Method for producing acrolein

Patent metadata

Field	Value
Publication number	US-2016107968-A1
Application number	US-201414894752-A
Country	US
Kind code	A1
Filing date	May 23, 2014
Priority date	Jun 3, 2013
Publication date	Apr 21, 2016
Grant date	—

Abstract

The present invention relates to a process for preparing acrolein from propylene by catalytic gas phase oxidation with molecular oxygen (for example air). The invention further relates to the use of particular propylene-containing starting materials, for example refinery grade propylene, for preparation of acrolein.

First claim

1 . Process for preparing acrolein by catalytic gas phase oxidation, said process comprising the following steps:
a) providing a reaction gas comprising propylene and molecular oxygen, and b) contacting the reaction gas with an oxidation catalyst to form a gas mixture comprising acrolein, the oxidation catalyst being a mixed oxide catalyst comprising or consisting of one or more base components selected from molybdenum, vanadium and tungsten, characterized in that more than 10 ppm by weight of sulphur in the form of any sulphur components is present in the reaction gas provided, but not more than 5000 ppm by weight of sulphur in the form of any sulphur components and not more than 5000 ppm by weight of unsaturated hydrocarbons selected from the group consisting of C 2 H 4 , C 3 H 4 , C4H 8 , C 4 H 6 , C 5 H 10 , C 5 H 8 and mixtures thereof is present in each case in the reaction gas provided.

2 . Process according to claim 1 , characterized in that more than 50 ppm by weight of unsaturated hydrocarbons selected from the group consisting of C 2 H 4 , C 4 H 8 , C 3 H 4 , C 4 H 6 , C 5 H 10 , C 5 H 8 and mixtures thereof is present in the reaction gas provided.

3 . Process according to claim 1 , characterized in that more than 20 ppm by weight but not more than 1000 ppm by weight of sulphur in the form of any sulphur components is present in the reaction gas provided.

4 . Process according to claim 1 , characterized in that more than 20 ppm by weight of sulphur in the form of H 2 S and/or SO 2 but not more than 1000 ppm by weight of sulphur in the form of any sulphur components is present in the reaction gas provided.

5 . Process according to claim 1 , characterized in that more than 100 ppm by weight but not more than 1500 ppm by weight of unsaturated hydrocarbons selected from the group consisting of C 2 H 4 , C 3 H 4 , C4H 8 , C 4 H 6 , C 5 H 10 , C 5 H 8 and mixtures thereof is present in the reaction gas provided.

6 . Process according to claim 1 , characterized in that more than 150 ppm by weight but not more than 1300 ppm by weight of unsaturated hydrocarbons selected from the group consisting of C 2 H 4 , C 3 H 4 , C 4 H 8 , C 4 H 6 , C 5 H 10 , C 5 H 8 and mixtures thereof is present in the reaction gas provided.

7 . Process according to claim 1 , characterized in that the mixed oxide catalyst additionally contains one or more additional components selected from bismuth, antimony, tellurium, tin, iron, cobalt, nickel and copper.

8 . Process according to claim 7 , characterized in that the oxidation catalyst is a mixed oxide catalyst of the general formula (I) or a mixture of various mixed oxide catalysts of the general formula (I) where:
(Mo 12 Bi a C b (CO+Ni) c D d E e F f G g H h )O x   (I)
C=iron, D=at least one of the elements from W, P, E=at least one of the elements from Li, K, Na, Rb, Cs, Mg, Ca, Ba, Sr, F=at least one of the elements from Ce, Mn, Cr, V, G=at least one of the elements from Nb, Se, Te, Sm, Gd, La, Y, Pd, Pt, Ru, Ag, Au, H=at least one of the elements from Si, Al, Ti, Zr, a=0 to 5.0, b=0.5 to 5.0, c=2 to 15, d=0.01 to 5.0, e=0.001 to 2, f=0.001 to 5, g=0 to 1.5, h=0 to 800, x=number which is determined by the valency and frequency of the elements other than oxygen.

9 . Process according to claim 1 , wherein the reaction gas provided is produced by mixing at least refinery grade propylene and air, the refinery grade propylene being characterized in that it contains 0.05 to 2.0% by weight of ethane and/or 9 to 40% by weight of propane.

10 . Use of a reaction gas for preparation of acrolein, characterized in that the reaction gas contains more than 10 ppm by weight of sulphur in the form of any sulphur components, the reaction gas in each case containing not more than 5000 ppm by weight of sulphur in the form of any sulphur components and not more than 5000 ppm by weight of unsaturated hydrocarbons, selected from the group consisting of C 2 H 4 , C 3 H 4 , C 4 H 8 , C 4 H 6 , C 5 H 10 , C 5 H 8 and mixtures thereof.

11 . Use according to claim 10 , wherein the reaction gas contains more than 50 ppm by weight of unsaturated hydrocarbons selected from the group consisting of C 2 H 4 , C 3 H 4 , C 4 H 8 , C 4 H 6 , C 5 H 10 , C 5 H 8 and mixtures thereof.

12 . Use of an acrolein-containing gas mixture prepared by the process according to claim 1 for preparation of acrylic acid.

13 . Use according to claim 12 , wherein the acrolein-containing gas mixture is mixed with further molecular oxygen and contacted with an oxidation catalyst to form an acrylic acid-containing gas mixture.

Assignees

• Steffan Martin
• MüLLER HELMUT
• Roth Philipp
• Weckbecker Christoph
• Jakob Harald
• Evonik Degussa Gmbh

Inventors

• Steffan Martin
• Mueller Helmut
• Roth Philipp
• Weckbecker Christoph
• Jakob Harald

Classifications

• B01J23/8898

  containing also molybdenum · CPC title

• B01J23/8885

  containing also molybdenum · CPC title

• C07C45/35 Primary

  in propene or isobutene · CPC title

• B01J23/8993

  with chromium, molybdenum or tungsten · CPC title

• C07C51/235

  of —CHO groups or primary alcohol groups · CPC title