Catalyst for producing unsaturated aldehyde and/or unsaturated carboxylic acid, method for producing same, and method for producing unsaturated aldehyde and/or unsaturated carboxylic acid

Patent metadata

Field	Value
Publication number	US-9656248-B2
Application number	US-201414784652-A
Country	US
Kind code	B2
Filing date	May 8, 2014
Priority date	May 9, 2013
Publication date	May 23, 2017
Grant date	May 23, 2017

Abstract

Provided is a catalyst having high activity and yield of a target product for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid and further having high mechanical strength. The catalyst is a catalyst prepared by a method in which a catalyst formulation satisfies specified atomic ratios; and in the preparation thereof, a molybdenum component raw material is an ammonium molybdate, a solvent for dissolving the ammonium molybdate is water, a bismuth component raw material is bismuth nitrate, and a solvent for dissolving bismuth nitrate is a nitric acid aqueous solution, and the weight of water for dissolving the ammonium molybdate, the weight of the nitric acid aqueous solution for dissolving the bismuth nitrate, and the acid concentration of the nitric acid aqueous solution are satisfied with specified ranges, respectively.

First claim

The invention claimed is:

1. A catalyst for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid, comprising:
a compound represented by the following formula (1),
the catalyst being prepared by a method in which in a step of preparing the compound represented by the following formula (1), a molybdenum component raw material is composed of only ammonium molybdate, the weight of water for dissolving the ammonium molybdate is 8.5 times or less relative to the weight of molybdenum contained in the ammonium molybdate, and a bismuth component raw material is composed of only bismuth nitrate, the weight of a nitric acid aqueous solution for dissolving the bismuth nitrate is 2.3 times or more relative to the weight of bismuth contained in the bismuth nitrate, and the nitric acid concentration of the nitric acid aqueous solution for dissolving the bismuth nitrate is 10% by weight or more:
Mo 12 Bi a Fe b Co c Ni d Z g O h   Formula (1)

wherein Z is one or more elements selected from the group consisting of potassium (K), rubidium (Rb) and cesium (Cs); a, b, c, d and g represent atomic ratios of the respective components; h is a numerical value determined by degrees of oxidations of the catalyst components; a=0.80 to 2.0, b=1 to 2.5; c=3 to 7; d=2 to 3.5; g=0.01 to 0.10; h is expressed by the numerical value satisfying oxidation states of other elements; d/a is 1.9 or more and 3.2 or less; d/g is 29 or more and 69 or less; and a/g is 18 or more and 35 or less.

2. The catalyst for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid according to claim 1 , which is prepared by shaping a preliminarily calcined powder obtained by calcining a dry powder obtained by drying a slurry containing the component of the formula (1), at a temperature of 200° C. or higher and 600° C. or lower and again calcining the preliminarily calcined powder at a temperature of 200° C. or higher and 600° C. or lower.

3. The catalyst for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid according to claim 2 , wherein the shaping method of the catalyst is the method of coating a catalytically active component on a spherical carrier, the average particle diameter of the obtained catalyst is 3.0 mm to 10.0 mm, and a portion of the weight of the catalytically active component occupying in the whole of the catalyst is 20 to 80% by weight.

4. A method for producing a catalyst, which is a production method of the catalyst for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid according to claim 1 , wherein in a step of preparing the compound represented by the formula (1), the molybdenum component raw material is composed of only ammonium molybdate, the weight of water for dissolving the ammonium molybdate is controlled to 8.5 times or less relative to the weight of molybdenum contained in the ammonium molybdate, and the bismuth component raw material is composed of only bismuth nitrate, the weight of a nitric acid aqueous solution for dissolving the bismuth nitrate is controlled to 2.3 times or more relative to the weight of bismuth contained in the bismuth nitrate, and the nitric acid concentration of the nitric acid aqueous solution for dissolving the bismuth nitrate is controlled to 10% by weight or more.

5. A method for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid comprising subjecting an alkene to gas-phase oxidation with molecular oxygen or a molecular oxygen-containing gas in the presence of the catalyst according to claim 1 .

Assignees

• Nippon Kayaku Kk

Inventors

• NAKAZAWA Yuuta
• SHOYA Yoshiko
• Nakahara Masaki
• Nishimura Eiji
• Shiraishi Kazuo
• Kurakami Tatsuhiko
• Hiraoka Ryota

Classifications

• B01J37/04 Primary

  Mixing {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• B01J37/0018

  Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat) · CPC title

• B01J2523/847

  Nickel · CPC title

• C07C45/35

  in propene or isobutene · CPC title

• C07C47/22

  Acryaldehyde; Methacryaldehyde · CPC title