Catalyst for methacrylic acid and production and process for producing the same

A method for preparing a catalyst for producing methacrylic acid by subjecting methacrolein, isobutylaldehyde or isobutyric acid to gas phase catalytic oxidation, the method comprising:

• step (A) of blending compounds A-1 to A-3 and, as needed, compound A-4 with water to prepare an aqueous solution or dispersion of the compounds (hereinafter, called a slurry, including both),
• wherein the compound A-1 is a compound containing Mo, a compound containing V, a compound containing P, and a compound containing Cu, the compound A-2 is a cesium weak acid salt or cesium hydroxide, the compound A-3 is ammonium acetate, and the compound A-4 is one or more compounds selected from the group consisting of compounds containing one of Sb, As, Ag, Mg, Zn, Al, B, Ge, Sn, Pb, Ti, Zr, Cr, Re, Bi, W, Fe, Co, Ni, Ce, Th, K and Rb;
• and
• step (B) of drying the slurry yielded in step (A) to obtain a dried slurry.

A method for preparing a coated catalyst for producing methacrylic acid by subjecting methacrolein, isobutylaldehyde or isobutyric acid to gas phase catalytic oxidation, the method comprising:

• step (a) of blending compounds a-1 to a-3 and, as needed, compound a-4 with water to prepare an aqueous solution or dispersion of the compounds (hereinafter, called a slurry, including both),
• wherein the compound a-1 is a compound containing Mo, a compound containing V, a compound containing P, and a compound containing Cu, the compound a-2 is a cesium weak acid salt or cesium hydroxide, the compound a-3 is ammonium acetate or ammonium hydroxide, and the compound a-4 is one or more compounds selected from the group consisting of compounds containing one of Sb, As, Ag, Mg, Zn, Al, B, Ge, Sn, Pb, Ti, Zr, Cr, Re, Bi, W, Fe, Co, Ni, Ce, Th, K and Rb;
• step (b) of drying the slurry yielded in step (a) to obtain a dried slurry;
• step (c) of coating a carrier with the dried slurry obtained in step (b) using a binder to obtain a coated molded product;
• and
• step (d) of calcining the coated molded product obtained in step (c).

A method for preparing a coated catalyst for producing methacrylic acid by subjecting methacrolein, isobutylaldehyde or isobutyric acid to gas phase catalytic oxidation, the method comprising:

• step (a) of blending compounds a-1 to a-3 and, as needed, compound a-4 with water to prepare a slurry of the compounds, wherein the compound a-1 is a compound containing Mo, a compound containing V, a compound containing P, and a compound containing Cu, the compound a-2 is a cesium weak acid salt or cesium hydroxide, the compound a-3 is ammonium acetate or ammonium hydroxide, and the compound a-4 is one or more compounds selected from the group consisting of compounds containing one of Sb, As, Ag, Mg, Zn, Al, B, Ge, Sn, Pb, Ti, Zr, Cr, Re, Bi, W, Fe, Co, Ni, Ce, Th, K and Rb;
• step (b) of drying the slurry yielded in step (a) to obtain a dried slurry;
• step (b′) of blending the dried slurry obtained in step (b) with a solid compound containing copper to obtain powders;
• step (c) of coating a carrier with the powders obtained in step (b′) using a binder to obtain a coated molded product;
• and
• step (d) of calcining the coated molded product obtained in step (c).