JP2008231044A - Process for producing unsaturated aldehyde and/or unsaturated carboxylic acid - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To subject at least one compound selected from propylene, isobutylene, and tertiary butyl alcohol to gas phase catalytic oxidation with good conversion to produce the corresponding unsaturated aldehyde and/or unsaturated carboxylic acid in a good yield. <P>SOLUTION: More than one kind of catalysts composed of predetermined composite oxides which differ in the kind and/or the content of constituting metallic elements from one another can be obtained by independently drying an aqueous solution or aqueous slurry containing the catalyst components, thereafter firing the dried product in the atmosphere of a molecular oxygen-containing gas, and successively heat treating the fired product in the presence of a reducing substance, and the obtained more than one kind of catalysts are filled in a reaction tube so as for the catalytic activity to become higher directed from the inlet for raw material gases to the outlet, and the above oxidation reaction is carried out by supplying the raw material gasses to the above reaction tube. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention provides a corresponding unsaturated aldehyde by gas phase catalytic oxidation by supplying a reaction gas with a raw material gas containing at least one compound selected from propylene, isobutylene and tertiary butyl alcohol and molecular oxygen. And / or a process for producing unsaturated carboxylic acids.

  By supplying a raw material gas containing at least one compound selected from propylene, isobutylene and tertiary butyl alcohol and molecular oxygen to a reaction tube filled with a catalyst, gas phase catalytic oxidation is performed, and corresponding unsaturation occurs. As a method for producing an aldehyde and / or an unsaturated carboxylic acid, for example, after preparing a plurality of types of catalysts having different catalytic activities by changing the type and amount of metal elements constituting the catalyst, these catalysts are added to the raw material gas inlet. A method has been proposed in which a reaction tube is filled so as to have higher catalytic activity toward the outlet portion and a raw material gas is supplied to the reaction tube (see Patent Documents 1 to 3).

JP-A-3-215441 JP-A-3-294238 JP 2000-351744 A

  However, the conventional methods are not always satisfactory in terms of the conversion rate of propylene and isobutylene tertiary butyl alcohol and the yield of unsaturated aldehyde and / or unsaturated carboxylic acid.

  Accordingly, an object of the present invention is to subject at least one compound selected from propylene, isobutylene and tertiary butyl alcohol to gas phase catalytic oxidation at a good conversion rate to obtain a corresponding unsaturated aldehyde and / or unsaturated carboxylic acid. The object is to provide a process which can be produced in good yield.

  As a result of diligent research, the present inventors have found that an aqueous solution containing a plurality of kinds of catalysts composed of predetermined complex oxides having different kinds and / or content ratios of constituent metal elements and containing the components of the catalyst. Or, after drying the aqueous slurry, calcining it in an atmosphere of molecular oxygen-containing gas, and then heat-treating it in the presence of a reducing substance, a plurality of types of catalysts are obtained from the raw material gas inlet to the outlet. It was found that the above object could be achieved by filling the reaction tube so as to be higher and supplying the raw material gas to the reaction tube, thereby completing the present invention.

  That is, the present invention provides gas phase catalytic oxidation by supplying a raw material gas containing at least one compound selected from propylene, isobutylene and tertiary butyl alcohol and molecular oxygen to a reaction tube, and corresponding unsaturation. A process for producing an aldehyde and / or an unsaturated carboxylic acid, comprising:

(1) The reaction tube is filled with a plurality of types of catalysts having different catalytic activities so that the catalytic activity becomes higher from the raw material gas inlet to the outlet.

(2) The plurality of types of catalysts are each independently represented by the following formula (I):

Mo _a Bi _b Fe _c A _{d Be} C _f D _g O _x (I)

(Wherein Mo, Bi and Fe represent molybdenum, bismuth and iron, A represents nickel and / or cobalt, and B represents at least one element selected from manganese, zinc, calcium, magnesium, tin and lead) C represents at least one element selected from phosphorus, boron, arsenic, tellurium, tungsten, antimony, silicon, aluminum, titanium, zirconium and cerium, and D represents at least selected from potassium, rubidium, cesium and thallium. Represents one element, O represents oxygen, and when a = 12, 0 <b ≦ 10, 0 <c ≦ 10, 1 ≦ d ≦ 10, 0 ≦ e ≦ 10, 0 ≦ f ≦ 10, (0 <g ≦ 2 and x is a value determined by the oxidation state of each element.)

Consisting of a complex oxide

(3) The plurality of types of catalysts differ from each other in the types and / or content ratios of the metal elements constituting the catalysts,

(4) The plurality of types of catalysts are each independently dried after drying an aqueous solution or aqueous slurry containing catalyst components, and then calcined in an atmosphere of molecular oxygen-containing gas, and then in the presence of a reducing substance. Be obtained by heat treatment,

A method for producing an unsaturated aldehyde and / or an unsaturated carboxylic acid is provided.

  According to the present invention, at least one compound selected from propylene, isobutylene and tertiary butyl alcohol is vapor-phase catalytically oxidized at a good conversion rate, and the corresponding unsaturated aldehyde and / or unsaturated carboxylic acid is obtained in good condition. It can be produced in a yield.

  Hereinafter, the present invention will be described in detail. In the present invention, at least selected from propylene, isobutylene and tertiary butyl alcohol in a reaction tube filled with a plurality of types of catalysts having different catalytic activities so that the catalytic activity becomes higher from the raw material gas inlet to the outlet. A raw material gas containing one kind of compound and molecular oxygen is supplied. The more types of catalyst, the more effective in terms of reaction results and temperature control in the reaction tube. However, since the production and filling operation of the catalyst becomes complicated, two types of catalysts are preferably used.

  The plurality of types of catalysts used in the present invention are each independently represented by the following formula (I):

Mo _a Bi _b Fe _c A _{d Be} C _f D _g O _x (I)

(Wherein Mo, Bi and Fe represent molybdenum, bismuth and iron, A represents nickel and / or cobalt, and B represents at least one element selected from manganese, zinc, calcium, magnesium, tin and lead) C represents at least one element selected from phosphorus, boron, arsenic, tellurium, tungsten, antimony, silicon, aluminum, titanium, zirconium and cerium, and D represents at least selected from potassium, rubidium, cesium and thallium. Represents one element, O represents oxygen, and when a = 12, 0 <b ≦ 10, 0 <c ≦ 10, 1 ≦ d ≦ 10, 0 ≦ e ≦ 10, 0 ≦ f ≦ 10, (0 <g ≦ 2 and x is a value determined by the oxidation state of each element.)

It consists of complex oxide shown by these.

  The plurality of types of catalysts differ from each other in the types and / or content ratios of the metal elements constituting them. A plurality of types of catalysts differ from each other in the types of metal elements constituting them. The elements of Group A, Group B, Group C, and Group D in one catalyst, and Group A, Group B in another catalyst, When the elements of Group C and Group D are compared, it means that at least one of the elements is different from each other. Further, the plurality of types of catalysts are different from each other in the content ratio of the metal elements constituting them. In one catalyst, the values of b, c, d, e, f, and g when a = 12. In other catalysts, when the values of b, c, d, e, f, and g when a = 12, respectively, it means that at least one of the values is different from each other.

  The plurality of types of catalysts are preferably represented by the following formula (II):

Mo _a Bi _b Fe _c Co _d Sb _f Cs _g O _x (II)

(Wherein Mo, Bi, Fe, Co, Sb and Cs represent molybdenum, bismuth, iron, cobalt, antimony and cesium, respectively, where a = 12, 0 <b ≦ 10, 0 <c ≦ 10, (1 ≦ d ≦ 10, 0 ≦ f ≦ 10, 0 <g ≦ 2, and x is a value determined by the oxidation state of each element.)

It consists of complex oxide shown by these. Also in this case, as described above, the plurality of types of catalysts differ from each other in the types and / or content ratios of the metal elements constituting them.

  As a more preferable catalyst and packing form, two kinds of catalysts are filled, and the raw material gas inlet is filled with a catalyst made of a composite oxide having a value of f in formula (II) other than 0, When the raw material gas outlet is filled with a catalyst made of a composite oxide having a value of f of 0 in formula (II), and the content ratios of molybdenum, bismuth, iron and cobalt in these catalysts are the same Is mentioned.

  Next, the manufacturing method of the said catalyst is demonstrated. A plurality of types of catalysts having different catalytic activities used in the present invention are produced independently. As a raw material of such a catalyst, compounds of respective elements constituting the catalyst, for example, oxides, nitrates, sulfates, carbonates, hydroxides, oxoacids and ammonium salts thereof, halides and the like are usually desired. It is used at a ratio that satisfies the content ratio. For example, molybdenum trioxide, molybdic acid, ammonium paramolybdate, etc. as the molybdenum compound, bismuth oxide, bismuth nitrate, bismuth sulfate, etc. as the bismuth compound, and iron (III) nitrate, iron sulfate as the iron compound (III), iron (III) chloride, etc., as cobalt compounds, cobalt nitrate, cobalt sulfate, cobalt chloride, etc., as antimony compounds, antimony trioxide, antimony (III) chloride, etc., as cesium compounds, Cesium nitrate, cesium carbonate, cesium hydroxide and the like can be used.

  In the present invention, the catalyst raw material is mixed in water to prepare an aqueous solution or aqueous slurry, dried, and then the dried product is calcined in an atmosphere of molecular oxygen-containing gas. Moreover, some catalyst raw materials such as antimony compounds may be added after drying. Each of these steps can be performed in accordance with a conventional method (for example, see JP-A-59-46132, JP-A-60-163830, and JP-A-2000-288396). For example, the drying can be performed using a kneader, a box-type dryer, a drum-type aeration dryer, a spray dryer, an air dryer, or the like. The molecular oxygen concentration in the molecular oxygen-containing gas is usually 1 to 30% by volume, preferably 10 to 25% by volume. As the molecular oxygen source, air or pure oxygen is usually used, and this is diluted with nitrogen, carbon dioxide, water, helium, argon or the like as necessary, and used as a molecular oxygen-containing gas. The firing temperature is usually 300 to 600 ° C., preferably 400 to 550 ° C., and the firing time is usually 5 minutes to 40 hours, preferably 1 hour to 20 hours.

  The fired product obtained by the firing is heat-treated in the presence of a reducing substance (hereinafter, heat treatment in the presence of the reducing substance may be simply referred to as a reduction treatment).

  Examples of the reducing substance include hydrogen, ammonia, carbon monoxide, hydrocarbon, alcohol, aldehyde, amine, and the like, and two or more of them can be used as necessary. Here, hydrocarbons, alcohols, aldehydes and amines each preferably have about 1 to 6 carbon atoms, and examples of such hydrocarbons include methane, ethane, propane, n-butane, and isobutane. Examples include saturated aliphatic hydrocarbons, unsaturated aliphatic hydrocarbons such as ethylene, propylene, α-butylene, β-butylene, and isobutylene, benzene, etc. Examples of alcohols include methyl alcohol, ethyl alcohol, and n-propyl alcohol. , Saturated aliphatic alcohols such as isopropyl alcohol, n-butyl alcohol, isobutyl alcohol, secondary butyl alcohol, and tertiary butyl alcohol, unsaturated aliphatic alcohols such as allyl alcohol, crotyl alcohol, and methallyl alcohol, and phenol. . Examples of aldehydes include saturated aliphatic aldehydes such as formaldehyde, acetaldehyde, propionaldehyde, n-butyraldehyde, isobutyraldehyde, unsaturated aliphatic aldehydes such as acrolein, crotonaldehyde, and methacrolein. Examples include saturated aliphatic amines such as methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine and triethylamine, unsaturated aliphatic amines such as allylamine and diallylamine, and aniline.

  The reduction treatment is usually performed by heat-treating the fired product in an atmosphere of a gas containing the reducing substance. The concentration of the reducing substance in the gas is usually 0.1 to 50% by volume, preferably 1 to 30% by volume, and the reducing substance is nitrogen, carbon dioxide, water, What is necessary is just to dilute with helium, argon, etc. In addition, although molecular oxygen may exist in the range which does not impair the effect of a reduction process, it is good not to exist normally.

  The temperature of the reduction treatment is usually 200 to 600 ° C, preferably 250 to 550 ° C. The reduction treatment time is usually 5 minutes to 20 hours, preferably 30 minutes to 10 hours. The reduction treatment is preferably carried out by putting the fired product into a tube-type or box-type container and circulating a gas containing a reducing substance therein. At this time, the gas discharged from the container is circulated and recycled as necessary. May be used.

  A reduction in mass is usually observed before and after the reduction treatment, which is considered because the catalyst loses lattice oxygen. And it is preferable that this mass decreasing rate is 0.05-6 mass%, More preferably, it is 0.1-5 mass%. When the reduction has progressed too much and the mass reduction rate exceeds 6% by mass, it is preferable that the mass reduction rate is lowered again by firing in an atmosphere of molecular oxygen-containing gas. The mass reduction rate is obtained by the following formula.

Mass reduction rate (%) = [(mass of calcined product before reduction treatment) − (mass of catalyst after reduction treatment)] ÷ (mass of calcined product before reduction treatment) × 100

  In the reduction treatment, depending on the type of reducing substance used, the heat treatment conditions, and the like, the reducing substance itself or a decomposition product derived from the reducing substance may remain in the catalyst after the reduction treatment. In such a case, the amount of the residual substance in the catalyst may be separately measured, and this may be subtracted from the catalyst mass including the residue to calculate the mass after the reduction treatment. Since the residue is typically carbon, its mass may be determined by, for example, total carbon (TC) measurement.

  The catalyst is usually used after being molded into a desired shape. This molding is preferably formed into a ring shape, a pellet, a spherical shape or the like by tableting molding or extrusion molding. Moreover, the shape of the multiple types of catalyst used by this invention may be the same, and may differ. This molding may be performed at a stage before firing in a molecular oxygen-containing gas atmosphere, may be performed after the firing, or may be performed after a reduction treatment. Further, during this molding, in order to improve the mechanical strength of the catalyst, for example, inorganic fibers that are substantially inert to the target oxidation reaction are added as described in JP-A-9-52053, for example. May be.

  Thus, a plurality of types of catalysts having different catalytic activities are prepared. The catalytic activity of these catalysts is determined by subjecting at least one raw material compound selected from propylene, isobutylene and tertiary butyl alcohol to gas phase catalytic oxidation with molecular oxygen in the presence of the catalyst, and measuring the conversion rate. Can be evaluated. Then, these catalysts are filled into a reaction tube so that the catalytic activity from the raw material gas inlet portion to the outlet portion, that is, the conversion rate becomes higher, and the raw material gas containing the raw material compound and molecular oxygen is contained in the reaction tube. Is carried out to carry out a gas phase catalytic oxidation reaction. Industrially, it is preferable to use a fixed-bed multitubular reactor including the reaction tube.

  As the molecular oxygen source, air is usually used, and the raw material gas may contain nitrogen, carbon dioxide, carbon monoxide, water vapor and the like as components other than the raw material compound and molecular oxygen.

  By the gas phase catalytic oxidation, acrolein and / or acrylic acid can be produced from propylene in a high yield, and methacrolein and / or methacrylic acid can be produced from isobutylene or tertiary butyl alcohol in a high yield. .

The reaction temperature is usually 250 to 400 ° C. and the reaction pressure can be reduced, but it is usually atmospheric pressure to 500 kPa. The amount of molecular oxygen relative to the raw material compound is usually 1 to 3 mol times. The space velocity SV of the source gas is usually 500 to 5000 h ^{−1 on the} basis of STP (Standard temperature and pressure).

  Examples of the present invention will be described below, but the present invention is not limited thereto. In the examples, ml / min representing the gas flow rate is based on STP unless otherwise specified. In the examples, the conversion rate (%) and yield (%) were defined as follows.

  Conversion (%) = [(moles of supplied isobutylene) − (moles of unreacted isobutylene)] ÷ (moles of supplied isobutylene) × 100

  Total yield (%) = (moles of methacrolein and methacrylic acid) ÷ (moles of supplied isobutylene) × 100

Reference Example 1 Preparation of catalyst a (unreduced product) 4414 g of ammonium molybdate [(NH ₄ ) ₆ Mo ₇ O ₂₄ · 4H ₂ O] was dissolved in 5000 g of warm water, and this was designated as solution A. Meanwhile, 2020 g of iron (III) nitrate [Fe (NO ₃ ) ₃ .9H ₂ O], 4366 g of cobalt nitrate [Co (NO ₃ ) ₂ .6H ₂ O] and 195 g of cesium nitrate [CsNO ₃ ] are dissolved in 2000 g of hot water. Subsequently, 970 g of bismuth nitrate [Bi (NO ₃ ) ₃ .5H ₂ O] was dissolved, and this was used as B solution. A liquid A was stirred, B liquid was added in this, the slurry was obtained, and this slurry was then dried using the airflow dryer, and the dried material was obtained. 6 parts by mass of silica-alumina fiber (RFC400-SL, manufactured by Saint-Gobain TM) is added to 100 parts by mass of the dried product and molded into a ring shape having an outer diameter of 6.3 mm, an inner diameter of 2.5 mm, and a length of 6 mm. Subsequently, the catalyst a was obtained by calcination at 525 ° C. for 6 hours under an air stream. This catalyst contains 0.96 atoms of bismuth, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.48 atoms of cesium with respect to 12 atoms of molybdenum.

Example 1 Preparation of catalyst A (reduced product) Catalyst a was filled in a glass tube, and a mixed gas of hydrogen / nitrogen = 5/95 (volume ratio) was supplied thereto at a space velocity of 240 h ^−1. A reduction treatment was performed at 0 ° C. for 8 hours to obtain Catalyst A. This catalyst contains 0.96 atoms of bismuth, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.48 atoms of cesium with respect to 12 atoms of molybdenum as in the case of the catalyst a, and the mass before and after the reduction treatment. The reduction rate was 0.90% by mass.

Reference Example 2 Preparation of catalyst b (unreduced product) 2.54 parts by mass of antimony trioxide (Sb ₂ O ₃ ) was added to 100 parts by mass of the dried product in Reference Example 1, and the calcination temperature was 546 ° C. A catalyst b was obtained in the same manner as in Reference Example 1 except that the catalyst b was changed. This catalyst contains 0.96 atoms of bismuth, 0.48 atoms of antimony, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.48 atoms of cesium with respect to 12 atoms of molybdenum.

Example 2 Preparation of catalyst B (reduced product) The above catalyst b was filled in a glass tube, and a mixed gas of hydrogen / nitrogen = 5/95 (volume ratio) was supplied thereto at a space velocity of 240 h ^−1. A reduction treatment was performed at 0 ° C. for 8 hours to obtain Catalyst B. Like the catalyst b, this catalyst contains bismuth 0.96 atoms, antimony 0.48 atoms, iron 2.4 atoms, cobalt 7.2 atoms, cesium 0.48 atoms with respect to 12 atoms of molybdenum, The mass reduction rate before and after the reduction treatment was 1.28% by mass.

Reference Example 3 Preparation of Catalyst c (Product not Reduced) Catalyst c was obtained in the same manner as in Reference Example 1 except that the amount of cesium nitrate used was changed to 273 g. This catalyst contains 0.96 atoms of bismuth, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.67 atoms of cesium with respect to 12 atoms of molybdenum.

Example 3 Preparation of catalyst C (reduced product) The above catalyst c was filled in a glass tube, and a mixed gas of hydrogen / nitrogen = 5/95 (volume ratio) was supplied thereto at a space velocity of 240 h ^−1. A reduction treatment was performed at 0 ° C. for 8 hours to obtain Catalyst C. Like the catalyst c, this catalyst contains 0.96 atoms of bismuth, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.67 atoms of cesium with respect to 12 atoms of molybdenum, and the mass before and after the reduction treatment. The reduction rate was 0.77% by mass.

Reference Example 4 Preparation of Catalyst d (Unreduced Product) 6 parts by mass of silica-alumina fiber (manufactured by Saint-Gobain TM, RFC400-SL) and 2.54 parts by mass of 100 parts by mass of the dried product in Reference Example 3 Antimony trioxide (Sb ₂ O ₃ ) was added to form a ring shape having an outer diameter of 6.3 mm, an inner diameter of 2.5 mm, and a length of 6 mm, and then calcined at 490 ° C. for 6 hours under an air stream. Catalyst d was obtained. This catalyst contains 0.96 atoms of bismuth, 0.29 atoms of antimony, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.67 atoms of cesium with respect to 12 atoms of molybdenum.

Example 4 Preparation of catalyst D (reduced product) The above catalyst d was filled in a glass tube, and a mixed gas of hydrogen / nitrogen = 5/95 (volume ratio) was supplied thereto at a space velocity of 240 h ^−1. The catalyst D was obtained by performing a reduction treatment at 8 ° C. for 8 hours. Like the catalyst d, this catalyst contains 0.96 atoms of bismuth, 0.29 atoms of antimony, 2.4 atoms of iron, 7.2 atoms of cobalt, and 0.67 atoms of cesium with respect to 12 atoms of molybdenum. The mass reduction rate before and after the reduction treatment was 1.17% by mass.

Comparative Example 1 Oxidation Reaction Using Catalyst A (Catalyst A Single Layer)
Into a glass reaction tube having an inner diameter of 18 mm, 14.30 ml of catalyst A was diluted with 30 g of silicon carbide (manufactured by Shinano Denki Co., Ltd., Shinano Random GC F16) and filled. Here, a mixed gas of isobutylene / oxygen / nitrogen / steam = 1.0 / 2.2 / 6.2 / 2.0 (molar ratio) was supplied at a flow rate of 157.5 ml / min, and the reaction temperature was raised to 330 ° C. The oxidation reaction was performed. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 2 Oxidation Reaction Using Catalyst A (Catalyst A Single Layer)
The oxidation reaction was performed in the same manner as in Comparative Example 1 except that the reaction temperature was 340 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 3 Oxidation Reaction Using Catalyst A (Catalyst A Single Layer)
The oxidation reaction was performed in the same manner as in Comparative Example 1 except that the reaction temperature was 350 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 4 Oxidation reaction using catalyst B (catalyst B single layer)
An oxidation reaction was performed in the same manner as in Comparative Example 1 except that the catalyst A was changed to the catalyst B. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 5 Oxidation reaction using catalyst C (catalyst C monolayer)
The oxidation reaction was performed in the same manner as in Comparative Example 1 except that the catalyst A was changed to the catalyst C and the reaction temperature was 340 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 6 Oxidation reaction using catalyst D (catalyst D monolayer)
The oxidation reaction was performed in the same manner as in Comparative Example 1 except that the catalyst A was changed to the catalyst D and the reaction temperature was 350 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Example 5 Oxidation reaction using catalyst B and catalyst A (catalyst B / catalyst A double layer)
7.15 ml of catalyst B is diluted and filled with 15 g of silicon carbide (Shinano Denki Co., Ltd., Shinano Random GC F16) on the raw material gas inlet side of a glass reaction tube having an inner diameter of 18 mm, and the catalyst is placed on the raw material gas outlet side. 7.15 ml of A was diluted and filled with 15 g of silicon carbide (manufactured by Shinano Denki Co., Ltd., Shinano Random GC F16). Here, a mixed gas of isobutylene / oxygen / nitrogen / steam = 1.0 / 2.2 / 6.2 / 2.0 (molar ratio) was supplied at a flow rate of 157.5 ml / min, and the reaction temperature was raised to 330 ° C. The oxidation reaction was performed. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Example 6 Oxidation reaction using catalyst C and catalyst A (catalyst C / catalyst A double layer)
The oxidation reaction was performed in the same manner as in Example 5 except that the catalyst B was changed to the catalyst C and the reaction temperature was 340 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Example 7 Oxidation reaction using catalyst D and catalyst A (catalyst D / catalyst A double layer)
The oxidation reaction was performed in the same manner as in Example 5 except that the catalyst B was changed to the catalyst D and the reaction temperature was 350 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 7 Oxidation reaction using catalyst b and catalyst a (catalyst b / catalyst a double layer)
An oxidation reaction was performed in the same manner as in Example 5 except that the catalyst B was changed to the catalyst b and the catalyst A was changed to the catalyst a. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 8 Oxidation reaction using catalyst c and catalyst a (catalyst c / catalyst a double layer)
The oxidation reaction was performed in the same manner as in Example 5 except that the catalyst B was changed to the catalyst c and the catalyst A was changed to the catalyst a, and the reaction temperature was 340 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Comparative Example 9 Oxidation reaction using catalyst d and catalyst a (catalyst d / catalyst a double layer)
The oxidation reaction was carried out in the same manner as in Example 5 except that the catalyst B was changed to the catalyst d and the catalyst A was changed to the catalyst a, respectively, and the reaction temperature was 350 ° C. Table 1 shows the conversion of isobutylene and the total yield of methacrolein and methacrylic acid.

Claims (8)

By supplying a raw material gas containing at least one compound selected from propylene, isobutylene and tertiary butyl alcohol and molecular oxygen to a reaction tube, gas phase catalytic oxidation is performed, and a corresponding unsaturated aldehyde and / or unsaturated aldehyde is obtained. A method for producing a saturated carboxylic acid, comprising:
(1) The reaction tube is filled with a plurality of types of catalysts having different catalytic activities so that the catalytic activity becomes higher from the raw material gas inlet to the outlet.
(2) The plurality of types of catalysts are each independently represented by the following formula (I):
Mo _a Bi _b Fe _c A _{d Be} C _f D _g O _x (I)
(Wherein Mo, Bi and Fe represent molybdenum, bismuth and iron, A represents nickel and / or cobalt, and B represents at least one element selected from manganese, zinc, calcium, magnesium, tin and lead) C represents at least one element selected from phosphorus, boron, arsenic, tellurium, tungsten, antimony, silicon, aluminum, titanium, zirconium and cerium, and D represents at least selected from potassium, rubidium, cesium and thallium. Represents one element, O represents oxygen, and when a = 12, 0 <b ≦ 10, 0 <c ≦ 10, 1 ≦ d ≦ 10, 0 ≦ e ≦ 10, 0 ≦ f ≦ 10, (0 <g ≦ 2 and x is a value determined by the oxidation state of each element.)
Consisting of a complex oxide
(3) The plurality of types of catalysts differ from each other in the types and / or content ratios of the metal elements constituting the catalysts,
(4) The plurality of types of catalysts are each independently dried after drying an aqueous solution or aqueous slurry containing catalyst components, and then calcined in an atmosphere of molecular oxygen-containing gas, and then in the presence of a reducing substance. Be obtained by heat treatment,
A process for producing an unsaturated aldehyde and / or an unsaturated carboxylic acid characterized by The plurality of catalysts are each independently represented by the following formula (II):
Mo _a Bi _b Fe _c Co _d Sb _f Cs _g O _x (II)
(Wherein Mo, Bi, Fe, Co, Sb and Cs represent molybdenum, bismuth, iron, cobalt, antimony and cesium, respectively, where a = 12, 0 <b ≦ 10, 0 <c ≦ 10, (1 ≦ d ≦ 10, 0 ≦ f ≦ 10, 0 <g ≦ 2, and x is a value determined by the oxidation state of each element.)
The method of Claim 1 which consists of complex oxide shown by these.   The method according to claim 1 or 2, wherein two kinds of catalysts are charged in the reaction tube. The raw material gas inlet of the reaction tube is filled with a catalyst made of a complex oxide in which the value of f in the formula (II) is not 0,
The raw material gas outlet of the reaction tube is filled with a catalyst made of a composite oxide having a value of f of 0 in the formula (II), and
The content ratio of molybdenum, bismuth, iron and cobalt in the catalyst filled in the raw material gas inlet is the same as the content ratio of molybdenum, bismuth, iron and cobalt in the catalyst filled in the raw material gas outlet. The method described.   The method according to claim 1, wherein the baking is performed at 300 to 600 ° C.   The method according to claim 1, wherein the heat treatment is performed at 200 to 600 ° C.   The method according to claim 1, wherein a mass reduction rate due to the heat treatment is 0.05 to 6 mass%.   The reducing substance is at least one selected from hydrogen, ammonia, carbon monoxide, a hydrocarbon having 1 to 6 carbon atoms, an alcohol having 1 to 6 carbon atoms, an aldehyde having 1 to 6 carbon atoms, and an amine having 1 to 6 carbon atoms. The method according to claim 1, which is a seed compound.