CATALYSTS, THEIR PREPARATION AND USE IN VAPOUR PHASE OXIDATION OF UNSATURATED ALDEHYDES

Abstract: Catalyst compositions for use in vapour phase oxidation of unsaturated aldehydes to unsaturated carboxylic acids, are represented by the formula: Mo₁₂P a X¹ b V c As d Cu e Sb f X² g O x wherein a to g and x define the number of atoms of the specified elements, X¹ is one or more of caesium, thallium and rubidium; X² is one or more of tungsten, niobium, tantalum, zirconium, tin, iron, zinc, cobalt, bismuth, boron, rhenium, tellurium and potassium. In a process for making the compositions, specific reactants and conditions are employed before isolating and calcining the catalyst precur­ sor to form active catalyst. The catalyst may provide improved conversion and yield in the catalytic oxidation of unsaturated aldehydes, particularly oxidation of methacro­ lein to methacrylic acid.

Description: CATALYSTS,THEIR PREPARATION AND USE IN VAPOUR PHASE OXIDATION OF UNSATURATED ALDEHYDES. This invention concerns catalysts, their preparation and use in vapour phase oxidation of unsaturated aldehydes. By the oxidation process of the invention unsaturated carboxylic acids especially acrylic acid and methacrylic acid can be made from unsaturated aldehydes especially acrolein and methacrolein. Catalysts and/or procedures known for the preparation of acrylic acid and methacrylic acid and other unsaturated acids are disclosed in the following U.S.Patents: 3,761,516; 3,795,703; 3,773,692; 3,875,220; 3,998,876; 4,000,088; 4,051,179; 4,070,397 and 4,075,244. According to this invention there is provided catalyst represented by the formula Mo12P a X1bAs Cu SbfX2g0 wherein X1 is one or more of the following elements: caesium, thallium and rubidium; X2 is one or more elements from the following: tungsten,niobium, tantalum,zirconium, tin,iron,zinc cobalt, bismuth,boron,rhenium,tellurium and potassium; a is 0.85 to 1.2, b is 0.75 to 1.25, c is 0.05 to 0.7, d is 0.5 to 2.0, e is G to 0.4, f is 0 to 0.3, g is 0 to 2.0, and x is the number of oxygen atoms required to satisfy the valence requirements of the other elements present. In embodiment of the invention wherein X1 (and/or X2) represents more than one element, then b (and/or g) represents(s) the individual number of atoms of each element represented. Preferred catalysts of this invention are those of the formula: wherein a is 1 to 1.2, b is 1 to 1.25, c is 0.2 to 0.7, d is 0.5 to 1.0, e is 0 to 0.25, f is 0 to 0.2, g is 0 to 1.0; and X is one or more of the following elements: bismuth, tungsten, cobalt, zinc or tin. The most preferred catalysts are those represented by the formula: Mo12PaCsbVcAsdCueSbfOx wherein a is 1 to 1.2, b is 1 to 1.25, c is 0.2 to 0.6, d is 0.5 to 1, e is 0.2 to 0.25, f is 0.1 to 0.2 x is as defined above. Catalysts having this formula may afford the highest yield of desired product. Of course in the case of individual catalysts a to g will be individual members wherein, as is often or usually the case, in a mixed catalyst one or more of said a to g will represent an average number in the stated range. The catalyst of this invention may be employed in the supported or unsupported form. If a support is employed, any known support, such as alumina, pumice, silicon carbide, zirconia, silica, alumina-silica and perlite that are stable under the reaction conditions, may be employed. Alumina-silica is the preferred carrier. The invention also provides a process for preparing a catalyst as defined above which comprises (a) forming a suspension of molybdenum trioxide in water, adding phosphoric acid to said suspension, heating the resulting suspension to 600 to 950C for at least sufficient time to form phosphomolybdic acid and then adding ammonium hydroxide thereto, the remaining required or allowable elements being added to the suspension in the form of oxides or salts or compounds convertible on heating into the corresponding oxides either before or after the addition of the phosphoric acid to form catalyst precursor (b) isolating the catalyst precursor, and (c) calcining the isolated precursor at a temperature of 3500 to 4500C. We have found that by employing particular chemicals and particular calcining techniques we may obtain catalysts which surprisingly yield conversion rates consistently in excess of 90% and selectivities consistently above 75%. In general, a suitable process for preparing catalyst according to the invention may be as follows: adding molybdenum trioxide to water followed by the addition of phosphoric acid. This reaction mixture is heated to a temperature of 600 to 950C for a period of time sufficient to form phosphomolybdic acid, usually at least one hour, and, preferably, three hours. The remaining desired catalyst elements are then added as their oxides or salts or compounds convertible on heating into oxides. Finally, ammonium hydroxide is added. The reaction to form the catalyst precursor, i.e. the uncalcined catalyst, may be regarded as substantially complete at this time. The water is removed conveniently by heating at a temperature of 500 to 700C, which usually takes from 10 to 20 hours. Other methods of removing water may be employed, such as spray drying. Any remaining water is removed by well known methods such as by heating at a temperature in excess of 100"C in a vacuum oven. We have found it convenient to remove the water at a temperature of from 160C to 1700C in a vacuum oven for at least 4 hours. Though not essential to the performance of the catalyst, for convenience in calcining and in loading the tubes of a tubular oxidation reactor, the dried, uncalcined catalyst is crushed to a convenient particle size, for example 8 to 18 mesh (ASTM Standard). The dried catalyst is then heated to a temperature of 350 te 4500C,and preferably at a temperature of 385C to 4150C, most preferably about 4000C, wherein the calcining temperature is achieved as rapidly as possible and, preferably, in no longer than about 1 hour and more preferably in no longer than about 20 minutes. Calcining is a thermal treatment of a catalyst precursor which causes a chemical or structural transformation of the precursor into a catalytically active form. The most preferred catalysts are those prepared employing molybdenum trioxide. Other sources of molybdenum such as ammonium heptamolybdate may afford poor catalysts. In addition, we have found that vanadium is essential for activation and that arsenic and vanadium are necessary if the catalyst is to have a reasonable life. We have found that potassium without cesium in the catalyst can cause a decrease in activity compared to the employment of caesium alone or caesium and potassium. Catalysts according to the invention may be used in the preparation of unsaturated carboxylic acid, such as methacrylic (or acrylic acid), by vapour phase oxidation of unsaturated aldehyde such as methacrolein (or acrolein). Conveniently the appropriate aldehyde or aldehydes are comprised in an organic feed. Another aspect of this invention is the use of the catalyst in the vapour phase oxidation of unsaturated aldehyde to unsaturated acid. Accordingly in a further process aspect of the invention a mixture of organic feed containing said aldehyde, in vapour form, and molecular oxygen, optionally, in the presence of steam or other diluents, is contacted with a catalyst of the above composition preferably at a temperature of 290 to 3200C for a contact time sufficient to convert the feed to the corresponding acid. The most interesting conversions are those of acrolein to acrylic acid and methacrolein to methacrylic acid, the latter being the more interesting of these two. The contact time may vary from about 2 to about 6 seconds or more. The reaction can be conducted under atmospheric, superatmospheric or subatmospheric pressures. However, in general, pressures slightly above atmospheric are preferred, such as 10 psig. Any source of oxygen may be employed in the process, but for economic reasons it is preferred that air be employed as the source of oxygen. Diluents such as water, nitrogen, carbon dioxide and the like may be present in the reaction mixture. In general, apparatus cf the type suitable for carrying out oxidation reactions in the vapour phase may be employed in this process. The process may be conducted either continuously or intermittently. The catalyst bed may be a fixed-bed employing a large particulate or pelletized catalyst, in the alternative, a so-called "fluidized" bed of catalyst may be employed. The products of the catalyst oxidation reaction may be recovered by any convenient method such as those known in the art. One such method involves scrubbing the effluent gases from the reactor with cold water or another appropriate solvent to remove the products of the reaction. The ultimate recovery of the product may be accompanied by conventional means, such as distillation or solvent extraction. In order that the invention may be further illustrated, the following embodiments of the invention are presented purely by way of example. General Reaction Equipment and Procedure A one litre glass resin kettle is equipped with high torque air stirrer, glass shaft and bearing with paddle 1/4 inch cut to fit. Other equipment includes a heating mantle, variable voltage heat control, 21 in. immersion thermometer, stainless steel seives (8 and 18 mesh) and catch pans. The molybdenum trioxide/phosphoric acid slurry is prepared as follows: charge kettle with 800 ml deionized water, set air stirrer to create vortex, and set temperature to 40"C. Add weighed molybdenum when 400C is reached and then add phosphoric acid. Raise the temperature to 80"C and stir 3 hours. Turn off the heat and add 300 ml water to the kettle, add the chemicals sequentially to the kettle, making sure previous chemical is dissolved. Add antimony pentachloride next to last (if used). Ammonium hydroxide is always added last. (All standard molybdenumtrioxide/phosphoric acid preparations contain ammonium hydroxide). When all chemicals have been added begin heating again to 550C to remove the water (overnight). Next day, if the catalyst precursor is not almost completely dry, increase the temperature two'65" - 750C. When dry, place in a vacuum oven for 4 hours at 1600C. Remove the dry material to a desiscator to cool. Grind the precursor with pestle and screen, 8-18 mesh material. Finally, calcine the 8-18 mesh catalyst precursor for 6 hours at about 400"C with 1 1/mien air flow through catalyst bed to afford active catalyst. Catalyst Examples Example 1 - Mo12P1Cs1 VOI2Asl 0.1 To 800 ml of deionized water is added molybdenum trioxide (120.9 grams). This reaction mixture is heated to 400C at which time is added phosphoric acid (8.07 grams). This mixture is stirred for three hours at 800C at which time there is added water (300 ml), caesium nitrate (13.64 grams), ammonium metavandate (1.64 grams), arsenic pentoxide (8.28 grams), antimony pentachloride (2.09 grams) and 29.2% ammonium hydroxide (12.25 grams). The reaction mixture is stirred for 16 hours at 570C and for 2.87 hours at 800C. The catalyst precursor is collected and dried in the vacuum oven four hours at reduced pressure (15 mmH g at 1650C to afford 150.2 grams of catalyst precursor. The material is ground with a pestle directly on to sieves to yield 106.9 grams of 8-18 mesh material and 43 grams of fines. The catalyst precursor is calcined for 6 hours at 4000C with an air flow of 1 litre/minute to afford active catalyst. Example 2 - Mo12P1Cs1V0.2As1Cu0.2 sh To 800 ml of water is added molybdenum trioxide (120.9 grams). The reaction mixture is warmed to 400C and phosphoric acid (8.07 grams) is added. The reaction mixture is stirred for three hours at 800C and then water (300 ml), caesium nitrate (13.64 grams), ammonium metavanadate (1.64), arsenic pentoxide (8.28 grams); cuprous nitrate (3.26 grams), antimony pentachloride (2.09 grams) and 29.2% ammonium hydroxide (12.25 grams) are added. The reaction mixture is stirred at 550C for 16.75 hours and at 800C for 4.25 hours. The catalyst precursor is collected and dried in a vacuum oven for 4 hours at 1650C at reduced pressure (IOmmHg) to yield 148 grams. The catalyst precursor is ground with a pestle to afford 93.0 grams of 8-18 mesh material and 54.9 grams of fines. Calcining of the 93 grams for 6 hours at 4000C with an air flow of 1 litre per minute yields 86.9 grams of active catalyst. Example 3 - Mo12P1.2Cs1.25V0.4As0.7Cu0.25Sb0.2 To 800 ml of water is added molybdenum trioxide (120.9 grams), arsenic pentoxide (5.8 grams) and cupric nitrate (4.07 grams). The reaction mixture is heated to 40"C. There is then added phosphoric acid (9.69 grams) and the reaction mixture heated for 3 hours at 800C at which time additional water (350 ml) and ammonium metavanadate (3.28 grams), antimony pentachloride (4.19 grams), caesium nitrate (17.05 grams) and ammonium hydroxide (12.25 grams) are added. The reaction mixture is stirred for 17 hours at 80 C. The catalyst precursor is collected and dried in a vacuum oven for 4.5 hours at 1650C at reduced pressure (30mmHg) to yield 153.9 grams. The catalyst precursor is ground with a pestle to afford 102.5 grams of 8-18 mesh material and 50.7 grams of fines. The 102.5 grams is calcined for 6 hours at 4000C with an airflow of 1 litre per minute to afford 87.8 grams of 8-18 mesh material and 9.6 grams of fines. Example 4 MO12P1CslV, As 1CU0.2SbO. I To 800 ml of water is added molybdenum trioxide (120.9 grams). The mixture is heated to 400C and phosphoric acid (8.07 grams) is added. This mixture is then heated for 3 hours at 800C. Additional water (300 ml) and caesium nitrate (13.64 grams), ammoniummetavanadate (1.64 grams); arsenic pentoxide (8.28 grams), cupric nitrate (3.26 grams) ,antimony pentachloride (2.09 grams) and ammonium hydroxide (12.5 grams) are added. The reaction mixture is stirred for 17.3 hours at 550C and 2.75 hours and 800C. The catalyst precursor is collected and dried for 4.5 hours at 165"C at reduced pressure (5 mmHg) to yield 149.1 grams of catalyst precursor. The precursor is ground to 4 mesh and calcined for 6 hours at 4000C with an airflow of 1 litre per minute to afford 140.8 grams of active catalyst. Example 5 Mo12P1.2Cs1.25V0.2As1Cu=.2Sb0.2 By following the general procedure and employing 120.9 grams of molybdenum trioxide, 9.69 grams phosphoric acid, 17.05 grams of caesium nitrate, 1.64 grams of ammonium metavanadate, 8.28 grams of arsenic pentoxide, 3.26 grams of copper nitrate, 4.19 grams of antomony pentachloride and 12.5 grams of ammonium hydroxide, there is obtained, after drying at 4.5¯hours at 1000C at reduced pressure (5mmHg) and for 5 hours at 1650C at reduced pressure, 135.0 grams of dried material which after grinding affords 79.2 grams of 8-18 mesh material and 55.4 grams of fines. The 8-18 mesh material is calcined for 6 hours at 4000C with an airflow of 1 litre per minute to afford 75.1 grams of active catalyst. By employing substantially the procedures described above and by employing the following amounts of ingredients, (numbers refer to grams of material) there are obtained additional active catalysts as shown in Examples 6-9. Ex.No. 6 7 8 9 MoO3 120.9 120.9 120.9 120.9 H3PO4 9.7 9.7 12.1 9.7 CsNO3 17.05 17.05 20.46 17.05 NH4V03 1.64 4.92 1.64 4.92 As2O5 8.28 4.14 8.28 5.8 SbCl5 4.19- 4.18 - 4.18 NH40E 12.5 12.5 12.5 12.5 (28.5%) Other Cu(NO3)2 - Cu (NO3)2 Cu (NO3)2 3.26 3.26 3.26 Zn (NO3) 2 7.26 WO3 8.1 Co(NO3)2 10.2 Example 6: - Mo12P1.2Cs1.25V0.2As1Cu0.2Sb0.2 Example 7: - Mo12P1.2Cs1.25V0.6As0.5Sb0.2 Example 8: Mo12P1.5V0.2As1Cu0.2W0,5Co0.5Zn0.5 Example 9: Mo12P1.2Cs1.25V0.6As0.7Cu0.2Sb0.2 STANDARD SCREENING PROCEDURE Pack 20.0 to 25 grams of the catalyst in a 3/8" stainless steel U-tube. Reactor catalyst volume is approximately 20.Occ. Immerse the tube in a salt bath for temperature control. Feed a mixture of air, nitrogen, water, and methacrolein over the catalyst. The water is vaporized in the air stream and the methacrolein is vaporized in the nitrogen -stream. Desired conditions are as follows: Salt bath temperature - 3000C Total flow rate - 1004 mmol/hr (corresponds to 3.2 sec. space time) Reactor pressure - 10.0 psig Air flow - 479.2 mmol/hr Nitrogen flow - 183.4 mmol/hr Methacrolein flow - 40.0 mmol/hr H20 flow - 301.4 mmol/hr Reactor effluent analyzed for acetaldehyde, acetone, acrolein, methacrolein, acetic acid, acrylic acid, and methacrylic acid by on line gas chromatography. Non-condensable gases analyzed by gas partitioning for CO2, 02, N2, and CO. Condensed effluent is titrated for total acidity. It can also be analyzed by GLC if necessary; particularly, for calibration purposes. A gaseous sample of effluent is automatically injected in to the online analytical system every 35 minutes, intergration performed, and results calculated by computer from analytical data, flow rates, temperatures, and pressures. Averages and standard deviations for conversions, selectivities and accountabilities are computed for each run using valid samples with accountabilities of approximately 90% to 105%. The first samples of each evaluation run are omitted from this calculation. The following tables illustrates the composition and catalytic activity of some of the catalysts of this invention. However, all catalysts embraced by the generic formula prepared by the method described in this application are expected to behave in a similar manner. TABLE 1 Catalyst Compositions Ex. No. Mo Po Cs V As Cu Sb X 1 12 1.0 1.0 0.2 1.0 - 0.l 2 12 1.0 1.0 0.2 1.0 0.2 0.1 3 12 1.2 1.25 0.4 0.7 0.25 0.2 4 12 1.0 1.0 0.2 1.0 0.2 0.1 5 12 1.2 1.25 C.2 1.0 0.2 0.2 6 12 1.2 1.25 0.2 1.0 0.2 0.2 7 12 1.2 1.25 0.6 0.5 - 0.2 8 12 1.5 1.25 0.2 1.0 0.2 - W0 5 CoO.5 Zn0.5 9 12 1.2 1.25 0.6 0.7 0.2 0.2 10 12 1.2 1.25 0.4 0.25 0.2 - 11 12 1.15 0.75 -0.05 1.7 0.3 - 12 12 1.0 1.0 0.2 1.0 0.2 - 13 12 1.15 1.25 0.05 1.3 0.3 - 14 12 1.0 1.0 0.2 1.6 0.2 - 15 12 1.0 1.0 0.2 1.5 0.2 - 16 12 1.1 1.12 0.3 0.85 0.2 0.15 17 12 1.0 1.0 0.2 1.4 0.2 - 18 12 1.0 1.0 0.2 1.0 0.2 - Bi0.2 19 12 1.0 1.0 0.2 1.4 0.2 0.1 20 12 1.1 1.12 0.3 0.85 0.1 0.15 21 12 1.0 1.2 0.45 0.6 0.15 - 22 12 1.05 1.0 0.2 1.5 0.2 - 23 12 1.0 1.0 0.2 1.6 0.2 - 24 12 1.0 1.0 0.2 1.0 0.2 0.1 W1 0 25 12 1.0 1.0 0.2 1.0 0.2 0.1 Te0.1Sn0.1 26 12 1.1 1.0 0.2 1.5 0.2 - 27 12 1.1 1.12 0.3 0.85 0.1 0.2 28 12 1.0 1.0 0.2 1.0 0.2 - Bi 29 12 1.0 1.0 0.2 1.0 0.2 0.1 Nb0.2 30 12 1.1 1.12 0.3 0.85 0.1 0.1 31 12 1.0 1.25 0.2 1.0 0.2 0.2 32 12 1.0 1.0 0.2 1.0 0.2 0.1 Te 0.1 33 12 1.1 1.12 0.2 0.85 0.1 0.15 34 12 1.1 1.25 0.3 0.55 0.25 0.15 35 12 1.15 0.75 0.35 1.3 0.3 - 36 12 1.2 1.0 0.2 1.0 0.2 0.2 37 12 1.0 1.0 0.2 1.0 0.3 0.1 38 12 1.0 1.0 0.2 1.0 0.4 0.1 39 12 1.1 1.4 0.6 0.8 0.3 - 40 12 1.0 1.0 0.2 1.0 0.2 0.1 W0.5 41 12 1.1 1.35 0.3 0.55 - 0.15 42 12 1.0 1.0 0.2 1.0 0.2 0.05 43 12 0.85 1.25 0.05 1.3 0.3 - 44 12 1.2 1.25 0.6 0.7 0.2 0.2 45 12 1.0 1.0 0.2 1.0 0.2 0.2 46 12 1.0 1.12 0.3 0.85 0.1 0.15 47 12 1.2 1.25 0.2 1.0 0.2 0.1 48 12 1.0 1.0 0.2 1.0 0.2 0.1 Ta 49 12 1.0 1.0 0.2 1.8 0.2 - 50 12 1.2 1.12 0.3 O.85 0.1 0.15 51 12 1.0 0.5 0.2 1.0 0.2 0.1 K0.5 52 12 1.0 1.25 0.4 0.7 0.2 0.2 53 12 1.1 1.12 0.4 0.4 0.85 0.1 0.15 54 12 1.0 0.75 0.2 1.4 0.2 - 55 12 1.0 1.2 1.0 0.2 0.1 - 56 12 1.15 0.75 0.05 1.3 0.1 - 57 12 1.2 1.25 0.4 0.7 0.25 0.05 58 12 1.0 0.5 0.2 1.4 0.2 - 59 12 1.05 1.25 0.3 0.55 - 0.15 60 12 0.85 0.75 0.35 1.3 0.1 - 61 12 0.9 1.0 0.2 1.5 0.2 - 62 12 1.0 1.0 0.2 1.0 0.2 0.1 63 12 1.0 1.25 0.2 1.4 0.2 - 64 12 1.2 - 0.2 1.0 0.2 0.2 T1 65 12 1.2 1.0 0.2 1.5 0.2 - 66 12 1.1 1.0 0.3 0.85 0.1 0.15 67 12 1.2 1.0 0.4 0.7 0.2 0.1 68 12 1.2 1.25 0.4 0.7 - 0.2 69 12 1.1 1.12 0.3 1.0 0.1 0.15 70 12 1.1 1.25 0.3 0.85 0.1 0.15 71 12 1.2 1.25 0.4 0.7 0.25 - 72 12 1.0 1.0 0.2 1.0 0-.2 0.1 B0.3 73 12 1.0 1.0 0.2 1.0 0.1 0.1 74 12 1.0 1.0 0.2 1.0 0.2 0.1 Wz 75 12 1.2 -1.25 0.18 0.7 - 0.2 76 12 1.2 1.25 0.8 0.4 0.2 0.2 77 12 1.0 1.0 0.2 0.2 0.2 - 78 12 1.1 1.12 0.3 0.7 0.1 0.15 79 12 1.0 1.0 0.6 0.85 0.2 0.1 80 12 1.15 0.75 0.35 1.7 0.1 - 81 12 1.0 - 0.2 1.0 0.2 0.1 Tl1.0 82 12 1.0 1.0 0.2 1.0 - - 83 12 1.0 1.0 0.2 1.2 0.2 - 84 12 1.2 1.25 0.4 0.7 0.25 0.1 85 12 1.0 1.0 0.2 1.0 0.5 0.1 86 12 1.0 1.0 0.2 1.1 0.2 - 87 12 1.0 1.25 0.2 0.7 0.2 0.1 88 12 1.15 1.25 0.35 1.3 0.1 - 89 12 1.0 1.25 0.4 1.0 - 0.1 90 12 1.0 - 0.2 1.0 0.2 0.1 Rb 91 12 1.2 1.25 0.4 0.7 0.05 0.2 92 12 1.0 0.2 1.0 0.2 0.1 - S3 12 1.2 1.25 0.5 0.5 - 0.2 94 12 1.0 1.0 0.2 1.0 0.2 0.1 Re 95 12 1.15 1.25 0.05 1.7 0.1 - 96 12 1.2 1.25 0.5 0.6 - 0.2 97 12 1.0 1.0 0.2 1.0 0.2 0.1 W0.3Nb0.3 98 12 1.1 1.25 0.3 0.55 - 0.1 99 12 1.1 1.45 0.3 0.55 - 0.15 100 12 1.0 1.0 0.2 1.0 0.2 0.1 Zr0.2 101 12 1.2 1.25 0.4 1.0 0.2 0.1 102 12 1.2 1.0 0.2 0.7 0.2 0.2 103 12 1.0 1.0 0.2 0.7 - 0.2 TABLE 11 CATALYTIC ACTIVITY Yield of Conversion Selectivity Methacrylic Acid Ex.No. (%) (%) (8) 2 99.2 82.8 82.1 3 92.1 87.1 80.2 5 99.5 80.9 80.5 6 99.0 79.5 78.7 7 88.9 83.2 73.9 9 90.3 87.2 78.7 10 93.4 86.8 81.1 11 96.4 86.3 83.2 12 96.4 86.1 83.0 13 97.8 84.8 82.9 14 98.0 83.7 82.0 15 98.6 85.2 84.0 16 94.9 84.7 80.4 17 95.5 86-.6 82.7 18 98.4 82.8 81.5 19 96.7 86.4 83.5 20 97.1 82.1 79.7 21 99.3 77.9 77.4 22 96.5 85.7 82.7 23 93.5 88.5 82.7 24 98.1 83.7 82.1 25 98.1 81.4 79.9 26 99.0 81.7 80.9 27 91.8 87.1 80.0 28 94.1 83.9 78.9 29 98.5 82.3 81.1 30 96.6 83.4 80.6 31 91.8 87.0 79.9 32 96.8 83.5 80.8 33 99.0 78.2 77.4 34 99.3 77.1 76.6 35 87.5 88.7 77.6 36 97.7 81.7 79.8 37 97.4 82.2 80.1 38 94.5 83.1 78.5 39 96.8 83.3 80.6 40 99.4 78.4 77.9 41 96.8 80.1 77.5 42 99.1 77.5 -76.8 43 97.3 83.3 81.1 44 90.3 87.2 78.1 45 99.8 72.2 72.1 46 92.0 86.7 79.8 47 98.7 79.4 78.4 48 98.4 81.5 80.2 49 84.8 89.8 76.2 50 88.6 87.0 77.1 51 90.3 86.4 78.0 52 88.7 88.1 78.1 53 93.4 86.3 80.6 54 99.3 79.3 78.6 55 98.7 79.4 78.4 56 98.1 80.2 78.7 57 98.0 81.0 79.4 58 97.7 82.0 80.1 59 88.6 82.6 73.2 60 95.0 81.0 77.0 61 90.7 87.1' 79.0 62 99.8 77.0 76.8 63 99.6 77.9 77.6 64 98.9 76.9 76.1 65 90.8 87.7 79.6 66 98.7 79.5 78.5 67 97.4 79.9 77.8 68 89.9 89.3 80.3 69 91.8 86.1 79.0 70 94.6 84.4 79.8 71 99.6 75.8 75.5 72 92.3 86.1 79.5 73 98.9 76.0 75.2 74 92.5 83.9 77.6 75 87.1 82.0 71.4 76 84.0 88.4 74.3 77 99.5 76.4 76.0 78 98.6 78.8 77.7 79 82.6 89.9 74.3 80 82.4 89.6 73.8 81 97.9 80.0 78.3 82 98.3 79.7 78.3 83 92.3 81.4 75.1 84 96.4 79.9 77.0 85 95.9 80.3 77.0 86 99.4 75.9 75.4 87 99.9 74.1 74.0 88 82.8 89.5 74.1 89 84.6 84.3 71.3 90 95.5 78.0 74.5 91 90.1 86.1 77.6 92 99.7 72.6 72.4 93 -84.4 84.6 71.4 94 97.8 78.5 76.8 95 78.1 91.1 71.1 96 85.2 84.3 71.8 97 99.7 74.6 74.4 98 97.0 73.6 71.4 99 91.7 80.4 73.7 100 89.3 82.3 73.5 101 87.5 86.4 76.6 102 99.7 69.8 69.6 103 97.6 74.7 72.9 Comparison of Catalysts of This Invention with Xnown Catalysts PREPARATION OF CATALYSTS OF THIS INVENTION: Five batches of catalyst were prepared by the following procedure. In a 1 lb. resin kettle equipped with overhead air-driven stirrer, thermometer, temperature controller and heating mantle and 120.9g of MoO3 (0.840 mole) to 800 ml of deionized water. Heat to 400C and add 8.07g of 85% H3PO4 (0.070 mole). Heat to 800C and hold at this temperature for 3 hours. Stop heating and replace evaporated water, then add sequentially 13.64g of CsNO3(0.070 mole), 1.64g of NH4VO3 (0.014 mole), 8.28g of As205(0.035 mole), 3.2 g of Cu(NO3)2 2.5 H20 (0.014 mole), 2.09g of SbCl5 (0.007 mole), and 3 moles of concentrated NH4OH for every 12 moles of Mo03 (0.021 mole). Heat at 550C for 17 hours then increase temperature to 800C to evaporate remaining water. Dry at 165 C for 4 hours at a pressure of 50 torr to give 148.2g. Calcine at 4000C for 6 hours. Grind to powder - yield 139.3g.- Add 1% graphite by weight and pelletize to 1/8 x 1/8t' pellets. Catalyst of Example numbers 104, 105, 106, 107 and 108 were prepared in this manner. The composition of these catalysts is Mo12P1CsV.2As1Cu.2Sb.1Ox (or in the terms of U.S. 4,051,179; Mo1P0.083Cs0.083V0.017As0.083Cu0.017 Sb0.083Ox) PREPARATION OF KNOWN CATALYST: Example 1 from U.S. 4,051,179. In the apparatus used in Examples 104 to 108 place 250 ml of deionized water and 88.5g of ammonium heptamolybdate (0.0716 mole). Heat to 600C and add 4.8g of 85% H3PO4(0.0416 mole) and 7.lg of 50% aqueous H As04(0.025 mole), then add 2.02g of Cu(NO3)2.3 H20 (0.00836 mole) in 50 ml of deionized water, 2.44g of WH4VO3(0.0209 mole) in 75 ml of deionized water, add 4.22g of KNO3 (0.0417 mole) and 5.37 g of Mg(NO3)2.6 H20 (0.0209 mole) in 50 ml of deionized water. Stir at 600C for 20 hours. Dry at 1300C (1 atm) for 16 hours to yield 99.5g of dry material. Grind to powder and add 2e stearic acid and 1% graphite by weight. Pelletize to 1/8 x 1/8" and calcine in a programmed furnace increasing the temperature by 20 C per hour from 1000 to 4000C and holding at 4000C for 5 hours. Five catalysts were made by this procedure and designated K-1, K-2, X-3, K-4 and K-5. The composition of these catalysts is Mo1P0.083As0.05V0.042K0.083Mg0.042Ox. EVALUATION: Catalysts were evaluated by placing about 22.5g of catalyst in a 3/8" stainless steel tube and passing a feed with a 02:N2:H20: Methacrolein ratio of 10:65:20:5 over the catalyst with a space time of about 3.6 sec. The feed was at a pressure of 8 psig. The reactor was held at 2900C with a molten salt bath. Samples of effluent were periodically evaluated by an on-line gas chromatograph and an on-line gas partitioner. One obvious physical difference between catalysts of this invention and those made according to the patent procedure is that the catalysts of this invention are about 30% denser than the other catalysts. RESULTS: The average conversion, selectivity, and yield of each catalyst is given in Table III. The mean results and their standard deviations were also calculated for each of the preparations and are presented in Table IV. A test of statistical significance at the 95% confidence level indicates that the catalysts of this invention have a significantly higher conversion and yield than the patent example catalysts. CONCLUSION: The data show that the catalysts of this invention are superior to the known catalysts of example 1 of U.S. 4,051,179. TABLE III EXAMPLE CONV SEL YIELD 104 99.1 75.2 74.5 105 99.4 69.6 69.2 106 99.3 72.6 72.1 107 99.2 68.4 67.9 108 99.3 74.7 74.2 K-l 63.2 81.8 51.7 K-2 60.6 80.6 48.8 K-3 51.5 83.1 42.8 K-4 22.7 84.1 19.1 K-5 64.4 82.1 52.9 TABLE IV STANDARD VARIABLE N MEAN DEVIATION CATALYSTS OF EXS. 104-108 CONV 5 99.26 0.11401754 SEL 5 72.10 3.02324329 YIELD 5 71.58 2.95245660 KOWN CATALYSTS CONV 5 52.48 17.39790217 SEL 5 82.34 1.32778010 YIELD 5 43.06 13.95145154

Claims: CLAIMS: 1. Catalyst represented by the formula Mo12PaXÚbVcAsdCueSbfXêgOx wherein X1 is one or more of the following elements: caesium, thallium and rubidium; X2is one or more elements from the following: tungsten,niobium, tantalum, zirconium, tin, iron, zinc, cobalt, bismuth-, boron, rhenium, tellurium, and potassium; a is 0.85 to 1.2, b is 0.75 to 1.25, c is 0.05 to 0.7, d is 0.5 to 2.0, e is 0 to 0.4, f is 0 to 0.3, g is 0 to 2.0, and x is the number of oxygen atoms required to satisfy the valence requirements of the other elements present. 2. Catalyst according to claim 1 represented by the formula: Mo12PaCsbVcAsdCueSbfXêgOx wherein a is 1 to 1.2. b is 1 to 1.25, c is 0.2 to 0.7, d is 0.5 to 1.0, e is 0 to 0.25, f is 0 to 0.2, g is 0 to 1.0, x is the number of oxygen atoms required to satisfy the valence requirements of the other elements present, and X2is one or more of the following elements: bismuth, tungsten, cobalt, zinc and tin. 3. Catalyst according to either preceding claim represented by the formula: Mo12PaCsbVcAsdCueSbfOx wherein a is 1 to 1.2, b is 1 to 1.25, c is 0.2 to 0.6 d is 0.5 to 1, e is 0.1 to 0.2, f is 0.1 to 0.2, and x is the number of oxygen atoms required to satisfy the valence-requirements of the other elements present. 4. Catalyst according to any preceding claim containing one or more of the following individual catalysts: Mo12P1.15Cs0.75V0.05As1.7Cu0.3Ox, Mo12P1Cs1V0.2As1Cu0.2Sb0.1Ox, Mo12P1.0Cs1.0V0.2As1.0Cu0.2Ox, Mo12P1.0Cs1.0V0.2As1.5Cu0.2Ox, Mo12P1.15Cs1.25V0.05As1.3Cu0.3Ox, Mo12P1.0Cs1.0V0.2As1.6Cu0.2Ox, Mo12P1.1Cs1.12V0.3As0.85Cu0.2Sb0.15O Mo12P1.0Cs1.0V0.2As1.4Cu0.2Ox, Mo12P1.2Cs1.25V0.4As0.7Sb0.2Ox, Mo12P1.2Cs1.25V0.2As1.0Cu0.2Sb0.2Ox, Mo12P1.15Cs0.75V0.35As1.3Cu0.3Ox, Mo12P1.2Cs1.25V0.6As0.5Sb0.2Ox, and Mo12P1.2Cs1.25V0.6As0.7Cu0.25b0.20x. 5. A process for preparing catalyst according to any preceding claim which comprises (a) forming a suspension of molybdenum trioxide in water, adding phosphoric acid to said suspension, heating the resulting suspension to 600 to 950C for at least sufficient time to form phosphomolybdic acid and then adding ammonium hydroxide thereto, the remaining required or allowable elements being added to the suspension in the form of oxides or salts or compounds convertible on heating into the corresponding oxides either before or after the addition of the phosphoric acid to form catalyst precursor (b) isolating the catalyst precursor, and (c) calcining the isolated precursor at a temperature of 3500 to 4500C. 6. A process as claimed in Claim 5 wherein the suspension formed in step (a) is heated for at least 1 hour preferably at least 3 hours. 7. A process according to Claim 5 or 6 wherein said precursor is calcined at a temperature of 3850 to 4150C, preferably about 4000C. 8. A process for the vapour phase oxidation of unsaturated aldehyde to unsaturated carboxylic acid which comprises oxidizing said aldehyde in the presence of molecular oxygen in the presence of catalyst as claimed in any of claims 1 to 4. 9. A process as claimed in Claim 7 wherein the aldehyde is acrolein and/or methacrolein and the acid iS acrylic and/or methacrylic acid. 10. A process as claimed in Claim :7 or 8 wherein the oxidation is carried out at a temperature of 290 to 3200C. 11. A process as claimed in Claim 7,8 or 9 wherein the catalyst has been prepared by a process as claimed in any one of claims 5 to 7. CLAIMS EMI26.1 1. A process for vapour phase oxidation of unsaturated aldehyde to unsaturated carboxylic acid which comprises oxidizing said aldehyde in the presence of molecular oxygen by passing the reaction mixture over catalyst represented by the formula: 12PaXÚbVcAsdCueSbfXêgOx wherein X is one or more of the following elements: caesium, thallium and rubidium; X2is one or more elements from the following: tungsten, riobium, tantalum, zirconium, tin, iron, zinc, cobalt, bismuth, boron, rhenium, tellurium potassium; a is 0.85 to 1.2, b is 0.75 to 1.25, c is 0.05 to 0.7, d is 0.5 to 2.0, e is 0 to 0.4, f is 0 to 0.3, g is 0 to 2.0, and x is the number of oxygen atoms required to satisfy the valence requirements of the other elements present. 2. A process as claimed in Claim 1 wherein the oxidation is carried out at a temperature of 2900C to 320 C. 3. A process as claimed in either preceding claim wherein the catalyst is represented by the formula: Mo12PaCsb5VcAsdCueSBfXêgOx, wherein a is 1 to 1.2, b is 1 to 1.25, c is 0.2 to 0.7, d is 0.5 to 1.0, e is 0 to 0.25, f is 0 to 0.2, g is 0 to 1.0 x is the number of oxygen atoms required to satisfy the valence requirements of the other elements present, and ZX2 is one or more of the following elements: bismuth, tungsten, cobalt, zinc and tin. 4. A process as claimed in any preceding claim wherein the catalyst is represented by the formula: Mo12PaCsbVcAsdCueSbf0x wherein a is 1 to 1.2, b is 1 to 1.25, c is 0.2 to 0.6, d is 0.5 to 1, e is 0.1 to 0.2 f is 0.1 to 0.2, and x is the number of oxygen atoms required to satisfy the valence requirements of the other elements present. 5. A process as claimed in any preceding claim wherein the catalyst contains one or more of the following individual catalysts: Mo12P1.15Cs0.75V0.05As1.7Cu0.3Ox, Mo12P1Cs1V0.2As1Cu0.2Sb0.1Ox, Mo As 10Cu 0.20 Mo12P1.0Cs1.0V0.2As1.5Cu0.2Ox, Mo12P1.0Cs1.0V0.2As1.5Cu0.2Ox, Mo12P1.15Cs1.25V0.05As1.3Cu0.3Ox, Mo12P1.0Cs1.0V0.2As1.6Cu0.2Ox, Mo12P1.1Cs1.12V0.03As0.85Cu0.2Sb0.15Ox, Mo12P1.1Cs1.0V0.2As1.4Cu0.2Ox, Mo12P1.2Cs1.25V0.4As0.7Sb0.2Ox, Mo12P1.2Cs1.25V0.2As1.0Cu0.2Sb0.2Ox, Mo12P1.15Cs0.75V0.35As1.3Cu0.3Ox, Mo12P1.2Cs1.25V0.6As0.5Sb0.2Ox, Mo12P1.2Cs1.25V0.6As0.7Cu0.2Sb0.20x. 6. A process as claimed in any preceding claim wherein the aldehyde is acrolein and/or methacrolein and the acid is acrylic and/or methacrylic acid. 7. A catalyst composition comprising catalyst as defined in any preceding claim in supported form. 8. A composition as claimed in claim 7 wherein the support is one of the following: alumina, pumice, silicon carbide, zirconia, silica, alumina-silica and perlite, preferably alumina-silica. 9. A method of making catalyst useful either in a process as claimed in any one of claims 1 to 6 or in forming a catalyst composition as claimed in claim 7 or 8, which method comprises (a) forming a suspension of molybdenum trioxide in water, adding phosphoric acid to said suspension, heating the resulting suspension to 600 to 950C for at least sufficient time to form phosphomolybdic acid and then adding ammonium hydroxide thereto, the remaining required or allowable elements being added to the suspension in the form of oxides or salts or compounds convertible on heating into the corresponding oxides either before or after the addition of the phosphoric acid to form catalyst precursor (b) isolating the catalyst precursor, and (c) calcining the isolated precursor at a temperature of 350 to 4500C. 10. A method as claimed in claim 9 wherein the suspension formed in step (a) is heated for at least 1 hour preferably at least 3 hours. 11. A method as claimed in Claim 9 or 10 wherein said precursor is calcined at a temperature of 3850 to 4150C preferably about 4000C. 12. A process as claimed in any one of claims 1 to 6 wherein the catalyst is a catalyst composition as claimed in claim 7 or 8 or catalyst made by a method as claimed in claim 9 or 10.

Inventors: KENNELLY, WILLIAM JAMES, KIRCH, LAWRENCE SAMUEL
Applicants: ROHM AND HAAS COMPANY
Application year: 1983
Main classification: C07C57
IPC codes: C07C57, C07C51, B01J27, C07B61, C07C67, C01B25