	US 12,331,014 B2
	Aldehyde byproduct reduction in acrylic acid production using highly active and elective catalysts
Jinsuo Xu, Berwyn, PA (US); Nelson I. Quiros, Houston, TX (US); Daniel A. Bors, Maple Glen, PA (US); and Joseph F. Dewilde, King of Prussia, PA (US)
Assigned to Rohm and Haas Company, Collegeville, PA (US); and Dow Global Technologies LLC, Midland, MI (US)
Appl. No. 17/601,751
Filed by Dow Global Technologies LLC, Midland, MI (US); and Rohm and Haas Company, Collegeville, PA (US)
PCT Filed Apr. 20, 2020, PCT No. PCT/US2020/028907 § 371(c)(1), (2) Date Oct. 6, 2021, PCT Pub. No. WO2020/223048, PCT Pub. Date Nov. 5, 2020.
Claims priority of provisional application 62/841,921, filed on May 2, 2019.
Prior Publication US 2022/0193640 A1, Jun. 23, 2022
Int. Cl. C07C 51/16 (2006.01); B01J 23/00 (2006.01); B01J 23/28 (2006.01); B01J 23/652 (2006.01); C07C 45/28 (2006.01); C07C 57/04 (2006.01)

CPC C07C 51/16 (2013.01) [B01J 23/002 (2013.01); B01J 23/28 (2013.01); B01J 23/6525 (2013.01); C07C 45/28 (2013.01); C07C 57/04 (2013.01); B01J 2523/55 (2013.01); B01J 2523/56 (2013.01); B01J 2523/64 (2013.01)]

6 Claims

1. A process for producing acrylic acid comprising:

a) contacting a gas stream comprising acrolein with an acrolein-oxidizing catalyst to form a product stream A, wherein at least one aldehyde byproduct is present in the product stream A;

b) contacting the product stream A with a finishing catalyst to form a product stream B comprising acrylic acid, wherein the product stream B comprises a lower weight percentage of the at least one aldehyde byproduct than product stream A;

wherein:

i) the acrolein-oxidizing catalyst comprises a mixed metal oxide catalyst of general formula (I):

MoV_aA¹_bA²_cA³_dO_m (I)

wherein:

A¹comprises at least one element selected from the group consisting of W and Cu;

A²comprises at least one element selected from the group consisting of Sb, Fe, and Nb;

A³comprises 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;

ii) the finishing catalyst comprising a mixed metal oxide catalyst of general formula (II):

MoV_wNb_xX¹_yX²_zO_n (II)

wherein:

X¹comprises at least one element selected from the group consisting of Te and Sb;

X²comprises at least one an element selected from the group consisting of Y, Ti, Zr, Hf, 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 0.001 to 1.0;

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°; and

the acrolein-oxidizing catalyst has a different chemical composition than the finishing catalyst.