Supported catalyst for production of unsaturated carboxylic acids from alkanes

Patent metadata

Field	Value
Publication number	US-9856200-B2
Application number	US-201414786000-A
Country	US
Kind code	B2
Filing date	Apr 22, 2014
Priority date	Apr 24, 2013
Publication date	Jan 2, 2018
Grant date	Jan 2, 2018

Abstract

The present disclosures and inventions relate to a supported catalyst composition for the catalytic oxidation of a hydrocarbon such as propane with oxygen or air, in the presence of a catalyst composition comprising a support material and a mixed metal composition comprising metals in the molar ratios described by the formula Mo a V b Ga c Pd d Nb e Z f , wherein the support material is neutral or oxidative.

First claim

What is claimed is:

1. A catalyst composition comprising a support material and a mixed metal composition comprising metals in the molar ratios described by the formula
Mo a V b Ga c Pd d Nb e Z f ,
wherein a is 1,
wherein b is from 0.01 to 0.9,
wherein c is from greater than 0 to 0.2,
wherein d is from 0.0000001 to 0.2,
wherein e is greater than 0 to 0.2,
wherein Z comprises La, Te, Ge, Zn, Si, In, or W, or a mixture thereof, and
wherein f is greater than 0 to 0.5,
wherein the support material is neutral or oxidative,
wherein the support material comprises acetate-SiO 2 , acetate-Al 2 O 3 , acetate-ZrO 2 , or actetate-CeO 2 , or a mixture thereof.

2. The catalyst composition of claim 1 , wherein the support material comprises acetate-SiO 2 .

3. The catalyst composition of claim 1 , wherein the support material comprises actetate-CeO 2 .

4. The catalyst composition of claim 1 , wherein the support material comprises acetate-ZrO 2 .

5. The catalyst composition of claim 1 , wherein the support material is oxidative.

6. The catalyst composition of claim 1 , wherein the support material is neutral.

7. The catalyst composition of claim 1 , wherein the support material is a microporous or mesoporous support material.

8. The catalyst composition of claim 1 , wherein the catalyst composition has a particle diameter size from 20 μm to 500 μm.

9. The catalyst composition of claim 1 , wherein Z comprises Te.

10. The catalyst composition of claim 1 , wherein the catalyst composition is stable to at least 600° C.

11. The catalyst composition of claim 1 , wherein the catalyst composition is at least 10% more effective in oxidizing propane to acrylic acid and propylene than a corresponding unsupported catalyst composition.

12. The catalyst composition of claim 1 , wherein the catalyst composition is at least 20% more effective in oxidizing propane to acrylic acid and propylene than a corresponding unsupported catalyst composition.

13. The catalyst composition of claim 1 , wherein the catalyst composition is at least 30% more effective in oxidizing propane to acrylic acid and propylene than a corresponding unsupported catalyst composition.

14. The catalyst composition of claim 1 , wherein the support material does not comprise a metal.

15. The catalyst composition of claim 1 , wherein the support material does not comprise a metal comprising B, La, Mn, Sb, Ti, Zr, La, Fe, Cs, Au, or Ce.

16. A method of oxidizing a C2-C12 alkane comprising, contacting the C2-C12 alkane with an oxygen containing stream and the catalyst composition of claim 1 , thereby oxidizing the C2-C12 alkane.

17. The method of claim 16 , wherein the C2-C12 alkane is propane.

18. The method of claim 16 , wherein the oxidation produces acrylic acid and propylene.

19. The method of claim 16 , wherein the oxidation is at least 30% more effective in oxidizing the C2-C12 alkane than a corresponding unsupported catalyst composition.

20. A method of making the catalyst composition of claim 1 comprising the step of
a) mixing a support material with an active phase comprising the mixed metal composition of claim 1 , thereby forming a catalyst composition, wherein the support material is neutral or oxidative and comprising acetate-SiO 2 , acetate-Al 2 O 3 , acetate-ZrO 2 , or actetate-CeO 2 , or a mixture thereof, thereby forming the catalyst composition of claim 1 .

Assignees

• Saudi Basic Ind Corp

Inventors

• Karim Khalid
• Al Jodai Abdulaziz

Classifications

• B01J2523/00

  Constitutive chemical elements of heterogeneous catalysts · CPC title

• B01J37/04

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

• B01J27/0576

  Tellurium; Compounds thereof · CPC title

• C07C51/215 Primary

  of saturated hydrocarbyl groups · CPC title

• C07C2527/057

  Selenium or tellurium; Compounds thereof · CPC title