Patent ID: 8772513

Claim:
A process to produce a carboxylic acid composition, said process comprising: (a) oxidizing in an primary oxidation zone an oxidizable compound in a oxidizable raw material stream in the presence of a solvent stream, an oxidizing gas stream, and a catalyst system, wherein said an oxidizable raw material stream comprises at least one compound selected from the group consisting of 5-(hydroxymethyl)furfural (5-HMF), 5-HMF esters (5-R(CO)OCH 2 -furfural where R=alkyl, cycloalkyl and aryl), 5-HMF ethers (5-R(CO)OCH 2 -furfural, where R′=alkyl, cycloalkyl and aryl), 5-alkyl furfurals (5-R″-furfural, where R″=alkyl, cycloalkyl and aryl), mixed feedstocks of 5-HMF and 5-HMF esters, mixed feedstocks of 5-HMF and 5-HMF ethers, and mixed feedstocks of 5-HMF and 5-alkyl furfurals to produce said carboxylic acid composition comprising furan-2,5-dicarboxylic acid (FDCA); wherein said catalyst system comprises cobalt in a range from about 500 ppm to about 6000 ppm with respect to the weight of the liquid in the primary oxidation zone, manganese in an amount ranging from about 2 ppm to about 600 ppm by weight with respect to the weight of the liquid in the primary oxidation zone and bromine in an amount ranging from about 300 ppm to about 4500 ppm by weight with respect to the weight of the liquid in the primary oxidation zone; and wherein the yield of furan-2,5-dicarboxylic acid is greater than 80%; (b) routing said carboxylic acid composition to a cooling zone; (c) routing cooled carboxylic acid composition to a solid-liquid separation zone generating a mother liquor stream and wet carboxylic acid composition; (d) routing the wet carboxylic acid composition to a drying zone to produce a dry crude carboxylic acid composition.