined at 550°C for 4–6 h for removal of template [2,47, 54–57].
The whole synthesis procedure for SBA-15 is shown in Fig.2.
For the triblock copolymer, EO: PO ratio affects the arrangement of SBA-15, with a lower ratio favoring a
p6mmhexagonal morphology and high EO:PO ratio forms the cubic mesoporous silica. No precipitation or formation of silica gel occurs at pH values from 2 to 6, above the isoelectric point of silica (pH 2) while at neutral pH, only disordered (amorphous) silica is obtained. At pH*1, there is an interaction between positively charged proto- nated silicate species with the more hydrophilic PEO units to encourage self-assembly of a silica-block-polymer–rich mesophase. In the presence of the block copolymer, more condensation of the silica species surfactant species out- come in the formation of the mesophase silica compound [41,57,58].
Due to synthesis with Pluronic P123 template, microp- ores are generated, perpendicular to hexagonal channel, which penetrate the silica wall during synthesis. Size of the micropores and mesopores are changeable, depending upon the temperature treatment during synthesis. The micropores in the mesopores wall of SBA-15 create from the more hydrophilic EO chains of the surfactant, which make a way into the silica wall during synthesis and leave microp- orosity after calcination [59–62]. This dual-porosity system makes the SBA materials perfect choice for adsorption and catalysis applications. Also change in microporosity depends upon the ratio of silica source to P 123 in the starting mixture as this ratio affects the network of siloxane in the pore walls and in this way it changes the microp- orosity [63–65].
The morphology and particle size of mesoporous silica can be controlled in different ways, depending on the rel- ative rates of hydrolysis and condensation of the silica Table 1 Overview of properties and synthesis pathways of different mesoporous materials
Mesoporous materials
Structure (mesophase)
Structure directing agent Medium Properties
MCM-41 p6m,
hexagonal
CetylTrimethyl Ammonium Bromide (CTAB) (cationic)
Basic
(pH*11–13)
One-dimensional mesopores (2–10 nm), not hydrothermally stable, less wall thickness (1.10 nm)
MCM-48 Ia3d, cubic CetylTrimethyl Ammonium Bromide (CTAB) (cationic)
Basic
(pH*11–13)
Three-dimensional mesopores, hydrothermally less stable and low wall thickness
MCM-50 p2, lamellar CetylTrimethyl Ammonium Bromide (CTAB) (cationic)
Basic
(pH*11–13)
Long range ordered pores, high surface area ([700 m2/g), hydrothermally not very stable
HMS Worm/
sponge type framework
Amines, e.g.
Dodecylamine (C12H27N) (non-ionic)
Basic (pH*9) Pore size distributions are somewhat broader, higher thermal stability, wall framework thicker compared to MCM-41 and crystallite size smaller than MCM-41
SBA-15 p6m, 2-D hexagonal
Pluronic P123
(EO20PO70EO20) (non- ionic)
Acidic (pH*1)
High definite surface area (400–900 m2/g), thicker pore walls (3.1–6.4 nm), tunable pore size (4–30 nm), high surface to volume ratio, variable framework compositions and high thermal stability
SBA-16 Im3m, 3-D cubic
Pluronic F127 (EO106PO70EO106) (non-ionic)
Acidic (pH*1)
High surface area, three dimensional mesopores, thicker pore walls, large cell parameter (a=176 A˚ ) and high thermal stability
source and the way of interaction between the growing silica polymer and the assembled templates. The different morphologies of SBA-15 materials (rod, sphere, hexagonal prism) can be obtained by varying the synthesis parameters or through the use of co-solvents, co-surfactants or by adding various inorganic salts [58,66]. Figure3shows the SEM and TEM images of SBA-15 synthesized at 30°C.
4 Functionalization of SBA-15
Pure silica based mesoporous materials have a number of limitations. They are rather inactive for transformation of any organic compounds into desired products. The low mechanical and hydrothermal stability of the amorphous silica walls might cause problem in catalytic applications.
Fig. 2 Synthesis route for preparation of SBA-15
Fig. 3 SEM and TEM images of SBA-15 synthesized at 30°C
744 J Porous Mater (2017) 24:741–749
Therefore functionalization is required to form active sites for metal anchoring [67].
In principal, synthetic approaches leading to active mesoporous catalysts can be divided into two methods, (1) co-condensation or one pot synthesis, where active phase is added to the reaction mixture which subsequently co- assemble and condense into the inorganic framework for the formation of the mesoporous material, and (2) post synthesis or grafting technique, where siliceous support is prepared followed by the modification with active moieties or their precursors [68,69]. The advantage of co-conden- sation approach is its simplicity as the incorporation of the functional moieties and the formation of mesoporous material occurs in a single step. However, addition of the active species can slow down the formation of the meso- porous matrix, even to limit its formation or provide a less ordered material [70]. In the post-synthesis approach, one can relatively easily synthesize a high-quality support by imparting desired functionality after the formation of silica.
Incorporation of organic functionality onto silica by co- condensation route leads to more even distribution of sites whereas grafting technique has the disadvantage of poor control over loading [71–73].
SBA-15 is a promising support material for synthesis of catalytic materials due to its uniform hexagonally arrayed channels with a narrow pore size distribution. These fea- tures together with high surface area and hydrothermal stability make it as an ideal support for incorporation of various active molecules on its surface. However, the wide applications of silica materials are limited due to the inherent catalytically inactive nature of unmodified meso- porous material. Therefore modification is required to expand its application for the development of new catalysts.
The functional moieties can be introduced inside the silica framework by introducing different metals e.g. Al, Ti, Ce, Zr and sulfonic and carboxylic groups either directly by co-condensation or by post synthesis. Grafting of the mesoporous surface with various functional groups (i.e. amines, thiol, nitriles, halides etc.) has been studied by various researchers in the past [74–77].
5 Application of SBA-15 in oxidation reactions
Catalytic oxidation reactions play a pivotal role in indus- trial chemistry since it represents the core of a variety of chemical processes for the production of many useful chemicals and intermediates such as diols, epoxides, alcohols and carbonyl. The catalytic oxidation of organic compounds with environment friendly oxidants such as hydrogen peroxide (H2O2), tert-butyl hydrogen peroxide (TBHP), ozone (O3) and molecular oxygen (O2) is the most
economical route for producing bulk and fine chemicals.
Therefore, there is a strong demand to develop new cata- lysts that are highly active and selective in the field of oxidation reactions using efficient oxidants.
Functional mesoporous silica has shown considerable growth in opening up new opportunities in many important catalytic processes. In last one decade SBA-15 mesoporous material has been explored as promising support in the field of catalysis [78,79]. SBA-15 materials are more versatile than any other mesoporous materials due to their intrinsic structural features like highly ordered pore structure, thick framework wall; which provide high hydrothermal stabil- ity, and large pore diameter allowing easy diffusion of substrate molecules. SBA-15 has shown excellent activity and selectivity in the catalytic oxidation of various hydrocarbons and alcohols to aldehydes, ketones, epoxides and acids [80,81].
5.1 Oxidation of hydrocarbons
Oxidation and epoxidation of hydrocarbons are an essential transformation in organic compound synthesis to produce many functional compounds. These reactions are per- formed by using peroxides, molecular oxygen, H2O2, TBHP or atmosphere air as oxidants at mild reaction conditions. Epoxidation of various alkenes such as styrene, cyclohexene, cyclooctene over various supported catalysts using TBHP, H2O2and O2oxidants have been reported by various researchers [82–85].
Many transition metal complexes such as Ni(II), Cu(II), Co(II), Mn(II) have been used as homogeneous catalysts for alkene oxidation [86–88]. However, homogeneous catalysts are difficult to separate from the reaction mixture and their low catalytic activity makes the entire process very slow and inefficient. Further, it is very difficult to regenerate these catalysts hence, huge amount of chemicals are required which makes the overall process uneconomi- cal for industrial application. Consequently, in past few years, great efforts have been made to develop more effi- cient and environment friendly reusable heterogeneous catalysts. In heterogeneous catalysts, supports are used to provide the mechanical strength to the catalysts together with increment in the effective surface area of the catalyst.
A large variety of supports such as silica, alumina, poly- mers, activated carbon and zeolites have been used for styrene, cyclohexene and cyclooctene oxidation [89–91].
The discovery of ordered mesoporous materials in 1992 by Zhao et al. [30] have opened many new opportunities in the field of heterogeneous catalysts because of their well defined porous structure, large pore size and exceptionally good dispersion of metal oxide particles.
In last one decade, ordered mesoporous materials i.e.
MCM-41, MCM-48, MCM-50, SBA-15 and SBA-16 have
Table 2 Applications of SBA-15 support in some catalytic oxidation reactions SBA-15
supported catalyst
Application Oxidant Reaction conditions Remarks References
Ti/SBA- 15
Oxidation of methyl phenyl sulfide (MPS) and 2,3,6 trimethylphenol(TMP)
H2O2 P=atmospheric T=20–80°C
Ti/SBA-15 catalyst showed higher catalytic activity for MPS oxidation (72%)than TMP (57%) at higher Si/Ti ratio
[107]
LaCoO3/ SBA-15
Oxidation of methane O2 P=atmospheric T=300–700°C Flow rate:
10–100 ml/min
Highly crystalline LaCoO3perovskites supported on SBA-15 was prepared by microwave assisted process and showed complete oxidation of methane at 620°C
[108]
Fe/SBA- 15
Oxidation of styrene H2O2 P=atmospheric T=50–70°C
Catalyst was prepared by new and simple method of physical vapour infiltration and benzaldehyde was found as the main reaction product ([90%)
[109]
Co/Ce- SBA-15
Oxidation of benzene O2 P=atmospheric Temp=200–340°C Flow rate: 320 ml/
min
Ce-SBA-15 support was first time reported for deep oxidation of benzene and showed high catalytic activity for oxidation of benzene
[110]
Pt/SBA- 15, Pd/
SBA-15
Oxidation of toluene O2 P=atmospheric T=25–300°C Flow rate: 100 ml/
min
SBA-15 support was prepared by direct and post synthesis technique. 0.5 wt% Pd/SBA-15 and 1.0 wt% Pt/SBA-15 catalysts were found to be most active
[111]
Cu/Ni/Co/
Mn/
SBA-15
Oxidation of styrene H2O2 P=atmospheric T=r.t.–80°C
Effect of various reaction parameters on oxidation of styrene was investigated and highest selectivity of benzaldehyde (95%) was obtained with Co loaded catalyst
[112]
Cu(II)/
VO(IV)/
SBA-15
Oxidation of styrene Air/
H2O2
P=atmospheric T=80°C
VO(IV) complex showed high selectivity to styrene oxide (71.2%) with air as oxidant and high selectivity to benzaldehyde (83.3%) when using H2O2as oxidant
[113]
Au/TiO2- SBA-15
Oxidation of carbon monooxide
Air P=atmospheric Temp=20–200°C
SBA-15 support was modified with variable quantity of TiO2and it was observed that 10 wt% of TiO2 loading increased the performance of Au/SBA-15 catalyst
[114]
Ru, Mo, Pt/SBA- 15
Oxidation of polycyclic aromatic hydrocarbons
O2 P=atmospheric Temp=150–500°C
Pt/SBA-15 catalyst was found to be more active than Ru/SBA-15 and Mo/SBA-15 catalysts
[115]
Pd/TiO2- SBA-15
Oxidation of methane O2 P=atmospheric Temp=200–600°C Flow rate: 50 ml/min
10 wt% of TiO2loading over Pd/SBA-15 increased the catalyst activity and sulphur tolerance in comparison to Pd/SBA-15
[116]
Au/CeO2- SBA-15
Oxidation of carbon mono oxide
O2 P=atmospheric Temp=30–500°C
Au catalyst supported over SBA-15 with different CeO2loadings (5–30 wt%) were prepared and optimum performance was found for 20 wt% ceria loading
[117]
MnOx/
SBA-15
Oxidation of Benzene O3 P=atmospheric Temp=80°C
Catalysts were prepared by two different manganese precursors, manganese acetate (MA) and manganese nitrate (MN). 15% MA/SBA-15 showed high catalytic activity and stability due to highly dispersed manganese oxides and high oxygen mobility
[118]
Cu/SBA- 15
Oxidation of alkylaromatics TBHP P=atmospheric Temp=27–100°C
10 wt% of Cu loading over SBA-15 support was found to be efficient for the benzyl oxidation of alkyl aromatics
[119]
Pd/Al- SBA-15
Oxidation of cinnamyl alcohol
O2 P=atmospheric Temp=90°C
Conversion wasC95% during the first hour and C90% after 24 h
[120]
Re/SBA- 15
Oxidation of n-alkanes O2 Pressure 15 bar Temp=80–200°C
For C5-alkane overall conversion was 19.6 and 22.6% for C6-alkane
[80]
746 J Porous Mater (2017) 24:741–749
shown remarkable growth as catalytic support for various oxidation reactions [92–94]. The mesoporous SBA-15 is one of the most widely studied mesoporous support because of their high specific surface area, large tunable pore size (4–30 nm) and thick framework wall (3.2–6.4 nm). Zhang et al. [95] investigated the perfor- mance of Mo(IV) Schiff base complex supported on SBA- 15 for catalytic epoxidation of cyclohexene using TBHP as oxidant.
Recently, bifunctional supported catalysts have shown excellent catalytic activity for epoxidation of alkenes [96,97]. Tang et al. studied the bimetallic oxide system CuO–NiO supported on SBA-15 for the epoxidation of alkenes (styrene, trans-stilbene, cis-cyclooctene, trans-b- methylstyrene, norbornene). The bi-metallic oxides were well-dispersed in the mesoporous channels of SBA-15 and the presence of Ni enhanced the surface segregation of Cu, improving the dispersion of CuO nanoparticles. Therefore the high dispersion of the active components i.e. CuO–
NiO/SBA-15 also resulted in 100% conversion and 92.3%
selectivity for styrene oxide [98].
5.2 Oxidation of alcohols
The selective oxidation of alcohols to corresponding aldehydes and ketones is of paramount importance in organic synthesis from both academic and industrial point of view. Synthesis of high grade benzaldehyde from selective oxidation of benzyl alcohol is an attractive reac- tion for modern researchers due to its widespread appli- cations in perfumery, pharmaceuticals and food industries [99, 100]. Tradionally, benzaldehyde is mainly produced by the gas/liquid phase oxidation of toluene and hydrolysis of benzal chloride which generates large amount of haz- ardous waste. However, due to incomplete conversion and low selectivity of these reactions separation processes are essential, which increases the cost. Therefore, liquid phase
direct oxidation of benzyl alcohol is a promising route for the synthesis of benzaldehyde in terms of easy recovery, high selectivity and catalytic activity [101].
Various transition metals such as Ru, Pt, Pd, Au and Ag have been developed for liquid phase oxidation of alcohols [102–104]. Among these transition metals, Au and Pd metals have attracted considerable attention due to their higher catalytic performance. However, for better catalytic activity they require higher surface area and good metal dispersion. In recent years, mesoporous materials (MCM- 41, MCM-48, SBA-15) have been considered as ideal catalytic support due to their high surface area and thermal stability and uniform interconnected pores which offer an interactive interaction between catalysts and reactants.
Among various mesoporous materials, SBA-15 has shown high catalytic performance for benzyl alcohol oxidation [105].
Ma et al. reported the synthesis of Au/SBA-15 and Au–
Pd/SBA-15 catalysts for selective oxidation of benzyl alcohol to benzaldehyde at mild reaction conditions (80°C temperature and 1 bar pressure) by using air as an oxidant.
The addition of Pd to Au/SBA-15 catalyst decreased the size of gold particles which lead to higher catalytic activity with 97% selectivity to benzaldehyde. It was also observed that metal nanoparticles can easily enter into pore channels of SBA-15 and hence prevent agglomeration and leaching [106].
Table2 summarized the study of different catalytic oxidations reactions supported on SBA-15.
6 Conclusion
Mesoporous materials in recent years have received great attention in many applications such as catalysis, separation and adsorption due to their numerous features such as large pore diameter and high thermal and hydrothermal stability.
Table 2continued SBA-15
supported catalyst
Application Oxidant Reaction conditions Remarks References
Ag/Al- SBA-15
Oxidation of carbon monoxide
O2 P=atmospheric Temp=20–140°C Flow rate: 30 ml/min
Catalysts were prepared by in situ ‘pH adjusting’
method and the effect of Si/Al ratio on the structure of Ag catalyst and catalytic activity was investigated
[121]
Cu/CuO/
SBA-15
Oxidation of benzyl alcohol H2O2 P=atmospheric Temp=80°C
73% conversion of benzyl alcohol and 54%
selectivity of benzaldehyde was achieved by chemical reduction synthesis method
[81]
Mesoporous SBA-15 has shown great advantages as cata- lyst support for large molecules because of their large surface area, tunable pore diameter (4–30 nm) and thick pore walls. SBA-15 materials are prepared by using non ionic triblock copolymer P123 (EO20PO70EO20) as surface directing agent in acidic media. The textural and morpho- logical properties of silica materials are extremely impor- tant for industrial applications. In last few years, SBA-15 has shown remarkable growth as catalyst support for var- ious reactions. In this review, different catalysts supported on SBA-15 have been discussed for different oxidation reactions in presence of various oxidants and all the cata- lysts have shown high activity and selectivity for the desired product.
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