A series of Zn-Ca-Al oxides with different CaO and ZnO contents have been prepared and evaluated in the synthesis of propylene carbonate (PC) from 1,2-propylene glycol (PG) and urea in a batch reactor. The effect of catalyst composition, basicity and reaction process parameters such as temperature, catalyst dose, molar ratio of PG to urea, purge gas flow and reaction time has been studied to find suitable reaction conditions for the PC synthesis. The PC selectivity and yield under the desired conditions could reach 98.4% and 90.8%, respectively. The best performing catalyst also exhibited a good reusabilitywithout appreciable loss in the PC selectivity and yield after five consecutive reaction runs. In addition, a stepwise reaction pathway involving a 2-hydroxypropyl carbamate intermediate was proposed for the urea alcoholysis to PC in the presence of Zn-Ca-Al catalysts, according to the time dependences of reaction intermediates and products. (C) 2016 The Chemical Industry and Engineering Society of China, and Chemical Industry Press. All rights reserved.