Rohm and Haas Company

Dow Global Technolgoies LLC

Jinsuo Xu

Andrew Michael Lemonds

Mark A Silvano

Dmitry A Krapchetov

Reetam Chakrabarti

Timothy Allen Hale

Donald Alan Ebert

Brian Robert Keyes

Justin Rose

Daniel Arthur Bors

Nelson I Quiros

Joseph F Dewilde

Andrew M Lemonds

A catalyst composition comprises an acrolein-oxidizing catalyst comprising a mixed metal oxide catalyst of general formula (1):MoVAAAO  (I)in which Acomprises at least one element selected from the group consisting of W and Cu; Acomprises at least one element selected from the group consisting of Sb, Fe, and Nb; Acomprises at least one element selected from the group consisting of Y, Ti, Zr, Hf, Ta, Cr, Mn, Re, Ru, Co, Rh, Ir, Ni, Pd, Pt, Ag, Au, Zn, B, Al, Ga, In, Ge, Sn, Si, Te, Pb, P, As, Bi, Se, rare earth elements, alkaline elements, and alkaline earth elements; a ranges from 0.01 to 1.0; b ranges from 0.01 to 1.5; c ranges from 0 to 1.5; d ranges from 0 to 1.0; and m is dependent on the oxidation state of the other elements. The catalyst composition further comprises a finishing catalyst comprising a mixed metal oxide catalyst of general formula (II):MoVNbXXO  (II)in which Xcomprises at least one element selected from the group consisting of Te and Sb; Xcomprises at least one an element selected from the group consisting of Y, Ti, Zr, Hf, Nb, Ta, Cr, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Pd, Pt, Ag, Au, Zn, B, Al, Ga, In, Ge, Sn, Pb, P, As, Bi, Se, rare earth elements and alkaline earth elements; w ranges from 0.01 to 1.0; x ranges from 0.01 to 1.0; y ranges from 0.01 to 1.0; z ranges from 0 to 1.0; and n is depended on the oxidation state of the other elements. The finishing catalyst does not contain W or Cu, and has an X-ray diffraction pattern showing an orthorhombic phase as the major crystal phase with main peaks with 2θ at 6.7°, 7.8°, 22.1°, and 27.2°. The acrolein-oxidizing catalyst has a different chemical composition than the finishing catalyst. A process for producing acrylic acid is also disclosed.

Aldehyde byproduct reduction in acrylic acid production using highly active and elective catalysts

Provided is a process for preparing acrylic acid comprising (1) preparing acrolein by catalytic gas phase oxidation comprising (a) providing a reaction gas comprising (i) 5 to 10 mol % propylene, (ii) 0.02 to 0.75 mol % propane, and (iii) 0.25 to 1.9 mol % of a fuel mixture comprising at least one of methane and ethane, wherein the molar ratio of the total amount of propane, methane, and ethane to the total amount of propylene is from 0.01:1 to 0.25:1, (b) contacting the reaction gas with a first mixed metal oxide catalyst to form a mixture comprising acrolein, wherein the first mixed metal oxide catalyst comprises one or more of molybdenum, bismuth, cobalt, and iron, and (2) contacting the acrolein mixture with a second mixed metal oxide catalyst to form a mixture comprising acrylic acid, wherein the second mixed metal oxide catalyst comprises one or more of molybdenum, vanadium, tungsten, copper, and antimony.

Method for preparing acrylic acid

Provided is a process for preparing acrolein by catalytic gas phase oxidation comprising (a) providing a reaction gas comprising (i) 5 to 10 mol % propylene, (ii) 0.02 to 0.75 mol % propane, and (iii) 0.25 to 1.9 mol % of a fuel mixture comprising at least one of methane and ethane, wherein the molar ratio of the total amount of propane, methane, and ethane to the total amount of propylene is from 0.01:1 to 0.25:1, and (b) contacting the reaction gas with a mixed metal oxide catalyst comprising one or more of molybdenum, bismuth, cobalt, and iron.

Method for preparing acrolein

A process for selecting an inert material for use in monomer production regarding the formation of heavy by-products during the reaction of propylene to acrolein and acrylic acid.

Method of determining the inertness of materials for use in monomer production

A method of determining the inertness of a material regarding the formation of heavy by-products during the reaction of propylene to acrolein and acrylic acid.

Provided is a process for preparing methacrolein which maximizes capture of methanol. Also provided are processes for producing methacrylic acid and methyl methacrylate.

Process for preparing methacrolein

The present invention provides methods for monomer production, for example, acrylic acid, wherein the methods comprise oxidizing one or more reactant gases, for example, propylene, in a fixed bed reactor, preferably, two fixed bed reactors, in the presence of oxygen and a mixed metal oxide catalyst to form an oxidized gaseous mixture and, at any point in the oxidizing, feeding or flowing the one or more reactant gases or the oxidized gaseous mixture through an inert macroporous material that has a pore volume of from 0.2 cm3/g to 2.0 cm3/g, a surface area of from 0.01 to 0.6 m2/g, and wherein from 30 to 98 wt. % of the total pore volume in the inert macroporous material has a pore diameter of at least 100 &#x3bc;m.

Methods for using macroporous inert materials in monomer production

A process for producing a catalyst for the (amm)oxidation of alkanes comprises calcination of a crystalline mixed metal oxide catalyst partially or wholly in the presence of steam.

Steam re-calcination of mixed metal oxide catalysts

A method for producing &#x3b1;-, &#x3b2;-unsaturated carboxylic acid esters in high yield from reaction by-product streams via the catalytic conversion of the by-products to additional &#x3b1;-, &#x3b2;-unsaturated carboxylic acid ester product. The catalyst comprises cesium, and phosphorous as a promoter, on a porous support.

Process for production of methacrylic acid esters

This invention provides a method for producing &#x3b1;,&#x3b2;-unsaturated carboxylic acid esters in high yield from acetone cyanohydrin and sulfuric acid through the separation and concurrent catalytic conversion of reaction side products to additional &#x3b1;,&#x3b2;-unsaturated carboxylic acid ester product. The catalyst comprises at least one Group IA element and may include a porous support and/or a promoter element selected from at least one of phosphorous, boron, titanium, zinc, zirconium, tin, bismuth, cerium, and alkaline earth metals. The method for producing methacrylic acid esters, such as methylmethacrylate (MMA), comprises the steps of: i) providing an alkyl alcohol and an organic traction comprising an alkyl methacrylate, an alkyl &#x3b1;-hydroxyisobutyrate and an alkoxyisobutyrate; ii) vaporizing at least a portion of the organic fraction and at least a portion of the alkyl alcohol; iii) contacting the vaporized organic fraction and alcohol with a catalyst comprising at least one element selected from the group consisting of lithium, sodium, potassium, rubidium, cesium and francium, to convert the alkyl ahydroxyisobutyrate and alkyl alkoxyisobutyrate to additional alkyl methacrylate and produce a mixture comprising alkyl methacrylate, methacrylic acid, alkyl alcohol, and water.

Process for production of methacrylic acid ester having increased yield

The present invention provides a method for extractive recovery and conversion of selected compounds, such as methacrylic acid (MAA) and 2-methacrylamide (MAM), from a stream derived from purification of methyl methacrylate (MMA) or methacrylic acid (MAA) produced via a conventional ACH route process.

Growing community of inventors

Fort Washington, PA, United States of America

Jinsuo Xu