E.i. Dupont De Nemours and Company

Invista North America S.a.r.l.

John Donal Sullivan

Kostantinos Kourtakis

Rashmikant M Contractor

Harold S Horowitz

Gregory Scott Patience

This invention concerns catalysts comprising a molybdenum compound of formula I, II, III, IV or VVMoAO&#x2003;&#x2003;INiMoBO&#x2003;&#x2003;IIVNiMoCO&#x2003;&#x2003;IIICoNiMoDO&#x2003;&#x2003;IVVNiCoMoEO&#x2003;&#x2003;Vwherein: A is at least one cation selected from the group consisting of cations of: Cr, Sb, Co, Ce and Pb; B is at least one cation selected from the group consisting of cations of: Sb, Al and W; C is at least one cation selected from the group consisting of cations of: Fe, Zn, Al, Sb, Bi, W, Li, Ba, Nb and Sn; D is at least one cation selected from the group consisting of cations of: Ba, Mn, Al, Sb, Sn, and W; E is at least one cation selected from the group consisting of cations of: Fe, Ca, Mn, Sr, Eu, La, Zr, Ga, Sn and Pb; q, r, w, x and y are each independently a number from 0.1 to 10 and y' is a number from 0 to 10, z, z&#x2032;, z&#x2033;, z&#x2032;&#x2033;, and z&#x2033;&#x2033; are determined using the amounts and oxidation states of all cations present in each formula. These catalysts can be used in Coxidation processes, especially butane oxidation processes.

Molybdenum based oxidation catalysts

This invention concerns catalysts comprising a molybdenum compound of formula (I): V,MoA,O,, (II): NiMo,B,O,&prime;, (III): VNi,Mo,C,&prime;O,&Prime;, (IV): CoNi,Mo,D,O,&prime;&Prime;, or (V): VNi,CO,Mo,E,O,&Prime;&Prime;, wherein: A is at least one cation selected from the group consisting of cations of Cr, Sb, Co, Ce and Pb; B is at least one cation selected from the group consisting of cations of Sb, Al and W; C is at least one cation selected from the group consisting of cations of Fe, Zn, Al, Sb, Bi, W, Li, Ba, Nb and Sn; D is at least one cation selected from the group consisting of cations of Ba, Mn, Al, Sb, Sn and W; E is at least one cation selected from the group consisting of cations of Fe, Ca, Mn, Sr, Eu, La, Zr, Ga, Sn and Pb; q, r, w, x, y, y&prime;, z, z&prime;, z&Prime;, z&prime;&Prime; and z&Prime;&Prime; are as defined in the disclosure. These catalysts can be used in C4 oxidation processes.

An improved process for calcination and activation of a catalyst containing mixed oxides of vanadium and phosphorus (V/P/O) involving the addition of spray dried catalyst precursor to a fluidizing oxygen containing gas at a controlled rate such that the temperature is maintained at a range of 370 to 410.degree. C. (preferably 390.+-.5.degree. C.). The catalyst precursor experiences, in addition to rapid temperature rise, dehydration/calcination at this elevated temperature in the fluidized state for an average range of residence time of less than about 4 hours at 3.5 atm of air or above, and up to 20 hours at 1 atm of air while simultaneously and continuously maintaining an average V.sub.ox of 4.55 or less. Such a process is useful in preparing a V/P/O catalyst that exhibits enhanced activity for the oxidation of n-butane to maleic anhydride. The novel process also provides an improved method for start-up of a commercial scale recirculating solids reactor.

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Wilmington, DE, United States of America

John Donal Sullivan