Method for preparing acrylic acid

Patent metadata

Field	Value
Publication number	US-2020407306-A1
Application number	US-201916980936-A
Country	US
Kind code	A1
Filing date	Feb 21, 2019
Priority date	Mar 21, 2018
Publication date	Dec 31, 2020
Grant date	—

Abstract

Provided is a process for preparing acrylic acid comprising (1) preparing acrolein by catalytic gas phase oxidation comprising (a) providing a reaction gas comprising (i) 5 to 10 mol % propylene, (ii) 0.02 to 0.75 mol % propane, and (iii) 0.25 to 1.9 mol % of a fuel mixture comprising at least one of methane and ethane, wherein the molar ratio of the total amount of propane, methane, and ethane to the total amount of propylene is from 0.01:1 to 0.25:1, (b) contacting the reaction gas with a first mixed metal oxide catalyst to form a mixture comprising acrolein, wherein the first mixed metal oxide catalyst comprises one or more of molybdenum, bismuth, cobalt, and iron, and (2) contacting the acrolein mixture with a second mixed metal oxide catalyst to form a mixture comprising acrylic acid, wherein the second mixed metal oxide catalyst comprises one or more of molybdenum, vanadium, tungsten, copper, and antimony.

First claim

What is claimed is:

1 . A process for preparing acrylic acid comprising:
(1) preparing acrolein by catalytic gas phase oxidation comprising
(a) providing a reaction gas comprising
(i) 5 to 10 mol % propylene,
(ii) 0.02 to 0.75 mol % propane, and
(iii) 0.25 to 1.9 mol % of a fuel mixture comprising at least one of methane and ethane,
wherein the molar ratio of the total amount of propane, methane, and ethane to the total amount of propylene is from 0.01:1 to 0.25:1;

(b) contacting the reaction gas with a first mixed metal oxide catalyst to form a mixture comprising acrolein, wherein the first mixed metal oxide catalyst comprises one or more of molybdenum, bismuth, cobalt, and iron; and
(2) contacting the acrolein mixture with a second mixed metal oxide catalyst to form a mixture comprising acrylic acid, wherein the second mixed metal oxide catalyst comprises one or more of molybdenum, vanadium, tungsten, copper, and antimony.

2 . The process of claim 1 , wherein the fuel mixture comprises methane.

3 . The process of claim 1 , wherein the reaction gas comprises propylene in an amount of from 7.5 to 8.2 mol %.

4 . The process of claim 1 , wherein the reaction gas comprises propane in an amount of from 0.03 to 0.62 mol %.

5 . The process of claim 1 , wherein the reaction gas comprises the fuel mixture in an amount of from 0.5 to 1.4 mol %.

6 . The process of claim 2 , wherein the reaction gas comprises methane in an amount of from 1.1 to 1.4 mol %.

7 . The process of claim 1 , wherein the molar ratio of the total amount of propane, methane, and ethane to the total amount of propylene is from 0.1:1 to 0.18:1.

8 . The process of claim 1 ,
wherein the first mixed metal oxide catalyst comprises a primary component selected from the group consisting of molybdenum, bismuth, and combinations thereof, and a secondary component selected from the group consisting of cobalt, iron, nickel, zinc, tungsten, phosphorous, manganese, potassium, magnesium, silicon, aluminum, and combinations thereof, wherein the primary component and secondary component are in an atomic ratio of from 9:28 to 28:9, and wherein the second mixed metal oxide catalyst comprises a primary component selected from the group consisting of molybdenum, vanadium, and combinations thereof, and a secondary component selected from the group consisting of tungsten, cobalt, copper, and combinations thereof, wherein the primary component and secondary component are in an atomic ratio of from 1:1 to 11:1.

9 . The process of claim 1 , wherein the fuel mixture comprises sulfur in an amount of less than 30 parts per million by volume of the fuel mixture.

10 . A process for preparing acrylic acid comprising:
(1) preparing acrolein by catalytic gas phase oxidation comprising
(a) providing a reaction gas comprising
(i) 7.5 to 8.2 mol % propylene,
(ii) 0.03 to 0.62 mol % propane, and
(iii) 0.5 to 1.4 mol % of a fuel mixture comprising at least one of methane and ethane, wherein the fuel mixture comprises sulfur in an amount of less than 30 parts per million by volume of the fuel mixture,
wherein the molar ratio of the total amount of propane, methane, and ethane to the total amount of propylene is from 0.1:1 to 0.18:1; and

(b) contacting the reaction gas with a first mixed metal oxide catalyst to form a mixture comprising acrolein, wherein the first mixed metal oxide catalyst comprises a primary component selected from the group consisting of molybdenum, bismuth, and combinations thereof, and a secondary component selected from the group consisting of cobalt, iron, nickel, zinc, tungsten, phosphorous, manganese, potassium, magnesium, silicon, aluminum, and combinations thereof, wherein the primary component and secondary component are in an atomic ratio of from 9:28 to 28:9; and
(2) contacting the acrolein mixture with a second mixed metal oxide catalyst to form a mixture comprising acrylic acid, wherein the second mixed metal oxide catalyst comprises a primary component selected from the group consisting of molybdenum, vanadium, and combinations thereof, and a secondary component selected from the group consisting of tungsten, cobalt, copper, and combinations thereof, wherein the primary component and secondary component are in an atomic ratio of from 1:1 to 11:1.

Assignees

• Rohm & Haas

Inventors

• Ebert Donald A
• Hale Timothy Allen
• Keyes Brian Robert
• Rose Justin
• Xu Jinsuo

Classifications

• C07C45/35 Primary

  in propene or isobutene · CPC title

• C07C57/04

  Acrylic acid; Methacrylic acid · CPC title

• C07C51/252 Primary

  of propene, butenes, acrolein or methacrolein · CPC title