Process of making mixed metal oxide catalysts for the production of unsaturated aldehydes from olefins
AssigneeSaudi Basic Industries Corporation
InventorsJames Kauffman, Angela McGuffey
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Abstract
The present invention is for a process for making a catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, said catalyst containing oxides of molybdenum, bismuth, iron, cesium, tungsten, cobalt, nickel, antimony, magnesium and zinc. The process is a synthesis of the catalyst with aging or digestion of the reaction slurry with little or no agitation. A catalyst precursor is formed from the water insoluble and water soluble components and is dried. The metal oxide catalyst is formed by calcination of the catalyst precursor.
Claims34
A process for preparing catalyst for the oxidation of an olefin to an unsaturated aldehyde comprising:
- a) dissolving compounds of molybdenum, bismuth, iron, cesium, and optional compounds of tungsten, M and M′ in water or acid to form a reaction solution, wherein M is one or more selected from antimony, phosphorus, boron, sulfur, silicon, aluminum, titanium, tellurium, vanadium, zirconium and niobium and M′ is one or more selected from cobalt, nickel, magnesium, zinc, potassium, rubidium, thallium, manganese, barium, chromium, cerium, tin, lead, cadmium and copper;
- b) precipitating a solid in the reaction solution to form a reaction slurry;
- c) aging the slurry for about 5 to about 10 hours with little or no agitation;
- d) evaporating liquid from the slurry to form a solid catalyst precursor;
- e) calcining the solid to form oxides of the metals to form a catalyst of the general formula:
- Mo12BiaWbFecCsgMmM′m′Ox
- wherein a is in the range from 0.1 to 1.5, b is 0 to 9, c is in the range from 0.2 to 5.0, g is in the range from 0.1 to 1.5, m is in the range from 0 to 9, m′ is from 0 to 9 and x is determined by the valences of the other components.
The process of claim 21 wherein the compounds are dissolved and precipitation occurs at a temperature in the range of from 60° C. to 95° C.
Dependencies are inferred from the claim text.