PROCESS FOR THE PRODUCTION OF METHACROLEIN AND METHACRYLIC ACID

Abstract: The present invention provides a process for the production of methacrolein and methacrylic acid by the gas phase catalytic oxidation of isobutylene or t-­ butanol at high temperature using molecular oxygen in the presence of catalyst consisting of molybdenum, tungsten, bismuth, iron, nickel, antimony, and an alkali metal, to which zinc or lead is added, and further phosphorus or boron, and magnesium, cobalt, manganese, or tin are added.

Description: BACKGROUND OF THE INVENTION FIELD OF THE INVENTION This invention relates to a process for the production of methacrolein and methacrylic acid by the gas phase catalytic oxidation of isobutylene or t-butanol using molecular oxygen, and more specifically to certain new catalysts used in the process thereof. DESCRIPTION OF THE PRIOR ART Numerous catalysts have been proposed for use in the production of methacrolein and methacrylic acid via the catalytic oxidation of isobutylene or t-butanol in a gas phase at high temperatures. For example, U.S. Patent Nos. 4,380,664 and 4,111,984 disclose the use of MoSbBiFeNi (Sn) [K,Rb,Cs] [Co,U,Ge,W,Ti] catalysts in the gas phase catalytic oxidation of isobutylene and t-butanol, respectively. Similarly, Japanese Patent Publication [Kokai] No. 27709/77 discloses the use of MoSbBiFeCo-­ [alkali metals] [Ni,Sn,Cr,Mn,Ti,W,Mg] catalysts in the gas phase catalytic oxidation of isobutylene. However, from an industrial standpoint, improvement still needs to be made in the performance of the catalysts used in this reaction, especially with regard to such properties as catalytic activity, selectivity for methacrolein and methacrylic acid, and life of the catalyst. DETAILED DESCRIPTION OF THE INVENTION According to the present invention, there is provided a process for the production of methacrolein and methacrylic acid comprising the gas phase catalytic oxidation of isobutylene or t-butanol using molecular oxygen in the presence of a catalyst having the formula Mo a W b Bi c Fe d Ni e Sb f X g Y h Z i A a O k wherein Mo, W, Bi, Fe, Ni, Sb, and O are respectively molybdenum, tungsten, bismuth, iron, nickel, antimony, and oxygen; X is at least one element selected from the group consisting of potassium, rubidium, and cesium; Y is at least one element selected from the group consisting of phosphorus, boron, sulfur, silicon, selenium, and germanium; Z is at least one element selected from the group consisting of zinc and lead; A is at least one element selected from the group consisting of magnesium, cobalt, manganese and tin; and a, b, c, d, e, f, g, h, i, j, and k represent the atomic ratios of the respective elements, such that when a = 12, b = 0.001-2 and pre­ ferably 0.01-2, c = 0.01-3 and preferably 0.1-2, d = 0.01-8 and preferably 0.1-5, e = 0.01-10 and preferably 0.1-10, f= 0.01-5 and preferably 0.1-3, g = 0.01-2 and preferably 0.1-2 , h = 0-5 and preferably 0.001-2, i = 0.01-5 and preferably 0.1-5, j = 0-10 and preferably 1-10, and k is the number of oxygen atoms sufficient to satisfy the valences of the above components. The molybdenum, tungsten, and antimony starting materials used in the preparation of catalyst employed in this invention should preferably be oxides or compounds that yield oxides under intense heating. Examples of such compounds include ammonium molybdate, ammonium paratungstate, antimony trioxide, and the like. The starting materials for the other elements should preferably be oxides, chlorides, sulfates, nitrates, carbonates, or mixtures thereof. Known methods such as evaporation to dryness, precipitation, and oxide mixture may be employed in the preparation of the catalyst. The use of carrier is desirable. Silica, alumina, silica/­ alumina, and the like may be used as the carrier. In working the invention, molecular oxygen is added to isobutylene or t-butanol as the starting material, and gas phase catalytic oxidation carried out in the presence of the above-described catalyst. The molar ratio of isobutylene or t-butanol to oxygen should lie within the range of 1:0.5 to 1:3. The feedstock gas should be diluted with an inert gas for use. The molecular oxygen used for oxidation may be pure oxygen gas or air, although air is more advantageous for industrial applications. The reaction pressure may range from normal pressure to several atmospheres. A tempera­ ture lying within the range of 250 to 450°C is preferable. The reaction may be conducted either on a fluid or fixed bed. The present invention makes possible the industrially advantageous production of methacrolein and methacrylic acid from isobutylene or t-butanol, in addi­ tion to which it has the effect of providing a long catalyst life. EXAMPLES All references to "parts" in the examples below signify parts by weight. Analyses were carried out by gas chromatography. The conversion (%) of isobutylene or t-butanol, the selectivities (%) for methacrolein and methacrylic acid, and the combined single-pass yield (%) of (methacrolein and methacrylic acid) are defined below: EXAMPLE 1 Ammonium molybdate (500 parts), 18.5 g of ammonium paratungstate, and 27.8 g of rubidium nitrate were added to 1000 parts of water, and the mixture heated under stirring, giving solution A. In a separate step, 250 parts of 60% nitric acid was added to 850 parts of water, then 114.5 parts of bismuth nitrate added and dissolved in this. This was followed by the successive addition and dissolution of 286.0 parts ferric nitrate, 480.4 parts nickel nitrate, 90.8 parts magnesium nitrate, and 35.1 parts zinc nitrate, giving solution B. After adding solution B to solution A, 51.6 parts of antimony trioxide was added to the resulting slurry, the mixture heated under stirring, and most of the water evaporated off. The cake-like substance obtained was dried at 120°C and molded by calcining for ten hours at 500°C. The composition of the catalyst thus obtained was Mo₁₂W 0.3 Bi₁Fe₃Ni₇Mg 1.5 Zn 0.5 Sb 1.5 Rb 0.8 O X . Since the atomic ratio X for oxygen is determined naturally by the valences of the other elements, this is omitted hereafter. This catalyst was packed into a stainless steel reactor and a gas mixture consisting of isobutylene (5%), oxygen (12%), steam (10%), and nitrogen (73%) was passed through the catalyst layer for a contact period of 2 seconds and reacted at 365°C. The conversion of isobutylene was 95%, the selectivity for methacrolein 87%, the selectivity for methacrylic acid 4.8%, and the single pass yield for methacrolein and methacrylic acid combined was 87.2%. EXAMPLE 2 Using the catalyst in Example 1 and t-butanol as the starting material, a reaction was carried out under the same conditions as in Example 1. This reaction gave a t-butanol conversion of 100%, a selectivity for methacrolein of 85.5%, a selectivity for methacrylic acid of 2.8%, and a combined single-pass yield for methacrolein and methacrylic acid of 88.3%. EXAMPLES 3-11 The following catalysts were prepared in the same manner as in Example 1. Example 3: Mo₁₂W 0.3 Bi 0.8 Fe 2.5 Ni₃Co₄Sn₁Pb 0.5 Sb 1.3 K 0.1 Cs 0.7 Example 4: Mo₁₂W 0.5 Bi 0.8 Fe₃Ni₅Co₁Mg₁Zn₁B 0.5 Sb 1.5 Cs 0.7 Example 5: Mo₁₂W 0.5 Bi₁Fe 2.7 Ni₇Mn 0.5 Co₁P 0.05 Sb₂Rb 0.5 Zn₁ Example 6: Mo₁₂W 0.5 Bi₁Fe₃Ni₇Mn₁Mg₂Zn 0.5 S 0.2 Sb₁Rb 0.2 Cs 0.3 Example 7: Mo₁₂W 0.2 Bi 0.7 Fe₃Ni₇Mg₁Pb₁Si 0.8 Sb 1.5 K 0.3 Example 8: Mo₁₂W 0.5 Bi 0.9 Fe 2.7 Ni₁Co₅Pb₁Si 0.8 Se 0.8 Sb 1.5 Cs 0.7 Example 9: Mo₁₂W 0.1 Bi₁Fe₃Ni₈Zn₁Sn₁Ge 0.1 Sb₁Rb 0.5 K 0.5 Example 10: Mo₁₂W 0.5 Bi₁Fe₃Ni 6.5 Rb 0.7 Sb₂Pb₂ Example 11: Mo₁₂W 0.5 Bi₁Fe 2.5 Ni₇P 0.08 Zn₂Pb 0.5 Sb 1.2 Cs 0.7 Using these catalysts, reactions were carried out under the same reaction conditions as in Example 1, save for the reaction temperature. The results are given in Table 1. EXAMPLES 12-20 These reactions were carried out on t-butanol as the starting material using the respective catalysts in Examples 3-11. All the other reaction conditions were the same as in the corresponding examples above. The results are given below in Table 2. COMPARATIVE EXAMPLE 1 A catalyst having the composition Mo₁₂Bi₁Fe₃Ni₇ Mg 1.5 Zn 0.5 Sb 1.5 Rb 0.8 was prepared in the same manner as in Example 1, but without using the 18.5 parts of ammonium paratungstate. A reaction was conducted using this catalyst under the same reaction conditions as in Example1, giving an isobutylene conversion of 91%, a selectivity for methacrolein of 86%, a selectivity for methacrylic acid of 5.3%, and a single-pass yield for methacrolein and methacrylic acid combined of 83.1%. The process was repeated in the same fashion using t-butanol, giving a t-butanol conversion of 100%, a selectivity for methacrolein of 80%, a selectivity for methacrylic acid of 3.6%, and a single-pass yield for methacrolein and methacrylic acid combined of 83.6%. COMPARATIVE EXAMPLE 2 A catalyst having the composition Mo₁₂W₃Bi₁Fe₃ Ni₇Sb 1.5 Rb 0.8 Mg 1.5 Zn 0.5 was prepared in the same manner as in Example 1, except for the amount of ammonium paratungstate, which was increased to 184.8 parts. A reaction was conducted using this catalyst under the same reaction conditions as in Example 1, giving an isobutylene conversion of 70%, a selectivity for methacrolein of 75%, a selectivity for methacrylic acid of 5%, and a single-pass yield for methacrolein and methacrylic acid combined of 56.0%. In addition, the same reaction as in Example 2 was carried out, giving a t-butanol conversion of 100%, a selectivity for methacrolein of 58%, a selectivity for methacrylic acid of 2.8%, and a single-pass yield for methacrolein and methacrylic acid combined of 60.8%. COMPARATIVE EXAMPLE 3 A catalyst having the composition Mo₁₂W 0.3 Bi₁ Fe₃Ni₇Sb 1.5 Rb 0.8 was prepared in the same manner as in Example 1, but without using the 90.8 parts of magnesium nitrate and 35.1 parts of zinc nitrate. A reaction was conducted using this catalyst under the same reaction conditions as in Example 1, giving an isobutylene con­ version of 90%, a selectivity for methacrolein of 84%, a selectivity for methacrylic acid of 5%, and a single-­ pass yield for methacrolein and methacrylic acid combined of 80.1%. In addition, the same reaction as in Example 2 was carried out, giving a t-butanol conversion of 100%, a selectivity for methacrolein of 76%, a selectivity for methacrylic acid of 5.2%, and a single-pass yield for methacrolein and methacrylic acid combined of 81.2%. COMPARATIVE EXAMPLE 4 A catalyst having the composition Mo₁₂W 0.3 Bi₄ Fe₃Ni₇Mg 1.5 Zn 0.5 Sb 1.5 Rb 0.8 was prepared in the same manner as in Example 1, except for the amount of bismuth nitrate, which was increased to 457.9 parts. A reaction was conducted using this catalyst under the same reaction conditions as in Example 1, giving an isobutylene con­ version of 75%, a selectivity for methacrolein of 78%, a selectivity for methacrylic acid of 3%, and a single-pass yield for methacrolein and methacrylic acid combined of 60.8%. In addition, the same reaction as in Example 2 was carried out, giving a t-butanol conversion of 100%, a selectivity for methacrolein of 60%, a selectivity for methacrylic acid of 1.6%, and a single-pass yield for methacrolein and methacrylic acid combined of 61.6%. COMPARATIVE EXAMPLE 5 A catalyst having the composition Mo₁₂W 0.3 Bi₁ Fe₃Ni₇Mg 1.5 Zn 0.5 Sb 1.5 Rb 2.5 was prepared in the same manner as in Example 1, except for the amount of rubidium nitrate, which was increased to 87.0 parts. A reaction was conducted using this catalyst under the same reaction conditions as in Example 1, giving an isobutylene conver­ sion of 70%, a selectivity for methacrolein of 80%, a selectivity for methacrylic acid of 4%, and a single-pass yield for methacrolein and methacrylic acid combined of 58.8%. In addition, the same reaction as in Example 2 was carried out, giving a tu-butanol conversion of 100%, a selectivity for methacrolein of 58.5%, a selectivity for methacrylic acid of 2.3%, and a single-pass yield for methacrolein and methacrylic acid combined of 60.8%. EXAMPLE 21 Reactions were conducted for 9000 hours under the same reaction conditions as in Example 1 using the catalysts in Examples 1 and 4. The results are given in Table 3. EXAMPLE 22 Reactions were conducted for 9000 hours under the same reaction conditions as in Example 2 using the catalysts in Examples 1 and 4. The results are given in Table 4. COMPARATIVE EXAMPLE 6 Table 5 gives the results obtained by running reactions for 9000 hours under the same reaction condi­ tions as in Example 1 using the catalysts in Comparative Examples 1-5. Table 6 gives the results obtained by conducting reactions for 9000 hours under the same reaction condi­ tions as in Example 2 using the catalysts in Comparative Examples 1-5.

Claims: 1. A process for the production of methacrolein and methacrylic acid comprising the gas phase catalytic oxidation of isobutylene or t-butanol using molecular oxygen in the presence of a catalyst having the composition MoaWbBicFedNieSbfXgYhZiAjOk wherein Mo, W, Bi, Fe, Ni, Sb, and O are respectively molybdenum, tungsten, bismuth, iron, nickel, antimony, and oxygen; X is at least one element selected from the group consisting of potassium, rubidium, and cesium; Y is at least one element selected from the group consisting of phosphorus, boron, sulfur, silicon, selenium, and germanium; Z is at least one element selected from the group consisting of zinc and lead; A is at least one element selected from the group consisting of magnesium cobalt manganese and tin; and a, b, c, d, e, f, g, h, i, j, and k represent the atomic ratios of the respective elements, such that when a = 12, b = 0.001-2 and preferably 0.01-2, c = 0.01-3 and preferably 0.1-2, d = 0.01-8 and preferably 0.1-5, e = 0.01 - 10 and preferably 0.1-10, f = 0.01-5 and preferably 0.1-3, g = 0.01-2 and preferably 0.1-2, h = 0-5 and preferably 0.001-2, i = 0.01-2, i = 0.01-5 and preferably 0.1-5, j = 0-10 and preferably 1-10, and k is the number of oxygen atoms sufficient to satisfy the valences of the above components. 2. A process according to Claim 1 wherein the catalyst employed contains zinc as the Z component. 3. A process according to Claim 1 wherein the catalyst employed contains zinc as the Z component and cobalt as the A component. 4. A process according to Claim 1 wherein the catalyst employed contains phosphorus or boron as the Y component.

Inventors: KATO, MASAAKI C/O MITSUBISHI RAYON CO. LTD., KOBAYASHI, MASAO C/O MITSUBISHI RAYON CO. LTD., OH-KITA, MOTOMU C/O MITSUBISHI RAYON CO. LTD., TANIGUCHI, YOSHIYUKI C/O MITSUBISHI RAYON CO. LTD.
Applicants: MITSUBISHI RAYON CO., LTD.
Application year: 1985
Main classification: C07C47
IPC codes: C07C45, C07C57, C07B61, B01J27, C07C27, C07C51, C07C47, B01J23, C07C67