Synthetic methods for the preparation of propylene ammoxidation catalysts

A process for producing a catalyst material, the catalyst material comprising

• a metal oxide catalyst in an amount in the range of at least about 25 wt %, the metal oxide catalyst having the formula MoxBiyFezAaBbCcDdOv, wherein
• x is in the range of 10 to 14;
• y is in the range of 0.05 to 5;
• z is in the range of 0.2 to 5;
• A is at least one element selected from Ni and Co;
• a is in the range of 1 to 10;
• B is at least one element selected from the lanthanides, Mg, Cr, Mn, Zn and Ca;
• b is in the range of 0.01 to 6;
• C is at least one element selected from W, Sn, V, Ti, Zr, Ga, Hf, Nb, Ta, In and Al;
• c is in the range of 0 to 8;
• D is at least one element selected from Li, Na, K, Rb and Cs;
• d is in the range of 0.02 to 2;
• and
• v is the number of oxygen atoms required to satisfy the valence requirements of the other component elements Mo, Bi, Fe, A, B, C, and D,
• the process comprising:
• providing a suspension or slurry of an inert carrier in a metal oxide precursor fluid, the inert carrier having an average particle size less than about 10 microns, the metal oxide precursor fluid comprising a solvent in admixture with a plurality of metal oxide precursors, the plurality of metal oxide precursors comprising at least
• a molybdenum oxide precursor,
• a bismuth oxide precursor, and
• an iron oxide precursor,
• wherein less than about 5 wt % of each of the molybdenum oxide precursor, the bismuth oxide precursor, and the iron oxide precursor is not dissolved in the solvent;
• spray drying the suspension or slurry of the inert carrier in the metal oxide precursor fluid to obtain a spray-dried precursor material;
• and
• heating the spray-dried precursor material to obtain the catalyst material.