Supported Ag/TS-1 catalysts were prepared by the cool plasma sputtering technique and characterized by BET, SEM/EDX, XRD, UV–Vis and TEM techniques. The Ag loading and particle size on TS-1 were tailored by sputtering time. The catalytic performance of the supported catalysts was tested in the gas-phase propene epoxidation reaction using H2 and O2 at a space velocity of 4000 h−1, and atmospheric pressure. Ag/TS-1 with 1.0–19.9 wt% Ag loading and a Ag particle size around 10–40 nm exhibited a selectivity above 90% in the propene epoxidation reaction at a suitable temperature. Catalysts with high Ag loading and large Ag size cause H2 combustion in O2, leading to propene combustion. The heat evolved in the reaction process may lead to over-oxidation of propene to CO2.
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