Highly active and selective catalysts for the production of unsaturated nitriles, methods of and using the same

Abstract: An improved catalyst for the production of unsaturated nitriles from their corresponding olefins, the catalyst composition having the atomic ratios described by the empirical formula Bi a Mo b V c Sb d Nb e Ag f A g B h O x and methods of using the same.

Description: The present invention relates to a catalyst system according to the preamble of claim 1 and a process for the production of unsaturated nitriles according to the preamble of claim 10. The present invention relates to new ammoxidation catalysts for the production of unsaturated nitriles starting from their corresponding olefins, in particular, for the production of acrylonitrile from propylene. More specifically, the present invention is directed to an improved ammoxidation catalyst containing niobium and silver as essential elements for enhancing the activity and selectivity of the catalyst system. Several publications are referenced in this application. The references describe the state of the art to which this invention pertains. A number of ammoxidation catalysts are known in this field such as those disclosed in U.S.-A- 4,405,498; 5,688,739; 4,600,541 and European Patent Publication Nos. 00 32 012 B1; 05 73 713 B1; 04 75 351 A1. All of these publications relate to molybdenum catalyst systems. It is known in the art that the bismuth-molybdenum system plays a role of electron donor/acceptor mechanisms for selective oxidation and ammoxidation. Therefore different mechanisms were proposed based on this property [Delmon et al. (New Development in Selective Oxidation by Heterogeneous Catalysis, Vol. 72, 1992, p. 399-413) and Encyclopedia of Chemical Technology (Kirk-Othmer, Vol. 1, 4th edition, page 358)]. In these mechanisms, molybdenum was shown to be responsible for oxygen and nitrogen uptake and insertion into the substrate, while bismuth plays the role of H-abstraction of the methyl group in the β position. Therefore, bismuth and molybdenum should be present on the catalyst surface in adjacent form in order to form the suitable active phase for this reaction. It should be noted that a deficiency of bismuth on the catalyst surface leads to total oxidation reactions of the substrate. It is also well known that antimony plays a role of a donor and thus could improve the selectivity of a catalytic system. Antimony can also play an additional role by isolating the vanadium active centers which are highly active towards oxidation reactions. This leads to minimizing the total oxidation reaction and directs the reaction towards the desired product. Many catalysts have been disclosed for the foregoing reactions. One such catalyst is described in U.S.-A-4,062,885, where BiMoSbV systems were used as active elements. The catalyst was used for the preparation of phthalonitrile by the ammoxidation of ortho-xylene. The use of such catalysts for oxidation or ammoxidation reactions involving unsaturated aliphatic hydrocarbon is not mentioned. U.S.-A- 4,040,978 relates to a catalyst for a ammoxidation reaction containing bismuth molybdate mixed with other elements. U.S.-A- 4,405,498 relates to a catalyst for oxidation and ammoxidation reactions containing BiMoVSb with additional elements of groups IA, IIA, IVA, VA, VIA, IB, IVB and VIIB of the periodic Table of the Elements. The patent does not disclose the use of niobium. Although, silver was disclosed, experimental results for the catalyst with silver did not reflect any performance improvement. U.S.-A- 4,600,541 relates to a catalyst comprising FeBiMo and promoters such as Pd, Pt, Os and Ir. More recently, European Patent Publication No. 0 475 351 A1 relates to a catalyst containing KFeSbMo which could be promoted by Nb and W. The best yield was achieved with a catalyst of the formula Fe 10 Sb 10 Mo 9 Bi 2 K 0.6 Ni 5.5 W 0.3 B 0.75 P 0.75 (SiO 2 ) 70 . European Patent Publication No. 0 573 713 B1 relates to a catalyst comprising MoBiFeCoNiCr promoted with at least three other promoters of alkali metals, alkaline earth metals, rare earth metals, Nb, Tl and As, with Fe, Co, Ni and Cr as essential catalyst components. U.S. -A- 5,688,739 relates to a multi-component catalyst. The base of this catalyst is bismuth molybdenum. Germanium was added as an essential element. None of the prior art references discloses or suggests catalysts which provide high performance for the selective production of unsaturated nitriles from their corresponding olefins. Accordingly, it would be desirable to produce an improved catalyst for use in the selective production of unsaturated nitriles from their corresponding olefins. US-A-5,472,925 describes a catalyst for the production of a nitrile from an alkane, which satisfies the following conditions 1 and 2: 1 the catalyst is represented by the empirical formula: Mo a V b Te c X x O n wherein X is at least one element selected from the group consisting of Nb, Ta, W, Ti, Al, Zr, Cr, Mn, Fe, Ru, Co, Rh, Ni, Pd, Pt, Sb, Bi, B and Ce, when a =1 b = 0.01 to 1.0, c = 0.01 to 1.0, x = 0.01 to 1.0 and n is a number such that the total valency of the metal elements is satisfied; and 2 the catalyst has X-ray diffraction peaks at the following angles of 2 in its X-ray diffraction pattern: Diffraction angles of 2 (°) 22.1 ± 0.3 28.2 ± 0.3 36.2 ± 0.3 45.2 ± 0.3 50.0 ± 0.3. EP 0603836 A1 discloses a process for preparing a catalyst useful for producing a nitrile by a gas phase catalytic oxidation reaction of an alkane with ammonia, which comprises drying a solution or slurry containing molybdenum, vanadium and tellurium by a spray drying method or a freeze-drying method and heat-treating the resulting dried product. It is an object of the invention to overcome the above-identified deficiencies. It is another object of the invention to provide a useful catalyst for the production of nitriles from their corresponding olefins, particularly for the production of acrylonitrile from propylene. It is a further object of the invention to provide a process for the production of acrylonitrile at high yields by vapor phase catalytic ammoxidation of propylene in a fluidized or fixed bed reactor. The foregoing and other objects and advantages of the invention will be set forth in or apparent from the following description. The catalyst system of the present invention is defined in the characterizing part of claim 1 and the process for the production of unsaturated nitriles is defined in the characterizing part of claim 10. The present invention relates to an improved catalyst for the production of unsaturated nitriles from their corresponding olefins, the catalyst including a catalytic composition having the atomic ratios described by the empirical formula set forth below: Bi a Mo b V c Sb d Nb e Ag f A g B h O x , wherein A = one or more elements selected from groups VB (e.g., V, Nb, Ta), VIB (e.g., Cr, Mo, W), VIIB (e.g., Mn, Tc Re) or VIII (e.g., Fe, Co, Ni) of the periodic table; B = at least one alkali promoter selected from group IA (e.g, Li, Na, K) or IIA (e.g., Mg, Ca) of the periodic table; a = 0.01 to 12; b = 0.01 to 12; c = 0.01 to 2; d = 0.01 to 10; e = 0.01 to 1; f = 0.0001 to 2, preferably 0.0001 to 1; g = 0 to 2, preferably, 0.01 to 1; h = 0 to 1, preferably, 0.001 to 0.5; and x = the number of oxygen atoms required to satisfy the valency requirements of the elements present. The numerical values of a, b , c, d , e, f, g, h and x represent the relative gram-atom ratios of the elements, respectively, in the catalyst composition, where x is a number required to satisfy the valence requirements of the other elements. The elements are present in combination with oxygen, preferably in the form of various oxides. The present invention also relates to a process for the catalytic preparation of unsaturated nitriles from their corresponding olefins, preferably for the production of acrylonitrile or metha acrylonitrile by the reactions of propylene or isobutylene with molecular oxygen and ammonia at temperatures between 200 to 550°C, using the active and selective catalyst of the invention. Other objects as well as aspects, features and advantages of the present invention will become apparent from a study of the present specification, including the claims and specific examples. One aspect of the invention relates to an improved ammoxidation catalytic system for the production of unsaturated nitriles from their corresponding olefins, in particular, for the production of acrylonitrile from propylene. More specifically, the present invention is directed to an improved ammoxidation catalyst containing niobium and silver as essential elements for enhancing activity and selectivity of the catalyst system. The aim of the present invention is to incorporate a new element into the Bi/Mo system which can improve the catalyst performance. This is achieved by incorporating niobium and silver into a bismuth/molybdenum/vanadium/antimony catalyst system. The improved ammoxidation catalytic system of the invention comprises the atomic catalyst composition described by the empirical formula set forth below: Bi a Mo b V c Sb d Nb e Ag f A g B h O x , wherein A = one or more elements selected from groups VB (e.g., V, Nb, Ta), VIB (e.g., Cr, Mo, W), VIIB (e.g., Mn, Tc Re) or VIII (e.g., Fe, Co, Ni) of the periodic table; B = at least one alkali promoter selected from group IA (e.g, Li, Na, K) or IIA (e.g., Mg, Ca) of the periodic table; a = 0.01 to 12; b = 0.01 to 12; c = 0.01 to 2; d = 0.01 to 10; e = 0.01 to 1; f = 0.0001 to 2, preferably 0.0001 to 1; g = 0 to 2, preferably, 0.01 to 1; h = 0 to 1, preferably, 0.001 to 0.5; and x = the number of oxygen atoms required to satisfy the valency requirements of the elements present. Accordingly, the aim of this invention is to incorporate silver as a new element in the Bi/Mo/V/Sb/Nb system which is disclosed in our copending U.S. application Serial No. (Attorney Docket No. KR80576-90), filed concurrently herewith , as a good catalyst for the ammoxidation reaction. The silver has the role of improving the performance of the catalyst. The catalysts of the invention can be used with or without a support. Suitable supports for the catalysts include alumina, silica, titania, zirconia, zeolites, silicon carbide, Mo, carbide, molecular sieves and other micro/nonporous materials, and mixtures thereof. When used on a support, the supported catalyst usually comprises from 10 to 50% by weight of the catalyst composition, with the remainder being the support material. Another aspect of the invention relates to methods of using the catalyst system of the invention. More specifically, the invention relates to an improved method of producing unsaturated nitriles from their corresponding olefins. One preferred embodiment of the invention relates to an improved process for the catalytic preparation of acrylonitrile or metha acrylonitrile by the reaction of propylene or isobutylene with molecular oxygen and ammonia at a temperature of between 200 to 550°C using the ammoxidation catalytic system of the invention. Preferably, the process achieves a propylene conversion of at least 70%, more preferably at least 75%, even more preferably at least 80%, and most preferred at least 90% using the catalytic system of the invention. Preferably, the selectivity in mol % to acrylonitrile is greater than 75%, more preferably greater than 80%. The yield of acrylonitrile in mol% is preferably greater than 50%, more preferably greater than 55%, even more preferably greater than 60% and most preferred greater than 65%. The following examples are illustrative of some of the products and methods of making and using the same falling within the scope of the present invention. They are, of course, not to be considered in any way limitative of the invention. The basic catalyst of present invention is a mixed metal oxide catalyst, which can be prepared according to any procedure well known by one of ordinary skill the art. Methods used to prepare representative catalysts are given below. The examples described below are illustrative only and are not considered to be in any way limiting to the methods used to make these catalysts. The catalysts of the examples were prepared by the methods described in U.S. Patent No. 4,405,498. As used in the following examples, the following terms are defined in the following manner: 1. "W/F" is defined as the weight of the catalyst in grams divided by the flow rate of reactant stream in ml/sec measured at S.T.P. 2. "Propylene (C 3 H 6 ) conversion" is defined as: Mols C 3 H 6 in feed - mols C 3 H 6 in effluent Mols C 3 H 6 in feed x 100% 3. "Acrylonitrile ( ACN ) selectivity" is defined as: Mols ACN in effluent Mols C 3 H 6 converted x 100% 4. "Acrylonitrile ( ACN ) yield" is defined as: Mols ACN formed Mols C 3 H 6 in feed x 100% EXAMPLE 1 : BiMoV 0.175 Sb 0.35 O x /50% Silica - Comparative example - Part A 10.2g of Sb 2 O 3 was slurried in 20ml water along with 3.18g V 2 O 5 . The mixture was boiled until it formed a paste. The paste was then dried at 120°C and calcined under airflow at 760°C for 2 hrs. Part B 97g Bi(NO 3 ) 3 5H 2 O was dissolved in 184ml water and 30 ml HNO 3 (concentrated). Separately, 28.78g MoO 3 was dissolved in 72ml water and 30 ml concentrated NH 4 OH. The two solutions were mixed together and the pH was adjusted to 4 using NH 4 OH. The mixture was then boiled ca. 2 hours, filtered and washed with ca. 1000ml water. Part C The pH of 297g of a silica solution 30% wt % was adjusted with HNO 3 to pH=2 to form Part C. Part A and Part B were then added to Part C. The mixture was stirred for several hours, then dried at 120°C and calcined under airflow at 550°C. EXAMPLE 2 : BiMoNb 0.1 V 0.175 Sb 0.35 O x /50% Silica - Comparative example - This catalyst was prepared according to the above described method. Niobium was introduced into the system using the required amount of niobium penta oxide to the molybdenum solution in Part B. However, any source of niobium could be used for the same purpose. EXAMPLE 3 : Ag 0.001 BiMoNb 0.1 V 0.175 Sb 0.35 / 50% Silica The catalyst was prepared according to the method set forth in Example 2. Silver was introduced by impregnating 7.147g of the catalyst of Example 2 in a solution of 0.0016g of silver nitrate in 100cc water. However, any source of silver could be used for the introduction of silver into the catalyst by any method. After impregnation, the catalyst was dried and heated to 550°C for 4 hr under airflow. EXAMPLE 4: Ag 0.01 BiMoNb 0.1 V 0.175 Sb 0.35 / 50% Silica The catalyst was prepared according to the method of Example 3, however, 0.0158g of silver nitrate was used for impregnation. EXAMPLE 5: BiMoNb 0.1 V 0.9 Sb 0.175 / 50% Silica - Comparative example - The catalyst was prepared according to the method of Example 1, however, the nominal amount of vanadium oxide and antimony oxide were reduced by half. EXAMPLE 6 : Ag 0.0001 BiMoNb 0.1 V 0.09 Sb 0.175 /50% Silica The catalyst was prepared as in Example 5, and impregnated in silver nitrate solution as in Example 3. Catalyst Test : The calcined catalysts of the above examples were crushed to 35-60 mesh fraction. The crushed catalysts were charged into a tubular fixed bed stainless steel reactor. The reaction was carried out at 475°C under atmospheric pressure with the following feed composition: propylene / O 2 /NH 3 / He = 7.9/16.8/10/65.3 and a space velocity "W/F"" of 3 or 1.5 as shown in Table No. I. Comparison : After reaching the steady state, the reactor effluent was analyzed using a modern gas chromatograph (HP 6890), equipped with both FID and TCD detectors. HCN was collected for a given period of time and then titrated according to the methods described in the literature. Activity results were calculated according to the equations given above. Results are summarized in Table I. Comparing Run Nos. 2 and 7 and Run Nos. 5 and 10 in Table I, it is clear that the presence of small amount of silver substantially increases the activity in terms of conversion and acrylonitrile yield. Comparison between Run Nos. 7 and 9 shows that, the addition of slightly more silver further improves catalyst performance. This clearly demonstrates that the presence of silver is essential in substantially enhancing the catalyst performance as claimed in the present invention. The addition of silver to the BiMoNbVSb catalyst also promotes the CO x and HCN formation. However, the overall yield of acrylonitrile was in general improved. Therefore, it can be concluded that silver enhances the activity of this catalyst system for acrylonitrile production.

Claims: A catalyst system for the production of unsaturated nitriles from the corresponding olefins comprising a catalyst composition having the empirical formula: Bi a Mo b V c Sb d Nb e Ag f A g B h O x , wherein A is one or more elements selected groups VB, VIB, VIIB or VIII of the periodic table. B is at least one alkali promoter selected from groups IA or IIA of the periodic table; a = 0.01 to 12; b = 0.01 to 12; c = 0.01 to 2; d = 0.01 to 10; e = 0.01 to 1; f = 0.0001 to 2; g = 0 to 2; h = 0 to 1; and x = the number of oxygen atoms required to satisfy the valency requirements of the elements present. The catalyst system of claim 1, wherein f is from 0.0001 to 1. The catalyst system of claim 1, wherein said catalyst composition is supported on a catalyst support material selected from silica, alumina, zirconia, titania, alundum, silicon carbide, alumina-silica, inorganic phosphates, silicates, aluminates, borates and carbonates, pumice, montmorillonite, or mixtures thereof. The catalyst system of claim 3, wherein said catalyst support material is silica. The catalyst system of claim 1, wherein the catalyst comprises 20-70% by weight of the catalyst composition. The catalyst system of claim 4, wherein the catalyst comprises 20-70% by weight of the catalyst composition. The catalyst system of claim 1, wherein the catalyst comprises 40-70% by weight of the catalyst composition. The catalyst system of claim 1, wherein g ranges from 0.01 to 1 and h ranges from 0.001 to 0.5. The catalyst system of claim 1, wherein the Ag in the catalyst composition is derived from a silver compound soluble in water. A process for the production of unsaturated nitriles from the corresponding olefins which comprises reacting the olefin with a molecular oxygen containing gas and ammonia in the vapor phase at a temperature from 200°C to 550°C in the presence of the catalyst system of claims 1 to 9. The process of claim 10, wherein said olefins are selected from propylene, isobutylene or mixtures thereof and said nitriles are selected from acrylonitrile, methacrylonitrile or mixtures thereof. The process of claim 10, wherein said process achieves an olefin conversion of at least 65%. The process of claim 10, wherein said process achieves a selectivity in mol % to nitriles greater than 80%. The process of claim 10, wherein said process achieves a nitriles yield in mol% greater than 50%.

Inventors: ABDULWAHED MAZHAR, EL YAHYAOUI KHALID, ABDULWAHED, MAZHAR, EL YAHYAOUI, KHALID
Applicants: SAUDI BASIC IND CORP SABIC, SAUDI BASIC INDUSTRIES CORPORATION (SABIC)
Application year: 2000
Main classification: C07C253
IPC codes: C07C253, B01J23, C07C255, C07B61