WO2005047226A1 - Verfahren zum langzeitbetrieb einer heterogen katalysierten gasphasenpartialoxidation von acrolein zu acrylsäure - Google Patents
Verfahren zum langzeitbetrieb einer heterogen katalysierten gasphasenpartialoxidation von acrolein zu acrylsäure Download PDFInfo
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- WO2005047226A1 WO2005047226A1 PCT/EP2004/011259 EP2004011259W WO2005047226A1 WO 2005047226 A1 WO2005047226 A1 WO 2005047226A1 EP 2004011259 W EP2004011259 W EP 2004011259W WO 2005047226 A1 WO2005047226 A1 WO 2005047226A1
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- 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
- C07C51/25—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of unsaturated compounds containing no six-membered aromatic ring
- C07C51/252—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of unsaturated compounds containing no six-membered aromatic ring of propene, butenes, acrolein or methacrolein
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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
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J23/20—Vanadium, niobium or tantalum
- B01J23/22—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
- B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J23/24—Chromium, molybdenum or tungsten
- B01J23/28—Molybdenum
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C57/00—Unsaturated compounds having carboxyl groups bound to acyclic carbon atoms
- C07C57/02—Unsaturated compounds having carboxyl groups bound to acyclic carbon atoms with only carbon-to-carbon double bonds as unsaturation
- C07C57/03—Monocarboxylic acids
- C07C57/04—Acrylic acid; Methacrylic acid
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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
- B01J2523/00—Constitutive chemical elements of heterogeneous catalysts
- B01J2523/50—Constitutive chemical elements of heterogeneous catalysts of Group V (VA or VB) of the Periodic Table
- B01J2523/55—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
- B01J2523/00—Constitutive chemical elements of heterogeneous catalysts
- B01J2523/60—Constitutive chemical elements of heterogeneous catalysts of Group VI (VIA or VIB) of the Periodic Table
- B01J2523/68—Molybdenum
Definitions
- the present invention relates to a process for the long-term operation of a heterogeneously catalyzed gas phase partial oxidation of acrolein to acrylic acid, in which an acrolein, molecular oxygen and at least one inert diluent gas is passed through a reaction gas starting mixture through a fixed catalyst bed at elevated temperature, the catalysts of which are made so that their Active composition is at least one multimetal oxide, which contains the elements Mo and V, and in which, in order to counteract the deactivation of the fixed catalyst bed, the temperature of the fixed catalyst bed is increased over time.
- Acrylic acid forms a reactive monomer which, as such or in the form of its alkyl esters, e.g. for the production of polymers that include can be used as adhesives or water-absorbing materials.
- EP-A 990 636 (for example page 8, lines 13 to 15) and EP-A 1 106598 (for example page 13, lines 43 to 45) propose to largely compensate for the reduction in the quality of the fixed catalyst bed by: the operating time, under otherwise largely unchanged operating conditions, the temperature of the catalytic converter the fixed bed is gradually increased in order to essentially maintain the acroiein conversion with a single passage of the reaction gas mixture through the fixed catalyst bed.
- the temperature of the fixed catalyst bed is understood to mean the temperature of the fixed catalyst bed when the partial oxidation process is carried out, however, in the fictitious absence of a chemical reaction (i.e. without the influence of the heat of reaction). This should also apply in this document.
- the effective temperature of the fixed catalyst bed is understood to mean the actual temperature of the fixed catalyst bed, taking into account the heat of reaction of the partial oxidation. If the temperature of the fixed catalyst bed along the fixed catalyst bed is not constant (e.g. in the case of several temperature zones), the term temperature of the fixed catalyst bed in this document means the (number) mean of the temperature along the fixed catalyst bed.
- the temperature of the reaction gas mixture (and thus also the effective temperature of the fixed catalyst bed) passes through a maximum value (the so-called hot point value) when it passes through the fixed catalyst bed.
- the difference between the hot spot value and the temperature of the fixed catalyst bed at the point of the hot spot value is referred to as the hot spot expansion.
- a disadvantage of the procedure recommended in EP-A 990 636 and in EP-A 1 106598 is that its aging process accelerates as the temperature of the fixed catalyst bed increases (certain movement processes within the catalysts that contribute to aging run, for example faster). This is mainly because the hot spot expansion usually increases even more with an increase in the temperature of the fixed catalyst bed than the temperature of the fixed catalyst bed itself (see, for example, page 12, lines 45 to 48 of EP-A 1 106598 and page 8, Lines 11 to 15 of EP-A 990 636). The effective temperature of the fixed catalyst bed therefore usually increases disproportionately in the hot spot area, which additionally promotes the aging of the fixed catalyst bed.
- DE-A 10232 748 recommends that instead of completely replacing the fixed catalyst bed, only a subset of the same should be replaced by a fresh catalyst feed.
- EP-A 614 872 recommends extending the service life of the fixed catalyst bed by interrupting the partial oxidation process after several years of operating the fixed catalyst bed, accompanied by increases in the temperature of the latter from 15 ° C to 30 ° C and more Fixed catalyst bed temperatures of 260 to 450 ° C by the same leads a gas mixture of oxygen, water vapor and inert gas and then continues the partial oxidation.
- inert gases in a gas mixture which is led through the fixed catalyst bed under certain conditions are to be understood as gases which, when carried out through the fixed catalyst bed, contain at least 95 mol%, preferably at least 98 mol%. %, very particularly preferably remain unchanged at least 99 mol% or 99.5 mol%.
- gas mixture G to be used according to the invention water vapor and CO should not be subsumed under the term inert gas.
- a method for long-term operation of a heterogeneously catalyzed gas phase partial oxidation of acrolein to acrylic acid would be desirable, in which the aging of the catalyst is counteracted in such a way that the extent of the hot spot expansion is less over time than in the prior art methods.
- a process for the long-term operation of a heterogeneously catalyzed gas phase partial oxidation of acrolein to acrylic acid in which an acrolein, molecular oxygen and at least one inert diluent reaction gas starting mixture is passed through a fixed catalyst bed at elevated temperature, the catalysts of which are such that their active mass is at least one multimetal oxide which contains the elements Mo and V and in which, in order to counteract the deactivation of the fixed catalyst bed, the temperature of the catalyst Fixed catalyst bed increased over time, which is characterized in that before the temperature increase of the fixed catalyst bed is permanently> 10 ° C or> 8 ° C, the gas phase partial oxidation is interrupted at least once, and at a temperature of the fixed catalyst bed of 200 to 450 ° C (preferably 250 to 400 ° C, often 300 to 400 ° C, or 250 to 350 ° C, or 250 to 300 ° C) an acrolein-free, molecular oxygen, inert gas and optionally water vapor
- an oxidizing gas mixture G is to be understood as a gas mixture G which, when the process according to the invention is used, does not reduce (but usually oxidizes) the oxidation states of the metals contained in the multimetal-oxidizing active composition when entering the fixed catalyst bed.
- a gas mixture G is characterized in that its molar content of molecular oxygen when the gas mixture G enters the fixed catalyst bed is greater (preferably at least twice as large) than the sum of its molar content of CO and its molar content of CO, inert gas, O 2 and H 2 O various components.
- preference is given to interrupting the gas phase partial oxidation at least once before the temperature increase in the fixed catalyst bed is permanently ⁇ 7 ° C, or> 6 ° C, or ⁇ 5 ° C, or> 4 ° C, in order to achieve a temperature of 200 fixed catalyst bed up to 450 ° C a molecular oxygen free of acrolein, inert gas and possibly water vapor and possibly containing CO, oxidizing gas mixture G through the fixed catalyst bed.
- the gas phase partial oxidation at least once before the temperature increase of the fixed catalyst bed is ⁇ 3 ° C or ⁇ 2 ° C, in order to achieve a molecular acid free of acrolein at a temperature of the fixed catalyst bed of 200 to 450 ° C - Guide substance, inert gas and optionally water vapor and possibly CO-containing, oxidizing gas mixture G through the fixed catalyst bed.
- the process according to the invention is also advantageous if, before the temperature increase of the fixed catalyst bed is permanently ⁇ 1 ° C or less, the gas phase partial oxidation is interrupted at least once and at a temperature of 200 to 450 ° C a molecular oxygen, inert gas and free of acrolein optionally water vapor and possibly CO-containing, oxidizing gas mixture G is passed through the fixed catalyst bed.
- the temperature increase of the fixed catalyst bed will be permanently ⁇ 0.1 ° C or ⁇ 0.2 ° C before the gas phase partial oxidation is interrupted at least once according to the invention.
- T G which essentially corresponds to the temperature T v of the fixed catalyst bed at which the partial oxidation was carried out before being interrupted to lead the gas mixture G through the fixed catalyst bed according to the invention.
- T v will be in the range of 200 to 400 ° C, often in the range of 220 to 350 ° C.
- the time period t G during which the gas mixture G is to be passed through the fixed catalyst bed in the process according to the invention will generally be 2 h or 6 h to 120 h, often 12 h to 72 h and often 20 to 40 h. However, it can also be 10 days or more. As a rule, a small oxygen content of the gas mixture G will require a longer period of time t G. Increased oxygen contents in the gas mixture G are advantageous according to the invention.
- the gas mixture G (unless stated otherwise, all contents of the gas mixture G in this document relate to the entry of the gas mixture G into the fixed catalyst bed) are preferably at least 1 or 2% by volume in the process according to the invention contain at least 3% by volume and particularly preferably at least 4% by volume of oxygen. As a rule, however, the oxygen content of the gas mixture G will be 21 21% by volume.
- a possible gas mixture G is air.
- Another possible gas mixture G is lean air. This is air that has been de-oxygenated.
- Lean air is advantageous according to the invention, which consists of 3 to 10, preferably 4 to 6,% by volume of oxygen and a residual amount of molecular nitrogen.
- the gas mixture G contains water vapor in addition to molecular oxygen and inert gas.
- the gas mixture G contains at least 0.1% by volume, often at least 0.5% by volume and often at least 1% by volume of water vapor.
- the water vapor content of the gas mixture G is normally ⁇ 75% by volume.
- the proportion of inert gas in the gas mixture G is generally ⁇ 95% by volume, usually ⁇ 90% by volume.
- Gas mixtures G suitable according to the invention can thus consist, for example, of 3 to 20% by volume of molecular oxygen, 1 to 75% by volume of water vapor and, as a residual amount, inert gas.
- Preferred inert gases are N 2 and CO 2 .
- all gas mixtures G recommended in EP-A 614 872 are suitable for the process according to the invention.
- all of the regeneration conditions recommended in EP-A 614 872 can be used for the process according to the invention.
- the CO content of a gas mixture G to be used according to the invention will generally not exceed 5% by volume. Often the CO content will be at values of ⁇ 3 vol.%, Or ⁇ 2 vol.%, Or ⁇ 1 vol.% Or will be completely vanishing.
- the CO 2 content of the gas mixture G can also vary within the time period t G.
- the oxygen content of the gas mixture G is increased from a lower value to a higher value within the time period t G.
- an oxygen content of the gas mixture G of approximately 1 to 3% by volume and within the time period t G to a value of up to 10% by volume, preferably of up to 6% by volume.
- the water vapor content of the gas mixture G is often chosen to fall within the time period t G.
- Initial values are often up to 10% by volume, while the final value is often ⁇ 3% by volume.
- gas mixtures G which contain: 1 to 8 (preferably 3 to 6) vol.% Oxygen, 0 to 3 vol.% CO, 0 to 5 vol.% CO 2 , 0 to 25 vol.% H 2 O, and at least 55 vol. % N 2 (G preferably consists of these components, nitrogen then forming the remaining amount up to 100% by volume).
- the H 2 O, as well as the CO and the CO 2 content of the gas mixture G * preferably decreases as described, while the O 2 content increases as described, within t G. It has proven to be particularly advantageous if the gas mixture G on entry into the fixed catalyst bed> 0 to ⁇ 20 ppm by weight, frequently ⁇ 15 or ⁇ 10 or ⁇ 5 or ⁇ 1 ppm by weight of gaseous Mo-containing compounds such as eg molybdenum oxide hydrate.
- This content can be adjusted, for example, by passing a gas mixture G containing water vapor at an elevated temperature (for example 250-500 ° C.) through a bed containing Mo oxide in advance of the use according to the invention.
- the amount of the gas mixture G passed through the fixed catalyst bed in the process according to the invention can be 5 or 100 to 5000 Nl / l «h, preferably 20 or 200 to 2000 Nl / l « h (reference is the volume of the total fixed catalyst bed, ie, including possibly used sections that consist exclusively of inert material).
- the gas mixture G is passed through the fixed catalyst bed at a fixed catalyst bed temperature of 200 to 450 ° C. with a frequency H of at least once per calendar year, preferably at least once per calendar three-quarter or per calendar half-year, particularly preferably from at least once per calendar quarter and particularly preferably from at least once per calendar month. Otherwise, the process of heterogeneously catalyzed gas phase partial oxidation of acrolein to acrylic acid will be carried out largely continuously.
- the gas mixture G is passed through the fixed catalyst bed at a fixed catalyst bed temperature of 200 to 450 ° C. at least once within 7500 or 7000 or 6000, preferably at least once within 5500 or 5000 and very particularly preferably at least once within 4000, or 3000 or 2000 or 1500, or 1000, or 500 operating hours of the partial oxidation. Frequent implementation of the method according to the invention has an advantageous effect.
- multimetal oxides which contain the elements Mo and V are suitable as the active composition for the catalysts of the fixed catalyst bed.
- Multimetal oxide active compositions which are suitable according to the invention and contain Mo and V can be described, for example, in US Pat. No. 3,775,474, US Pat. No. 3,954,555, US Pat. No. 3,893,951 and US Pat. No. 4,339,355, or EP-A 614872 or EP-A 1 041 062 or WO 03/055835 and WO 03/057653 can be found.
- the multimetal oxide active compositions of DE-A 10 325 487 and DE-A 10 325 488 are also particularly suitable.
- EP-A 427 508, DE-A 2 909 671, DE-C 31 51 805, DE-AS 2 626 887, DE-A 43 02 991, EP- A 700 893, EP-A 714 700 and DE-A 19 73 6105 as active compositions for fixed bed catalysts suitable for the process according to the invention.
- the exemplary embodiments of EP-A 714 700 and DE-A 19 73 6105 are particularly preferred.
- Active masses can be calculated using the general formula I, Mo 12 V a X 1 b X 2 0 X 3 d X 4 e X 5 f X 6 g O n (I),
- X 1 W, Nb, Ta, Cr and / or Ce
- X 2 Cu, Ni, Co, Fe, Mn and / or Zn
- X 3 Sb and / or Bi
- X 4 one or more alkali metals
- X 5 one or more alkaline earth metals
- X 1 W, Nb, and / or Cr
- X 2 Cu, Ni, Co, and / or Fe
- X 5 Ca, Sr and / or Ba
- X 6 Si, Al, and or Ti
- a 1.5 to 5
- b 0.5 to 2
- c 0.5 to 3
- d 0 to 2
- e 0 to 0.2
- f 0 to 1
- n a number which is determined by the valency and frequency of the elements in I other than oxygen.
- multimetal oxides I are those of the general formula II,
- Y 5 Ca and / or Sr
- multimetal oxide active compositions (I) which are suitable according to the invention are obtainable in a manner known per se, for example disclosed in DE-A 4335973 or in EP-A 714700.
- the multimetal oxide active compositions of DE-A 10261 186 are also particularly suitable.
- multimetal oxide active compositions suitable for the fixed bed catalysts to be used for the process according to the invention in particular those of the general formula I, can be prepared in a simple manner by generating an intimate, preferably finely divided, dry mixture composed of suitable stoichiometry from suitable sources of their elemental constituents this calcined at temperatures of 350 to 600 ° C.
- the calcination can take place both under inert gas and under an oxidative atmosphere such as air (mixture of inert gas and oxygen) and also under a reducing atmosphere (eg mixtures of inert gas and reducing gases such as H 2 , NH 3 , CO, methane and / or acrolein or the reducing gases mentioned are carried out by themselves).
- the calcination time can range from a few minutes to a few hours and usually decreases with temperature.
- Suitable sources for the elemental constituents of the multimetal oxide active compositions I are those compounds which are already oxides and / or those compounds which can be converted into oxides by heating, at least in the presence of oxygen.
- the intimate mixing of the starting compounds for the production of multimetal oxide compositions I can be carried out in dry or in wet form. If it is carried out in dry form, the starting compounds are expediently used as finely divided powders and, after mixing and optionally compacting, are subjected to the calcination. However, the intimate mixing is preferably carried out in wet form.
- the starting compounds are mixed with one another in the form of an aqueous solution and / or suspension.
- Particularly intimate dry mixtures are obtained in the mixing process described if only sources of the elementary constituents present in dissolved form are used. Water is preferably used as the solvent.
- the aqueous mass obtained is then dried, the drying process preferably being carried out by spray drying the aqueous mixture at exit temperatures of 100 to 150 ° C.
- the multimetal oxide active compositions suitable for the fixed bed catalysts to be used for the process according to the invention can be used for the process according to the invention both in powder form and in the form of certain catalyst geometries, the shaping being able to take place before or after the final calcination.
- full catalysts can be produced from the powder form of the active composition or its uncalcined precursor composition by compression to the desired catalyst geometry (for example by tableting, extrusion or extrusion), with auxiliaries such as graphite or stearic acid optionally being used as lubricants and / or shaping auxiliaries and reinforcing agents such as microfibers Glass, asbestos, silicon carbide or potassium titanium tanate can be added.
- Suitable full catalyst geometries are, for example, full cylinders or hollow cylinders with an outer diameter and a length of 2 to 10 mm.
- a wall thickness of 1 to 3 mm is appropriate.
- the full catalyst can also have a spherical geometry, the spherical diameter being 2 to 10 mm.
- the powdery active composition or its powdery, not yet calcined, precursor composition can also be shaped by application to preformed inert catalyst supports.
- the coating of the support bodies for the production of the coated catalysts is usually carried out in a suitable rotatable container, as is e.g. is known from DE-A 2909671, EP-A 293859 or from EP-A 714700.
- the powder mass to be applied is expediently moistened and, after application, e.g. using hot air, dried again.
- the layer thickness of the powder composition applied to the carrier body is expediently selected in the range from 10 to 1000 ⁇ m, preferably in the range from 50 to 500 ⁇ m and particularly preferably in the range from 150 to 250 ⁇ m.
- carrier bodies can have a regular or irregular shape, with regularly shaped carrier bodies with a clearly formed surface roughness, e.g. Balls or hollow cylinders are preferred. It is suitable to use essentially non-porous, rough-surface, spherical supports made of steatite, the diameter of which is 1 to 8 mm, preferably 4 to 5 mm. However, it is also suitable to use cylinders as carrier bodies, the length of which is 2 to 10 mm and the outside diameter is 4 to 10 mm.
- the wall thickness is moreover usually 1 to 4 mm.
- Annular support bodies to be used preferably according to the invention have a length of 3 to 6 mm, an outer diameter of 4 to 8 mm and a wall thickness of 1 to 2 mm.
- Particularly suitable according to the invention are rings of geometry 7 mm x 3 mm x 4 mm (outer diameter x length x inner diameter) as the carrier body.
- the fineness of the catalytically active oxide compositions to be applied to the surface of the carrier body is of course adapted to the desired shell thickness (cf. EP-A 714700).
- compositions to be used for fixed bed catalysts suitable for the process according to the invention are furthermore compositions of the general formula III,
- Z 1 W, Nb, Ta, Cr and / or Ce
- Z 2 Cu, Ni, Co, Fe, Mn and / or Zn
- Z 3 Sb and / or Bi
- Z 6 Si, Al, Ti and / or Zr
- Z 7 Mo, W, V, Nb and / or Ta
- starting mass 1 separately in finely divided form (starting mass 1) and then the preformed solid starting mass 1 in an aqueous solution, an aqueous suspension or in a fine one-part dry mixture of sources of the elements Mo, V, Z 1 , Z 2 , Z 3 , Z 4 , Z 5 , Z 6 , the aforementioned elements in the stoichiometry D,
- Multimetal oxide active compositions for the catalysts of the fixed catalyst bed of the process according to the invention are furthermore multielement oxide active compositions of the general formula IV,
- A Mo 12 V a X b X 2 c X 3 d X 4 e X 5 , X 6 gO x ,
- X 1 W, Nb, Ta, Cr and / or Ce, preferably W, Nb and / or Cr,
- X 2 Cu, Ni, Co, Fe, Mn and / or Zn, preferably Cu, Ni, Co and / or Fe,
- X 3 Sb and / or Bi, preferably Sb,
- X 6 Si, Al, Ti and / or Zr, preferably Si, Al and / or Ti,
- X 7 Mo, W, V, Nb and / or Ta, preferably Mo and / or W,
- X 8 Cu, Ni, Zn, Co, Fe, Cd, Mn, Mg, Ca, Sr and / or Ba, preferably Cu and / or Zn, particularly preferably Cu,
- the areas A, B and optionally C being distributed relative to one another as in a mixture of finely divided A, finely divided B and optionally finely divided C, and all variables within the predetermined ranges being selected with the proviso that the molar fraction of the element Mo in the total amount of all elements of the multielement oxide active composition IV other than oxygen is 20 mol% to 80 mol%, the molar ratio of Mo contained in the catalytically active multielement oxide composition IV to V, Mo contained in the catalytically active multielemethylene oxide composition IV / V, 15: 1 to 1: 1, the corresponding molar ratio Mo / Cu 30: 1 to 1: 3 and the corresponding molar ratio Mo / (total amount of W and Nb) is 80: 1 to 1: 4.
- Preferred multielement oxide active materials IV are those whose areas A have a composition in the subsequent stoichiometric grid of the general formula V,
- X 1 W and / or Nb
- X 2 Cu and / or Ni
- X 5 Ca and / or Sr
- X 6 Si and / or Al
- a 2 to 6
- b 1 to 2
- c 1 to 3
- f 0 to 0.75
- g 0 to 10
- x a number which is determined by the valency and frequency of the elements other than oxygen in (V).
- phase used in connection with the multielement oxide active materials V means three-dimensionally extended areas whose chemical composition is different from that of their surroundings.
- the phases are not necessarily homogeneous by X-ray diffraction.
- phase A forms a continuous phase in which Particles of phase B and optionally C are dispersed.
- the finely divided phases B and optionally C advantageously consist of particles whose size diameter, that is to say the longest connecting section through the center of gravity of the particles, of two points on the surface of the particles of up to 300 ⁇ m, preferably 0.1 to 200 ⁇ m, particularly preferred 0.5 to 50 ⁇ m and very particularly preferably 1 to 30 ⁇ m. Particles with a size of 10 to 80 ⁇ m or 75 to 125 ⁇ m are also suitable.
- phases A, B and optionally C in the multielement oxide active materials IV can be amorphous and / or crystalline.
- the intimate dry mixtures on which the multielement oxide active compositions of the general formula IV are based and which are subsequently to be thermally treated for conversion into active compositions can e.g. can be obtained as described in WO 02/24327, DE-A 4405514, DE-A 4440891, DE-A 19528646, DE-A 19740493, EP-A 756894, DE-A 19815280, DE-A 19815278, EP -A 774297, DE-A 19815281, EP-A 668104 and DE-A 19736105.
- the basic principle of the production of intimate dry mixtures which lead to multielement oxidative compositions of the general formula IV in the case of thermal treatment is to use at least one multielement oxide composition B (X / CU h HOy) as starting mass 1 and optionally one or more multielement oxide compositions C (X ⁇ Sb j H k Oz) as starting mass 2 either separated from one another or combined with one another in fine-particle form and then the starting masses 1 and given if necessary 2 with a mixture that swells the elementary constituents of the multielement oxide mass A.
- the intimate contact of the constituents of the starting materials 1 and optionally 2 with the mixture containing the sources of the elemental constituents of the multimetal oxide composition A (starting material 3) can be carried out either dry or wet. In the latter case, it is only necessary to ensure that the pre-formed phases (crystallites) B and possibly C do not go into solution. The latter is guaranteed in aqueous medium at pH values that do not deviate too much from 7 and that are usually guaranteed at not too high temperatures. If the intimate contact is made wet, then the intimate dry mixture to be thermally treated according to the invention is normally dried (e.g. by spray drying). Such a dry mass is automatically obtained during dry mixing.
- the finely pre-formed phases B and optionally C can also be incorporated into a plastically deformable mixture which contains the sources of the elementary constituents of the multimetal oxide composition A, as recommended by DE-A 10046928.
- the intimate contact of the constituents of starting materials 1 and optionally 2 with the sources of multielement oxide material A (starting material 3) can also be carried out as described in DE-A 19815281.
- the thermal treatment to obtain the active composition and the shaping can be carried out as described for the multimetal oxide active compositions I to III.
- multimetal oxide active compositions I to IV catalysts can advantageously be produced in accordance with the teaching of DE-A 10 325487 or DE-A 10 325488.
- the fixed catalyst bed to be used in the process according to the invention is in the simplest way in the uniformly charged metal tubes of a tube bundle reactor and a temperature control medium (single-zone driving wise), usually a molten salt.
- Salt melt (temperature control medium) and reaction gas mixture can be carried out in simple cocurrent or countercurrent.
- the temperature control medium the molten salt
- the molten salt can also be passed through the reactor, viewed in a meandering manner, around the tube bundle, so that only 5, viewed across the entire reactor, is a cocurrent or countercurrent to the direction of flow of the reaction gas mixture.
- the volume flow of the temperature control medium (heat exchange medium) is usually dimensioned such that the temperature rise (due to the exothermic nature of the reaction) of the heat exchange medium from the entry point into the reactor to the exit point from the reactor 0 to 0 10 ° C, often 2 to 8 ° C, often 3 to 6 ° C.
- the inlet temperature of the heat exchange medium in the tube bundle reactor (in this document corresponds to the temperature of the fixed catalyst bed) is generally 220 to 350 ° C, often 245 to 285 ° C or 245 to 265 ° C.
- Fluid heat transfer media are particularly suitable as heat exchange medium.
- melts of salts such as potassium nitrate, potassium nitrite, sodium nitrite and / or sodium nitrate, or of low-melting metals such as sodium, mercury and alloys of various metals is particularly favorable.
- Ionic liquids can also be used.
- reaction gas mixture of the feed with fixed bed catalyst is expediently supplied preheated to the desired reaction temperature.
- the process according to the invention is expediently carried out in a two-zone tube reactor (carried out in However, a single-zone tube bundle reactor is also possible).
- a preferred variant of a two-zone tube bundle reactor which can be used according to the invention for this purpose is disclosed in DE-C 2830765. But also those in DE-C 2513405, US-A 3147084, DE-A 2201528, EP-A 383224 and DE-A 2903582 The two-zone tube bundle reactors disclosed are suitable.
- the fixed catalyst bed to be used according to the invention is located in the uniformly charged metal tubes of a tube bundle reactor, and two temperature-regulating media which are essentially spatially separated from one another, usually molten salts, are guided around the metal tubes.
- the pipe section over which the respective salt bath extends represents a temperature or reaction zone.
- a salt bath A preferably flows around that section of the tubes (reaction zone A) in which the oxidative conversion of acrolein (in the single pass) takes place until a conversion value in the range of 55 to 85 mol% is reached and a salt bath B flows around the Section of the tubes (the reaction zone B), in which the oxidative subsequent conversion of acrolein (in the simple Pass) until a conversion value of at least 90 mol% is generally achieved (if necessary, reaction zones A, B can be followed by further reaction zones which are kept at individual temperatures).
- the salt bath can be conducted within the respective temperature zone as in the single-zone mode.
- the inlet temperature of salt bath B is normally at least 5 to 10 ° C. above the temperature of salt bath A. Otherwise, the inlet temperatures can be in the temperature range recommended for the single-zone procedure for the inlet temperature.
- the two-zone high-load mode e.g. as in DE-A 19948523, EP-A 1106598 or as described in DE-A 19948248.
- the method according to the invention is suitable for acrolein loading of the fixed catalyst bed of> 70 Nl / I • h, ⁇ 90 Nl / I • h, ⁇ 110 Nl / I • h,> 130 Nl / I • h, ⁇
- the inert gas to be used for the feed gas mixture can be e.g. ⁇ 20 vol.%, Or ⁇ 30 vol.%, Or ⁇ 40 vol.%, Or ⁇ 50 vol.%, Or> 60 vol.%, Or ⁇ 70 vol. %, or> 80 vol .-%, or> 90 vol .-%, or ⁇ 95 vol .-% consist of molecular nitrogen.
- the inert diluent gas is often 5 to 25 or 20% by weight H 2 O (formed in the first reaction stage and optionally added) and 70 up to 90 vol .-% consist of N 2 .
- inert diluent gases such as propane, ethane, methane, butane, pentane, CO 2 , CO, water vapor and / or noble gases is recommended for the process according to the invention.
- these gases can also be used with lower acrolein loads.
- the working pressure in the gas phase partial oxidation of acrolein according to the invention can be both below normal pressure (for example up to 0.5 bar) and above normal pressure.
- the working pressure in the gas phase partial oxidation of acrolein will be from 1 to 5 bar, often 1 to 3 bar.
- the reaction pressure in the partial acrolein oxidation according to the invention will not exceed 100 bar.
- the molar ratio of O 2 : acrolein in the reaction gas starting mixture which is passed through the fixed catalyst bed in the process according to the invention will normally be ⁇ 1. This ratio will usually be at values ⁇ 3. Frequently, the molar ratio of O 2 : acrolein in the aforementioned feed gas mixture according to the invention will be 1 to 2 or 1 to 1.5.
- the process according to the invention will be carried out with an acid: oxygen: steam: inert gas: volume ratio (NI) of 1: (1 to 3): (0 to 20): (3 to 30), preferably 3: 30, preferably 1: (1 to 3): (0.5 to 10): execute (7 to 10).
- the acrolein content in the reaction gas starting mixture can e.g. with values of 3 or 6 to 15% by volume, frequently 4 or 6 to 10% by volume or 5 to 8% by volume (in each case 5 based on the total volume).
- shaped catalyst bodies having the corresponding multimetal oxide active composition or else largely homogeneous mixtures of multimetal oxide active composition comprising O shaped catalyst bodies and no multimetal oxide active composition which are essentially inert (consisting of inert material) (shaped body) with respect to the heterogeneously catalyzed partial gas phase oxidation become.
- all those materials are suitable as materials for such inert shaped bodies which are also suitable as support material for coated catalysts which are suitable according to the invention.
- Such materials include, for example, porous or non-porous aluminum oxides, silicon dioxide, thorium dioxide, zirconium dioxide, silicon carbide, silicates such as magnesium or aluminum silicate or the aforementioned steatite (eg steatite C-220 from CeramTec).
- the geometry of such inert shaped diluent bodies can be arbitrary. This means, for example, spheres, polygons, solid cylinders or rings. According to the invention, preference will be given to choosing inert inert shaped bodies whose geometry corresponds to that of the shaped catalyst bodies to be diluted with them.5 As a rule, it is advantageous if the chemical composition of the active composition used does not change via the fixed catalyst bed.
- the active composition used for a single shaped catalyst body may be a mixture of different multimetal oxides containing the elements Mo and V, but it is then advantageous to use the same mixture for all shaped catalyst bodies of the fixed catalyst bed.
- the volume-specific activity ie the activity normalized to the unit of volume
- the volume-specific activity within the fixed catalyst bed increases continuously, abruptly or step-wise in the flow direction of the reaction gas starting mixture.
- the volume-specific activity can e.g. can be reduced in a simple manner by homogeneously diluting a basic amount of uniformly produced shaped catalyst bodies with shaped diluent bodies.
- a volume-specific activity which increases at least once in the direction of flow of the reaction gas mixture over the fixed catalyst bed can thus be achieved in a simple manner for the process according to the invention, e.g. adjust by starting the bed with a high proportion of inert diluent shaped bodies based on a type of shaped catalyst body, and then reducing this proportion of diluent shaped bodies in the flow direction either continuously or at least once or several times abruptly (e.g. stepwise).
- An increase in volume-specific activity is also e.g.
- mixtures of catalysts with chemically different active composition and, as a result of this different composition, different activity can also be used for the fixed catalyst bed.
- These mixtures can in turn be diluted with inert diluents.
- the fixed catalyst bed containing the active composition there can only be beds consisting of inert material (for example only dilution moldings) (in this document, unless otherwise stated, they are conceptually assigned to the fixed catalyst bed). This can also be brought to the temperature of the fixed catalyst bed.
- the shaped dilution bodies used for the inert bed can have the same geometry as the shaped catalyst bodies used for the sections of the fixed catalyst bed having the active composition.
- the geometry of the shaped diluent bodies used for the inert bed can also be different from the aforementioned geometry of the shaped catalyst bodies (for example spherical instead of annular).
- the section of the fixed catalyst bed having the active composition is often structured as follows in the flow direction of the reaction gas mixture.
- the weight fraction of the shaped diluent bodies is normally 10 to 50% by weight, preferably 20 to 45% by weight and particularly preferably 25 to 35% by weight.
- This first zone is then advantageously either up to the end of the section of the fixed catalyst bed having active composition (ie, for example over a length of 2.00 to 3.00 m, preferably 2.50 to 3.00 m) either a bed of the shaped catalyst bodies diluted only to a lesser extent (than in the first zone), or, very particularly preferably, a single bed of the same shaped catalyst bodies which were also used in the first zone.
- both the shaped catalyst bodies or! their carrier rings and the shaped dilution bodies in the process according to the invention essentially have the ring geometry 7 mm x 3 mm x 4 mm (outer diameter x length x inner diameter).
- shaped catalyst moldings are used whose active mass fraction is 2 to 15% by weight points lower than the active mass fraction of the shell catalyst shaped bodies at the end of the fixed catalyst bed.
- a pure bed of inert material generally introduces the fixed catalyst bed in the direction of flow of the reaction gas mixture. It is normally used as a heating zone for the reaction gas mixture.
- the contact tubes in the tube bundle reactors are usually made of ferritic steel and typically have a wall thickness of 1 to 3 mm. Their inside diameter is usually (uniformly) 20 to 30 mm, often 21 to 26 mm. Appropriately from an application point of view, the number of contact tubes accommodated in the tube bundle container is at least 5000, preferably at least 10,000. The number of contact tubes accommodated in the reaction vessel is often 150,000 to 30,000. Tube bundle reactors with a number of contact tubes above 40,000 are rather the exception.
- the contact tubes are normally arranged homogeneously distributed within the container, the distribution being expediently chosen such that the distance between the central inner axes from the closest contact tubes (the so-called contact tube division) is 35 to 45 mm (cf., for example, EP-B 468290 ).
- the loading of the fixed catalyst bed (here only pure inert sections) with reaction gas mixture is typical in the process according to the invention
- a fresh fixed catalyst bed after its formation will normally be operated in such a way that, after the composition of the reaction gas mixture has been determined and the loading of the fixed catalyst bed with the reaction gas mixture has been established, the temperature of the fixed catalyst bed (or the entry temperature of the temperature control medium into the temperature control zone) of the tube bundle reactor ) so that the conversion U acr of acrolein is at least 90 mol% when the reaction gas mixture passes through the fixed catalyst bed once.
- values for U Acr are also ⁇ 92 mol%, or> 94 mol%, or ⁇ 96 mol%, or ⁇ 98 mol%, and often even ⁇ 99 mol% and more possible.
- the composition of the reaction gas starting mixture and the loading of the fixed catalyst bed with the reaction gas starting mixture will be kept essentially constant (if necessary, the load on the fluctuating de market demand adjusted).
- a decrease in the activity of the fixed catalyst bed over time under these production conditions will normally be countered by increasing the temperature of the fixed catalyst bed (the temperature of the temperature of the temperature control medium entering the temperature zone of the tube bundle reactor) from time to time (the flow rate of the temperature control medium is usually essentially also retained) in order to reduce the acrolein conversion in a single passage of the reaction gas mixture in the desired target corridor (ie, at values of ⁇ 90 mol% or> 92 mol% or ⁇ 94 mol% or> 96 mol%). %, or ⁇ 98 mol%, or ⁇ 99 mol%) to keep.
- such a procedure entails the disadvantages described at the beginning of this document.
- the procedure is such that before the temperature increase of the fixed catalyst bed is permanently ⁇ 10 ° C or ⁇ 8 ° C (based on the previously set temperature of the fixed catalyst bed), the gas phase partial oxidation is interrupted at least once in order to
- the temperature of the fixed catalyst bed from 200 to 450 ° C a molecular oxygen free of acrolein, inert gas and possibly water vapor and possibly containing CO, oxidizing gas mixture (e.g. consisting of molecular oxygen, inert gas and possibly water vapor) through the fixed catalyst bed.
- oxidizing gas mixture e.g. consisting of molecular oxygen, inert gas and possibly water vapor
- the partial oxidation is continued while largely maintaining the process conditions (preferably the acrolein load on the fixed catalyst bed is slowly readjusted as in a fresh fixed catalyst bed, for example as described in DE-A 10337788) and the temperature of the fixed catalyst bed is adjusted so that the acrolein conversion is the desired target value reached.
- this temperature value will be at a somewhat lower value than the temperature which the fixed catalyst bed had before the interruption of the partial oxidation and the treatment according to the invention with the gas mixture G.
- the partial oxidation is continued while largely maintaining the other conditions, and the decrease in the activity of the fixed catalyst bed over time is expediently counteracted by increasing the temperature of the fixed catalyst bed from time to time.
- the partial oxidation according to the invention is again interrupted at least once in order to lead the gas mixture G through the fixed catalyst bed in the manner according to the invention. Thereafter, the partial oxidation according to the invention is advantageously resumed as described, etc.
- the wording "before the temperature increase of the fixed catalyst bed is permanently ⁇ 10 ° C or ⁇ 8 ° C (generally ⁇ X ° C)" takes into account that the temperature of the fixed catalyst bed in large-scale operation can be subject to certain fluctuations for various reasons. In this case do you wear the The characteristic course of the temperature of the fixed catalyst bed over time and uses the measuring points according to the method of the smallest sum of the squares of deviations developed by Legendre and Gauss to create a compensation curve. If a temperature increase of ⁇ 10 ° C or ⁇ 8 ° C (generally ⁇ X ° C) is reached on this compensation curve, the characteristic "permanent" is considered fulfilled.
- the extent of the hotspot expansion in long-term operation of a heterogeneously catalyzed gas phase partial oxidation of acrolein to acrylic acid shows a more favorable behavior than in the processes according to the prior art.
- the process according to the invention thus enables on the one hand longer service lives of a fixed catalyst bed in a reactor before it has to be partially or completely replaced.
- the acrolein conversion achieved integrally over time is also increased and the selectivity of acrylic acid formation is also promoted, since the location of the hot spot in the process according to the invention normally migrates over time in the direction of the entry point of the reaction gas mixture into the fixed catalyst bed.
- the hot spot in the reaction gas mixture thus increasingly moves into the area in which the acrylic acid content is still not very pronounced. This reduces the possibility that acrylic acid which has already been formed suffers partially undesired full combustion under the action of the hot point temperature.
- the hot point temperature can be determined in the process according to the invention in tube bundle reactors e.g. by means of thermotubes as described in EP-A 873783, WO 03-076373 and in EP-A 1 270 065.
- the number of such thermotubes within a tube bundle reactor is expediently 4 to 20.
- they are arranged uniformly distributed inside the tube bundle.
- the catalyst fixed bed temperature will often be increased such that the acrolein conversion when the reaction gas mixture passes through the catalyst fixed bed once is 90 mol%, or 92 mol%, or 94 mol%, or 96 mol%, or 98 mol% or 99 mol%.
- the fixed catalyst bed temperature will normally be increased at least once before 7500 or 7000, mostly before 6000 and often before 5000 or 4000 hours of partial oxidation.
- the increase in the fixed catalyst bed temperature over time in the process according to the invention using particularly favorable catalysts is preferably (mostly essentially continuously and) carried out in such a way that the acrolein content in the product gas mixture is 1500 wt. -ppm, preferably not more than 600 ppm by weight and particularly preferably not more than 350 ppm by weight.
- acrolein has a disruptive effect in the process of separating acrylic acid from the product gas mixture of the partial oxidation insofar as it affects the tendency of acrylic acid to polymerize promotes (cf. EP-A 1 041 062).
- the residual oxygen in the product gas mixture should generally be at least 1% by volume, preferably at least 2% by volume and particularly preferably at least 3% by volume.
- the process according to the invention is particularly advantageous when it is operated with a fixed catalyst bed with acrolein of 110 110 Nl / I »h, or ⁇ 120 Nl / I » h, or ⁇ 130 Nl / I «h.
- the freshly charged fixed catalyst bed will be designed so that, as described in EP-A 990636 and EP-A 1106598, both the formation of the hot spots and their temperature sensitivity are as low as possible.
- the loading of the fixed catalyst bed with acrolein is advantageously initially maintained at values ⁇ 100 Nl / lh until stable operation has been established.
- FIG. 1 A schematic representation of the rotary kiln is shown in FIG. 1 attached to this document. The following reference numbers refer to this FIG. 1.
- the central element of the rotary kiln is the rotary tube (1). It is 4000 mm long and has an inside diameter of 700 mm. It is made of stainless steel 1.4893 and has a wall thickness of 10 mm.
- lances On the inner wall of the rotary kiln, lances are attached, which have a height of 5 cm and a length of 23.5 cm. They primarily serve the purpose of lifting the material to be treated thermally in the rotary kiln and thereby mixing it.
- the rotary tube rotates freely in a cuboid (2) which has four electrically heated (resistance heating) heating zones, which each follow the same length in the length of the rotary tube, each of which encloses the circumference of the rotary tube furnace.
- Each of the Heating zones can heat the corresponding rotary tube section to temperatures between room temperature and 850 ° C.
- the maximum heating output of each heating zone is 30 kW.
- the distance between the electrical heating zone and the outer surface of the rotary tube is approximately 10 cm. At the beginning and at the end, the rotary tube protrudes approx. 30 cm from the cuboid.
- the speed of rotation can be variably set between 0 and 3 revolutions per minute.
- the rotary tube can be turned left as well as right. When turning to the right, the material remains in the rotary tube; when turning to the left, the material is conveyed from the entry (3) to the discharge (4).
- the angle of inclination of the rotary tube to the horizontal can be variably set between 0 ° and 2 °. In discontinuous operation, it is actually 0 °. In continuous operation, the lowest point of the rotary tube is at the material discharge.
- the rotary tube can be rapidly cooled by switching off the electrical heating zones and switching on a fan (5). This sucks in ambient air through holes (6) in the lower floor of the cuboid and conveys it through three flaps (7) in the lid with a variably adjustable opening.
- the material input is checked via a rotary valve (mass control).
- the material discharge is controlled via the direction of rotation of the rotary tube.
- a material quantity of 250 to 500 kg can be thermally treated. It is usually located exclusively in the heated part of the rotary tube.
- thermocouples From a lance (8) lying on the central axis of the rotary tube, a total of three thermocouples (9) lead vertically into the material at intervals of 800 mm. They enable the temperature of the material to be determined.
- the temperature of the material is understood to mean the arithmetic mean of the three thermocouple temperatures.
- the maximum deviation of two measured temperatures is expediently less than 30 ° C., preferably less than 20 ° C., particularly preferably less than 10 ° C. and very particularly preferably less than 5 or 3 ° C.
- Gas streams can be passed through the rotary tube, by means of which the calcining atmosphere or generally the atmosphere of the thermal treatment of the material can be adjusted.
- the heater (10) offers the possibility of heating the gas flow into the rotary tube to the desired temperature in advance of its entry into the rotary tube (for example to the temperature desired for the material in the rotary tube).
- the maximum performance of the Heater is 1 x 50 kW + 1 x 30 kW. In principle, it can be with the heater
- (10) e.g. act as an indirect heat exchanger.
- a heater can also be used as a cooler.
- it is an electric heater in which the gas flow is conducted over metal wires heated by current (expediently a CSN instantaneous heater, type 97D / 80 from C. Schniewindt KG, 58805 Neuerade - DE).
- the rotary tube device provides the possibility of partially or completely circulating the gas flow guided through the rotary tube.
- the circuit line required for this is movably connected to the rotary tube at the rotary tube inlet and at the rotary tube outlet via ball bearings or via graphite press seals. These compounds are flushed with inert gas (e.g. nitrogen) (sealing gas).
- inert gas e.g. nitrogen
- the rotary tube expediently tapers at its beginning and at its end and protrudes into the tube of the circular line which leads in or out.
- a cyclone (12) is located behind the outlet of the gas stream guided through the rotary tube, for separating solid particles entrained in the gas stream (the centrifugal separator separates solid particles suspended in the gas phase by the interaction of centrifugal and gravity forces; the centrifugal force of the gas stream rotating as a spiral vortex accelerates the sedimentation of the suspended particles).
- the circulating gas flow (24) (the gas circulation) is conveyed by means of a circulating gas compressor (13) (fan) which draws in in the direction of the cyclone and presses in the other direction.
- a circulating gas compressor (13) fan
- the gas pressure is usually above one atmosphere.
- a cover located behind the outlet (cross-sectional taper by a factor of 3, pressure reducer) (15) facilitates the outlet.
- the pressure behind the rotary tube outlet can be regulated via the control valve. This is done in conjunction with a pressure sensor (16) located behind the rotary tube outlet, the exhaust gas compressor (17) (fan), which draws in towards the control valve, the circulating gas compressor (13) and the fresh gas supply. Relative to the external pressure, the pressure (directly) behind the rotary tube outlet can be set, for example, up to +1, 0 mbar above and, for example, up to -1, 2 mbar below. That is, the pressure of the gas stream flowing through the rotary tube can be below the ambient pressure of the rotary tube when it leaves the rotary tube.
- connection between the cyclone (12) and the cycle gas compressor (13) is closed according to the three-way valve principle (26) and the gas flow is passed directly into the exhaust gas purification device (23) guided.
- the connection to the exhaust gas cleaning device located behind the cycle gas compressor is also closed in this case according to the three-way valve principle. If the gas flow consists essentially of air, in this case it is sucked in (27) via the cycle gas compressor (13).
- the connection to the cyclone is closed according to the three-way valve principle. In this case, the gas stream is preferably sucked through the rotary tube, so that the internal pressure of the rotary tube is less than the ambient pressure.
- the pressure behind the rotary tube outlet is advantageously set to be -0.2 mbar below the external pressure.
- the pressure behind the rotary tube outlet is advantageously set to be -0.8 mbar below the external pressure.
- the slight negative pressure serves the purpose of avoiding contamination of the ambient air with gas mixture from the rotary kiln.
- the ammonia sensor preferably works according to an optical measuring principle (the absorption of light of a certain wavelength correlates proportionally to the ammonia content of the gas) and is expediently a device from Perkin & Eimer of the type MCS 100.
- the oxygen sensor is based on the paramagnetic properties of oxygen and is expedient an Oximat from Siemens of the type Oxymat MAT SF 7MB1010-2CA01 -1 AA1 -Z.
- Gases such as air, nitrogen, ammonia or other gases can be metered in between the orifice (15) and the heater (10) to the actually recirculated gas fraction (19).
- a base load of nitrogen is often added (20).
- nitrogen / air splitter (21) you can react to the measured value of the oxygen sensor.
- the discharged recycle gas portion (22) (exhaust gas) often contains gases that are not completely harmless, such as NO x , acetic acid, NH 3 , etc.), which is why they are normally separated off in an exhaust gas cleaning device (23).
- the exhaust gas is usually first passed through a scrubbing column (is essentially a column free of internals, which contains a separating packing before its exit; the exhaust gas and aqueous spray mist are conducted in cocurrent and in countercurrent (2 spray nozzles with opposite spraying direction).
- a scrubbing column is essentially a column free of internals, which contains a separating packing before its exit; the exhaust gas and aqueous spray mist are conducted in cocurrent and in countercurrent (2 spray nozzles with opposite spraying direction).
- the exhaust gas is led into a device which contains a fine dust filter (usually a bundle of bag filters), from the inside of which the penetrated exhaust gas is carried away. Then it is finally burned in a muffle.
- nitrogen always means nitrogen with a purity> 99% by volume.
- the aqueous solution 1 was stirred into the solution 2 having 90 ° C., the temperature of the overall mixture not falling below 80 ° C.
- the resulting aqueous suspension was 30 min. stirred at 80 ° C.
- it was spray-dried with a spray dryer from Niro-Atomizer (Copenhagen), type S-50-N / R (gas inlet temperature: 315 ° C, gas outlet temperature: 110 ° C, direct current).
- the spray powder had a particle diameter of 2 to 50 ⁇ m.
- the dried strands were then thermally treated (calcined) in the rotary kiln described under “1.” as follows: the thermal treatment was carried out continuously with a material input of 50 kg / h Strfitlingen; the angle of inclination of the rotary tube to the horizontal was 2 °; - in counterflow to the material, an air flow of 75 Nm 3 / h was passed through the rotary tube, which was supplemented by a total of (2 x 25) 50 NrrrVh sealing gas at a temperature of 25 ° C; the pressure behind the rotary tube outlet was 0.8 mbar below the external pressure; the rotary tube rotated to the left at 1.5 revolutions / min; - no recycle gas mode was used; the tempering became the first time the strands passed through the rotary tube
- the outside wall of the rotary tube was set to 340 ° C, the air flow was fed into the rotary tube at a temperature of 20 to 30 ° C; the extrudates were then passed through the rotary tube with the
- the strands which had a red-brown color, were then ground on a biplex cross-flow classifier mill (BQ 500) from Hosokawa-Alpine (Augsburg) to an average particle diameter of 3 to 5 ⁇ m.
- BQ 500 biplex cross-flow classifier mill
- the starting mass 1 thus obtained had a BET surface area 1 1 m 2 / g.
- the following phases were determined by means of X-ray diffraction:
- the aqueous suspension (Niro Atomizer (Copenhagen) of the type S-5O-N / R, gas inlet temperature 360 C C, gas outlet temperature 110 ° C, direct current spray Fa.) was spray dried.
- the spray powder had a particle diameter of 2 to 50 ⁇ m.
- 75 kg of the spray powder obtained in this way were metered in a kneader from AMK (Aachen mixing and kneading machine factory type VIU 160 (Sigma blades) and kneaded with the addition of 12 l of water (residence time: 30 min, temperature 40 to 50 ° C. Then the kneaded material was emptied into an extruder (same extruder as in phase B production) and formed into strands (length 1-10 cm; diameter 6 mm) by means of the extruder. The strands were heated on a belt dryer for 1 hour at a temperature of 120 ° C (material temperature) dried.
- the thermal treatment was carried out discontinuously with a material quantity of 250 kg; the angle of inclination of the rotary tube to the horizontal was ⁇ 0 ° C; the rotating tube rotated clockwise at 1.5 revolutions / min; a gas flow of 205 Nm / h was passed through the rotary tube; at the beginning of the thermal treatment, this consisted of 180 Nm 3 / h air and 1 x 25 Nm 3 / h N 2 as sealing gas; the gas stream leaving the rotary tube was supplemented by a further 1 x 25 Nm 3 / h N 2 ; 22 - 25 vol .-% of this total flow were returned to the rotary tube and the rest were left out; the outlet volume was supplemented by the sealing gas and the remaining volume by fresh air; - The gas stream was fed into the rotary tube at 25 ° C; the pressure behind the rotary tube outlet was 0.5 mbar below the external pressure (normal pressure); the temperature in the material was first increased linearly from 25 ° C.
- the temperature in the material was increased linearly from 250 ° C. to 300 ° C. within 2 hours and this temperature was maintained for 2 hours; the temperature in the material was then increased linearly from 300 ° C. to 405 ° C. in the course of 3 hours and this temperature was then maintained for 2 hours; then were the heating zones are switched off and the temperature inside the material is reduced to below 100 ° C within 1 h by activating the rapid cooling of the rotary tube by drawing in air and finally cooled to ambient temperature.
- the resulting pulverulent starting mass 2 had a specific BET surface area of 0.6 m / g and the composition CuSb 2 O 6 .
- the powder X-ray diagram of the powder obtained essentially showed the diffraction reflections of CuSb 2 O 6 (comparison spectrum 17-0284 from the JCPDS-ICDD file).
- Spray powder formed the starting mass 3 and had a particle diameter of 2 to 50 ⁇ m.
- the kneaded material was then emptied into an extruder (same extruder as in phase B production) and shaped into strands (1 to 10 cm in length, 6 mm in diameter) by means of the extruder. These were dried on a belt dryer for 1 h at a temperature (material temperature) of 120 ° C.
- the sealing gas nitrogen was supplied at a temperature of 25 ° C.
- the mixture of the other two nitrogen streams was fed into the rotary tube at the temperature that the material in the rotary tube had.
- the material temperature was then heated from 100 ° C to 320 ° C at a heating rate of 0.7 ° C / min; until a material temperature of 300 ° C was reached, a gas flow of 205 Nm 3 / h was passed through the rotary tube, which was composed as follows:
- the sealing gas nitrogen was supplied at a temperature of 25 ° C.
- the mixture of the other two gas streams was fed into the rotary tube at the temperature that the material had in the rotary tube.
- the oxygen content of the gas stream fed to the rotary tube was increased from 0% by volume to 1.5% by volume and maintained over the subsequent 4 hours.
- the material temperature passed through a temperature maximum above 325 ° C, which did not exceed 340 ° C before the material temperature dropped again to 325 ° C.
- composition of the gas flow of 205 Nm 3 / h passed through the rotary tube was changed as follows during this period of 4 h:
- the sealing gas nitrogen was supplied at a temperature of 25 ° C.
- the mixture of the other gas streams was fed into the rotary tube at the temperature that the material had in the rotary tube.
- the temperature of the material was raised to 400 ° C in about 1.5 hours at a heating rate of 0.85 ° C / min.
- the composition of the gas flow of 205 Nm 3 / h fed to the rotary tube was as follows: 95 Nm 3 / h composed of base load - nitrogen (20) and gases released in the rotary tube; 15 Nm h air (splitter (21)); 25 Nm 3 / h sealing gas nitrogen (11); and 70 Nm 3 / h recirculated cycle gas.
- the sealing gas nitrogen was supplied at a temperature of 25 ° C.
- the mixture of the other gas streams was fed into the rotary tube at the temperature that the material had in the rotary tube.
- the calcination was terminated by reducing the temperature of the material;
- the heating zones were switched off and the rapid cooling of the rotary tube was switched on by sucking in air, and the temperature of the material goods was reduced to a temperature below 100 ° C. within 2 hours and finally cooled to ambient temperature;
- the composition of the gas flow fed to the rotary tube was changed from 205 Nm 3 / h to the following mixture:
- Nrr ⁇ Vh composed of base load - nitrogen (20) and gases released in the rotary tube; 0 Nm 3 / h air (splitter (21)); 25 Nrr Vh sealing gas nitrogen (11); and 70 NrrrVh recirculated cycle gas.
- the gas stream was fed to the rotary tube at a temperature of 25 ° C. During the entire thermal treatment, the pressure (immediately) behind the rotary tube outlet was 0.2 mbar below the external pressure.
- the catalytically active material obtained in "5.” was ground using a Biplex cross-flow classifier mill (BQ 500) (from Hosokawa-Alpine Augsburg) to form a finely divided powder, of which 50% of the powder particles were a sieve with a mesh size of 1 to 10 ⁇ m passed and its proportion of particles with a longest expansion above 50 ⁇ m was less than 1%.
- BQ 500 Biplex cross-flow classifier mill
- annular carrier bodies 7 mm outside diameter, 3 mm length, 4 mm inside diameter, steatite of the type were used C220 from CeramTec with a surface roughness Rz of 45 ⁇ m) coated.
- the binder was an aqueous solution of 75% by weight of water and 25% by weight of glycerin.
- the active mass fraction of the resulting coated catalysts was chosen to be 20% by weight (based on the total weight of the support body and active mass).
- the ratio of powder and binder has been adjusted proportionally.
- FIG. 2 shows the percentage of M A as a function of the material temperature in ° C.
- Figure 3 shows the ammonia concentration of the atmosphere A in vol .-% over the thermal treatment as a function of the material temperature in ° C.
- Heat exchange medium used molten salt, consisting of 60% by weight of potassium nitrate and 40% by weight of sodium nitrite
- Reactor cylindrical vessel with a diameter of 6800 mm; ring-shaped tube bundle with a free central space.
- Contact tube pitch 38 mm.
- the ends of the contact tubes were sealed in contact tube bottoms with a thickness of 125 mm and each of their openings opened into a hood connected to the container at the upper and lower ends.
- the tube bundle was divided by three equidistant (10 mm thickness) in 4 between the contact tubesheets along the same sequentially mounted deflection pulleys' in each case 730 mm) longitudinal sections (zones).
- the bottom and the top deflection plate had ring geometry, the inner ring diameter being 1000 mm and the outer ring diameter extending sealingly up to the container wall.
- the contact tubes were not attached in a sealing manner to the deflection disks. Rather, a gap width of ⁇ 0.5 mm was left in such a way that the cross-flow velocity of the molten salt was as constant as possible within a zone.
- the middle baffle was circular and extended to the outermost contact tubes of the tube bundle.
- the circulation of the molten salt was accomplished by two salt pumps, each of which supplied one half of the tube bundle.
- the pumps pressed the molten salt into an annular channel around the bottom of the reactor jacket, which distributed the molten salt over the circumference of the vessel.
- the salt melt reached the tube bundle in the lowest longitudinal section through windows in the reactor jacket.
- the molten salt then flowed in the sequence following the specification of the baffle plates
- composition of the reaction gas starting mixture was in the following pattern over the operating time: 4 to 6% by volume of acrolein,
- Reactor charge molten salt and reaction gas mixture were passed through the reactor in countercurrent. The molten salt entered at the bottom, the reaction gas mixture at the top.
- the inlet temperature of the molten salt was approximately 265 ° C. at the beginning (after the formation of the fixed catalyst bed).
- the associated outlet temperature of the molten salt was initially around 267 ° C.
- the pumping capacity was 6200 m 3 molten salt / h.
- the reaction gas starting mixture was fed to the reactor at a temperature of 240 ° C.
- Acrolein load of the fixed catalyst bed 95 to 110 Nl / l « h
- Zone A 20 cm advance fill of steatite rings of geometry 7 mm x 7 mm x 4 mm (outer diameter x length x inner diameter).
- Zone B 100 cm catalyst feed with a homogeneous mixture of 30% by weight of steatite rings of geometry 7 mm x 3 mm x 4 mm (outer diameter x length x inner diameter) and 70% by weight of the ring-shaped (approx. 7 mm x 3 mm x 4 mm) manufactured catalyst.
- Zone C 200 cm catalyst feed with the ring-shaped (approx. 7 mm x 3 mm x 4 mm) cup catalyst.
- the thermotubes (their number was 10, which were evenly distributed in the central area of the tube bundle) were designed and loaded as follows: (they were used to determine the hot point temperature; it is an arithmetic mean value from independent measurements in the 10 thermotubes)
- thermotubes had a central thermowell with 40 temperature measuring points (that is, each thermotube contained 40 thermocouples, which were integrated into a thermowell with different lengths and thus formed a multithermocouple, with which the temperature could be determined simultaneously within the thermotube at different heights ).
- At least 13 and at most 30 of the 40 temperature measuring points were located in the area of the first meter of the active section of the fixed catalyst bed (in the flow direction of the reaction gas mixture).
- thermotube The inside diameter of a thermotube was 27 mm.
- the wall thickness and the pipe material were the same as for the working pipes.
- the outer diameter of the thermal sleeve was 4 mm.
- thermotube was filled with the ring-shaped coated catalyst produced.
- spherical shell catalyst was added to the thermal tube (same active mass as the ring-shaped shell catalyst, the diameter of the Steatit C220 (CeramTec) carrier balls was 2-3 mm; the active mass fraction was 20% by weight, and the production was carried out as for the ring-shaped shell catalyst described, but the binder was a corresponding amount of water).
- the spherical coated catalyst was charged homogeneously over the entire active section of the fixed catalyst bed of the respective thermal tube so that the pressure loss of the reaction gas mixture when it passed through the thermal tube corresponded to that when the reaction gas mixture was passed through a working tube (based on the active section of the Fixed catalyst bed (ie excluding the inert sections) in the thermotube required 5 to 20% by weight of spherical coated catalyst).
- the respective total filling level of active and inert sections in the working and thermotubes was dimensioned the same and the ratio of the total amount of active mass contained in the tube to the heat transfer area of the tube for working and thermotubes was set to the same value.
- the sales target for the acrolein to be converted in a single passage of the reaction gas mixture through the fixed catalyst bed was set at 99.3 mol%.
- the partial oxidation was interrupted once per calendar month (the increase in the inlet temperature of the molten salt up to the monthly interruption was always ⁇ 0.3 ° C and ⁇ 4 ° C), the last used inlet temperature of the molten salt was maintained and for a period t G from 24 h to 48 h a gas mixture G with a loading of the fixed catalyst bed of 30 Nl / l »h through the fixed catalyst bed.
- the oxygen content of the gas mixture G was increased from approx. 2% by volume to 6% by volume in the course of the time period t G.
- the CO and CO 2 content of the gas mixture G was reduced from values ⁇ 1% by volume (CO) and 4 4% by volume (CO 2 ) to 0% by volume over the course of time t G , the water vapor content was ⁇ 6% by volume, the content of molybdenum oxide hydrate was ⁇ 1 ppm by weight and the remaining amount of the gas mixture G consisted essentially of nitrogen.
- the location of the hot spot temperature moved about 25 cm towards the entry point of the reaction gas mixture.
- the hike of the hot spot temperature location was as above.
- the temperature data (apart from the beginning) relate to the point in time just before the interruption of the partial oxidation and the treatment of the fixed catalyst bed with the gas mixture G.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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EP04765891.9A EP1682477B1 (de) | 2003-10-29 | 2004-10-08 | Verfahren zum langzeitbetrieb einer heterogen katalysierten gasphasenpartialoxidation von acrolein zu acrylsäure |
JP2006537102A JP4611311B2 (ja) | 2003-10-29 | 2004-10-08 | アクロレインからアクリル酸への不均一系触媒作用による気相部分酸化の長期運転のための方法 |
CNB2004800321666A CN100543005C (zh) | 2003-10-29 | 2004-10-08 | 将丙烯醛多相催化气相部分氧化为丙烯酸的长期运行方法 |
BRPI0416081-9A BRPI0416081B1 (pt) | 2003-10-29 | 2004-10-08 | Processo para a operação a longo prazo de uma oxidação parcial em fase gasosa heterogeneamente catalisada de acroleína a ácido acrílico |
KR1020067008103A KR101096355B1 (ko) | 2003-10-29 | 2004-10-08 | 아크릴산을 형성하기 위한 아크롤레인의 불균질 촉매된기체 상 부분 산화의 장기 수행 방법 |
ZA200604227A ZA200604227B (en) | 2003-10-29 | 2006-05-25 | Method for long term operation of heterogeneously catalysed gas phase partial oxidation of acrolein in order to form acrylic acid |
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US51491803P | 2003-10-29 | 2003-10-29 | |
US60/514,918 | 2003-10-29 | ||
DE10350822.8 | 2003-10-29 | ||
DE2003150822 DE10350822A1 (de) | 2003-10-29 | 2003-10-29 | Verfahren zum Langzeitbetrieb einer heterogen katalysierten Gasphasenpartialoxidation von Acrolein zu Acrylsäure |
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WO2005047226A1 true WO2005047226A1 (de) | 2005-05-26 |
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PCT/EP2004/011259 WO2005047226A1 (de) | 2003-10-29 | 2004-10-08 | Verfahren zum langzeitbetrieb einer heterogen katalysierten gasphasenpartialoxidation von acrolein zu acrylsäure |
Country Status (11)
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US (1) | US7022877B2 (de) |
EP (1) | EP1682477B1 (de) |
JP (1) | JP4611311B2 (de) |
KR (1) | KR101096355B1 (de) |
CN (1) | CN100543005C (de) |
BR (1) | BRPI0416081B1 (de) |
MY (1) | MY139360A (de) |
RU (1) | RU2365577C2 (de) |
TW (1) | TWI332496B (de) |
WO (1) | WO2005047226A1 (de) |
ZA (1) | ZA200604227B (de) |
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- 2004-10-08 BR BRPI0416081-9A patent/BRPI0416081B1/pt active IP Right Grant
- 2004-10-08 EP EP04765891.9A patent/EP1682477B1/de active Active
- 2004-10-08 KR KR1020067008103A patent/KR101096355B1/ko active IP Right Grant
- 2004-10-08 JP JP2006537102A patent/JP4611311B2/ja active Active
- 2004-10-08 WO PCT/EP2004/011259 patent/WO2005047226A1/de active Application Filing
- 2004-10-08 CN CNB2004800321666A patent/CN100543005C/zh active Active
- 2004-10-13 US US10/962,570 patent/US7022877B2/en active Active - Reinstated
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Also Published As
Publication number | Publication date |
---|---|
MY139360A (en) | 2009-09-30 |
BRPI0416081B1 (pt) | 2014-08-19 |
BRPI0416081A (pt) | 2007-01-02 |
CN100543005C (zh) | 2009-09-23 |
EP1682477A1 (de) | 2006-07-26 |
RU2006118149A (ru) | 2007-12-10 |
US20050096483A1 (en) | 2005-05-05 |
RU2365577C2 (ru) | 2009-08-27 |
JP2007509864A (ja) | 2007-04-19 |
JP4611311B2 (ja) | 2011-01-12 |
CN1874985A (zh) | 2006-12-06 |
US7022877B2 (en) | 2006-04-04 |
TW200533649A (en) | 2005-10-16 |
TWI332496B (en) | 2010-11-01 |
KR101096355B1 (ko) | 2011-12-20 |
ZA200604227B (en) | 2007-09-26 |
KR20060109876A (ko) | 2006-10-23 |
EP1682477B1 (de) | 2016-04-13 |
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