Abstract:
The present invention provides a Mo-Bi-Nb based composite metal oxide (with
the proviso that Te is not included); a method for producing (meth)acrylic acid
from at least one reactant selected from the group consisting of propylene,
propane, isobutylene, t-butyl alcohol and methyl-t-butyl ether, in which a Mo-Bi-
Nb based composite metal oxide (with the proviso that Te is not included) is used
as a catalyst; and a reactor used for producing (meth)acrylic acid from at least
one reactant selected from the group consisting of propylene, propane,
isobutylene, t-butyl alcohol and methyl-t-butyl ether, in which a Mo-Bi-Nb based
composite metal oxide (with the proviso that Te is not included) is used as a
catalyst. Further, the present invention provides a method for producing
(meth)acrylic acid from at least one reactant selected from the group consisting
of propylene, propane, isobutylene, t-butyl alcohol and methyl-t-butyl ether by
using a Mo-Bi-Nb based composite metal oxide as a catalyst, without any
additional process of converting (meth)acrolein into (meth)acrylic acid.
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Notices, Deadlines & Correspondence
20, YOIDO-DONG, YOUNGDUNGPO-GU, SEOUL, 150-721, KOREA
Inventors
1. SHIN HYUN-JONG
102-1807, JUNGHEUNG APT., 331-93, JINWOL-DONG, NAM-GU, GWANGIU METROPOLITAN CITY 503-330 KOREA
2. CHOI BYUNG-YUI
NA-203, LG COMPANY'S HOUSING, 1, SONGWOL-DONG, NAJU-SI, JEOLLANAM-DO, 520-130, REPUBLIC OF KOREA
3. YOO YEON-SHICK
NA-106, LG COMPANY'S HOUSING, SONGWOL-DONG, NAJU-SI, JEOLLANAM-DO, 520-130, REPUBLIC OF KOREA
4. CHO YOUNG-JIN
#304, LG CHEMISTRY DORMITORY, 1, SONGWOL-DONG, NAJU-SI, JEOLLANAM-DO 520-130, REPUBLIC OF KOREA
Specification
[DESCRIPTION]
[Invention Title]
MULTI-METAL OXIDE CATALYST AND METHOD FOR PRODUCING
(METH)ACRYLIC ACID BY USING THE SAME
[Technical Field]
The present invention relates to a Mo-Bi-Nb based composite metal oxide(multi-metal
oxide), and a method for producing (meth)acrylic acid from propylene or the like by using the
Mo-Bi-Nb based composite metal oxide as a catalyst. Further, the present invention relates to
a method for producing (meth)acrylic acid from propylene or the like by an one-step catalyst
reaction.
This application claims priority from Korea Patent Application No. 10-2006-71061 filed
on July 27, 2006 in the KIPO, the disclosure of which is incorporated herein by reference in its
entirety.
[Background Art]
A process for producing an unsaturated fatty acid from olefin by way of an unsaturated
aldehyde is a typical process of gas-phase catalytic oxidation.
Particular examples thereof include a process of producing (meth)acrylic acid from a
staring material such as propylene, propane, isobutylene, t-butyl alcohol or methyl-t-butyl ether
(referred to as 'propylene or the like', hereinafter) by way of corresponding (meth)acrolein.
In this connection, in the first step of partially oxidizing olefins to unsaturated aldehyde,
1
composite metal oxides containing molybdenum and bismuth are generally used as a catalyst.
In the second step of partially oxidizing the unsaturated aldehyde, which is a main product of the
first step, to unsaturated fatty acid, composite metal oxides containing molybdenum and
vanadium are used as a catalyst.
More particularly, in the first step, propylene or the like is oxidized by oxygen, inert gas
for dilution, water steam and a certain amount of a catalyst, so as to produce (meth)acrolein as a
main product. Then, in the second step, the (meth) acrolein is oxidized by oxygen, inert gas for
dilution, water steam and a certain amount of a catalyst, so as to produce (meth)acrylic acid.
The catalyst used in the first step is a Mo-Bi based multinary metal oxide, which oxidizes
propylene or the like to produce (meth)acrolein as a main product. Also, some (meth)acrolein
is continuously oxidized on the same catalyst to partially produce (meth)acrylic acid. The
catalyst used in the second step is a Mo-V based multinary metal oxide, which mainly oxidizes
(meth)acrolein of the mixed gas containing the (meth)acrolein produced from the first step to
produce (meth)acrylic acid as a main product.
A reactor for performing the aforementioned process is provided either in such a
manner that both the two-steps can be performed in one system, or in such a manner that the two
steps can be performed in different systems.
As mentioned above, the first-step catalyst involved in gas-phase partial oxidation using
propylene or the like as a starting material is the Mo-Bi based multi-metal oxide, with which
(meth)acrolein is produced as a main product and 10% or less of (meth)acrylic acid is produced.
2
As disclosed in JP-A-8-3093, a conventional first-step catalyst is a composite oxide
represented by the formula of Moa-Bib-Fec-Ad-Be-Cf Dg-Ox (wherein Mo, Bi and Fe represent
molybdenum, bismuth and iron, respectively; A is nickel and/or cobalt; B is at least one element
selected from the group consisting of manganese, zinc, calcium, magnesium, tin and lead; C is at
least one element selected from the group consisting of phosphorus, boron, arsenic, Group 6B
elements in the Periodic Table, tungsten, antimony and silicon; D is at least one element selected
from the group consisting of potassium, rubidium, cesium and thallium; when a=12, 0
Preparation Example 1: Catalyst 1
2500 ml of distilled water was heated and stirred at 70 to 85 °C and 1000 g of
ammonium molybdate was dissolved therein to form a solution 1. Then, 274 g of bismuth
nitrate, 228 g of ferrous nitrate and 2.3 g of potassium nitrate were added to 400 ml of distilled
water, the materials were mixed thoroughly, 71 g of nitric acid was added thereto, and the
materials were dissolved sufficiently to form a solution 2. 686 g of cobalt nitrate was dissolved
in 200 ml of distilled water, so as to form a solution 3. After mixing the solution 2 with the
solution 3, the mixed solution was further mixed with the solution 1 while the temperature was
maintained at 40 to 60 °C, so as to provide a catalyst suspension.
14
The catalyst suspension was dried and the obtained cake-shaped solid was pulverized
into a size of 150 μm or less. The resultant catalyst powder was mixed with a predetermined
amount of water for 2 hours, and formed into a cylindrical shape. The catalyst was formed to
have a diameter of 5.0 mm and a height of 5.0 mm, and calcined at 5001) for 5 hours under the
air, resulting in a catalyst 1. The produced catalyst had the elemental composition of except
oxygen. The resulting catalyst had the following elemental composition except oxygen:
Mo12 Bi1..2 Fe1..2 CO5 K0.05
Preparation Example 2: Catalyst 2
Catalyst 2 was provided in the same manner as described in Preparation Example 1,
except that 64 g of niobium chloride were further added to form a solution 1. The resulting
catalyst had the following elemental composition except oxygen:
Mo12 Nb0.5 Bi1..2 Fe1..2 C05 K0.05
Preparation Example 3: Catalyst 3
Catalyst 3 was provided in the same manner as described in Preparation Example 1,
except that 64 g of niobium chloride were further added to form a solution 1 and the molded
catalyst was allowed to have a diameter of 7 mm and a height of 7 mm. The resulting catalyst
had the following elemental composition except oxygen:
Mo12 Nb0.5 Bi1..2 Fe1..2 C05 K0.05
Preparation Example 4: Catalyst 4
Catalyst 4 was provided in the same manner as described in Preparation Example 1,
15
except that 32 g of niobium chloride were further added to form a solution 1. The resulting
catalyst had the following elemental composition except oxygen:
Mo12 Nb0.5 Bi1..2 Fe1..2 C05 K0.05
Preparation Example 5: Catalyst 5
Catalyst 5 was provided in the same manner as described in Preparation Example 1,
except that 32 g of niobium chloride were further added to form a solution 1 and the molded
catalyst was allowed to have a diameter of 7 mm and a height of 7 mm. The resulting catalyst
had the following elemental composition except oxygen:
Mo12 Nb0.5 Bi1..2 Fe1..2 C05 K0.05
To a 3 m stainless steel reactor having an inner diameter of 1 inch and heated with
molten nitrate salt, alumina silica was packed to a height of 150 mm as an inert material, and
any one or a mixture of Catalysts 1 to 5 prepared in Catalyst Preparation Examples 1 to 5 shown
in Table 1 was packed to have a height of 2800 mm, from the inlet of the reaction gas toward the
outlet.
The oxidation was performed by introducing feed gas containing 7 vol% of propylene,
13 vol% of oxygen, 12 vol% of water steam, and 68 vol% of inert gas onto the catalyst with a
space velocity of 1500 hr-1 (STP), at a reaction temperature of 320 "C under a reaction pressure
of 0.7 arm.
16
In Tables 1, conversion ratio of a reactant and yield are calculated, based on the
following Mathematical Formulae 1 and 2.
[Mathematical Formula 1]
Conversion ratio of propylene (%) = [(mole number of reacted propylene)/(mole
number of supplied propylene)] x 100
[Mathematical Formula 2]
Yield (%) of acrylic acid = [(mole number of produced acrylic acid)/(mole number of
supplied propylene)] x 100
The experimental results of the Examples and Comparative Example are shown in the
following Table 1.
[Table 1]
Section
Comparative 1
Example 1
Example 2
Example 3
Catalyst packed
Catalyst 1 (2800mm)
Catalyst 2 (2800mm)
Catalyst 3 (800mm)
+ Catalyst 2 (2000mm)
Catalyst 5 (800mm)
+ Catalyst 4 (2000mm)
Conversion ratio of
propylene (%)
3201
98.67
92.21
91.44
93.87
Yield (mole %) of
acrylic acid
9.51
67.40
72.65
76.84
17
We claim:
[Claim 1]
A method for producing (meth)acrylic acid using one or more reactant selected from
the group consisting of propylene, propane, isobutylene, t-butyl alcohol and methyl-t-butyl
5 ether,
wherein a Mo-Bi-Nb based composite metal oxide represented by the following
Formula 1 is used as a catalyst:
[Formula 1]
Moa Bib NbcAd Be Cf Dg Eh Fj Oj
10 wherein Mo represents molybdenum, Bi represents bismuth, and Nb represents
niobium;
A is one or more element selected from the group consisting of W, Sb, As, P, Sn and
Pb;
B is one or more element selected from the group consisting of Fe, Zn, Cr, Mn, Cu, Pd,
15 Ag and Ru;
C is one or more element selected from the group consisting of Co, Cd, Ta, Pt and Ni;
D is one or more element selected from the group consisting of Si, Al, Zr, V and Ce;
E is one or more element selected from the group consisting of Se, Ga, Ti, Ge, Rh
and Au;
20 F is one or more element selected from the group consisting of Na, K, Li, Rb, Cs, Ca,
Mg, Sr, Ba and MgO;
each of a, b, c, d, e, f, g, h, i, and j represents the atomic ratio of each element; and
when a=12, b is 0.01 to 20, c is 0.001 to 20, d is 0 to 15, e is 0 to 20, f is 0 to 20, g is 0
to 10, h is 0 to 10, i is 0 to 10, and j is a value defined by the oxidation state of each of the
25 above elements, proviso that g is zero and Te is not included.
[Claim 2]
The method as claim in claim 1, wherein a yield of (meth)acrylic acid of products
obtained by catalytic action of the Mo-Bi-Nb based composite metal oxide is 60 mole% or
30 more.
[Claim 3]
The method as claim in claim 1, wherein the method is performed in a fluidized bed
reactor.
18
25
C l a im 41 •^- ^ . .o,>J
The method as claim in claim 1, further comprising a process of converting
(meth)acrolein of the products produced by the catalytic action of the Mo-Bi-Nb based
composite metal oxide into (meth)acrylic acid.
[Claim 5]
The method as claim in claim 1, wherein a reaction zone in which (meth)acrylic acid is
produced using one or more reactant selected from the group consisting of propylene,
propane, isobutylene, t-butyl alcohol and methyl-t-butyl ether is packed with two or more
10 catalyst beds, and the Mo-Bi-Nb based composite metal oxide is used as a catalytic
effective component of one or more catalyst bed.
[Claim 6]
The method as claim in claim 5, wherein the reaction zone is packed with two or more
15 of catalyst beds having different catalytic activities in order to increase the catalytic activity
of the catalyst bed from the inlet, in which the reactants are introduced, to the outlet, in
which the reaction products are outputted.
[Claim 7]
20 The method as claim in claim 5, wherein the reaction zone is packed with two or more
different catalyst beds so that the particle size of the catalyst in the catalyst beds having an
effective component of Mo-Bi-Nb based composite metal oxide decreases from the inlet, in
which the reactants are introduced, to the outlet, in which the reaction products are
outputted.
[Claim 8]
The method as claim in claim 6, wherein the reaction zone is packed with two or more
different catalyst beds having an effective component of Mo-Bi-Nb based composite metal
oxide and the different molar ratios of Nb to Mo ([Nb]/[Mo]) and the catalytic activity of
30 each of the catalyst beds increases from the inlet, in which the reactants are introduced, to
the outlet, in which the reaction products are outputted.