Processes for the manufacture of acrolein derivatives

A process for producing an acrolein derivative comprising:

• (i) passing a propylene feedstream comprising propylene, oxygen and a recycle gas comprising propane, oxygen and at least one of carbon monoxide or carbon dioxide to an acrolein reaction zone wherein the propylene feedstream is contacted with an acrolein reaction catalyst at conditions effective to promote the formation of acrolein to provide an acrolein effluent stream comprising acrolein, propane, acetaldehyde and water;
• (ii) passing the acrolein effluent stream to an acrolein separation zone wherein the acrolein effluent stream is partially condensed to provide a liquid acrolein product stream comprising acrolein, acetaldehyde and water and a recycle gas stream comprising the recycle gas;
• (iii) passing the acrolein product stream and a co-reactant to an acrolein derivative reaction zone and contacting the acrolein and co-reactant under conditions effective to convert the acrolein and the co-reactant into an acrolein derivative;
• and
• (iv) recycling at least a portion of the recycle gas stream to the acrolein reaction zone:
• characterized in that the propylene feedstream comprises an amount of propane of from about 5 to 70 volume percent and effective to provide a propylene-to-acrolein reaction efficiency of from about 75 to 90 mole percent.