JP2004351297A - Catalyst for methacrylic acid production, its production method, and production method of methacrylic acid - Google Patents
Catalyst for methacrylic acid production, its production method, and production method of methacrylic acid Download PDFInfo
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- JP2004351297A JP2004351297A JP2003150697A JP2003150697A JP2004351297A JP 2004351297 A JP2004351297 A JP 2004351297A JP 2003150697 A JP2003150697 A JP 2003150697A JP 2003150697 A JP2003150697 A JP 2003150697A JP 2004351297 A JP2004351297 A JP 2004351297A
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- Prior art keywords
- catalyst
- methacrylic acid
- oxide
- precursor
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- 239000003054 catalyst Substances 0.000 title claims abstract description 122
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 title claims abstract description 31
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 25
- 239000002243 precursor Substances 0.000 claims abstract description 43
- 238000007254 oxidation reaction Methods 0.000 claims abstract description 32
- 230000003647 oxidation Effects 0.000 claims abstract description 13
- 238000002156 mixing Methods 0.000 claims abstract description 8
- 229910052742 iron Inorganic materials 0.000 claims abstract description 5
- 229910052720 vanadium Inorganic materials 0.000 claims abstract description 5
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 5
- 229910052783 alkali metal Inorganic materials 0.000 claims abstract description 4
- 150000001340 alkali metals Chemical class 0.000 claims abstract description 4
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims abstract description 4
- 150000001342 alkaline earth metals Chemical class 0.000 claims abstract description 4
- 229910052787 antimony Inorganic materials 0.000 claims abstract description 4
- 229910052785 arsenic Inorganic materials 0.000 claims abstract description 4
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 4
- 229910052802 copper Inorganic materials 0.000 claims abstract description 4
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 4
- 229910052758 niobium Inorganic materials 0.000 claims abstract description 4
- 229910052763 palladium Inorganic materials 0.000 claims abstract description 4
- 229910052703 rhodium Inorganic materials 0.000 claims abstract description 4
- 229910052711 selenium Inorganic materials 0.000 claims abstract description 4
- 229910052709 silver Inorganic materials 0.000 claims abstract description 4
- 229910052714 tellurium Inorganic materials 0.000 claims abstract description 4
- 229910052718 tin Inorganic materials 0.000 claims abstract description 4
- 229910052721 tungsten Inorganic materials 0.000 claims abstract description 4
- 239000000203 mixture Substances 0.000 claims description 37
- STNJBCKSHOAVAJ-UHFFFAOYSA-N Methacrolein Chemical compound CC(=C)C=O STNJBCKSHOAVAJ-UHFFFAOYSA-N 0.000 claims description 15
- AMIMRNSIRUDHCM-UHFFFAOYSA-N Isopropylaldehyde Chemical compound CC(C)C=O AMIMRNSIRUDHCM-UHFFFAOYSA-N 0.000 claims description 12
- KQNPFQTWMSNSAP-UHFFFAOYSA-N isobutyric acid Chemical compound CC(C)C(O)=O KQNPFQTWMSNSAP-UHFFFAOYSA-N 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 11
- 239000003365 glass fiber Substances 0.000 claims description 11
- 238000001354 calcination Methods 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 8
- 229910052760 oxygen Inorganic materials 0.000 claims description 8
- 239000001301 oxygen Substances 0.000 claims description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical group [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 6
- 230000003197 catalytic effect Effects 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- 239000000835 fiber Substances 0.000 claims description 6
- 239000012210 heat-resistant fiber Substances 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 239000000919 ceramic Substances 0.000 claims description 5
- 239000010439 graphite Substances 0.000 claims description 5
- 229910002804 graphite Inorganic materials 0.000 claims description 5
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 4
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 239000011733 molybdenum Substances 0.000 claims description 4
- 239000002245 particle Substances 0.000 claims description 4
- 229910052698 phosphorus Inorganic materials 0.000 claims description 4
- 239000011574 phosphorus Substances 0.000 claims description 4
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical group [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- BUGBHKTXTAQXES-UHFFFAOYSA-N Selenium Chemical compound [Se] BUGBHKTXTAQXES-UHFFFAOYSA-N 0.000 claims description 3
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 claims description 3
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 claims description 3
- 229910052797 bismuth Inorganic materials 0.000 claims description 3
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims description 3
- 239000011651 chromium Chemical group 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- 239000010941 cobalt Substances 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- 238000006356 dehydrogenation reaction Methods 0.000 claims description 3
- 229910052732 germanium Inorganic materials 0.000 claims description 3
- GNPVGFCGXDBREM-UHFFFAOYSA-N germanium atom Chemical compound [Ge] GNPVGFCGXDBREM-UHFFFAOYSA-N 0.000 claims description 3
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical group [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 3
- 239000010955 niobium Substances 0.000 claims description 3
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 3
- 239000010948 rhodium Substances 0.000 claims description 3
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 3
- 239000011669 selenium Substances 0.000 claims description 3
- 239000004332 silver Substances 0.000 claims description 3
- PORWMNRCUJJQNO-UHFFFAOYSA-N tellurium atom Chemical compound [Te] PORWMNRCUJJQNO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052716 thallium Inorganic materials 0.000 claims description 3
- BKVIYDNLLOSFOA-UHFFFAOYSA-N thallium Chemical compound [Tl] BKVIYDNLLOSFOA-UHFFFAOYSA-N 0.000 claims description 3
- 239000011135 tin Substances 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 239000011701 zinc Substances 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 abstract 1
- 238000006243 chemical reaction Methods 0.000 description 27
- 239000002002 slurry Substances 0.000 description 21
- 238000005259 measurement Methods 0.000 description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 14
- NLSCHDZTHVNDCP-UHFFFAOYSA-N caesium nitrate Chemical compound [Cs+].[O-][N+]([O-])=O NLSCHDZTHVNDCP-UHFFFAOYSA-N 0.000 description 12
- 230000000052 comparative effect Effects 0.000 description 12
- 239000011964 heteropoly acid Substances 0.000 description 12
- 239000000047 product Substances 0.000 description 11
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 8
- 239000003570 air Substances 0.000 description 8
- 239000012071 phase Substances 0.000 description 8
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 7
- 239000008188 pellet Substances 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- 238000010304 firing Methods 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 235000011007 phosphoric acid Nutrition 0.000 description 4
- 239000012744 reinforcing agent Substances 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical class [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 230000001143 conditioned effect Effects 0.000 description 3
- XTVVROIMIGLXTD-UHFFFAOYSA-N copper(II) nitrate Chemical compound [Cu+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O XTVVROIMIGLXTD-UHFFFAOYSA-N 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 2
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical group CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- UNTBPXHCXVWYOI-UHFFFAOYSA-O azanium;oxido(dioxo)vanadium Chemical compound [NH4+].[O-][V](=O)=O UNTBPXHCXVWYOI-UHFFFAOYSA-O 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- GNTDGMZSJNCJKK-UHFFFAOYSA-N divanadium pentaoxide Chemical compound O=[V](=O)O[V](=O)=O GNTDGMZSJNCJKK-UHFFFAOYSA-N 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- JKQOBWVOAYFWKG-UHFFFAOYSA-N molybdenum trioxide Chemical compound O=[Mo](=O)=O JKQOBWVOAYFWKG-UHFFFAOYSA-N 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000005839 oxidative dehydrogenation reaction Methods 0.000 description 2
- SQGYOTSLMSWVJD-UHFFFAOYSA-N silver(1+) nitrate Chemical compound [Ag+].[O-]N(=O)=O SQGYOTSLMSWVJD-UHFFFAOYSA-N 0.000 description 2
- 239000012808 vapor phase Substances 0.000 description 2
- 239000004254 Ammonium phosphate Substances 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- DKGAVHZHDRPRBM-UHFFFAOYSA-N Tert-Butanol Chemical compound CC(C)(C)O DKGAVHZHDRPRBM-UHFFFAOYSA-N 0.000 description 1
- 235000018660 ammonium molybdate Nutrition 0.000 description 1
- 229910000148 ammonium phosphate Inorganic materials 0.000 description 1
- 235000019289 ammonium phosphates Nutrition 0.000 description 1
- GCPXMJHSNVMWNM-UHFFFAOYSA-N arsenous acid Chemical compound O[As](O)O GCPXMJHSNVMWNM-UHFFFAOYSA-N 0.000 description 1
- XUFUCDNVOXXQQC-UHFFFAOYSA-L azane;hydroxy-(hydroxy(dioxo)molybdenio)oxy-dioxomolybdenum Chemical compound N.N.O[Mo](=O)(=O)O[Mo](O)(=O)=O XUFUCDNVOXXQQC-UHFFFAOYSA-L 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052792 caesium Inorganic materials 0.000 description 1
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- 229910001882 dioxygen Inorganic materials 0.000 description 1
- BNIILDVGGAEEIG-UHFFFAOYSA-L disodium hydrogen phosphate Chemical compound [Na+].[Na+].OP([O-])([O-])=O BNIILDVGGAEEIG-UHFFFAOYSA-L 0.000 description 1
- 238000002036 drum drying Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- VLAPMBHFAWRUQP-UHFFFAOYSA-L molybdic acid Chemical compound O[Mo](O)(=O)=O VLAPMBHFAWRUQP-UHFFFAOYSA-L 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 description 1
- OGUCKKLSDGRKSH-UHFFFAOYSA-N oxalic acid oxovanadium Chemical compound [V].[O].C(C(=O)O)(=O)O OGUCKKLSDGRKSH-UHFFFAOYSA-N 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 229910001961 silver nitrate Inorganic materials 0.000 description 1
- CMZUMMUJMWNLFH-UHFFFAOYSA-N sodium metavanadate Chemical compound [Na+].[O-][V](=O)=O CMZUMMUJMWNLFH-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- UUUGYDOQQLOJQA-UHFFFAOYSA-L vanadyl sulfate Chemical compound [V+2]=O.[O-]S([O-])(=O)=O UUUGYDOQQLOJQA-UHFFFAOYSA-L 0.000 description 1
- 229940041260 vanadyl sulfate Drugs 0.000 description 1
- 229910000352 vanadyl sulfate Inorganic materials 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
Abstract
Description
【０００１】
【発明の属する技術分野】
本発明はメタクリル酸製造用触媒、その製造方法およびメタクリル酸の製造方法に関する。詳しくは、本発明はメタクリル酸の製造に使用するに好適なヘテロポリ酸系触媒、その製造方法、およびこのヘテロポリ酸系触媒の存在下にメタクロレイン、イソブチルアルデヒドおよび／またはイソ酪酸を気相酸化または気相酸化脱水素してメタクリル酸を製造する方法に関する。
【０００２】
【従来の技術】
メタクロレイン、イソブチルアルデヒドおよび／またはイソ酪酸を気相酸化してメタクリル酸を製造するためにヘテロポリ酸系触媒が用いられることはよく知られている。
【０００３】
しかし、これらのヘテロポリ酸系触媒は成型性が非常に悪く、機械的強度も悪い。したがって、実用触媒とするために触媒の形態、補強剤の検討が種々行われている。
【０００４】
触媒の形態については、適当な担体上に触媒成分を付着させる担持触媒、打錠成型や押し出し成型による加圧成型触媒、転動造粒による造粒触媒などが検討されている。また、補強剤については、触媒物質にグラファイト、セラミックファイバー、ウィスカーなどの耐熱性繊維を混ぜた押し出し成型触媒が提案されている（例えば、特許文献１参照）。
【特許文献１】特公平２−３６２９６号公報
【０００５】
【発明が解決しようとする課題】
しかしながら、これら従来の触媒は実用化されているものの、取り扱いに十分な強度を有しておらず、工業触媒として更なる強度向上が望まれている。また、強度が不良であるため、歩留まりが悪く、触媒製造コストが増大している。一方、触媒性能面においても、これまで提案されている触媒は、メタクリル酸の収率および選択性が低く、工業的に満足のいくものではない。
【０００６】
本発明は上記の問題点を解決し、従来方法によって得られたヘテロポリ酸系触媒よりも、性能、強度および製造コストの点において、より優れたヘテロポリ酸系触媒を提供しようとするものである。
また、本発明は、上記ヘテロポリ酸系触媒の製造方法を提供するものである。
また、本発明は、上記ヘテロポリ酸系触媒を用い、メタクロレイン、イソブチルアルデヒドおよび／またはイソ酪酸を気相酸化または気相脱水素してメタクリル酸を製造する方法を提供するものである。
【０００７】
【課題を解決するための手段】
本発明者らは、上記の課題を解決するために、ヘテロポリ酸系触媒の改良について検討を行い、成型前の触媒物質に焼成後触媒を特定量混ぜて成型することで、触媒強度が著しく向上し、併せてメタクリル酸生成の選択率が向上し、さらに製造コストが低下することを見出し、本発明を完成した。
【０００８】
すなわち、本発明は、一般式Ｉ：
ＭｏａＰｂＡｃＢｄＣｅＤｆＯｘ （Ｉ）
（ここで、Ｍｏはモリブデン、Ｐはリン、Ａはヒ素、アンチモン、ゲルマニウム、ビスマス、ジルコニウムおよびセレンから選ばれる少なくとも１種の元素、Ｂは銅、鉄、クロム、ニッケル、マンガン、コバルト、スズ、銀、亜鉛、パラジウム、ロジウムおよびテルルから選ばれる少なくとも１種の元素、Ｃはバナジウム、タングステンおよびニオブから選ばれる少なくとも１種の元素、Ｄはアルカリ金属、アルカリ土類金属およびタリウムから選ばれる少なくとも１種の元素、Ｏは酸素を表し、ａ、ｂ、ｃ、ｄ、ｅ、ｆおよびｘは、それぞれ、Ｍｏ、Ａ、Ｂ、Ｃ、ＤおよびＯの原子比を表し、ａ＝１２のとき、ｂ＝０．５〜４、ｃ＝０〜５、ｄ＝０〜３、ｅ＝０〜４、ｆ＝０．０１〜４であり、ｘはそれぞれの元素の酸化状態によって定まる数値である）
で表される酸化物の前駆体［Ｍ］と一般式Ｉで表される酸化物［Ｎ］とを混合し、焼成して得られたものであることを特徴とするメタクリル酸製造用触媒である。
【０００９】
また、本発明は、上記一般式Ｉで表される酸化物の前駆体［Ｍ］と一般式Ｉで表される酸化物［Ｎ］とを混合し、次いで乾燥、焼成することを特徴とするメタクリル酸製造用触媒の製造方法である。
また、本発明はメタクロレイン、イソブチルアルデヒドおよび／またはイソ酪酸を接触気相酸化または接触気相脱水素してメタクリル酸を製造する際に、上記触媒を用いることを特徴とするメタクリル酸の製造方法である。
【００１０】
【発明の実施の形態】
本発明の一般式Ｉで表される酸化物の前駆体［Ｍ］とは、一般式Ｉの各元素を含む原料化合物を水などの媒体中に溶解または懸濁させて得られる溶液またはスラリー（以下、これらを「スラリー」と総称する。）、またはこのスラリーを３００℃未満の温度で乾燥して得られる乾燥物であって、このスラリーまたは乾燥物を、スラリーについては蒸発乾固して乾燥した後、３００〜６００℃の温度で焼成することにより一般式Ｉで表される酸化物を形成するものを意味する。
【００１１】
上記スラリーの調製は、従来からよく知られている沈殿法、酸化物混合法などの方法で行うことができる。具体的には、一般式Ｉの各元素を含む原料化合物を所要量の水などの媒体中に適宜溶解または懸濁させればよい。
【００１２】
原料化合物については特に制限はなく、ヘテロポリ酸系触媒の調製に一般的に用いられている化合物を使用することができる。例えば、モリブデン原料としては、パラモリブデン酸アンモニウム、ジモリブデン酸アンモニウム等のモリブデン酸アンモニウム類、モリブデン酸、三酸化モリブデンなどを用いることができる。バナジウム原料としては、五酸化バナジウム、メタバナジン酸アンモニウム、メタバナジン酸ナトリウム、シュウ酸バナジル、硫酸バナジルなどを用いることができる。また、リン原料としては、オルトリン酸、リン酸水素二ナトリウム、リン酸アンモニウムなどを用いることができる。もちろん、２種以上の元素を含むモリブドリン酸、モリブドバナドリン酸などを使用してもよい。
【００１３】
前駆体［Ｍ］の乾燥物は、上記スラリーを一般的な乾燥法によって乾燥して得られる。例えば、蒸発乾固法、噴霧乾燥法、ドラム乾燥法などが用いられる。この際、乾燥時の温度は３００℃未満であり、好ましくは２５０℃未満、さらに好ましくは１００〜２００℃、なおさらに好ましくは１１０〜１９０℃である。なお、補強剤としてグラスファイバー、グラファイト、セラミックファイバー、ウィスカー等の耐熱性繊維をスラリー中および／または乾燥物中に含有させることもできる。
【００１４】
酸化物［Ｎ］は、一般式Ｉの各元素を含む原料化合物を水などの媒体中に溶解または懸濁させて得られるスラリーを乾燥した後、酸素流通下、空気流通下または窒素流通下で焼成して得られる。具体的には、例えば、上記のスラリーまたは乾燥物を焼成すればよい。この際、酸化物［Ｎ］の組成は、前駆体［Ｍ］と同一であってもかまわないし、異なっていてもよい。焼成温度は３００〜６００℃であり、好ましくは３００〜５００℃、さらに好ましくは３５０〜４５０℃である。焼成時間は特に限定されないが、通常１〜５０時間程度が好ましい。
【００１５】
酸化物［Ｎ］としては、上記のように新たに製造したものを用いても、あるいは反応に使用して性能の劣化した触媒や、触媒製造時に発生する非製品（割れたり、欠けたりしたもの、粉塵、端切品など）を用いてもよい。
【００１６】
上記のようにして得られた前駆体［Ｍ］と酸化物［Ｎ］とを混合するが、両者の混合割合は、通常、［Ｍ］：［Ｎ］＝１００：１〜１００：５０（質量比；以下同じ。）であり、好ましくは１００：１〜１００：３０、さらに好ましくは１００：３〜１００：１５である。なお、前駆体［Ｍ］がスラリーの場合、その固形分として換算する。
【００１７】
酸化物［Ｎ］を混合することなく前駆体［Ｍ］のみを用いて得られる触媒は、機械的強度が十分でなく、一方、酸化物［Ｎ］の割合が大きくなると触媒の機械的強度、転化率およびメタクリル酸の選択率が低下する。
【００１８】
酸化物［Ｎ］はそのまま用いてもよいが、最大粒径が１ｍｍ以下、好ましくは０．５ｍｍ以下に粉砕して使用するのが、触媒の機械的強度が向上するとの理由で好ましいものである。なお、水に溶解または懸濁させて使用することもできる。また、前駆体［Ｍ］と同様に、補強剤としてグラスファイバー、グラファイト、セラミックファイバー、ウィスカー等の耐熱性繊維を含有させてもよい。
【００１９】
このように前駆体［Ｍ］および／または酸化物［Ｎ］にグラスファイバー、グラファイト、セラミックファイバー、ウィスカー等の耐熱性繊維の少なくとも一種を含有させることにより、触媒の機械的強度を更に向上させることができる。なお、耐熱性繊維は、前駆体［Ｍ］および／または酸化物［Ｎ］の調製時、それらのスラリーの段階で添加するのが一般的である。
【００２０】
こうして得られた混合物は、このまま焼成しても触媒として使用できるが、通常、必要に応じ、成型助剤として水などを添加して所望形状に成型してから、焼成を行う。この際、混合物がスラリー状の場合は、一般的な乾燥法により乾燥物としてから成型を行う。焼成は酸素流通下、空気流通下または窒素流通下で行う。焼成温度は、通常、３００〜６００℃であり、好ましくは３００〜５００℃、さらに好ましくは３５０〜４５０℃である。また、焼成時間は特に限定されないが、通常１〜５０時間程度が好ましい。
【００２１】
上記触媒の存在下でのメタクロレイン、イソブチルアルデヒドおよび／またはイソ酪酸の気相酸化または酸化脱水素反応の条件については特に制限はなく、この種の反応に一般的に用いられている条件下にて行うことができる。例えば、メタクロレインの気相酸化の場合、メタクロレイン１〜１０容量％、これに対する容量比で１〜１０倍の範囲の分子状酸素、希釈剤としての、窒素、炭酸ガス、水蒸気（特に水蒸気の場合には、副生成物の生成を抑制し、目的性生物の収率向上に有利である。）などの不活性ガスからなる混合ガスを触媒上に２００〜４００℃の温度範囲および常圧ないし１ＭＰａの圧力下、空間速度１００〜５，０００ｈｒ−１（ＳＴＰ）で導入する。原料メタクロレインは必ずしも純粋である必要はなく、イソブチレンまたはターシャリーブタノールを接触的に反応させて得られるメタクロレイン含有ガスを用いることもできる。この方法は工業的プロセスにおいては特に推奨される。
【００２２】
【発明の効果】
本発明の触媒は、性能、強度および製造コストに優れたヘテロポリ酸系触媒である。そして、このヘテロポリ酸系触媒を用いることによりメタクリル酸を高収率で製造することができる。
【００２３】
【実施例】
以下、実施例を挙げて本発明を更に具体的に説明する。なお、転化率、選択率および単流収率は次の通り定義される。
転化率（モル％）＝（反応したメタクロレインのモル数／供給したメタクロレインのモル数）×１００
選択率（モル％）＝（生成したメタクリル酸のモル数／反応したメタクロレインのモル数）×１００
単流収率（モル％）＝（生成したメタクリル酸のモル数／供給したメタクロレインのモル数）×１００
実施例１
加熱したイオン交換水１０００ｍｌにパラモリブデン酸アンモニウム５００ｇとメタバナジン酸アンモニウム２７．６ｇとを加え攪拌した。これにオルトリン酸（８５質量％）３５．４ｇを加え、続いて硝酸セシウム４６．０ｇを溶かした溶液を加え、攪拌下に加熱濃縮した。得られたスラリーを１２０℃で４時間乾燥した後、粉砕した（以下、この粉体を前駆体［Ｍ］という。）。この前駆体［Ｍ］の組成は酸素を除いた原子比でＭｏ１２Ｐ１．３Ｖ１．０Ｃｓ１．０ であった。
新たに、前駆体［Ｍ］を同量作り、更に、空気流中４００℃で３時間焼成し、粉砕して粒径０．５ｍｍ以下の酸化触媒（以下、これを酸化物［Ｎ］という。）を得た。この酸化物［Ｎ］の組成は酸素を除いた原子比でＭｏ１２Ｐ１．３Ｖ１．０Ｃｓ１．０であった。
前駆体［Ｍ］に酸化物［Ｎ］の全回収量の１／１０を混合し、水で調湿した後、スクリュー式押出し成型機で直径５ｍｍ、長さ６ｍｍのペレット状に成型し、乾燥した後、空気流中４００℃で３時間焼成してペレット状触媒を得た。前駆体［Ｍ］と酸化物［Ｎ］との質量比は１００：１０であった。
上記のようにして得られた触媒５０ｍｌを内径２５ｍｍφのステンレス製Ｕ字管に充填し、２８０℃の溶融塩浴中に浸漬し、この管内にイソブチレンをモリブデン、コバルト、ビスマス、鉄などの酸化物多元系触媒の存在下に気相酸化して得られた下記組成の混合ガスを導入し、反応温度２８０℃、空間速度１，０００ｈ−１（ＳＴＰ）で反応を行った。
メタクロレイン：３．５容量％
イソブチレン：０．０４容量％
メタクリル酸＋酢酸：０．２４容量％
水蒸気：２０．０容量％
酸素：９．０容量％
その他（窒素、炭酸ガスを主体とする不活性ガス）：６７．２２容量％
また、触媒の機械的強度の測定を次の方法で行った。
磨耗度：
内径１００ｍｍφ、幅１００ｍｍの１２メッシュステンレス製金網からできた円筒の中に触媒５０ｇを入れ、この円筒を毎分１００回転の速度で３０分間連続してまわした後、円筒内に残った触媒の質量を計り、次の式により磨耗率を計算した。
磨耗率（％）＝｛（触媒質量（５０ｇ）−回転後金網内に残った触媒質量（ｇ））／触媒質量（５０ｇ）｝×１００
落下強度：
垂直に立てた内径２５ｍｍφで長さが５０００ｍｍＬの鉄パイプの上部から触媒３０ｇを落下させ４メッシュの篩で受け止め、篩上に残った触媒の質量を計り、次の式により落下強度率を計算した。
落下強度率（％）＝｛（触媒質量（３０ｇ）−篩上に残った触媒質量（ｇ））／触媒質量（３０ｇ）｝×１００
触媒の組成および機械的強度を表１に、また反応結果を表２に示す。
実施例２
実施例１において、前駆体［Ｍ］および酸化物［Ｎ］を調製する際、それらのスラリーの段階でシリコンカーバイドウィスカー９．８ｇ（ウィスカー含有量２質量％）を添加した以外は、実施例１と同様にして触媒調製および酸化反応を行った。触媒の組成および機械的強度を表１に、また反応結果を表２に示す。
実施例３
実施例１において、前駆体［Ｍ］および酸化物［Ｎ］の乾燥物の段階にグラスファイバー（８〜１２μｍφ）９．８ｇ（グラスファイバー含有量２質量％）を添加した以外は、実施例１と同様にして触媒調製および酸化反応を行った。触媒の組成および機械的強度を表１に、また反応結果を表２に示す。
実施例４
実施例１において、前駆体［Ｍ］および酸化物［Ｎ］を調製する際、それらのスラリーにシリコンカーバイドウィスカー９．８ｇ（ウィスカー含有量２質量％）を添加し、乾燥物の段階にグラスファイバー（８〜１２μｍφ）９．８ｇ（グラスファイバー含有量２質量％）を添加した以外は、実施例１と同様に触媒調製および酸化反応を行った。触媒の組成および機械的強度を表１に、また反応結果を表２に示す。
【表１】
実施例１において、前駆体［Ｍ］のみを水で調湿した後、スクリュー式押出し成型機で直径５ｍｍ、長さ６ｍｍのペレット状に成型し、乾燥した後、空気流中４００℃で３時間焼成してペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表３に、また反応結果を表４に示す。
比較例２
比較例１において、前駆体［Ｍ］のスラリーの段階にシリコンカーバイドウィスカー９．８ｇ（ウィスカー含有量２質量％）を添加した以外は、比較例１と同様にしてペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表３に、また反応結果を表４に示す。
比較例３
比較例１において、前駆体［Ｍ］の乾燥物の段階にグラスファイバー（８〜１２μｍφ）９．８ｇ（グラスファイバー含有量２質量％）を添加した以外は、比較例１と同様にしてペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表３に、また反応結果を表４に示す。
比較例４
比較例１において、前駆体［Ｍ］のスラリーの段階にシリコンカーバイドウィスカー９．８ｇ（ウィスカー含有量２質量％）を添加し、乾燥物の段階にグラスファイバー（８〜１２μｍφ）９．８ｇ（グラスファイバー含有量２質量％）を添加した以外は、比較例１と同様にしてペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表３に、また反応結果を表４に示す。
【表３】
実施例１において、前駆体［Ｍ］に酸化物［Ｎ］の全回収量の３／１００を混合する以外は、実施例１と同様にして触媒調製を行った。この際の、前駆体［Ｍ］と酸化物［Ｎ］との質量比は１００：３であった。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表５に、また反応結果を表６に示す。
実施例６
実施例１において、前駆体［Ｍ］に酸化物［Ｎ］の全回収量の１５／１００を混合する以外は、実施例１と同様にして触媒調製を行った。この際の、前駆体［Ｍ］と酸化物［Ｎ］との質量比は１００：１５であった。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表５に、また反応結果を表６に示す。
実施例７
実施例１において、前駆体［Ｍ］に酸化物［Ｎ］の全回収量の３０／１００を混合する以外は、実施例１と同様にして触媒調製を行った。この際の、前駆体［Ｍ］と酸化物［Ｎ］との質量比は１００：３０であった。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表５に、また反応結果を表６に示す。
【表５】
実施例１において、酸化物［Ｎ］の粒径を０．１ｍｍ以下とした以外は、実施例１と同様にして触媒調製を行った。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表７に、また反応結果を表８に示す。
実施例９
実施例１において、前駆体［Ｍ］を乾燥前のスラリーに置き換えた以外は、実施例１と同様にして触媒調製を行った。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表７に、また反応結果を表８に示す。
実施例１０
実施例１において、前駆体［Ｍ］を乾燥前のスラリーに置き換え、酸化物［Ｎ］を水に懸濁させてスラリーとした以外は、実施例１と同様にして触媒調製を行った。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表７に、また反応結果を表８に示す。
【表７】
実施例１において、前駆体［Ｍ］の組成が、Ｍｏ１２Ｐ１．５Ｃｕ０．２Ｖ１．０Ｃｓ１．５となるように、オルトリン酸と硝酸セシウムを増量し、硝酸銅を硝酸セシウムと同時に添加した以外は、実施例１と同様にして触媒調製を行った。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表９に、また反応結果を表１０に示す。
実施例１２
実施例１において、前駆体［Ｍ］の組成が、Ｍｏ１２Ｐ１．３Ｓｂ１．０Ｃｕ０．２Ｖ１．０Ｃｓ１となるように、三酸化アンチモンと硝酸銅を硝酸セシウムと同時に添加した以外は、実施例１と同様にして触媒調製を行った。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表９に、また反応結果を表１０に示す。
実施例１３
実施例１において、前駆体［Ｍ］の組成が、Ｍｏ１２Ｐ１．３Ａｓ０．５Ａｇ０．２Ｖ１．０Ｃｓ１となるように、亜ヒ酸と硝酸銀を硝酸セシウムと同時に添加し、また酸化物［Ｎ］の組成がＭｏ１２Ｐ１．５Ｃｕ０．２Ｖ１．０Ｃｓ１．５となるように、オルトリン酸と硝酸セシウムを増量し、硝酸銅を硝酸セシウムと同時に添加した以外は、実施例１と同様にして触媒調製を行った。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表９に、また反応結果を表１０に示す。
【表９】
実施例１１において、前駆体［Ｍ］のみを水で調湿した後、スクリュー式押出し成型機で直径５ｍｍ、長さ６ｍｍのペレット状に成型し、乾燥した後、空気流中４００℃で３時間焼成してペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表１１に、また反応結果を表１２に示す。
比較例６
実施例１２において、前駆体［Ｍ］のみを水で調湿した後、スクリュー式押出し成型機で直径５ｍｍ、長さ６ｍｍのペレット状に成型し、乾燥した後、空気流中４００℃で３時間焼成してペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表１１に、また反応結果を表１２に示す。
比較例７
実施例１３において、前駆体［Ｍ］のみを水で調湿した後、スクリュー式押出し成型機で直径５ｍｍ、長さ６ｍｍのペレット状に成型し、乾燥した後、空気流中４００℃で３時間焼成してペレット状触媒を得た。この触媒について、実施例１と同様に、強度測定および酸化反応を行った。触媒の組成および機械的強度を表１１に、また反応結果を表１２に示す。
【表１１】
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a catalyst for producing methacrylic acid, a method for producing the same, and a method for producing methacrylic acid. Specifically, the present invention relates to a heteropolyacid-based catalyst suitable for use in the production of methacrylic acid, a method for producing the same, and gas-phase oxidation or oxidation of methacrolein, isobutyraldehyde and / or isobutyric acid in the presence of the heteropolyacid-based catalyst. The present invention relates to a method for producing methacrylic acid by gas phase oxidative dehydrogenation.
[0002]
[Prior art]
It is well known that heteropolyacid based catalysts are used to produce methacrylic acid by gas phase oxidation of methacrolein, isobutyraldehyde and / or isobutyric acid.
[0003]
However, these heteropolyacid catalysts have very poor moldability and poor mechanical strength. Therefore, various studies have been made on the form of the catalyst and the reinforcing agent to make it a practical catalyst.
[0004]
Regarding the form of the catalyst, a supported catalyst for attaching a catalyst component to an appropriate carrier, a press-molded catalyst by tableting or extrusion, a granulated catalyst by tumbling granulation, and the like have been studied. As for the reinforcing agent, an extruded catalyst in which heat-resistant fibers such as graphite, ceramic fibers, and whiskers are mixed with a catalytic substance has been proposed (for example, see Patent Document 1).
[Patent Document 1] Japanese Patent Publication No. 2-36296
[Problems to be solved by the invention]
However, although these conventional catalysts have been put to practical use, they do not have sufficient strength for handling, and further improvement in strength as an industrial catalyst is desired. In addition, since the strength is poor, the yield is poor, and the catalyst production cost is increasing. On the other hand, in terms of catalytic performance, the catalysts proposed so far have low methacrylic acid yield and selectivity, and are not industrially satisfactory.
[0006]
The present invention is intended to solve the above problems and provide a heteropolyacid-based catalyst which is more excellent in performance, strength and production cost than the heteropolyacid-based catalyst obtained by the conventional method.
The present invention also provides a method for producing the above heteropolyacid catalyst.
The present invention also provides a method for producing methacrylic acid by vapor-phase oxidation or gas-phase dehydrogenation of methacrolein, isobutyraldehyde and / or isobutyric acid using the above-mentioned heteropolyacid catalyst.
[0007]
[Means for Solving the Problems]
The present inventors have studied the improvement of heteropolyacid catalysts in order to solve the above problems, and by mixing a specific amount of the catalyst after calcination with the catalyst material before molding, the catalyst strength is significantly improved. In addition, they have found that the selectivity of methacrylic acid generation is improved and the production cost is further reduced, and the present invention has been completed.
[0008]
That is, the present invention provides a compound of the general formula I:
Mo a P b A c B d C e D f O x (I)
(Where Mo is molybdenum, P is phosphorus, A is at least one element selected from arsenic, antimony, germanium, bismuth, zirconium and selenium, B is copper, iron, chromium, nickel, manganese, cobalt, tin, At least one element selected from silver, zinc, palladium, rhodium and tellurium, C is at least one element selected from vanadium, tungsten and niobium, D is at least one element selected from alkali metals, alkaline earth metals and thallium The species element, O, represents oxygen, a, b, c, d, e, f, and x represent the atomic ratio of Mo, A, B, C, D, and O, respectively, and when a = 12, b = 0.5 to 4, c = 0 to 5, d = 0 to 3, e = 0 to 4, f = 0.01 to 4, and x is determined by the oxidation state of each element. Is a numerical value)
A catalyst for producing methacrylic acid, characterized by being obtained by mixing a precursor [M] of the oxide represented by the formula [I] and an oxide [N] represented by the general formula I and calcining the mixture. is there.
[0009]
Further, the present invention is characterized in that the precursor [M] of the oxide represented by the general formula I and the oxide [N] represented by the general formula I are mixed, and then dried and fired. This is a method for producing a catalyst for producing methacrylic acid.
In addition, the present invention provides a method for producing methacrylic acid, which comprises using the above catalyst when producing methacrylic acid by catalytic gas phase oxidation or catalytic gas phase dehydrogenation of methacrolein, isobutyraldehyde and / or isobutyric acid. It is.
[0010]
BEST MODE FOR CARRYING OUT THE INVENTION
The oxide precursor [M] represented by the general formula I of the present invention refers to a solution or a slurry obtained by dissolving or suspending a raw material compound containing each element of the general formula I in a medium such as water. Hereinafter, these are collectively referred to as “slurries.”) Or a dried product obtained by drying the slurry at a temperature of less than 300 ° C., and drying the slurry or the dried product by evaporating the slurry to dryness. And then firing at a temperature of 300 to 600 ° C. to form an oxide represented by the general formula I.
[0011]
The slurry can be prepared by a conventionally well-known method such as a precipitation method and an oxide mixing method. Specifically, a raw material compound containing each element of the general formula I may be appropriately dissolved or suspended in a required amount of a medium such as water.
[0012]
The starting compound is not particularly limited, and a compound generally used for preparing a heteropolyacid catalyst can be used. For example, as a molybdenum raw material, ammonium molybdates such as ammonium paramolybdate and ammonium dimolybdate, molybdic acid, molybdenum trioxide and the like can be used. As the vanadium raw material, vanadium pentoxide, ammonium metavanadate, sodium metavanadate, vanadyl oxalate, vanadyl sulfate, or the like can be used. Further, orthophosphoric acid, disodium hydrogen phosphate, ammonium phosphate and the like can be used as the phosphorus raw material. Of course, molybdophosphoric acid, molybdovanadophosphoric acid, or the like containing two or more elements may be used.
[0013]
A dried product of the precursor [M] is obtained by drying the slurry by a general drying method. For example, an evaporation to dryness method, a spray drying method, a drum drying method and the like are used. At this time, the drying temperature is lower than 300 ° C, preferably lower than 250 ° C, more preferably 100 to 200 ° C, and still more preferably 110 to 190 ° C. Note that heat-resistant fibers such as glass fibers, graphite, ceramic fibers, and whiskers may be contained in the slurry and / or the dried product as a reinforcing agent.
[0014]
The oxide [N] is obtained by drying a slurry obtained by dissolving or suspending a raw material compound containing each element of the general formula I in a medium such as water, and then flowing the mixture under oxygen, air or nitrogen. Obtained by firing. Specifically, for example, the above slurry or dried product may be fired. In this case, the composition of the oxide [N] may be the same as or different from that of the precursor [M]. The firing temperature is from 300 to 600 ° C, preferably from 300 to 500 ° C, and more preferably from 350 to 450 ° C. The firing time is not particularly limited, but is preferably about 1 to 50 hours.
[0015]
As the oxide [N], a newly manufactured product as described above, or a catalyst whose performance has been deteriorated by use in the reaction, or a non-product (cracked or chipped) generated during the manufacture of the catalyst. , Dust, trimmings, etc.).
[0016]
The precursor [M] and the oxide [N] obtained as described above are mixed, and the mixing ratio of both is usually [M]: [N] = 100: 1 to 100: 50 (mass Ratio; the same shall apply hereinafter), preferably 100: 1 to 100: 30, more preferably 100: 3 to 100: 15. When the precursor [M] is a slurry, it is converted as its solid content.
[0017]
The catalyst obtained by using only the precursor [M] without mixing the oxide [N] has insufficient mechanical strength, whereas when the proportion of the oxide [N] increases, the mechanical strength of the catalyst increases. The conversion and the selectivity of methacrylic acid decrease.
[0018]
Although the oxide [N] may be used as it is, it is preferable to use the oxide [N] after being pulverized to a maximum particle size of 1 mm or less, preferably 0.5 mm or less, because the mechanical strength of the catalyst is improved. . In addition, it can also be used by dissolving or suspending it in water. Further, similarly to the precursor [M], a heat-resistant fiber such as glass fiber, graphite, ceramic fiber, or whisker may be contained as a reinforcing agent.
[0019]
By adding at least one kind of heat-resistant fiber such as glass fiber, graphite, ceramic fiber, or whisker to the precursor [M] and / or the oxide [N], the mechanical strength of the catalyst is further improved. Can be. The heat-resistant fiber is generally added at the stage of preparing the precursor [M] and / or the oxide [N] at the stage of slurry thereof.
[0020]
The mixture thus obtained can be used as a catalyst even when calcined as it is. However, if necessary, water or the like is added as a molding aid to mold the mixture into a desired shape, and then calcining is performed. At this time, when the mixture is in the form of a slurry, the mixture is formed into a dry product by a general drying method and then molded. The calcination is performed under a flow of oxygen, a flow of air, or a flow of nitrogen. The firing temperature is usually 300 to 600 ° C, preferably 300 to 500 ° C, and more preferably 350 to 450 ° C. The firing time is not particularly limited, but is preferably about 1 to 50 hours.
[0021]
The conditions for the gas-phase oxidation or oxidative dehydrogenation of methacrolein, isobutyraldehyde and / or isobutyric acid in the presence of the above-mentioned catalyst are not particularly limited, and the conditions generally used for this type of reaction are not limited. Can be done. For example, in the case of gas-phase oxidation of methacrolein, 1 to 10% by volume of methacrolein, molecular oxygen in a volume ratio of 1 to 10 times the volume thereof, nitrogen, carbon dioxide gas, and water vapor (particularly water vapor) as a diluent are used. In this case, it is advantageous to suppress the generation of by-products and to improve the yield of the target product. It is introduced under a pressure of 1 MPa at a space velocity of 100 to 5,000 hr -1 (STP). The raw material methacrolein does not necessarily need to be pure, and a methacrolein-containing gas obtained by reacting isobutylene or tertiary butanol catalytically can also be used. This method is particularly recommended in industrial processes.
[0022]
【The invention's effect】
The catalyst of the present invention is a heteropolyacid catalyst excellent in performance, strength and production cost. Then, methacrylic acid can be produced in high yield by using this heteropolyacid catalyst.
[0023]
【Example】
Hereinafter, the present invention will be described more specifically with reference to examples. The conversion, selectivity and single-stream yield are defined as follows.
Conversion (mol%) = (mol number of reacted methacrolein / mol number of supplied methacrolein) × 100
Selectivity (mol%) = (mol number of generated methacrylic acid / mol number of reacted methacrolein) × 100
Single stream yield (mol%) = (mol number of methacrylic acid generated / mol number of supplied methacrolein) × 100
Example 1
500 g of ammonium paramolybdate and 27.6 g of ammonium metavanadate were added to 1000 ml of heated ion-exchanged water and stirred. To this, 35.4 g of orthophosphoric acid (85% by mass) was added, followed by the addition of a solution of 46.0 g of cesium nitrate, and the mixture was heated and concentrated under stirring. The obtained slurry was dried at 120 ° C. for 4 hours, and then pulverized (hereinafter, this powder is referred to as a precursor [M]). The composition of this precursor [M] was Mo 12 P 1.3 V 1.0 Cs 1.0 in atomic ratio excluding oxygen.
A new precursor [M] is prepared in the same amount, and further calcined at 400 ° C. for 3 hours in an air stream, pulverized, and oxidized with a particle size of 0.5 mm or less (hereinafter referred to as oxide [N]). ) Got. The composition of this oxide [N] was Mo 12 P 1.3 V 1.0 Cs 1.0 in atomic ratio excluding oxygen.
The precursor [M] was mixed with 1/10 of the total recovered amount of the oxide [N], humidified with water, formed into a pellet having a diameter of 5 mm and a length of 6 mm by a screw type extruder, and dried. After that, the mixture was calcined at 400 ° C. for 3 hours in an air stream to obtain a pellet catalyst. The mass ratio between the precursor [M] and the oxide [N] was 100: 10.
50 ml of the catalyst obtained as described above is filled in a stainless U-shaped tube having an inner diameter of 25 mmφ and immersed in a molten salt bath at 280 ° C. A mixed gas having the following composition obtained by vapor-phase oxidation in the presence of a multicomponent catalyst was introduced, and the reaction was performed at a reaction temperature of 280 ° C. and a space velocity of 1,000 h −1 (STP).
Methacrolein: 3.5% by volume
Isobutylene: 0.04% by volume
Methacrylic acid + acetic acid: 0.24% by volume
Steam: 20.0% by volume
Oxygen: 9.0% by volume
Others (inert gas mainly composed of nitrogen and carbon dioxide): 67.22% by volume
Further, the mechanical strength of the catalyst was measured by the following method.
Wear degree:
50 g of the catalyst was placed in a cylinder made of a 12 mesh stainless steel wire mesh having an inner diameter of 100 mmφ and a width of 100 mm, and the cylinder was continuously rotated at a speed of 100 rotations per minute for 30 minutes, and then the mass of the catalyst remaining in the cylinder Was measured, and the wear rate was calculated by the following equation.
Wear rate (%) = {(mass of catalyst (50 g) −mass of catalyst remaining in wire mesh after rotation (g)) / mass of catalyst (50 g)} × 100
Drop strength:
30 g of the catalyst was dropped from the upper part of an iron pipe having an inner diameter of 25 mmφ and a length of 5,000 mmL, received by a 4-mesh sieve, the weight of the catalyst remaining on the sieve was measured, and the drop strength factor was calculated by the following equation. .
Drop strength rate (%) = {(mass of catalyst (30 g) −mass of catalyst remaining on sieve (g)) / mass of catalyst (30 g)} × 100
Table 1 shows the composition and mechanical strength of the catalyst, and Table 2 shows the reaction results.
Example 2
Example 1 was repeated except that, when preparing the precursor [M] and the oxide [N], 9.8 g of silicon carbide whiskers (whisker content 2% by mass) were added at the slurry stage. Preparation of a catalyst and an oxidation reaction were carried out in the same manner as described above. Table 1 shows the composition and mechanical strength of the catalyst, and Table 2 shows the reaction results.
Example 3
Example 1 Example 1 was repeated except that 9.8 g (glass fiber content: 2% by mass) of glass fiber (8 to 12 µmφ) was added to the dried product of the precursor [M] and the oxide [N]. Preparation of a catalyst and an oxidation reaction were carried out in the same manner as described above. Table 1 shows the composition and mechanical strength of the catalyst, and Table 2 shows the reaction results.
Example 4
In Example 1, when preparing the precursor [M] and the oxide [N], 9.8 g of silicon carbide whiskers (whisker content: 2% by mass) were added to the slurry thereof, and glass fiber was added to the dried product. Catalyst preparation and oxidation reaction were carried out in the same manner as in Example 1 except that 9.8 g (8 to 12 μmφ) (glass fiber content: 2% by mass) was added. Table 1 shows the composition and mechanical strength of the catalyst, and Table 2 shows the reaction results.
[Table 1]
In Example 1, only the precursor [M] was conditioned with water, molded into a pellet having a diameter of 5 mm and a length of 6 mm by a screw-type extruder, dried, and then dried at 400 ° C. for 3 hours in an air stream. Calcination gave a pelletized catalyst. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 3 shows the composition and mechanical strength of the catalyst, and Table 4 shows the reaction results.
Comparative Example 2
A pellet-shaped catalyst was obtained in the same manner as in Comparative Example 1, except that 9.8 g of silicon carbide whiskers (whisker content: 2% by mass) were added to the slurry of the precursor [M]. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 3 shows the composition and mechanical strength of the catalyst, and Table 4 shows the reaction results.
Comparative Example 3
In Comparative Example 1, pellets were prepared in the same manner as in Comparative Example 1, except that 9.8 g (glass fiber content: 2% by mass) of glass fiber (8 to 12 μmφ) was added at the stage of drying the precursor [M]. A catalyst was obtained. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 3 shows the composition and mechanical strength of the catalyst, and Table 4 shows the reaction results.
Comparative Example 4
In Comparative Example 1, 9.8 g of silicon carbide whiskers (whisker content: 2% by mass) were added to the slurry of the precursor [M], and 9.8 g of glass fibers (8 to 12 μmφ) were added to the dry matter. A pellet-shaped catalyst was obtained in the same manner as in Comparative Example 1 except that a fiber content of 2% by mass) was added. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 3 shows the composition and mechanical strength of the catalyst, and Table 4 shows the reaction results.
[Table 3]
A catalyst was prepared in the same manner as in Example 1 except that 3/100 of the total recovered amount of the oxide [N] was mixed with the precursor [M]. At this time, the mass ratio between the precursor [M] and the oxide [N] was 100: 3. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 5 shows the composition and mechanical strength of the catalyst, and Table 6 shows the reaction results.
Example 6
A catalyst was prepared in the same manner as in Example 1 except that 15/100 of the total recovered amount of the oxide [N] was mixed with the precursor [M]. At this time, the mass ratio between the precursor [M] and the oxide [N] was 100: 15. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 5 shows the composition and mechanical strength of the catalyst, and Table 6 shows the reaction results.
Example 7
A catalyst was prepared in the same manner as in Example 1 except that 30/100 of the total recovered amount of the oxide [N] was mixed with the precursor [M]. At this time, the mass ratio between the precursor [M] and the oxide [N] was 100: 30. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 5 shows the composition and mechanical strength of the catalyst, and Table 6 shows the reaction results.
[Table 5]
A catalyst was prepared in the same manner as in Example 1 except that the particle size of the oxide [N] was changed to 0.1 mm or less. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 7 shows the composition and mechanical strength of the catalyst, and Table 8 shows the reaction results.
Example 9
A catalyst was prepared in the same manner as in Example 1 except that the precursor [M] was replaced with the slurry before drying. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 7 shows the composition and mechanical strength of the catalyst, and Table 8 shows the reaction results.
Example 10
A catalyst was prepared in the same manner as in Example 1, except that the precursor [M] was replaced with a slurry before drying, and the oxide [N] was suspended in water to form a slurry. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 7 shows the composition and mechanical strength of the catalyst, and Table 8 shows the reaction results.
[Table 7]
In Example 1, orthophosphoric acid and cesium nitrate were increased and copper nitrate was converted to nitric acid so that the composition of the precursor [M] was Mo 12 P 1.5 Cu 0.2 V 1.0 Cs 1.5. A catalyst was prepared in the same manner as in Example 1 except that it was added simultaneously with cesium. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 9 shows the composition and mechanical strength of the catalyst, and Table 10 shows the reaction results.
Example 12
In Example 1, antimony trioxide and copper nitrate were added simultaneously with cesium nitrate so that the composition of the precursor [M] was Mo 12 P 1.3 Sb 1.0 Cu 0.2 V 1.0 Cs 1. A catalyst was prepared in the same manner as in Example 1 except that the catalyst was added. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 9 shows the composition and mechanical strength of the catalyst, and Table 10 shows the reaction results.
Example 13
In Example 1, arsenous acid and silver nitrate were added simultaneously with cesium nitrate so that the composition of the precursor [M] was Mo 12 P 1.3 As 0.5 Ag 0.2 V 1.0 Cs 1. Orthophosphoric acid and cesium nitrate are increased so that the composition of the oxide [N] becomes Mo 12 P 1.5 Cu 0.2 V 1.0 Cs 1.5, and copper nitrate is added simultaneously with cesium nitrate. A catalyst was prepared in the same manner as in Example 1 except that the catalyst was added. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. Table 9 shows the composition and mechanical strength of the catalyst, and Table 10 shows the reaction results.
[Table 9]
In Example 11, only the precursor [M] was conditioned with water, molded into a pellet having a diameter of 5 mm and a length of 6 mm by a screw-type extruder, dried, and then dried at 400 ° C. for 3 hours in an air stream. Calcination gave a pelletized catalyst. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. The composition and mechanical strength of the catalyst are shown in Table 11, and the reaction results are shown in Table 12.
Comparative Example 6
In Example 12, only the precursor [M] was humidified with water, molded into a pellet having a diameter of 5 mm and a length of 6 mm with a screw-type extruder, dried, and then dried at 400 ° C. for 3 hours in an air stream. Calcination gave a pelletized catalyst. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. The composition and mechanical strength of the catalyst are shown in Table 11, and the reaction results are shown in Table 12.
Comparative Example 7
In Example 13, only the precursor [M] was conditioned with water, molded into a pellet having a diameter of 5 mm and a length of 6 mm by a screw-type extruder, dried, and then dried at 400 ° C. for 3 hours in an air stream. Calcination gave a pelletized catalyst. This catalyst was subjected to strength measurement and oxidation reaction in the same manner as in Example 1. The composition and mechanical strength of the catalyst are shown in Table 11, and the reaction results are shown in Table 12.
[Table 11]
Claims (7)
ＭｏａＰｂＡｃＢｄＣｅＤｆＯｘ （Ｉ）
（ここで、Ｍｏはモリブデン、Ｐはリン、Ａはヒ素、アンチモン、ゲルマニウム、ビスマス、ジルコニウムおよびセレンから選ばれる少なくとも１種の元素、Ｂは銅、鉄、クロム、ニッケル、マンガン、コバルト、スズ、銀、亜鉛、パラジウム、ロジウムおよびテルルから選ばれる少なくとも１種の元素、Ｃはバナジウム、タングステンおよびニオブから選ばれる少なくとも１種の元素、Ｄはアルカリ金属、アルカリ土類金属およびタリウムから選ばれる少なくとも１種の元素、Ｏは酸素を表し、ａ、ｂ、ｃ、ｄ、ｅ、ｆおよびｘは、それぞれ、Ｍｏ、Ａ、Ｂ、Ｃ、ＤおよびＯの原子比を表し、ａ＝１２のとき、ｂ＝０．５〜４、ｃ＝０〜５、ｄ＝０〜３、ｅ＝０〜４、ｆ＝０．０１〜４であり、ｘはそれぞれの元素の酸化状態によって定まる数値である）
で表される酸化物の前駆体［Ｍ］と一般式Ｉで表される酸化物［Ｎ］とを混合し、焼成して得られたものであることを特徴とするメタクリル酸製造用触媒。General formula I:
Mo a P b A c B d C e D f O x (I)
(Where Mo is molybdenum, P is phosphorus, A is at least one element selected from arsenic, antimony, germanium, bismuth, zirconium and selenium, B is copper, iron, chromium, nickel, manganese, cobalt, tin, At least one element selected from silver, zinc, palladium, rhodium and tellurium, C is at least one element selected from vanadium, tungsten and niobium, D is at least one element selected from alkali metals, alkaline earth metals and thallium The species element, O, represents oxygen, a, b, c, d, e, f, and x represent the atomic ratio of Mo, A, B, C, D, and O, respectively, and when a = 12, b = 0.5 to 4, c = 0 to 5, d = 0 to 3, e = 0 to 4, f = 0.01 to 4, and x is determined by the oxidation state of each element. Is a numerical value)
A catalyst for producing methacrylic acid, characterized by being obtained by mixing an oxide precursor [M] represented by the formula [I] and an oxide [N] represented by the general formula I and calcining the mixture.
ＭｏａＰｂＡｃＢｄＣｅＤｆＯｘ （Ｉ）
（ここで、Ｍｏはモリブデン、Ｐはリン、Ａはヒ素、アンチモン、ゲルマニウム、ビスマス、ジルコニウムおよびセレンから選ばれる少なくとも１種の元素、Ｂは銅、鉄、クロム、ニッケル、マンガン、コバルト、スズ、銀、亜鉛、パラジウム、ロジウムおよびテルルから選ばれる少なくとも１種の元素、Ｃはバナジウム、タングステンおよびニオブから選ばれる少なくとも１種の元素、Ｄはアルカリ金属、アルカリ土類金属およびタリウムから選ばれる少なくとも１種の元素、Ｏは酸素を表し、ａ、ｂ、ｃ、ｄ、ｅ、ｆおよびｘは、それぞれ、Ｍｏ、Ａ、Ｂ、Ｃ、ＤおよびＯの原子比を表し、ａ＝１２のとき、ｂ＝０．５〜４、ｃ＝０〜５、ｄ＝０〜３、ｅ＝０〜４、ｆ＝０．０１〜４であり、ｘはそれぞれの元素の酸化状態によって定まる数値である）
で表される酸化物の前駆体［Ｍ］と一般式Ｉで表される酸化物［Ｎ］とを混合し、次いで乾燥、焼成することを特徴とするメタクリル酸製造用触媒の製造方法。General formula I:
Mo a P b A c B d C e D f O x (I)
(Where Mo is molybdenum, P is phosphorus, A is at least one element selected from arsenic, antimony, germanium, bismuth, zirconium and selenium, B is copper, iron, chromium, nickel, manganese, cobalt, tin, At least one element selected from silver, zinc, palladium, rhodium and tellurium, C is at least one element selected from vanadium, tungsten and niobium, D is at least one element selected from alkali metals, alkaline earth metals and thallium The species element, O, represents oxygen, a, b, c, d, e, f, and x represent the atomic ratio of Mo, A, B, C, D, and O, respectively, and when a = 12, b = 0.5 to 4, c = 0 to 5, d = 0 to 3, e = 0 to 4, f = 0.01 to 4, and x is determined by the oxidation state of each element. Is a numerical value)
A method for producing a catalyst for producing methacrylic acid, comprising mixing an oxide precursor [M] represented by the formula (I) and an oxide [N] represented by the general formula I, followed by drying and calcining.
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| JP2008535646A (en) * | 2005-03-08 | 2008-09-04 | ビーエーエスエフ ソシエタス・ヨーロピア | How to charge the reactor |
| EP2540393A1 (en) | 2005-05-12 | 2013-01-02 | Nippon Kayaku Kabushiki Kaisha | Method for preparing catalyst for production of methacrylic acid |
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