EP2470301A1 - Précurseur de catalyseur pour la production d'anhydride d'acide maléique et son procédé de production - Google Patents

Précurseur de catalyseur pour la production d'anhydride d'acide maléique et son procédé de production

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Publication number
EP2470301A1
EP2470301A1 EP10744601A EP10744601A EP2470301A1 EP 2470301 A1 EP2470301 A1 EP 2470301A1 EP 10744601 A EP10744601 A EP 10744601A EP 10744601 A EP10744601 A EP 10744601A EP 2470301 A1 EP2470301 A1 EP 2470301A1
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EP
European Patent Office
Prior art keywords
oxygen
catalyst precursor
carbon atoms
vanadium
catalyst
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP10744601A
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German (de)
English (en)
Inventor
Stefan Altwasser
Cornelia Katharina Dobner
Hagen Wilmer
Frank Rosowski
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BASF SE
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BASF SE
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Publication date
Application filed by BASF SE filed Critical BASF SE
Priority to EP10744601A priority Critical patent/EP2470301A1/fr
Publication of EP2470301A1 publication Critical patent/EP2470301A1/fr
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/14—Phosphorus; Compounds thereof
    • B01J27/186—Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J27/195—Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium with vanadium, niobium or tantalum
    • B01J27/198—Vanadium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/002—Mixed oxides other than spinels, e.g. perovskite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/16—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation
    • C07C51/21—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen
    • C07C51/215—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of saturated hydrocarbyl groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2523/00—Constitutive chemical elements of heterogeneous catalysts
    • B01J35/30—
    • B01J35/40—
    • B01J35/50—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/03—Precipitation; Co-precipitation
    • B01J37/031—Precipitation

Definitions

  • the present invention relates to a vanadium, phosphorus and oxygen containing catalyst precursor and to a process for the preparation thereof for the production of maleic anhydride by heterogeneously catalyzed gas phase oxidation of a hydrocarbon having at least four carbon atoms.
  • the present invention relates to a vanadium, phosphorus and oxygen-containing catalyst and a process for its preparation using the catalyst precursor according to the invention. Furthermore, the present invention relates to a process for the preparation of maleic anhydride by heterogeneously catalyzed gas phase oxidation of a hydrocarbon having at least four carbon atoms using the catalyst according to the invention.
  • Maleic anhydride is an important intermediate in the synthesis of
  • the production of maleic anhydride by oxidation of hydrocarbons such as n-butane, n-butenes or benzene to suitable catalysts has been known for a long time.
  • this vanadium, phosphorus and oxygen catalysts (known as VPO catalysts) are used (see Ullmann's Encyclopedia of Industrial Chemistry, 6 th edition, 2000 electronic release, Chapter "MALEIC AND Fumaric ACIDS, Maleic Anhydride - Production” ).
  • the vanadium used generally, phosphorus and oxygen-containing catalysts are generally prepared as follows: (1) synthesis of a vanadyl phosphate hemihydrate precursor (VOHPO 4 ⁇ / 4 H2O) from a pentavalent vanadium compound (for example, V2O5), a five- or trivalent phosphorus compound (eg ortho- and / or pyrophosphoric acid, phosphoric acid ester or phosphorous acid) and a reducing alcohol (eg isobutanol), isolation of the precipitate and drying, optionally shaping (eg tableting); and
  • a vanadyl phosphate hemihydrate precursor for example, V2O5
  • a pentavalent vanadium compound for example, V2O5
  • a five- or trivalent phosphorus compound eg ortho- and / or pyrophosphoric acid, phosphoric acid ester or phosphorous acid
  • a reducing alcohol eg isobutanol
  • WO 99/67021 A1 (Pantochim) describes in Example 1 the preparation of a catalyst precursor wherein isobutyl alcohol, benzyl alcohol vanadium pentoxide and 106% phosphoric acid are reacted at about 107 0 C, the precipitate is filtered and in open dishes in a convection oven ( "forced-draft oven") at 150 0 C for 10 hours is dried.
  • WO 99/67021 does not disclose that the precipitate initially dried up to a certain isobutanol and then determined with a gas having a specific Sauerstofgehalt, at a Temperature is flowed through.
  • WO 95/29006 A1 (Pantochim) describes in Example 1 the preparation of a catalyst precursor wherein isobutyl alcohol, benzyl alcohol and vanadium pentoxide 106% phosphoric acid are reacted at about 107 0 C, the precipitate is filtered and in open dishes in a convection oven ( "forced-draft oven") at 150 0 C for 10 hours is dried. Thereafter, this powder will cylindrical tablets formed which then, inter alia, in a 25 air / 75 nitrogen mixture with a temperature program of room temperature to 150 0 C, and more up to 420 0 C calcinated be defined.
  • WO 95/29006 does not disclose that the precipitate is first dried to a certain isobutanol content and then passed through at a certain temperature with a gas which has a certain oxygen content.
  • the object of the present invention was to find a process for preparing a vanadium, phosphorus and oxygen-containing catalyst precursor for the production of maleic anhydride by heterogeneously catalyzed gas-phase oxidation of a hydrocarbon having at least four carbon atoms, which no longer has the abovementioned disadvantages, technically is simple and economical to carry out and leads to a technically easy to perform preformation to a particulate catalyst and which has a high activity and high selectivity.
  • a process for the preparation of a catalyst-precursor containing vanadium, phosphorus and oxygen for the production of maleic anhydride by heterogeneously catalyzed gas-phase oxidation of a hydrocarbon having at least four carbon atoms, which comprises (a) vanadium pentoxide in the presence of isobutane. Butanol and optionally in the presence of a primary or secondary, noncyclic or cyclic, unbranched or branched, saturated alcohol having 3 to 6 carbon atoms with 102 to 1 10% phosphoric acid in a temperature range of 80 to 160 0 C reacted; (b) isolating the precipitate formed;
  • the phosphoric acid to be used in the process according to the invention has a calculated content of HsPO 4 VOn 102 to 110 wt .-%. It is simply referred to as 102 to 1 10% phosphoric acid.
  • the 102 to 1 10% phosphoric acid is a mixture containing orthophosphoric acid (H3PO4), phosphoric acid (H4P2O7) and polyphosphoric acids of the general formula
  • the phosphoric acid to be used is generally prepared by incorporation of phosphorus pentoxide in water or aqueous, for example 85 to 100%, phosphoric acid.
  • the reducing component used in the process according to the invention is isobutanol (2-methyl-1-propanol) and optionally a primary or secondary, noncyclic or cyclic, unbranched or branched, saturated alcohol having 3 to 6 carbon atoms and mixtures thereof.
  • Suitable alcohols include n-propanol (1-propanol), isopropanol (2-propanol), n-butanol (1-butanol), sec-butanol (2-butanol), 1-pentanol, 2-pentanol, 3-pentanol , 2-methyl-1-butanol, 3-methyl-1-butanol, 3-methyl-2-butanol, 2,2-dimethyl-1-propanol, 1-hexanol, 2-hexanol, 3-hexanol, 2-methyl 1-hexanol, 3-methyl-1-pentanol, 4-methyl-1-pentanol, 3-methyl-2-pentanol, 4-methyl-2-pentanol, 2,2-d
  • isobutanol primary, unbranched or branched C3 to Cs alkanols and cyclohexanol used.
  • isobutanol n-propanol (1-propanol), n-butanol (1-butanol), 1-pentanol, 2-methyl-1-butanol, 3-methyl-1-butanol and cyclohexanol , 90 to 100 wt .-% of isobutanol is particularly preferably used in the process according to the invention as a reducing component, most preferably only isobutanol (2-methyl-1-propanol) is used.
  • other reducing agents such as benzyl alcohol or its decomposition products from the reduction are much worse to remove, which ultimately causes a disadvantageous high content of organic carbon.
  • further reducing components can be used in the process according to the invention. Examples which may be mentioned are ethanol, formic acid and oxalic acid.
  • the process according to the invention is preferably carried out without addition of further, reducing components.
  • the vanadium pentoxide is generally used in the form of a powder, more preferably in a particle size range of 50 to 500 micrometers. If significantly larger particles are present, the solid is usually comminuted before being used and optionally sieved. Suitable apparatus are, for example, ball mills or planetary mills.
  • promoter components can be added in the preparation of the catalyst precursor.
  • Suitable promoters are the elements of groups 1 to 15 of the periodic table and their compounds. Suitable promoters are described, for example, in WO 97/12674 and WO 95/26817, as well as in US Pat. Nos. 5,137,860, 5,296,436, 5,158,923 and 4,795,818.
  • Preferred promoters are compounds of the elements cobaldium, molybdenum, iron, zinc, hafnium, zirconium, lithium, titanium, chromium, manganese, nickel, copper, boron, silicon, antimony, tin, niobium and bismuth, particularly preferably molybdenum, iron, zinc , Antimony, bismuth, lithium.
  • the promoted catalysts may contain one or more promoters.
  • the content of promoters in total in the finished catalyst is generally not more than about 5 wt .-%, each calculated as oxide.
  • the promoter is generally obtained by combining the vanadium pentoxide, the 102 to 110% phosphoric acid and the isobutanol and optionally the primary or secondary, noncyclic or cyclic, unbranched or branched , saturated alcohol having 3 to 6 carbon atoms in the form of an inorganic or organic salt.
  • Suitable promoter compounds are, for example, the acetates, acetylacetonates, oxalates, oxides or alkoxides of the abovementioned promoter metals, such as cobalt (II) acetate, cobalt (II) acetylacetonate, cobalt (II) chloride, molybdenum (VI) oxide , Molybdenum (III) chloride, iron (III) acetylacetonate, iron (III) chloride, zinc (II) oxide, zinc (II) acetylacetonate, lithium chloride, lithium oxide, bismuth (III) chloride, bismuth (III ) -ethylhexanoate, nickel (II) ethylhexanoate, nickel (II) oxalate, zirconyl chloride, zirconium (IV) butoxide, silicon (IV) ethoxide, niobium (V) chloride
  • the components mentioned can be thinned, diluted or slurried in the case of vanadium pentoxide or added.
  • the dilution or slurry is generally carried out with the primary or secondary, non-cyclic or cyclic, unbranched or branched, saturated alcohol having 3 to 6 carbon atoms.
  • the reaction is carried out in the reaction apparatus suitable for the subsequent reaction, for example a stirred tank, with mixing.
  • the components to be brought together in undiluted, dilute or slurried form are usually tempered to a temperature in the range of 0 to 160 0 C, wherein the components to be brought together can of course have a different temperature.
  • the relative molar ratio of the 102 to 1 10% phosphoric acid to vandium pentoxide is generally adjusted according to the desired ratio in the catalyst precursor.
  • the molar phosphorus / vanadium ratio in the reaction mixture for the preparation of the catalyst precursor is 1, 0 to 1, 5 and particularly preferably 1, 1 to 1, 3.
  • the amount of isobutanol and optionally of the primary or secondary, noncyclic or cyclic, unbranched or branched, saturated alcohol having 3 to 6 carbon atoms should advantageously be above that for the reduction of vanadium from +5 oxidation state to + + oxidation state 3.5 to +4.5 stoichiometrically required amount.
  • the amount should also be such that a slurry can be formed with the vanadium pentoxide which allows for intensive mixing with the 102 to 110% phosphoric acid.
  • the molar ratio of the total amount of isobutanol plus, if appropriate, the primary or secondary, noncyclic or cyclic, unbranched or branched, saturated alcohol having 3 to 6 carbon atoms to the vanadium pentoxide is 10 to 25 and preferably 12 to 20.
  • the mixture for the reaction of said compounds over a period of usually several Heated to a temperature of 80 to 160 0 C hours.
  • the temperature range to be selected depends on various factors, for example the boiling point of the added alcohol, and can be obtained by simple experiments optimize.
  • isobutanol is preferably heated to a temperature of 90 to 120 0 C and more preferably from 100 to 110 0 C.
  • the volatile compounds such as water, the alcohol and its degradation products, such as aldehyde or carboxylic acid, evaporate usually from the reaction mixture and can either be removed or partially or completely condensed and recycled. Preference is given to partial or complete recycling by heating under reflux. Particularly preferred is the complete recycling.
  • the reaction at elevated temperature generally takes several hours and depends on many factors such as the type of components added or the temperature.
  • the properties of the catalyst precursor can also be adjusted and influenced over a certain range via the temperature and the selected heating duration.
  • the parameters temperature and time can be easily optimized for an existing system by a few tests. Usually, the time required for said reaction is 1 to 25 hours.
  • the precipitate formed is isolated, wherein before the isolation optionally a cooling phase and a storage or aging phase of the cooled reaction mixture can be interposed.
  • the precipitate is separated from the liquid phase. Suitable methods are for example filtering, decanting or centrifuging.
  • the precipitate is isolated by filtration or centrifugation.
  • the isolation of the precipitate is generally also in a temperature range from 0 to 160 0 C, with temperatures in the range of 50 to 150 0 C, in particular from 80 to 150 ° C are preferred.
  • the isolated precipitate can be processed unwashed or washed.
  • the washing of the isolated precipitate has the advantage that still adhering residues of the alkanol and its degradation products can be further reduced.
  • suitable solvents for the washing process are alcohols (for example methanol, ethanol, 1-propanol, 2-propanol) and the primary or secondary, noncyclic or cyclic, unbranched or branched, saturated alcohol having 3 to 6 carbon atoms selected in the preceding reaction).
  • Step (c) (i) The isolated precipitate is then dried.
  • the drying can be carried out under different conditions. In general, they are carried out at atmospheric pressure (0.1 MPa abs) or lower pressure.
  • the drying temperature is generally from 130 to 200 0 C, with lower temperatures may be used at a drying under vacuum over a drying under atmospheric pressure in many cases.
  • the drying is carried out at a low pressure in the range of 1 to 30 kPa in the temperature range from 130 to 200 0 C.
  • the gas atmosphere optionally present during drying may contain very little oxygen (usually less than 0.5% by volume oxygen), water vapor and / or inert gases such as nitrogen, carbon dioxide or noble gases.
  • the drying is carried out at a pressure of 1 to 30 kPa abs and a temperature of 50 to 200 0 C under low-oxygen (usually less than 0.5% by volume of oxygen) or very preferably virtually oxygen-free residual gas atmosphere, for example in Nitrogen, through.
  • the drying can be carried out, for example, in the filtration device itself or in a separate apparatus, for example a drying cabinet or a continuous belt dryer.
  • the isolated and dried precipitate has an isobutanol content of less than 5% by weight, preferably less than 2% by weight.
  • the isobutanol content is determined as described in the examples.
  • the precipitate obtained in step (c) (i) may preferably be further treated in the vessel in which it has been dried according to (c) (i), as described below. But it can also be isolated and further treated in another vessel, as described below. In both variants, the further treatment may take place immediately or shortly after drying or else the precipitate obtained in step (c) (i) may be further treated after filling and, if appropriate, transport and / or storage, as described below.
  • the precipitate obtained in step (c) (i) is preferably further treated in the same vessel immediately after drying as described below.
  • the precipitate obtained in step (c) (i) is in the temperature range of 130 to 200 0 C with a gas which in addition to one or more inert gases from 0.1 vol .-% to 9 vol .-%, preferably 2 vol. % to 7 vol .-%, oxygen flows through, preferably flows through homogeneously.
  • Inert gases are in this case those which undergo no chemical reaction under the conditions mentioned.
  • examples of such inert gases are the noble gases, for example argon and particularly preferably nitrogen.
  • the volume flow of the gas mixture described is generally in the range of 10 to 500 Nm 3 / h.
  • the treatment is usually carried out until the isobutanol content described below is reached.
  • the resulting precipitate usually has an isobutanol content in the range of 0.0 wt .-% to 0.1 wt .-%.
  • the isobutanol content is determined as described in the examples.
  • the method is described in the examples.
  • Organic carbon is to be understood as meaning that carbon which can not be expelled from the powdery sample by addition of 10% strength by weight aqueous hydrochloric acid and subsequent heating while passing through a stream of nitrogen.
  • the content of organic carbon is calculated from the difference between the total carbon content and the content of inorganic carbon.
  • To determine the total carbon content a precisely weighed powdery sample in the presence of a pure oxygen stream is placed in a quartz tube heated to about 1000 ° C., annealed and the carbon dioxide contained in the combustion gas is determined quantitatively. From the amount of detected carbon dioxide and the sample weight then the total carbon content can be recalculated. An exact method description can be found in the examples under "Determination of total carbon content".
  • inorganic carbon In order to determine the content of inorganic carbon, a precisely weighed powdery sample is mixed with 10% strength by weight aqueous hydrochloric acid, the liberated carbon dioxide is expelled with slow heating while passing a stream of nitrogen, and the quantity of carbon dioxide evolved is determined quantitatively. The content of inorganic carbon can then be recalculated from the amount of detected carbon dioxide and the sample weight. An exact method description is given in the examples under "Determination of the content of inorganic carbon".
  • the treatment in step (c) (ii) generally sets an organic carbon content in the range from 1 to 5% by weight, preferably from 2 to 3% by weight.
  • the treatment in step (c) (ii) generally sets a content of inorganic carbon, determined by the method as described in the examples, of generally less than 0.01% by weight.
  • the pulverulent precipitate intimately mixed with 3% by weight of graphite is used.
  • the recording of the powder X-ray diffraction diagram is carried out with a so-called powder diffractometer with variable aperture and scattered radiation aperture, wherein reflection is measured.
  • the respective peak height results from the difference between the maximum intensity of the respective signal and the determined background.
  • An exact method description can be found in the examples under "X-ray diffractometric analysis of the annealed precipitate".
  • the catalyst precursor obtained in (c) (ii) is still molded and generally activated by calcination.
  • step (d) the product obtained from step (c) can be formed into particles having an average diameter of at least 2 mm, preferably with a diameter in the range of 10 mm to 2 mm.
  • the average diameter of a particle is the average of the smallest and the largest dimension between two plane-parallel plates.
  • Particles are both irregularly shaped particles and geometrically shaped particles, so-called shaped bodies.
  • the product obtained from step (c) is molded into shaped articles.
  • Suitable shaped bodies are tablets, cylinders, hollow cylinders, balls, strands, carriage wheels or extrudates.
  • multi-hole shaped bodies having a substantially cylindrical structure with more than one coaxial inner bore
  • the inner bores having any type of cross-sectional geometry, for example round, oval, or angular, and these holes can be uniform (for example, only round) or mixed (for example, round and oval) may be present in the molding.
  • shaped bodies such as “trilobes” and “tristars” (see WO 93/01 155) or shaped bodies with at least one notch on the outside (see US Pat. No. 5,168,090) are likewise possible.
  • a tabletting aid is generally added to the powder and intimately mixed. Tabletting aids are generally catalytically inert and improve the tabletting properties of the so-called powder, for example by increasing the lubricity and flowability. As a suitable and preferred Tablettierangeskar is called graphite.
  • the added tabletting aids usually remain in the activated catalyst. Typically, the content of tabletting aids in the finished catalyst is about 2 to 6 wt .-%. Moldings having a substantially hollow cylindrical structure and the multi-hole shaped bodies described above are particularly preferred.
  • a substantially hollow-cylindrical structure means a structure which essentially comprises a cylinder with an opening extending between the two cover surfaces.
  • the cylinder is characterized by two substantially parallel cover surfaces and a lateral surface, the cross-section of the cylinder, i. parallel to the lid surfaces, substantially of circular structure.
  • the cross-section of the through-going aperture, i. parallel to the lid surfaces of the cylinder is also essentially of a circular structure.
  • the opening therethrough is located centrally to the lid surfaces, whereby other spatial arrangements are not excluded.
  • a multi-hole shaped body is to be understood as meaning a structure which essentially comprises a cylinder with more than one coaxial opening (“inner bore”) passing between the two cover surfaces, characterized by two substantially parallel cover surfaces and a lateral surface, wherein the cross-section of the cylinder, ie parallel to the cover surfaces, is substantially circular in shape
  • the cross-sectional geometry of the apertures ("inner bores"), ie parallel to the lid surfaces of the cylinder is arbitrary, for example, substantially of circular, oval or angular geometry.
  • the more than one, preferably 2 to 20, more preferably 3 to 6 passing openings are arranged around the cylinder axis, preferably symmetrically.
  • substantially indicates that deviations from the ideal geometry, such as slight deformations of the circular structure, non-plane parallel lid surfaces, chipped corners and edges, surface roughness or indentations in the outer surface, the lid surfaces or the inner surface of the passing therethrough Bore in the catalyst according to the invention are included.
  • circular lid surfaces, a circular cross-section of the bore therethrough, parallel lid surfaces, and macroscopically smooth surfaces are preferred.
  • the substantially hollow cylindrical structure and the multi-hole formed body may be described by an outer diameter di, a height h as a distance of the two lid surfaces, and a diameter of the inner hole (penetrating opening) d2 and the inner holes, respectively.
  • the outer diameter di is preferably 3 to 10 mm, more preferably 4 to 8 mm, most preferably 4.5 to 6 mm.
  • the height h is preferably 1 to 10 mm, more preferably 2 to 6 mm, most preferably 2 to 5 mm.
  • the diameter of the opening d2 passing through is preferably 1 to 8 mm, particularly preferably 2 to 6 mm, very particularly preferably 2 to 3 mm.
  • a hollow cylindrical structure which (a) has a ratio of the height h to the diameter of the through hole d2 of at most 1, 5 and (b) a ratio of the geometric surface Ag eo to the geometric volume V geo of at least 2 mm -1 , as described for example in WO 01/68245.
  • the diameter of the more than one openings 62 passing through is preferably 0.5 to 3.0 mm, more preferably 1.0 to 2.5 mm, very particularly preferably 1.5 to 2.5 mm, wherein not every opening must have the same diameter.
  • said openings have a substantially circular cross-sectional geometry.
  • a catalyst precursor for the production of maleic anhydride by heterogeneously catalyzed gas phase oxidation of a hydrocarbon having at least four carbon atoms was found, which is obtainable according to the inventive method described above.
  • the inventive method allows the preparation of a vanadium, phosphorus and oxygen-containing catalyst precursor for the production of maleic anhydride by heterogeneously catalyzed gas phase oxidation of a hydrocarbon having at least four carbon atoms, wherein the preparation of the catalyst precursor is technically easy to perform.
  • the invention further provides a process for the preparation of a vanadium, phosphorus and oxygen-containing catalyst for the production of maleic anhydride by heterogeneously catalyzed gas-phase oxidation of a hydrocarbon having at least four carbon atoms, by treating a vanadium, phosphorus and oxygen-containing catalyst precursor in at least an atmosphere comprising oxygen (O 2), hydrogen oxide (H 2 O) and / or inert gas in a temperature range from 250 to 600 ° C., which is characterized in that a catalyst precursor according to the invention is used as the catalyst precursor. used above description.
  • suitable inert gases are nitrogen, carbon dioxide and noble gases.
  • the calcination can be carried out batchwise, for example in a shaft furnace, tray furnace, muffle furnace or heating cabinet, or continuously, for example in a rotary kiln, belt kiln or rotary kiln, and successively different sections in terms of temperature such as heating, keeping the temperature constant
  • Suitable preforming methods are described, for example, in US Pat. Nos. 5,137,860 and 4,933,312, and in the publication WO 95/29006, to which, however, expressly and not by way of limitation, reference is made
  • Particular preference is given to continuous calcination in a belt calcination furnace having at least two, for example two to ten calcining zones, which optionally has a different gas atmosphere and have a different temperature.
  • the catalyst precursor is preferably used in an oxidizing atmosphere containing from about 2 to 21% by volume, and preferably from 5 to 21% by volume, of molecular oxygen at a temperature of 200 to 350 ° C from 250 to 350 0 C over a period of time which is effective to the desired average oxidation state of vanadium set, left.
  • an oxidizing atmosphere containing from about 2 to 21% by volume, and preferably from 5 to 21% by volume, of molecular oxygen at a temperature of 200 to 350 ° C from 250 to 350 0 C over a period of time which is effective to the desired average oxidation state of vanadium set, left.
  • Step (i) mixtures of oxygen, inert gases (eg nitrogen or argon), hydrogen oxide (water vapor) and / or air and air.
  • inert gases eg nitrogen or argon
  • hydrogen oxide water vapor
  • air and air air
  • the period over which the heat treatment in step (i) is maintained is preferably to be selected in the process according to the invention such that a mean oxidation state of the vanadium has a value of +3.9 to +4.4, preferably +4.0 to +4.3.
  • the determination of the mean oxidation state of the vanadium is carried out by potentiometric titration according to the method described in the examples. Since the determination of the mean oxidation state of vanadium during calcination is extremely difficult to determine for reasons of apparatus and time, the period of time required is advantageously to be determined experimentally in preliminary experiments. As a rule, this is done using a measurement series in which the mixture is annealed under defined conditions, the samples being removed from the system after different times, cooled and analyzed with respect to the mean oxidation state of the vanadium.
  • the time required in step (i) is generally dependent on the nature of the catalyst precursor, the set temperature and the selected gas atmosphere, in particular the oxygen content.
  • the period at step (i) extends to a duration of over 0.5 hours, and preferably over 1 hour.
  • a period of up to 4 hours, preferably up to 2 hours is sufficient to set the desired average oxidation state. Under appropriately adjusted conditions (eg lower range of the temperature interval and / or low content of molecular oxygen), however, a period of more than 6 hours may be required.
  • the catalyst intermediate obtained is stored in a non-oxidizing atmosphere containing ⁇ 0.5% by volume of molecular oxygen and 20 to 75% by volume, preferably 30 to 60%, of hydrogen oxide (water vapor) Vol .-% at a temperature of 300 to 500 0 C and preferably from 350 to 450 0 C over a period of> 0.5 hours, preferably 2 to 10 hours and more preferably 2 to 4 hours leave.
  • the non-oxidizing atmosphere generally contains nitrogen and / or noble gases, such as, for example, argon, in addition to the abovementioned hydrogen oxide, although this is not intended to be limiting. Gases, such as carbon dioxide are suitable in principle.
  • the non-oxidizing atmosphere preferably contains> 40% by volume of nitrogen.
  • step (ii) From the point of view of the ziniansszone (n) guided catalyst precursor, the temperature during the calcination step (ii) can be kept constant, average or fall. If step (ii) is carried out at a temperature higher or lower than step (i), there is generally a heating or cooling phase between steps (i) and (ii), which is optionally implemented in a further calcination zone , In order to facilitate improved separation to the oxygen-containing atmosphere of step (i), this further calcination zone may be purged between (i) and (ii), for example, for purging with inert gas, such as nitrogen. Preferably, step (ii) is carried out at a temperature higher by 50 to 150 ° C. than step (i).
  • the calcination comprises a further step (iii) to be carried out after step (ii), in which the calcined Katalysatorprecursor in an inert gas atmosphere to a temperature of ⁇ 300 0 C, preferably of ⁇ 200 0 C and particularly preferably of ⁇ 150 0 C cools down.
  • further steps are possible in the calcination according to the inventive method.
  • further steps include, for example, changes in temperature (heating, cooling), changes in the gas atmosphere (conversion of the gas atmosphere), further holding times, transfers of the catalyst intermediate into other apparatus or interruptions of the entire calcination process.
  • the catalyst precursor usually has a temperature of ⁇ 100 ° C. before the beginning of the calcination, this is usually to be heated before step (i).
  • the heating can be carried out using various gas atmospheres.
  • the heating is carried out in an oxidizing atmosphere as defined under step (i) or in an inert gas atmosphere as defined under step (iii).
  • a change of the gas atmosphere during the heating phase is possible.
  • the heating in the oxidizing atmosphere which is also used in step (i).
  • a catalyst for the production of maleic anhydride has been found by heterogeneously catalyzed gas phase oxidation of a hydrocarbon having at least four carbon atoms, which is obtainable according to the inventive method described above.
  • the catalyst produced by the process according to the invention preferably has a phosphorus / vanadium atomic ratio of from 0.9 to 1.5, more preferably from 0.9 to 1.2, and very particularly preferably from 1.0 to 1.1, an average oxidation state of vanadium of from + 3.9 to + 4.4, and more preferably from 4.0 to 4.3, a BET surface area of from 10 to 50 m 2 / g, and more preferably from 20 to 40 m 2 / g Pore volume of 0.1 to 0.5 ml / g and particularly preferably from 0.2 to 0.4 ml / g and a bulk density of 0.5 to 1, 5 kg / l and particularly preferably 0.5 to 1, 0 kg / l.
  • the catalyst obtainable by calcination of the catalyst precursor according to the invention is distinguished by a substantially homogeneous oxidation state of the vanadium within the individual catalyst particles and between the various catalyst particles with one another.
  • the catalyst according to the invention enables a high hydrocarbon load with simultaneously high conversion, high activity, high selectivity and a high space / time yield.
  • the invention further provides a process for the preparation of maleic anhydride by heterogeneously catalyzed gas-phase oxidation of a hydrocarbon having at least four carbon atoms with oxygen-containing gases, which comprises using a catalyst according to the invention as described above.
  • tube bundle reactors are generally used.
  • hydrocarbons are generally aliphatic and aromatic, saturated and unsaturated hydrocarbons having at least four carbon atoms, such as 1, 3-butadiene, 1-butene, 2-cis-butene, 2-trans-butene, n-butane, C4 mixture, 1, 3-pentadiene, 1, 4-pentadiene, 1-pentene, 2-cis-pentene, 2-trans-pentene, n-pentane, cyclopentadiene, dicyclopentadiene, cyclopentene, cyclopentane, Cs mixture, hexenes, hexanes, Cyclohexane and benzene suitable.
  • n-butane Preference is given to using 1-butene, 2-cis-butene, 2-trans-butene, n-butane, benzene or mixtures thereof. Particularly preferred is the use of n-butane and n-butane-containing gases and liquids.
  • the n-butane used may, for example, come from natural gas, from steam crackers or FCC crackers.
  • the addition of the hydrocarbon is generally quantified, i. under constant specification of a defined amount per time unit.
  • the hydrocarbon can be metered in liquid or gaseous form.
  • the metering is preferably in liquid form with subsequent evaporation before entry into the tube bundle reactor.
  • oxygen-containing gases such as air, synthetic air, an oxygen-enriched gas or so-called "pure", ie, for example, derived from the air separation oxygen are used.
  • the oxygen-containing gas is also added with volume control.
  • the gas to be passed through the shell-and-tube reactor generally contains a hydrocarbon concentration of 0.5 to 15% by volume and an oxygen concentration of 8 to 25% by volume.
  • the missing one hundred vol .-% share is composed of other gases such as nitrogen, noble gases, carbon monoxide, carbon dioxide, water vapor, oxygenated hydrocarbons (eg methanol, formaldehyde, formic acid, ethanol, acetaldehyde, acetic acid, propanol, propionaldehyde, propionic acid, Acolein, crotonaldehyde) and mixtures thereof.
  • oxygenated hydrocarbons eg methanol, formaldehyde, formic acid, ethanol, acetaldehyde, acetic acid, propanol, propionaldehyde, propionic acid, Acolein, crotonaldehyde
  • the n-butane content of the total amount of hydrocarbon is preferably> 90% and particularly preferably> 95%.
  • the gas is preferably fed to the gas in the process according to the invention a volatile phosphorus compound. Its concentration at the beginning, ie at the reactor inlet, at least 0.2 ppm by volume, ie 0.2-10 "6 volume of the volatile phosphorus compounds based on the total volume of gas at the reactor inlet.
  • the volatile phosphorus compounds are to be understood as meaning all those phosphorus-containing compounds which are gaseous in the desired concentration under the conditions of use
  • Suitable phosphorous compounds which are suitable are, for example, phosphines and phosphoric acid esters
  • Particular preference is given to the C 1 -C 4 -alkyl phosphoric esters, very particularly preferably trimethyl phosphate, triethyl phosphate and tripropyl phosphate, in particular triethyl phosphate
  • the process according to the invention is generally carried out at a temperature of from 350 to 480 ° C.
  • the temperature of the Ka in the tube bundle reactor is located understood in the absence of a chemical reaction. If this temperature is not exactly the same at all points, the term means the number average of the temperatures along the reaction zone. In particular, this means that the true, present at the catalyst temperature due to the exothermicity of the oxidation reaction may also be outside the range mentioned.
  • the process according to the invention is preferably carried out at a temperature of from 380 to 460 ° C., more preferably from 380 to 430 ° C.
  • the process according to the invention can be carried out at a pressure below atmospheric pressure (eg up to 0.05 MPa abs) as well as above normal pressure (eg up to 10 MPa abs). This is understood to mean the pressure present in the tube bundle reactor unit. Preference is given to a pressure of 0.1 to 1.0 MPa abs, more preferably 0.1 to 0.5 MPa abs.
  • the process according to the invention can be carried out in two preferred process variants, the "straight through” variant and the "recirculation” variant. In the "straight pass", maleic anhydride and possibly oxygenated hydrocarbon by-products are removed from the reactor effluent and the remaining gas mixture is discharged and optionally thermally recovered. which contains unreacted hydrocarbon, wholly or partially recycled to the reactor Another variant of the "recycle” is the removal of the unreacted hydrocarbon and its return to the reactor.
  • n-butane is used as the starting hydrocarbon and the heterogeneously catalyzed gas phase oxidation is carried out in the "straight pass" on the catalyst according to the invention.
  • the inventive method using the catalysts of the invention allows a high hydrocarbon loading of the catalyst at a high conversion due to a high activity.
  • the process according to the invention furthermore allows a high selectivity and a high yield of maleic anhydride.
  • Sales U n (KW, reactor input) - n (KW, reactor output / s (KW, reactor input)
  • V (KW) volume of the hydrocarbon in the gas phase [NI] normalized to O 0 C and 0.1013 MPa (Calculated size) If a hydrocarbon is present in the liquid phase under these conditions, the ideal gas law becomes the hypothetical gas volume calculated.)
  • the content of organic carbon is calculated as the difference between the total carbon content and the content of inorganic carbon.
  • the respective peak height results from the difference between the maximum intensity of the respective signal and the determined background.
  • the hollow cylinders with the rounded side surface were placed on the flat metal support plate of a corresponding measuring device in successive measurements.
  • the two plane-parallel cover surfaces were thus in the vertical direction.
  • a flat metal stamp was fed from above at a feed rate of 1, 6 mm / min on the hollow cylinder and recorded the time course of the force on the hollow cylinder until its break.
  • the lateral compressive strength of the single hollow cylinder corresponds to the maximum impacted force.
  • the determination of the mean oxidation state of the vanadium was carried out by potentiometric titration.
  • the amount of V 4+ could be calculated from the consumption of the 0.1 molar potassium permanganate solution.
  • the reaction mixture was refluxed to about 100 to 108 ° C and left under these conditions for 14 hours. Subsequently, the suspension was drained into a previously inertized with nitrogen and heated Druckfilternutsche, rinsed the line for suction with 200 kg of isobutanol and filtered off at a temperature of about 100 0 C at a pressure above the suction filter of up to 0.35 MPa abs. The filtration end was reached when the liquid level in the filtrate vessel increased by less than 0.5% within 20 minutes and a filtrate amount of about 5.0 m 3 was reached, which corresponds mathematically to a residual isobutanol content of the filter cake of about 35%.
  • the Filter cake was then blown dry by continuous introduction of nitrogen at 100 0 C and with a centrally arranged, height-adjustable stirrer within about one hour. After dry-blowing was heated to a jacket temperature of 170 0 C and evacuated to a pressure of 10 kPa abs (100 mbar abs). After 1 10 min drying time under vacuum, the vacuum was broken by lean air (nitrogen-oxygen mixture having an oxygen content of about 6 vol .-%) and the jacket temperature increased to 200 0 C. In the following, the filter cake was flowed through from bottom to top with a volume flow of about 30 Nm 3 / h of lean air until a residual isobutanol content of ⁇ 0.1% by weight had been reached.
  • the dried catalyst precursor powder had levels of organic carbon, inorganic carbon, and total carbon of 2.3 wt%, ⁇ 0.01 wt%, and 2.3 wt%, respectively.
  • Example 1 b (for comparison, analogously to Example WO 03/078058 A1)
  • the suspension was discharged into a previously inertized with nitrogen and heated Druckfilternutsche and filtered off at a temperature of about 100 0 C at a pressure above the suction filter of up to 0.35 MPa abs.
  • the filter cake was blown dry by continuous introduction of nitrogen at 100 0 C and with stirring with a centrally arranged, height-adjustable stirrer within about one hour.
  • After dry-blowing was heated to about 155 ° C and evacuated to a pressure of 15 kPa abs (150 mbar abs). The drying was carried out to a residual isobutanol content of
  • the dried powder was treated under air for 2 hours in a rotary tube having a length of 6.5 m, an inner diameter of 0.9 m and internal helical coils.
  • the speed of the rotary tube was 0.4 U / min.
  • the powder was fed into the rotary kiln at a rate of 60 kg / h.
  • the air supply was 100 m 3 / h.
  • the temperatures measured directly on the outside of the rotary kiln of the five equal-length heating zones were 250 ° C, 300 ° C, 345 ° C, 345 ° C and 345 ° C.
  • the catalyst precursor powder thus treated had contents of organic carbon, inorganic carbon and total carbon of 0.7 wt%, 0.5 wt% and 1.2 wt%, respectively.
  • the corresponding catalyst precursor powder was mixed with 20% by weight of malonic acid and 1% by weight of graphite (in each case based on the catalyst precursor powder) and compacted.
  • the mixture was mixed with further 1% by weight of graphite (based on the original catalyst precursor powder) in a tabletting machine into hollow cylinders with the dimensions 6.5 mm ⁇ 4.2 mm ⁇ 3.7 mm (outer diameter ⁇ height ⁇ diameter of the inner hole) deformed.
  • compression forces of about 14 kN were set during tableting.
  • the corresponding hollow cylinders were then calcined under the following conditions:
  • precursor powder from example 1 a 32 min
  • precursor powder from example 1 b 12 min
  • the pilot plant was equipped with a feed unit and a reactor tube.
  • the plant was operated in a "straight pass" as described in EP-B 1 261 424.
  • the hydrocarbon was added in a controlled amount in liquid form via a pump.
  • As an oxygen-containing gas air was added with volume control.
  • Triethyl phosphate (TEP) was also added in a controlled amount, dissolved in water, in liquid form.
  • the oxygen concentration was adjusted to the desired value by the quantity-controlled addition of nitrogen.
  • the length of the reactor tube was 6.5 m, the inner diameter 22.3 mm.
  • a multi-thermocouple with 20 temperature measuring points was located in a protective tube with 6 mm outer diameter.
  • the temperature of the reactor was carried out by a heat transfer circuit with a length of 6.5 m.
  • a molten salt was used as a heat transfer medium.
  • the reactor tube was flowed through by the reaction gas mixture from top to bottom.
  • the upper 0.2 m of the 6.5 m long reactor tube remained unfilled.
  • the catalyst bed was followed, containing a total of 2180 ml of catalyst.
  • gaseous product was removed and fed to the gas chromatographic on-line analysis.
  • the main stream of gaseous reactor effluent was discharged from the plant.
  • the measurements were carried out after a minimum running time of the catalysts of 150 h. The results are shown in Table 2.
  • Catalyst precursor (catalyst precursor according to Example 1 a prepared according to Example 1 b))

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Abstract

L'invention concerne un procédé de production d'un précurseur de catalyseur contenant du vanadium, du phosphore et de l'oxygène, pour la production d'anhydride d'acide maléique par oxydation catalytique hétérogène en phase gazeuse d'un hydrocarbure présentant au moins quatre atomes de carbone. Ce procédé est caractérisé en ce qu'il comporte les étapes consistant à: (a) faire réagir du pentoxyde de vanadium en présence d'isobutanol et éventuellement en présence d'un alcool saturé primaire ou secondaire, non cyclique ou cyclique, non ramifié ou ramifié, qui comporte 3 à 6 atomes de carbone, avec de l'acide phosphorique à 102 à 110 % dans une plage de température comprise entre 80 et 160 °C; (b) isoler le précipité produit; (c) (i) sécher le précipité isolé jusqu'à l'obtention d'une teneur restante d'isobutanol inférieure à 5% en poids; (ii) puis faire traverser le précipité séché, directement ou après son isolement, dans une plage de température comprise entre 130 °C et 200 °C, par un gaz qui contient, outre un ou plusieurs gaz inertes, 0,1% vol. à 9% vol. d'oxygène.
EP10744601A 2009-08-26 2010-08-23 Précurseur de catalyseur pour la production d'anhydride d'acide maléique et son procédé de production Withdrawn EP2470301A1 (fr)

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EP10744601A EP2470301A1 (fr) 2009-08-26 2010-08-23 Précurseur de catalyseur pour la production d'anhydride d'acide maléique et son procédé de production

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US20110230668A1 (en) * 2010-03-19 2011-09-22 Basf Se Catalyst for gas phase oxidations based on low-sulfur and low-calcium titanium dioxide
US8323610B2 (en) 2010-04-12 2012-12-04 Basf Se Catalyst for the oxidation of SO2 to SO3
US8901320B2 (en) 2010-04-13 2014-12-02 Basf Se Process for controlling a gas phase oxidation reactor for preparation of phthalic anhydride
US8859459B2 (en) 2010-06-30 2014-10-14 Basf Se Multilayer catalyst for preparing phthalic anhydride and process for preparing phthalic anhydride
US9212157B2 (en) 2010-07-30 2015-12-15 Basf Se Catalyst for the oxidation of o-xylene and/or naphthalene to phthalic anhydride
US8785344B2 (en) 2012-02-20 2014-07-22 Basf Se Gas phase oxidation catalyst with low charge transport activation energy
JP2015521094A (ja) * 2012-02-20 2015-07-27 ビーエーエスエフ ソシエタス・ヨーロピアＢａｓｆ Ｓｅ 低い電荷移動活性化エネルギーを有する気相酸化触媒
CN105618094A (zh) * 2016-03-21 2016-06-01 唐伟 一种氧化型催化剂的制备设备及其工艺
US11289700B2 (en) 2016-06-28 2022-03-29 The Research Foundation For The State University Of New York KVOPO4 cathode for sodium ion batteries
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