WO2018181544A1 - 不飽和カルボン酸製造用触媒、不飽和カルボン酸の製造方法、および不飽和カルボン酸エステルの製造方法 - Google Patents
不飽和カルボン酸製造用触媒、不飽和カルボン酸の製造方法、および不飽和カルボン酸エステルの製造方法 Download PDFInfo
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- WO2018181544A1 WO2018181544A1 PCT/JP2018/012918 JP2018012918W WO2018181544A1 WO 2018181544 A1 WO2018181544 A1 WO 2018181544A1 JP 2018012918 W JP2018012918 W JP 2018012918W WO 2018181544 A1 WO2018181544 A1 WO 2018181544A1
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- Prior art keywords
- component
- unsaturated carboxylic
- carboxylic acid
- catalyst
- producing
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- 238000004519 manufacturing process Methods 0.000 title claims description 58
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- 150000001732 carboxylic acid derivatives Chemical class 0.000 title 2
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- 150000007522 mineralic acids Chemical class 0.000 claims abstract description 21
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- 150000001875 compounds Chemical class 0.000 claims abstract description 9
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- 150000001299 aldehydes Chemical class 0.000 claims description 38
- 238000000034 method Methods 0.000 claims description 29
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- 238000007254 oxidation reaction Methods 0.000 claims description 17
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- 229910052723 transition metal Inorganic materials 0.000 claims description 3
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- 229940085991 phosphate ion Drugs 0.000 claims description 2
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 abstract 1
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- 239000000243 solution Substances 0.000 description 16
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- 238000002360 preparation method Methods 0.000 description 15
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- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
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- 229910021536 Zeolite Inorganic materials 0.000 description 2
- 125000003172 aldehyde group Chemical group 0.000 description 2
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 2
- 238000004821 distillation Methods 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 2
- 229910052741 iridium Inorganic materials 0.000 description 2
- ZXEKIIBDNHEJCQ-UHFFFAOYSA-N isobutanol Chemical compound CC(C)CO ZXEKIIBDNHEJCQ-UHFFFAOYSA-N 0.000 description 2
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- NWUYHJFMYQTDRP-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;1-ethenyl-2-ethylbenzene;styrene Chemical compound C=CC1=CC=CC=C1.CCC1=CC=CC=C1C=C.C=CC1=CC=CC=C1C=C NWUYHJFMYQTDRP-UHFFFAOYSA-N 0.000 description 1
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- IYDGMDWEHDFVQI-UHFFFAOYSA-N phosphoric acid;trioxotungsten Chemical compound O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.OP(O)(O)=O IYDGMDWEHDFVQI-UHFFFAOYSA-N 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
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- 235000019260 propionic acid Nutrition 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- IUVKMZGDUIUOCP-BTNSXGMBSA-N quinbolone Chemical compound O([C@H]1CC[C@H]2[C@H]3[C@@H]([C@]4(C=CC(=O)C=C4CC3)C)CC[C@@]21C)C1=CCCC1 IUVKMZGDUIUOCP-BTNSXGMBSA-N 0.000 description 1
- 238000006479 redox reaction Methods 0.000 description 1
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- 229910052702 rhenium Inorganic materials 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
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- 239000001384 succinic acid Substances 0.000 description 1
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- 229910052726 zirconium Inorganic materials 0.000 description 1
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Classifications
-
- 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
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
- B01J35/391—Physical properties of the active metal ingredient
- B01J35/393—Metal or metal oxide crystallite size
-
- 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
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
- B01J21/08—Silica
-
- 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
- B01J23/26—Chromium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- B01J27/02—Sulfur, selenium or tellurium; Compounds thereof
- B01J27/053—Sulfates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- B01J27/14—Phosphorus; Compounds thereof
- B01J27/186—Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J27/188—Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium with chromium, molybdenum, tungsten or polonium
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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
- C07C51/23—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of oxygen-containing groups to carboxyl groups
- C07C51/235—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of oxygen-containing groups to carboxyl groups of —CHO groups or primary alcohol groups
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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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- 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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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C67/00—Preparation of carboxylic acid esters
- C07C67/08—Preparation of carboxylic acid esters by reacting carboxylic acids or symmetrical anhydrides with the hydroxy or O-metal group of organic compounds
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C69/00—Esters of carboxylic acids; Esters of carbonic or haloformic acids
- C07C69/52—Esters of acyclic unsaturated carboxylic acids having the esterified carboxyl group bound to an acyclic carbon atom
- C07C69/533—Monocarboxylic acid esters having only one carbon-to-carbon double bond
- C07C69/54—Acrylic acid esters; Methacrylic acid esters
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07B—GENERAL METHODS OF ORGANIC CHEMISTRY; APPARATUS THEREFOR
- C07B61/00—Other general methods
Definitions
- the present invention relates to a catalyst for producing an unsaturated carboxylic acid, a method for producing an unsaturated carboxylic acid, and a method for producing an unsaturated carboxylic acid ester.
- Patent Document 1 proposes a method of mixing a platinum-supported oxide and solid acid particles as a method for producing a solid acid catalyst useful for a hydrocarbon conversion reaction or the like.
- Patent Document 2 discloses a catalyst in which zeolite, gold and iron metal oxides are supported on ceramic fibers as a deodorizing catalyst.
- Patent Document 3 discloses a catalyst in which platinum and iridium are supported on a carrier made of acid-type zeolite and zirconium oxide as a catalyst for oxidizing and removing methane in combustion exhaust gas.
- JP 2000-102729 A Japanese Unexamined Patent Publication No. 5-131138 JP 2009-56455 A
- An object of the present invention is to provide a novel catalyst used for obtaining an unsaturated carboxylic acid from an unsaturated aldehyde, a method for producing an unsaturated carboxylic acid using the catalyst, and a method for producing an unsaturated carboxylic acid ester. It is.
- the present invention includes the following [1] to [18] and [1 ′] to [8 ′].
- Unsaturated carboxylic acid used to obtain unsaturated carboxylic acid from unsaturated aldehyde comprising component A represented by the following formula (I) and component B which is a compound containing an inorganic acid or an organic acid Catalyst for production.
- M x M ′ x ′ O y (I) (In the formula (I), M is at least one element selected from the fourth periodic metal elements of the periodic table, M ′ is at least one element selected from metal elements other than the fourth periodic period elements, and O is oxygen.
- the inorganic acid includes at least one selected from the group consisting of H 3 BO 3 , H 3 PO 4 , H 2 SO 4 , HNO 3 and a heteropolyacid.
- catalyst for producing methacrylic acid according to any one of [1] to [14], wherein the unsaturated aldehyde is methacrolein and the unsaturated carboxylic acid is methacrylic acid.
- [1 ′] A catalyst for producing an unsaturated carboxylic acid used for obtaining an unsaturated carboxylic acid from an unsaturated aldehyde, comprising Component A having oxidizing ability and Component B having acid characteristics.
- the catalyst for producing an unsaturated carboxylic acid according to [1 ′] which further contains Component C, which is an insoluble or hardly soluble component, as a catalyst component.
- [4 ′] The unsaturated carboxylic acid production catalyst according to any one of [1 ′] to [3 ′], wherein the component A includes at least one selected from Cr, Mn, and Co.
- the component B includes at least one compound selected from the group consisting of H 3 BO 3 , H 3 PO 4 , H 2 SO 4 , HNO 3 and a heteropolyacid [1 ′] to [5 ′ ]
- the catalyst for unsaturated carboxylic acid manufacture in any one of.
- [7 ′] Catalytic gas phase oxidation of unsaturated aldehyde and molecular oxygen or molecular oxygen-containing gas in the presence of the unsaturated carboxylic acid production catalyst according to any one of [1 ′] to [6 ′] A method for producing an unsaturated carboxylic acid.
- [8 ′] A method for producing an unsaturated carboxylic acid ester, wherein the unsaturated carboxylic acid produced by the method for producing an unsaturated carboxylic acid according to [7 ′] is esterified.
- a novel catalyst used for obtaining an unsaturated carboxylic acid from an unsaturated aldehyde a method for producing an unsaturated carboxylic acid using the catalyst, and a method for producing an unsaturated carboxylic acid ester.
- Catalyst for unsaturated carboxylic acid production As a result of intensive studies on a catalyst that can be suitably used for producing an unsaturated carboxylic acid from an unsaturated aldehyde, the present inventors have found that the catalyst includes an oxidizing component and an acid component, and the oxidizing component, the acid component, It was found that an unsaturated carboxylic acid can be produced from an unsaturated aldehyde by using a catalyst having different chemical species, and the present invention was completed.
- the unsaturated carboxylic acid production catalyst according to the present invention is an unsaturated carboxylic acid production catalyst containing at least two different components A and B used to obtain an unsaturated carboxylic acid from an unsaturated aldehyde.
- the component A is a component having oxidation ability
- the component B is a component having acid characteristics.
- component A and component B coexist as different types of components, so that component A essentially functions as an oxidation catalyst and component B functions as an acid catalyst.
- component B is believed to contribute to the protonation of unsaturated aldehydes.
- Component A is believed to contribute to the addition of oxygen atoms to the protonated unsaturated aldehyde. Therefore, it is estimated that the reaction from an unsaturated aldehyde to an unsaturated carboxylic acid proceeds by using the catalyst according to the present invention.
- Component A is a component having an oxidizing ability, and is a component capable of oxidizing a reaction substrate (unsaturated aldehyde) used in the catalytic reaction represented by the following formula (I). In order to function as a catalyst, it is preferable that its own oxidation-reduction reaction occurs reversibly.
- M is at least one element selected from the fourth periodic metal elements of the periodic table
- M ′ is at least one element selected from metal elements other than the fourth periodic period elements
- O is oxygen
- X, x ′ and y represent the atomic ratio of each component
- x is an integer of 1 or more
- y is 0 or (This is the atomic ratio of oxygen necessary to satisfy the atomic ratio of each component.)
- Component A includes a metal or a metal oxide, and contains M as a main component.
- M is at least one selected from K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, and Ga, which are metal elements in the fourth period of the periodic table. It is an element.
- M is a transition metal element of the fourth period of the periodic table, Sc, Ti, V, Cr, Mn, Fe, Co, It is preferably at least one element selected from Ni, Cu and Zn, more preferably at least one element selected from Cr, Mn, Co, Cu and Fe, and selected from Cr and Fe More preferably, it is at least one element.
- M may use 1 type and may use 2 or more types together.
- M ′ is at least one element selected from metal elements other than the fourth period of the periodic table, and is particularly preferably an element that can form an alloy with M or an element that can form a composite metal oxide with M. .
- M ′ is more preferably at least one element selected from Zr, Nb, Mo, Ru, Rh, Pd, Ag, Cd, Ta, W, Re, Os, Ir, Pt, and Au.
- Component A may be M element alone (single metal), an alloy composed of two or more kinds of M, an alloy represented by M x M ′ x ′ , or a metal oxide (including a composite metal oxide).
- a metal oxide is preferable from the viewpoint that the reaction from an unsaturated aldehyde to an unsaturated carboxylic acid is more likely to proceed.
- metal oxides represented by the following formula (II) are preferable.
- MO y ' (II) (In the formula (II), M is at least one element selected from the fourth periodic metal elements of the periodic table, and y ′ is an atomic ratio of oxygen corresponding to the valence of M.)
- M in formula (II) can be exemplified by the same elements as M described in formula (I).
- M element for example, Cr 2 O 3 , Mn 2 O 3 , Co 3 O 4 , CuO, Fe 2 O 3 , and Cr 2 O 3 , Fe 2 O 3. Is more preferable.
- Component B is a component having acid characteristics, and is an inorganic acid or an organic acid, and a component exhibiting Bronsted acidity, Lewis acidity, or both.
- examples of the inorganic acid include H 3 PO 4 , H 3 BO 3 , HNO 3 , H 2 SO 4, and heteropolyacid.
- examples of the organic acid include formic acid, acetic acid, propionic acid, butyric acid, valeric acid, citric acid, malic acid, succinic acid and the like.
- heteropolyacid examples include H 3 PW 12 O 40 , H 4 SiW 12 O 40 , H 3 PMo 12 O 40 , H 6 PV 3 Mo 9 O 40 , H 5 PV 2 Mo 10 O 40 , and H 5 PV 2.
- W 10 O 40, H 4 PVMo 11 O 40, etc. H 4 PVW 11 O 40 and the like Since the oxidation reaction of unsaturated aldehyde is generally carried out at a high temperature of about 200 to 450 ° C., component B is preferably an inorganic acid.
- the inorganic acid is boron (B), silicon (Si), germanium (Ge), nitrogen (N), phosphorus (P), arsenic (As), antimony (Sb), bismuth (Bi) and sulfur (S). It is preferable to include at least one element selected from the group consisting of Among these, the inorganic acid is a group consisting of H 3 BO 3 , H 3 PO 4 , H 2 SO 4 , HNO 3 , and heteropoly acid from the viewpoint that the reaction from the unsaturated aldehyde to the unsaturated carboxylic acid is more likely to proceed. It is more preferable to include at least one selected from more.
- the inorganic acid preferably contains at least one selected from the group consisting of borate ion, phosphate ion, sulfate ion, nitrate ion and heteropolyacid ion.
- the stronger the acid strength of the inorganic acid the more the protonation of the aldehyde group of the unsaturated aldehyde is promoted, and the subsequent oxidation by the component A is facilitated.
- These component B may use 1 type and may use 2 or more types together.
- the catalyst according to the present invention preferably further contains component C, which is an insoluble or hardly soluble component, as a catalyst component.
- Component C is a solid component for holding component A and component B, which is different from component A and component B, and serves as a catalyst support. That is, component C is a carrier component, and component A and component B can be supported on component C.
- insoluble means completely insoluble in water.
- lightly soluble means that the solubility in water at 25 ° C. is 100 mg / 100 mL or less.
- Component A and component B can be dissolved or dispersed in water or other solvent, and component A and component B can be retained on component C in a solution or slurry state. Therefore, it is preferable that component C hardly dissolves even when mixed with the solution or slurry of component A and component B.
- Component C is not particularly limited, but is preferably an inorganic compound having high thermal stability. Specifically, SiO 2 , Al 2 O 3 , SiO 2 —Al 2 O 3 , ZrO 2 , various zeolites (zeolites), activated carbon, and the like can be used. These may use 1 type and may use 2 or more types together.
- the oxidizing power of the metal oxide is evaluated by heat generated - [Delta] H 0 f per oxygen atom indicates that enough oxidizing power - [Delta] H 0 f is less strong.
- - ⁇ H 0 f of various metal oxides is, for example, Y. Morooka and A.M. Ozaki, J. et al. Catal. 5, 116 (1966), Tetsuro Kiyoyama et al., Catalysts, 8, 306 (1966), and the like.
- the content ratio of component A and component B (m A / m B , hereinafter referred to as A / B mass ratio) are also preferably from 0.0001 to 1000, more preferably from 0.001 to 500, still more preferably from 0.01 to 400, and particularly preferably from 0.1 to 300, from the viewpoint of the yield of unsaturated carboxylic acid.
- the content ratio of component A (m A / (m A + m), where m A , m B , and m C are the masses of component A, component B, and component C, respectively.
- C ) ⁇ 100) is preferably 1 to 99% by mass, more preferably 5 to 90% by mass, further preferably 10 to 85% by mass, particularly preferably 20 to 80% by mass, and most preferably 30 to 60% by mass.
- the content ratio of component B (m B / (m A + m B + m C ) ⁇ 100) is preferably 0.001 to 99% by mass, more preferably 0.01 to 90% by mass, and 0.1 to 70% by mass. More preferred is 0.1 to 50% by mass.
- the preferable range of the content ratio of Component C is naturally determined from the preferable range of the content ratio of Component A and Component B described above.
- a raw material compound of each component there is no restriction
- a raw material compound of each component Although it does not specifically limit as a raw material of the component A and the component B, For example, the hydroxide, chloride, sulfate, nitrate, oxide, acetate, etc. of a component element are mentioned.
- a raw material having high solubility in the solvent to be used is preferable.
- the raw material of component A includes Cr (NO 3 ) 3 , Mn (NO 3 ) 2 , Co (NO 3 ) 2 and hydrates thereof.
- a solvent is not specifically limited, For example, water, organic solvents, such as ethanol and acetone, are mentioned.
- step (C) it is preferable to fire the solid content after drying of the solution or solvent dispersion containing component A and component C.
- the component A is sufficiently immobilized on the component C by firing. Firing is performed, for example, at 200 to 600 ° C. for 1 to 100 hours in an air atmosphere.
- the component B is preferably mixed with the fired product and fired again.
- the obtained catalyst may be used as it is for the reaction from unsaturated aldehyde to unsaturated carboxylic acid, or may be used after calcination. The calcination is carried out, for example, at 200 to 600 ° C. for 1 to 100 hours.
- the catalyst which concerns on this invention can be prepared by the method including the following process, for example.
- Step (1) The component A raw material is dissolved or dispersed in a solvent to obtain a solution or solvent dispersion.
- the raw material of the said component A Although it does not specifically limit as a raw material of the said component A, for example, the hydroxide, chloride, sulfate, nitrate, oxide, acetate, etc. of a component element are mentioned.
- a raw material having high solubility in the solvent to be used is preferable.
- the raw materials for component A include Cr (NO 3 ) 3 , Mn (NO 3 ) 2 , Co (NO 3 ) 2 , Fe (NO 3 ) 3 , Cu (NO 3 ) 2 and The hydrate etc. are mentioned.
- a solvent is not specifically limited, For example, water, organic solvents, such as ethanol and acetone, are mentioned.
- Process (2) As the component C, SiO 2 , Al 2 O 3 , SiO 2 —Al 2 O 3 , ZrO 2 , various zeolites, activated carbon, and the like can be used as described above. These may use 1 type and may use 2 or more types together. As a method for removing the solvent from the solution or solvent dispersion, it is preferable to use vacuum distillation. Moreover, when using the component C, it is preferable to bake solid content i in this process. The component A is sufficiently immobilized on the component C by firing. Firing is performed, for example, at 200 to 600 ° C. for 1 to 100 hours in an air atmosphere.
- the component B raw material can be dissolved or dispersed in a solvent and added to the solid matter i.
- a solvent is not specifically limited, For example, water, organic solvents, such as ethanol and acetone, are mentioned.
- the solid component ii can be obtained by dissolving or dispersing the raw material of the component B in a solvent and adding it to the solid material i, and then removing the solvent. Moreover, what carried the said component B on the said component C can be mixed with the said solid substance i, and solid content ii can also be obtained.
- the solid content ii may be used as it is for the reaction from an unsaturated aldehyde to an unsaturated carboxylic acid, but is preferably used after firing.
- the calcination is carried out, for example, at 200 to 600 ° C. for 1 to 100 hours.
- the catalyst which concerns on this invention can be prepared by the method including the following process, for example.
- Step (1 ′) The raw material of component A is dissolved or dispersed in a solvent to obtain a solution or solvent dispersion.
- the raw material of the said component A Although it does not specifically limit as a raw material of the said component A, for example, the hydroxide, chloride, sulfate, nitrate, oxide, acetate, etc. of a component element are mentioned.
- a raw material having high solubility in the solvent to be used is preferable.
- the raw materials for component A include Cr (NO 3 ) 3 , Mn (NO 3 ) 2 , Co (NO 3 ) 2 , Fe (NO 3 ) 3 , Cu (NO 3 ) 2 and The hydrate etc. are mentioned.
- a solvent is not specifically limited, For example, water, organic solvents, such as ethanol and acetone, are mentioned.
- SiO 2 , Al 2 O 3 , SiO 2 —Al 2 O 3 , ZrO 2 , various zeolites, activated carbon, and the like can be used as described above. These may use 1 type and may use 2 or more types together.
- a solvent is not specifically limited, For example, water, organic solvents, such as ethanol and acetone, are mentioned.
- the solvent is preferably removed using vacuum distillation to obtain solid iii.
- the solid content iii may be used as it is for the reaction from an unsaturated aldehyde to an unsaturated carboxylic acid, but is preferably used after firing.
- the calcination is carried out, for example, at 200 to 600 ° C. for 1 to 100 hours.
- the solid content ii or the catalyst obtained in the firing step of the solid content iii is pulverized and sized to have a particle size of several tens to several hundreds of microns ( ⁇ m), or formed into pellets.
- the catalyst according to the present invention can be applied to any reaction mode such as a fixed bed, a fluidized bed, and a moving bed, but is preferably used for a reaction in a fixed bed. When used in a fixed bed, it is preferable to mix with an inert diluent such as sea sand or silicon carbide for heat removal.
- a catalytic gas phase oxidation reaction with molecular oxygen of an unsaturated aldehyde or a molecular oxygen-containing gas is performed in the presence of the unsaturated carboxylic acid production catalyst according to the present invention.
- an unsaturated carboxylic acid can be obtained from an unsaturated aldehyde.
- the unsaturated aldehyde include (meth) acrolein, crotonaldehyde (also known as ⁇ -methylacrolein), cinnamaldehyde (also known as ⁇ -phenylacrolein), and the like.
- the unsaturated carboxylic acid produced from the unsaturated aldehyde is an unsaturated carboxylic acid in which the aldehyde group of the unsaturated aldehyde is changed to a carboxyl group.
- (meth) acrylic acid Is obtained. “(Meth) acrolein” indicates acrolein and methacrolein, and “(meth) acrylic acid” indicates acrylic acid and methacrylic acid.
- dilution gas nitrogen, carbon dioxide gas, etc. are preferable.
- the catalytic gas phase oxidation reaction may be carried out under pressure or under reduced pressure, but is preferably carried out at a pressure near atmospheric pressure.
- the reaction temperature is preferably 200 to 400 ° C, more preferably 220 to 350 ° C.
- the supply amount of the raw material gas is preferably 100 ⁇ 100000hr -1 at a space velocity (SV), and more preferably 400 ⁇ 30000 hr -1.
- the unsaturated carboxylic acid obtained by the method according to the present invention is esterified.
- an unsaturated carboxylic acid ester can be obtained using an unsaturated carboxylic acid obtained from an unsaturated aldehyde.
- the alcohol to be reacted with the unsaturated carboxylic acid include methanol, ethanol, isopropanol, n-butanol, and isobutanol.
- Examples of the unsaturated carboxylic acid ester to be obtained include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate and the like.
- the reaction can be carried out in the presence of an acidic catalyst such as a sulfonic acid type cation exchange resin.
- the reaction temperature is preferably 50 to 200 ° C.
- the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the following examples unless it exceeds the gist.
- the content ratio of component A and the content ratio of component B in the following examples are defined as follows.
- Cr, Mn, Co, Cu, and Fe supported on the carrier (component C) are all based on the results of X-ray diffraction measurement, respectively Cr 2 O 3 , Mn 2 O 3 , and Co 3 O. 4 and calculated as CuO, Fe 2 O 3 .
- m A mass of component A (metal oxide)
- m B mass of component B (H 3 PW 12 O 40 , H 3 PO 4 or H 2 SO 4 )
- m C component C (SiO 2 or SiO 2 -Al 2 O 3 ) Mass Note that m A , m B and m C are values determined from the amount of raw materials charged.
- the content ratio (A / B mass ratio) of the component A and the component B is defined as follows.
- a / B mass ratio m A / m B.
- Example 1 (Preparation of catalyst) Cr (NO 3) 3 ⁇ 9H 2 O ( formula weight 400) 9.895g (0.02474mol, Cr Mass: 1.286g) was stirred with ultrapure water 100 mL, and completely dissolved.
- 3 g of SiO 2 (trade name: Aerosil 300, manufactured by Nippon Aerosil Co., Ltd.) was added and stirred at room temperature for 1 hour.
- the solution was transferred to an eggplant flask, and the solvent was distilled off under reduced pressure using an evaporator until the solution was dried at about 5 Torr (about 7 ⁇ 10 2 N / m 2 ) and a water bath temperature of 50 ° C.
- the resulting solid was dried at 100 ° C.
- phosphotungstic acid manufactured by Nippon Inorganic Chemical Industry Co., Ltd.
- 100 g of phosphotungstic acid was added to 30 mL of ultrapure water and stirred to dissolve completely. When dissolution was insufficient, ultrapure water was added little by little until completely dissolved.
- the mixture was transferred to a separatory funnel, 50 mL of diethyl ether was added, and the mixture was shaken while removing the gas, and then allowed to stand overnight.
- the lower ether phase was transferred to another separatory funnel, 50 mL of ultrapure water was added thereto, and the mixture was shaken while removing the gas, and then allowed to stand overnight. This operation was performed 5 times in total.
- the lower ether phase was transferred to an eggplant flask and 50 mL of ultrapure water was added.
- the solvent was distilled off under reduced pressure under conditions of about 5 Torr (about 7 ⁇ 10 2 N / m 2 ) and a water bath temperature of 40 ° C.
- the evaporator was temporarily stopped, and 50 mL of ultrapure water was added thereto.
- the solvent was distilled off under reduced pressure using a rotary evaporator. This operation was repeated 5 times. The fifth time, when a small amount of crystals had precipitated on the liquid surface, the distillation under reduced pressure was stopped.
- the eggplant flask was immersed in a hot water bath to redissolve the precipitated crystals.
- the resulting saturated aqueous solution was allowed to stand overnight at room temperature.
- the produced crystals were separated from the mother liquor by decantation, dried overnight at 60 ° C., and then air-dried at room temperature for 2 days to obtain H 3 PW 12 O 40 ⁇ nH 2 O.
- the TG-DTA profile of the H 3 PW 12 O 40 ⁇ nH 2 O was measured, and the number of crystal waters (value of n) was calculated. Based on this value, 50 mL of 0.08 mol / L aqueous H 3 PW 12 O 40 solution was prepared.
- SV space velocity
- Example 2 Example 1 except that the amount of the H 3 PW 12 O 40 aqueous solution used for loading on CrO x / SiO 2 was changed to 0.868 mL (mass of H 3 PW 12 O 40 : 0.20 g). Similarly, an H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst having a content ratio of Component B of 10.00% by mass was prepared. A catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 3 Example 1 except that the amount of the H 3 PW 12 O 40 aqueous solution used for loading onto CrO x / SiO 2 was changed to 7.81 mL (mass of H 3 PW 12 O 40 : 1.80 g). Similarly, an H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst having a content ratio of Component B of 49.99% by mass was prepared. A catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 4 Example 1 except that the amount of the H 3 PW 12 O 40 aqueous solution used for loading onto CrO x / SiO 2 was changed to 18.2 mL (mass of H 3 PW 12 O 40 : 4.19 g). Similarly, an H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst having a content ratio of Component B of 69.97% by mass was prepared. A catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 1 A catalyst evaluation test was conducted in the same manner as in Example 1 except that CrO x / SiO 2 (solid content i) prepared in Example 1 and having a content ratio of Component A of 38.52% by mass was used as a catalyst. It was. The results of the evaluation test are shown in Table 1.
- Example 5 A catalyst evaluation test was conducted in the same manner as in Example 1 except that the reaction temperature was changed to 350 ° C. The results of the evaluation test are shown in Table 1.
- Example 6 A catalyst evaluation test was conducted in the same manner as in Example 1 except that the reaction temperature was changed to 400 ° C. The results of the evaluation test are shown in Table 1.
- Example 8 Cr (NO 3) in place of 3 ⁇ 9H 2 O, Mn ( NO 3) 2 ⁇ 6H 2 O ( formula weight 287) 6.717g (0.0234mol, Mn mass: 1.286g) except for using the In the same manner as in the preparation of CrO x / SiO 2 in Example 1, MnO x / SiO 2 (solid content i) having a content ratio of Component A of 38.11% by mass was prepared.
- Component B was prepared in the same manner as in the preparation of the H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst of Example 1, except that the MnO x / SiO 2 was used instead of CrO x / SiO 2 .
- H 3 PW 12 O 40 —MnO x / SiO 2 catalyst having a content ratio of 33.35% by mass was prepared.
- X-ray diffraction (using Cu—K ⁇ rays) of the obtained catalyst was measured, a crystal structure of trivalent manganese oxide and H 3 PW 12 O 40 was observed, and at least Mn which is component A having oxidation ability It was confirmed that 2 O 3 and H 3 PW 12 O 40 , which is component B having acid characteristics, were present.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 3 A catalyst evaluation test was conducted in the same manner as in Example 1 except that MnO x / SiO 2 (solid content i) having a content ratio of Component A of 38.11% by mass prepared in Example 8 was used as a catalyst. It was. The results of the evaluation test are shown in Table 1.
- Example 9 Cr (NO 3) 3 ⁇ 9H 2 O usage of 23.083G, except for changing the amount of ultrapure water 233.28mL is by the same method as the preparation of CrO x / SiO 2 of Example 1 CrO x / SiO 2 (solid content i) having a content ratio of component A of 59.37% by mass was prepared. Except for using the CrO x / SiO 2 , the content ratio of Component B was 33.35% by mass in the same manner as in the preparation of the H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst of Example 1. A H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst was prepared. A catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 10 Instead of SiO 2, SiO 2 -Al 2 O 3 (Catalysis Society reference catalyst, JRC-SAL-2) except for using the components A in the same manner as the preparation of CrO x / SiO 2 of Example 1 CrO x / SiO 2 —Al 2 O 3 (solid content i) having a content ratio of 38.52% by mass was prepared. Except for using the CrO x / SiO 2 —Al 2 O 3 , the content ratio of the component B was changed in the same manner as in the preparation of the H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst of Example 1.
- Example 11 Cr (NO 3) 3 ⁇ 9H 2 O usage of 53.869G, except for changing the amount of ultrapure water 544.32mL is by the same method as the preparation of CrO x / SiO 2 of Example 1 CrO x / SiO 2 (solid content i) having a content ratio of Component A of 77.33% by mass was prepared. Except for using the CrO x / SiO 2 , the content ratio of Component B was 33.35% by mass in the same manner as in the preparation of the H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst of Example 1. A H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst was prepared. A catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 12 Instead of Cr (NO 3 ) 3 ⁇ 9H 2 O, 12.69 g (0.04360 mol, Co mass: 2.570 g) of Co (NO 3 ) 2 ⁇ 6H 2 O (formula weight 291.03) was used. Except that, CoO x / SiO 2 (solid content i) in which the content ratio of Component A was 53.85% by mass was prepared in the same manner as in the preparation of CrO x / SiO 2 in Example 1. Component B was prepared in the same manner as in the preparation of the H 3 PW 12 O 40 —Cr 2 O 3 / SiO 2 catalyst of Example 1, except that the CoO x / SiO 2 was used instead of CrO x / SiO 2 .
- H 3 PW 12 O 40 —CoO x / SiO 2 catalyst having a content ratio of 33.35% by mass was prepared.
- the crystal structure of spinel-type cobalt oxide and H 3 PW 12 O 40 having a mixed valence of divalent and trivalent was found. It was confirmed that Co 3 O 4 as component A having at least oxidizing ability and H 3 PW 12 O 40 as component B having acid characteristics were present.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 4 A catalyst evaluation test was conducted in the same manner as in Example 1 except that CoO x / SiO 2 (solid content i) having a content ratio of Component A of 53.85% by mass prepared in Example 12 was used as a catalyst. It was. The results of the evaluation test are shown in Table 1.
- Example 13 The content ratio of Component B was 0.15% by mass in the same manner as in Example 1 except that 0.343 mL of a 0.08 mol / L H 3 PO 4 aqueous solution was used instead of the H 3 PW 12 O 40 aqueous solution.
- An H 3 PO 4 —Cr 2 O 3 / SiO 2 catalyst was prepared.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 14 The content ratio of Component B was 0.22% by mass in the same manner as in Example 1 except that 0.515 mL of 0.08 mol / L H 2 SO 4 aqueous solution was used instead of the H 3 PW 12 O 40 aqueous solution.
- An H 2 SO 4 —Cr 2 O 3 / SiO 2 catalyst was prepared.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 15 The content ratio of Component B was 1.43% by mass in the same manner as in Example 1 except that 3.34 mL of 0.08 mol / L H 3 PO 4 aqueous solution was used instead of the H 3 PW 12 O 40 aqueous solution.
- An H 3 PO 4 —Cr 2 O 3 / SiO 2 catalyst was prepared.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 16 The content ratio of Component B was 2.14% by mass in the same manner as in Example 1 except that 5.01 mL of 0.08 mol / L H 2 SO 4 aqueous solution was used instead of the H 3 PW 12 O 40 aqueous solution.
- An H 2 SO 4 —Cr 2 O 3 / SiO 2 catalyst was prepared.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 18 Except for using 4.889 g (0.020 mol, Cu mass 1.286 g) of Cu (NO 3 ) 2 .3H 2 O (formula weight 241.6) instead of Cr (NO 3 ) 3 .9H 2 O Then, CuO x / SiO 2 (solid content i) having a content ratio of Component A of 34.92% by mass was prepared in the same manner as in the preparation of CrO x / SiO 2 in Example 1. The content ratio of component B was the same as the preparation of the H 3 PW 12 O 40 —CrO x / SiO 2 catalyst of Example 1 except that the CuO x / SiO 2 was used instead of CrO x / SiO 2.
- H 3 PW 12 O 40 —CuO x / SiO 2 catalyst having a ratio of 33.35% by mass was prepared.
- X-ray diffraction (using Cu—K ⁇ ray) of the obtained catalyst was measured, a crystal structure of divalent copper oxide and H 3 PW 12 O 40 was observed, and at least CuO as component A having oxidation ability And H 3 PW 12 O 40 , which is Component B having acid characteristics, was confirmed to be present.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- H 3 PW 12 O 40 FeO x / SiO 2 having a mass of 33.35% by mass was prepared.
- X-ray diffraction using Cu—K ⁇ ray
- a crystal structure of trivalent iron oxide and H 3 PW 12 O 40 was found, and at least Fe which is component A having oxidation ability It was confirmed that 2 O 3 and H 3 PW 12 O 40 , which is component B having acid characteristics, were present.
- a catalyst evaluation test was conducted in the same manner as in Example 1 except that the catalyst was used. The results of the evaluation test are shown in Table 1.
- Example 20 The content ratio of CrO x / SiO 2 (solid content i) prepared in Example 1 having a content ratio of Component A of 38.52% by mass and Component B prepared by the same method as in Comparative Example 2 was 33.52%.
- H 3 PW 12 O 40 / SiO 2 of 35% by mass was sized to 250 to 500 ⁇ m.
- 0.5 g of CrO x / SiO 2 and 0.5 g of H 3 PW 12 O 40 / SiO 2 are physically mixed, and the content ratio of A component (mass of A component / (mass of A component + C component (total SiO 2 )) Of 100) is 23.11% by mass, and the content ratio of component B is 16.68% by mass.
- methacrylic acid could be obtained from methacrolein.
- methacrylic acid cannot be obtained from methacrolein. It was found that the reaction of producing methacrylic acid from methacrolein proceeds when A and component B coexist.
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Abstract
Description
[1]下記式(I)で表される成分Aと、無機酸または有機酸を含む化合物である成分Bを含んでなる、不飽和アルデヒドから不飽和カルボン酸を得るために用いる不飽和カルボン酸製造用触媒。
MxM’x’Oy (I)
(式(I)中、Mは周期表第4周期金属元素より選択される少なくとも一種の元素、M’は周期表第4周期以外の金属元素から選択される少なくとも一種の元素、Oは酸素を示す。x、x’およびyは各成分の原子比率を表し、xは1以上の整数であり、x’はx=1に対して0≦x’≦0.4であり、yは0又は前記各成分の原子比を満足するのに必要な酸素の原子比率である。)
[3]前記式(I)において、MがCr、Mn、Co、CuおよびFeより選択される少なくとも一種である[1]に記載の不飽和カルボン酸製造用触媒。
[4]前記式(I)において、0≦x’<0.1である[1]から[3]のいずれかに記載の不飽和カルボン酸製造用触媒。
[5]前記成分Bが無機酸を含む化合物である[1]から[4]のいずれかに記載の不飽和カルボン酸製造用触媒。
[6]前記無機酸が、B、Si、Ge、N、P、As、Sb、BiおよびSからなる群から選択される少なくとも一種の元素を含む[5]に記載の不飽和カルボン酸製造用触媒。
[7]前記無機酸がホウ酸イオン、リン酸イオン、硫酸イオン、硝酸イオンおよびヘテロポリ酸イオンからなる群から選択される少なくとも一種を含む[5]に記載の不飽和カルボン酸製造用触媒。
[8]前記ヘテロポリ酸イオンがリンタングステン酸イオンである[7]に記載の不飽和カルボン酸製造用触媒。
[9]さらに、不溶性または難溶性の成分Cを含む[1]から[8]のいずれか1項に記載の不飽和カルボン酸製造用触媒。
[10]成分Cが、SiO2、Al2O3、SiO2-Al2O3、ZrO2、ゼオライト類、活性炭からなる群から選択される少なくとも1種である[9]に記載の不飽和カルボン酸製造用触媒。
[11]成分Aと成分Bの質量比(A/B)が、0.0001~1000である[1]から[10]のいずれか1項に記載の不飽和カルボン酸製造用触媒。
[12]前記質量比(A/B)が0.1~300である、[11]に記載の不飽和カルボン酸製造用触媒。
[14]前記無機酸がH3BO3、H3PO4、H2SO4、HNO3およびヘテロポリ酸からなる群から選択される少なくとも一種を含む[13]に記載の不飽和カルボン酸製造用触媒。
[15]前記不飽和アルデヒドがメタクロレイン、前記不飽和カルボン酸がメタクリル酸である[1]から[14]のいずれかに記載のメタクリル酸製造用触媒。
[17][16]に記載の不飽和カルボン酸の製造方法により製造された不飽和カルボン酸をエステル化する不飽和カルボン酸エステルの製造方法。
[18][1]から[15]のいずれかに記載の不飽和カルボン酸製造用触媒の存在下で、不飽和アルデヒドと分子状酸素または分子状酸素含有ガスを接触気相酸化して不飽和カルボン酸を製造する工程と、該不飽和カルボン酸をエステル化する工程とを含む不飽和カルボン酸エステルの製造方法。
[2’]さらに、不溶性または難溶性の成分である成分Cを触媒成分として含む[1’]に記載の不飽和カルボン酸製造用触媒。
[3’]前記成分Aが金属または金属酸化物である[1’]または[2’]に記載の不飽和カルボン酸製造用触媒。
[4’]前記成分Aとして、Cr、MnおよびCoより選択される少なくとも一種を含む[1’]から[3’]のいずれかに記載の不飽和カルボン酸製造用触媒。
[5’]前記成分Bとして無機酸を含む[1’]から[4’]のいずれかに記載の不飽和カルボン酸製造用触媒。
[6’]前記成分Bとして、H3BO3、H3PO4、H2SO4、HNO3およびヘテロポリ酸からなる群から選択される少なくとも一種の化合物を含む[1’]から[5’]のいずれかに記載の不飽和カルボン酸製造用触媒。
[7’][1’]から[6’]のいずれかに記載の不飽和カルボン酸製造用触媒の存在下で、不飽和アルデヒドと分子状酸素または分子状酸素含有ガスを接触気相酸化する不飽和カルボン酸の製造方法。
[8’][7’]に記載の不飽和カルボン酸の製造方法により製造された不飽和カルボン酸をエステル化する不飽和カルボン酸エステルの製造方法。
本発明者らは、不飽和アルデヒドから不飽和カルボン酸を製造するのに好適に使用できる触媒について鋭意検討した結果、酸化成分および酸成分を含む触媒であって、前記酸化成分と前記酸成分とが異なる化学種である触媒を用いることによって、不飽和アルデヒドから不飽和カルボン酸を製造することができることを見出し、本発明を完成させた。
成分Aは酸化能を有する成分であり、下記式(I)で表される、触媒反応に用いる反応基質(不飽和アルデヒド)を酸化することができる成分である。また、触媒として機能させるためには、自身の酸化還元反応が可逆的に起こることが好ましい。
(式(I)中、Mは周期表第4周期金属元素より選択される少なくとも一種の元素、M’は周期表第4周期以外の金属元素から選択される少なくとも一種の元素、Oは酸素を示す。x、x’およびyは各成分の原子比率を表し、xは1以上の整数であり、x’はx=1に対して0≦x’≦0.4であり、yは0又は前記各成分の原子比を満足するのに必要な酸素の原子比率である。)
M’は周期表第4周期以外の金属元素から選択される少なくとも一種の元素であり、特にMとともに合金を形成し得る元素、あるいはMとともに複合金属酸化物を形成し得る元素であることが好ましい。M’としては、Zr、Nb、Mo、Ru、Rh、Pd、Ag、Cd、Ta、W、Re、Os、Ir、Pt及びAuより選択される少なくとも一種の元素であることがより好ましい。
前記式(I)において、x=1に対してx’は0≦x’≦0.4を満たし、0≦x’<0.1を満たすことが好ましく、0≦x’≦0.01を満たすことが更に好ましく、x’=0が特に好ましい。
成分Aは、M元素単独(単体金属)、二種以上のMからなる合金、MxM’x’で表される合金、あるいは金属酸化物(複合金属酸化物を含む)であってもよいが、不飽和アルデヒドから不飽和カルボン酸への反応がより進行しやすい観点から、金属酸化物であることが好ましい。中でも、下記式(II)で表される金属酸化物が好ましい。
MOy’ (II)
(式(II)中、Mは周期表第4周期金属元素より選択される少なくとも一種の元素、y’はMの価数に対応する酸素の原子比である。)
式(II)中のMは、式(I)で説明したMと同じ元素が例示できる。特に一種のM元素の酸化物、例えば、Cr2O3、Mn2O3、Co3O4、CuO、Fe2O3であることが好ましく、Cr2O3、Fe2O3であることがより好ましい。
成分Bは酸特性を有する成分であり、無機酸または有機酸であって、ブレンステッド酸性またはルイス酸性、或いはその両方を示す成分である。具体的には、無機酸としては例えば、H3PO4、H3BO3、HNO3、H2SO4およびヘテロポリ酸等が挙げられる。有機酸としては例えば、ギ酸、酢酸、プロピオン酸、酪酸、吉草酸、クエン酸、リンゴ酸、コハク酸等が挙げられる。前記ヘテロポリ酸としては、例えばH3PW12O40、H4SiW12O40、H3PMo12O40、H6PV3Mo9O40、H5PV2Mo10O40、H5PV2W10O40、H4PVMo11O40、H4PVW11O40などが挙げられる。不飽和アルデヒドの酸化反応は一般に200~450℃程度の高温で実施されるため、成分Bは無機酸であることが好ましい。また前記無機酸はホウ素(B)、ケイ素(Si)、ゲルマニウム(Ge)、窒素(N)、リン(P)、ヒ素(As)、アンチモン(Sb)、ビスマス(Bi)および硫黄(S)からなる群から選択される少なくとも一種の元素を含むことが好ましい。これらの中でも、不飽和アルデヒドから不飽和カルボン酸への反応がより進行しやすい観点から、前記無機酸はH3BO3、H3PO4、H2SO4、HNO3、ヘテロポリ酸からなる群より選択される少なくとも一種を含むことがより好ましい。また前記無機酸は、ホウ酸イオン、リン酸イオン、硫酸イオン、硝酸イオンおよびヘテロポリ酸イオンからなる群から選択される少なくとも一種を含むことが好ましい。また、前記無機酸の酸強度が強いほど不飽和アルデヒドのアルデヒド基のプロトン化が促進され、続く成分Aによる酸化が進みやすくなることから、前記無機酸として、構成元素にMoやWを含むヘテロポリ酸を用いることが好ましく、リンタングステン酸イオンを含むヘテロポリ酸を用いることが特に好ましい。これらの成分Bは一種を用いてもよく、二種以上を併用してもよい。
本発明に係る触媒は、成分Aおよび成分B以外に、さらに不溶性または難溶性の成分である成分Cを触媒成分として含むことが好ましい。成分Cは、成分Aおよび成分Bとは異なる、成分Aおよび成分Bを保持するための固体成分であって、触媒担体の役割を果たす。すなわち、成分Cは担体成分であり、成分Aおよび成分Bは成分C上に担持されることができる。ここで、「不溶性」とは水に全く不溶であることを示す。また、「難溶性」とは25℃の水に対する溶解度が100mg/100mL以下であることを示す。成分Aおよび成分Bを水やその他の溶媒に溶解または分散させ、溶液またはスラリーの状態で成分Aおよび成分Bを成分C上に保持することができる。そのため、成分Cは成分Aおよび成分Bの溶液またはスラリーと混合してもほとんど溶解しないことが好ましい。
本発明に係る触媒に含まれる、成分Aと成分Bの各質量をそれぞれmA、mBとしたとき、成分Aと成分Bとの含有比率(mA/mB、以下A/B質量比とも示す)は、不飽和カルボン酸収率の観点から、0.0001~1000が好ましく、0.001~500がより好ましく、0.01~400がさらに好ましく、0.1~300が特に好ましい。
本発明に係る触媒の製造方法は特に限定されないが、例えば下記工程を含む方法により調製することができる。
工程(A):成分Aを溶媒に溶解または分散させて、溶液または溶媒分散液を得る。
工程(B):工程(A)で得られた溶液または溶媒分散液に成分Cを加えて撹拌し、減圧留去などにより溶媒を除去して固形分を得る。
工程(C):工程(B)で得られた固形分を焼成して焼成物を得る。
工程(D):成分Bを溶媒に溶解または分散させて、溶液または溶媒分散液を得る。
工程(E):工程(C)で得られた焼成物に工程(D)で得られた溶液または溶媒分散液を加えて撹拌し、乾燥して溶媒を除去して固形分を得る。
工程(F):工程(E)で得られた固形分を焼成して焼成物を得る。
得られた触媒はそのまま不飽和アルデヒドから不飽和カルボン酸への反応に用いてもよいが、焼成してから用いてもよい。焼成は、例えば200~600℃で1~100時間実施される。
工程(1):成分Aの原料を溶媒に溶解または分散させて、溶液または溶媒分散液を得る。
工程(2):前記溶液または溶媒分散液に成分Cを加え、溶媒を除去して固形分iを得る。
工程(3):前記固形物iに成分Bの原料を含む化合物を加え、成分A、成分Bおよび成分Cを含む固形分iiを得る。
前記成分Aの原料としては特に限定されないが、例えば成分元素の水酸化物、塩化物、硫酸塩、硝酸塩、酸化物、酢酸塩等が挙げられる。成分Cを用いる場合には、成分Cとの混合のしやすさを考えると、用いる溶媒への溶解性が高い原料が好ましい。例えば水を溶媒として用いる場合、成分Aの原料としては、Cr(NO3)3、Mn(NO3)2、Co(NO3)2、Fe(NO3)3、Cu(NO3)2およびその水和物などが挙げられる。溶媒は特に限定されないが、例えば水や、エタノール、アセトンなどの有機溶媒が挙げられる。
前記成分Cとしては、前述の通りSiO2、Al2O3、SiO2-Al2O3、ZrO2、各種ゼオライト、活性炭などを用いることができる。これらは一種を用いてもよく、二種以上を併用してもよい。
また前記溶液または溶媒分散液から溶媒を除去する方法としては、減圧蒸留を用いることが好ましい。
また、成分Cを用いる場合には、本工程において固形分iを焼成することが好ましい。焼成により、成分Aが成分C上に十分に固定化される。焼成は例えば、空気雰囲気下、200~600℃で1~100時間実施される。
前記成分Bの原料としては、H3PW12O40、H4SiW12O40、H3PMo12O40、H6PV3Mo9O40、H5PV2Mo10O40、H5PV2W10O40、H4PVMo11O40、H4PVW11O40、H3BO3、H3PO4、H2SO4、HNO3などが挙げられる。
本工程において、前記成分Bの原料は溶媒に溶解又は分散させて前記固形物iに添加することができる。溶媒は特に限定されないが、例えば水や、エタノール、アセトンなどの有機溶媒が挙げられる。この場合、前記成分Bの原料を溶媒に溶解又は分散させて前記固形物iに添加した後、溶媒を除去することにより固形分iiを得ることができる。
また前記成分Bを前記成分Cに担持させたものを前記固形物iに混合し、固形分iiを得ることもできる。
前記固形分iiはそのまま不飽和アルデヒドから不飽和カルボン酸への反応に用いてもよいが、焼成してから用いることが好ましい。焼成は、例えば200~600℃で1~100時間実施される。
工程(1’):成分Aの原料を溶媒に溶解または分散させて、溶液または溶媒分散液を得る。
工程(2’):前記溶液または溶媒分散液に成分Cおよび成分Bの原料を加え、溶媒を除去して成分A、成分Bおよび成分Cを含む固形分iiiを得る。
前記成分Aの原料としては特に限定されないが、例えば成分元素の水酸化物、塩化物、硫酸塩、硝酸塩、酸化物、酢酸塩等が挙げられる。成分Cを用いる場合には、成分Cとの混合のしやすさを考えると、用いる溶媒への溶解性が高い原料が好ましい。例えば水を溶媒として用いる場合、成分Aの原料としては、Cr(NO3)3、Mn(NO3)2、Co(NO3)2、Fe(NO3)3、Cu(NO3)2およびその水和物などが挙げられる。溶媒は特に限定されないが、例えば水や、エタノール、アセトンなどの有機溶媒が挙げられる。
前記成分Cとしては、前述の通りSiO2、Al2O3、SiO2-Al2O3、ZrO2、各種ゼオライト、活性炭などを用いることができる。これらは一種を用いてもよく、二種以上を併用してもよい。
前記成分Bの原料としては、H3PW12O40、H4SiW12O40、H3PMo12O40、H6PV3Mo9O40、H5PV2Mo10O40、H5PV2W10O40、H4PVMo11O40、H4PVW11O40、H3BO3、H3PO4、H2SO4、HNO3などが挙げられる。これらは溶媒に溶解又は分散させて前記固形物iに添加することができる。溶媒は特に限定されないが、例えば水や、エタノール、アセトンなどの有機溶媒が挙げられる。
また溶媒は減圧蒸留を用いて除去し、固形物iiiを得ることが好ましい。
前記固形分iiiはそのまま不飽和アルデヒドから不飽和カルボン酸への反応に用いてもよいが、焼成してから用いることが好ましい。焼成は、例えば200~600℃で1~100時間実施される。
また、前記固形分ii又は前記固形分iiiの焼成工程において得られた触媒は、粉砕、整粒してその粒子径を数十~数百ミクロン(μm)としたり、ペレット状に成形したりして使用することができる。本発明に係る触媒は、固定床、流動床、移動床等のいずれの反応様式にも適用できるが、固定床での反応に用いることが好ましい。固定床で使用する場合、除熱のため、海砂、シリコンカーバイドなどの不活性な希釈剤と混合して用いることが好ましい。
本発明に係る不飽和カルボン酸の製造方法は、本発明に係る不飽和カルボン酸製造用触媒の存在下で、不飽和アルデヒドの分子状酸素または分子状酸素含有ガスによる接触気相酸化反応を行う。該方法によれば、不飽和アルデヒドから不飽和カルボン酸を得ることができる。不飽和アルデヒドとしては、例えば(メタ)アクロレイン、クロトンアルデヒド(別名:β-メチルアクロレイン)、シンナムアルデヒド(別名:β-フェニルアクロレイン)等が挙げられる。中でも(メタ)アクロレインが好適である。不飽和アルデヒドから製造される不飽和カルボン酸は、該不飽和アルデヒドのアルデヒド基がカルボキシル基に変化した不飽和カルボン酸であり、例えば不飽和アルデヒドが(メタ)アクロレインの場合、(メタ)アクリル酸が得られる。なお、「(メタ)アクロレイン」はアクロレインおよびメタクロレインを示し、「(メタ)アクリル酸」はアクリル酸およびメタクリル酸を示す。
本発明に係る不飽和カルボン酸エステルの製造方法は、本発明に係る方法により得られる不飽和カルボン酸のエステル化を行う。該方法によれば、不飽和アルデヒドから得られる不飽和カルボン酸を用いて、不飽和カルボン酸エステルを得ることができる。不飽和カルボン酸と反応させるアルコールとしては、メタノール、エタノール、イソプロパノール、n-ブタノール、イソブタノール等が挙げられる。得られる不飽和カルボン酸エステルとしては、例えば(メタ)アクリル酸メチル、(メタ)アクリル酸エチル、(メタ)アクリル酸プロピル、(メタ)アクリル酸ブチル等が挙げられる。反応は、スルホン酸型カチオン交換樹脂等の酸性触媒の存在下で行うことができる。反応温度は50~200℃が好ましい。
成分Bの含有比率(質量%)=mB/(mA+mB+mC)×100。
mA:成分A(金属酸化物)の質量
mB:成分B(H3PW12O40、H3PO4またはH2SO4)の質量
mC:成分C(SiO2またはSiO2-Al2O3)の質量
なお、mA、mBおよびmCは原料の仕込み量から求めた値とする。
A/B質量比=mA/mB。
また、以下の実施例におけるメタクリル酸収率は次の通り定義される。
メタクリル酸収率(モル%)=(生成したメタクリル酸のモル数)/(供給したメタクロレインのモル数)×100。
(触媒の調製)
Cr(NO3)3・9H2O(式量400)9.895g(0.02474mol、Crの質量:1.286g)を超純水100mLに加えて撹拌し、完全に溶解させた。この水溶液にSiO2(商品名:アエロジル300、日本アエロジル株式会社製)3gを加え、室温で1時間撹拌した。ナスフラスコに移し、エバポレーターを用いて約5Torr(約7×102N/m2)、ウォーターバス温度50℃で乾固するまで溶媒を減圧留去した。得られた固体を100℃で一晩乾燥させた。マッフル炉にて空気中、550℃(昇温速度10℃/min)にて5時間焼成し、成分Aの含有比率が38.52質量%であるCrOx/SiO2(固形分i)を得た。
得られたH3PW12O40-Cr2O3/SiO2触媒を250~500μmに整粒した。触媒1gと、250~500μmに整粒した海砂(和光純薬工業(株)製)3gとを物理混合し、ガラス製反応管内に充填し、反応装置に接続した。O2:H2O:N2=10.7:17.9:71.4(体積比)の混合ガスを空間速度(SV)1680hr-1で流しながら320℃に昇温し、1時間加熱した。その後、反応浴温度(反応温度)300℃にて、メタクロレイン:酸素:水蒸気:窒素=3:6:13:78(モル比)の原料ガスを空間速度(SV)4320hr-1の条件で流し、メタクリル酸収率の評価を行った。評価試験の結果を表1に示す。
CrOx/SiO2への担持の際に使用したH3PW12O40水溶液の量を0.868mL(H3PW12O40の質量:0.20g)に変更した以外は、実施例1と同様にして成分Bの含有比率が10.00質量%であるH3PW12O40-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
CrOx/SiO2への担持の際に使用したH3PW12O40水溶液の量を7.81mL(H3PW12O40の質量:1.80g)に変更した以外は、実施例1と同様にして成分Bの含有比率が49.99質量%であるH3PW12O40-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
CrOx/SiO2への担持の際に使用したH3PW12O40水溶液の量を18.2mL(H3PW12O40の質量:4.19g)に変更した以外は、実施例1と同様にして成分Bの含有比率が69.97質量%であるH3PW12O40-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
実施例1において調製した、成分Aの含有比率が38.52質量%であるCrOx/SiO2(固形分i)を触媒として用いたこと以外は、実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
CrOxを担持していないSiO2に対して、実施例1と同様の方法によりH3PW12O40水溶液をincipient wetness法で担持し、成分Bの含有比率が33.35質量%であるH3PW12O40/SiO2触媒を得た。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
反応温度を350℃に変更した以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
反応温度を400℃に変更した以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
実施例1における触媒評価試験後、続けて温度300℃のままで水蒸気の供給を停止し、原料ガス組成をメタクロレイン:酸素:窒素=3:6:76(モル比)、空間速度(SV)を3670hr-1に変更してメタクリル酸収率の評価を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2Oに代えて、Mn(NO3)2・6H2O(式量287)6.717g(0.0234mol、Mnの質量:1.286g)を用いた以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が38.11質量%であるMnOx/SiO2(固形分i)を調製した。CrOx/SiO2に代えて前記MnOx/SiO2を用いた以外は、実施例1のH3PW12O40-Cr2O3/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-MnOx/SiO2触媒を調製した。得られた触媒のX線回折(Cu-Kα線を使用)を測定したところ、三価の酸化マンガンおよびH3PW12O40の結晶構造が認められ、少なくとも酸化能を有する成分AであるMn2O3と、酸特性を有する成分BであるH3PW12O40とが存在していることが確認された。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
実施例8において調製した、成分Aの含有比率が38.11質量%であるMnOx/SiO2(固形分i)を触媒として用いたこと以外は、実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2Oの使用量を23.083g、超純水の使用量を233.28mLに変更した以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が59.37質量%であるCrOx/SiO2(固形分i)を調製した。前記CrOx/SiO2を用いた以外は、実施例1のH3PW12O40-Cr2O3/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
SiO2に代えて、SiO2-Al2O3(触媒学会参照触媒、JRC-SAL-2)を用いた以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が38.52質量%であるCrOx/SiO2-Al2O3(固形分i)を調製した。前記CrOx/SiO2-Al2O3を用いた以外は、実施例1のH3PW12O40-Cr2O3/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-Cr2O3/SiO2-Al2O3触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2Oの使用量を53.869g、超純水の使用量を544.32mLに変更した以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が77.33質量%であるCrOx/SiO2(固形分i)を調製した。前記CrOx/SiO2を用いた以外は、実施例1のH3PW12O40-Cr2O3/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2Oに代えて、Co(NO3)2・6H2O(式量291.03)12.69g(0.04360mol、Coの質量:2.570g)を用いた以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が53.85質量%であるCoOx/SiO2(固形分i)を調製した。CrOx/SiO2に代えて前記CoOx/SiO2を用いた以外は、実施例1のH3PW12O40-Cr2O3/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-CoOx/SiO2触媒を調製した。得られた触媒のX線回折(Cu-Kα線を使用)を測定したところ、二価と三価の混合原子価となっているスピネル型の酸化コバルトおよびH3PW12O40の結晶構造が認められ、少なくとも酸化能を有する成分AであるCo3O4と、酸特性を有する成分BであるH3PW12O40とが存在していることが確認された。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
実施例12において調製した、成分Aの含有比率が53.85質量%であるCoOx/SiO2(固形分i)を触媒として用いたこと以外は、実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
H3PW12O40水溶液に代えて、0.08mol/LのH3PO4水溶液0.343mLを用いた以外は、実施例1と同様にして成分Bの含有比率が0.15質量%であるH3PO4-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
H3PW12O40水溶液に代えて、0.08mol/LのH2SO4水溶液0.515mLを用いた以外は、実施例1と同様にして成分Bの含有比率が0.22質量%であるH2SO4-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
H3PW12O40水溶液に代えて、0.08mol/LのH3PO4水溶液3.34mLを用いた以外は、実施例1と同様にして成分Bの含有比率が1.43質量%であるH3PO4-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
H3PW12O40水溶液に代えて、0.08mol/LのH2SO4水溶液5.01mLを用いた以外は、実施例1と同様にして成分Bの含有比率が2.14質量%であるH2SO4-Cr2O3/SiO2触媒を調製した。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2O(式量400)9.895g(0.02474mol、Crの質量:1.286g)を超純水100mLに加えて撹拌し、完全に溶解させた。この水溶液にSiO2(商品名:アエロジル300、日本アエロジル株式会社製)を3g加え、さらに0.08mol/LのH3PW12O40水溶液9.02mL(H3PW12O40の物質量0.7216mmol、H3PW12O40の質量2.078g)を加え1時間、室温で撹拌した。その後、ナスフラスコに移し、エバポレーターを用いて約5Torr、ウォーターバス温度50℃で乾固するまで溶媒を減圧留去した。得られた固体(固形分iii)を100℃で一晩乾燥させた。マッフル炉にて空気中、250℃にて1時間焼成し、成分Aの含有比率が38.52質量%、成分Bの含有比率が29.87質量%であるH3PW12O40-CrOx/SiO2触媒を得た。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2Oに代えてCu(NO3)2・3H2O(式量 241.6)4.889g(0.020mol、Cuの質量1.286g)を用いた以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が34.92質量%であるCuOx/SiO2(固形分i)を調製した。CrOx/SiO2に代えて前記CuOx/SiO2を用いた以外は、実施例1のH3PW12O40-CrOx/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-CuOx/SiO2触媒を調製した。得られた触媒のX線回折(Cu-Kα線を使用)を測定したところ、二価の酸化銅およびH3PW12O40の結晶構造が認められ、少なくとも酸化能を有する成分AであるCuOと、酸特性を有する成分BであるH3PW12O40とが存在していることが確認された。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
Cr(NO3)3・9H2Oに代えてFe(NO3)3・9H2O(式量 404.0)9.301g(0.023mol、Feの質量1.286g)を用いた以外は、実施例1のCrOx/SiO2の調製と同様の方法により成分Aの含有比率が37.99質量%であるFeOx/SiO2(固形分i)を調製した。CrOx/SiO2に代えて前記FeOx/SiO2を用いた以外は、実施例1のH3PW12O40-CrOx/SiO2触媒の調製と同様の方法により、成分Bの含有比率が33.35質量%であるH3PW12O40-FeOx/SiO2を調製した。得られた触媒のX線回折(Cu-Kα線を使用)を測定したところ、三価の酸化鉄およびH3PW12O40の結晶構造が認められ、少なくとも酸化能を有する成分AであるFe2O3と、酸特性を有する成分BであるH3PW12O40とが存在していることが確認された。前記触媒を用いた以外は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
実施例1において調製した、成分Aの含有比率が38.52質量%であるCrOx/SiO2(固形分i)と、比較例2と同様の方法により調製した成分Bの含有比率が33.35質量%であるH3PW12O40/SiO2を、それぞれ250~500μmに整粒した。0.5gのCrOx/SiO2と0.5gのH3PW12O40/SiO2を物理混合し、A成分の含有比率(A成分の質量/(A成分の質量+C成分(全SiO2)の質量)×100)が23.11質量%、成分Bの含有比率が16.68質量%であるCrOx/SiO2-H3PW12O40/SiO2(固形分ii)を得た。この触媒に250~500μmに整粒した海沙3.0gをさらに物理混合し、ガラス製反応管内に充填した。その後は実施例1と同様に触媒評価試験を行った。評価試験の結果を表1に示す。
*2 成分A~C中の含有比率
*3 原料ガス組成 メタクロレイン:酸素:窒素=3:6:76(モル比)。その他はメタクロレイン:酸素:水蒸気:窒素=3:6:13:78(モル比)。
Claims (18)
- 下記式(I)で表される成分Aと、無機酸または有機酸を含む化合物である成分Bを含んでなる、不飽和アルデヒドから不飽和カルボン酸を得るために用いる不飽和カルボン酸製造用触媒。
MxM’x’Oy (I)
(式(I)中、Mは周期表第4周期金属元素より選択される少なくとも一種の元素、M’は周期表第4周期以外の金属元素から選択される少なくとも一種の元素、Oは酸素を示す。x、x’およびyは各成分の原子比率を表し、xは1以上の整数であり、x’はx=1に対して0≦x’≦0.4であり、yは0又は前記各成分の原子比を満足するのに必要な酸素の原子比率である。) - 前記式(I)において、Mが周期表第4周期の遷移金属元素より選択される少なくとも一種の元素である請求項1に記載の不飽和カルボン酸製造用触媒。
- 前記式(I)において、MがCr、Mn、Co、CuおよびFeより選択される少なくとも一種である請求項1に記載の不飽和カルボン酸製造用触媒。
- 前記式(I)において、0≦x’<0.1である請求項1から3のいずれか1項に記載の不飽和カルボン酸製造用触媒。
- 前記成分Bが無機酸を含む化合物である請求項1から4のいずれか1項に記載の不飽和カルボン酸製造用触媒。
- 前記無機酸が、B、Si、Ge、N、P、As、Sb、BiおよびSからなる群から選択される少なくとも一種の元素を含む請求項5に記載の不飽和カルボン酸製造用触媒。
- 前記無機酸が、ホウ酸イオン、リン酸イオン、硫酸イオン、硝酸イオンおよびヘテロポリ酸イオンからなる群から選択される少なくとも一種を含む請求項5に記載の不飽和カルボン酸製造用触媒。
- 前記ヘテロポリ酸イオンがリンタングステン酸イオンである請求項7に記載の不飽和カルボン酸製造用触媒。
- さらに、不溶性または難溶性の成分Cを含む請求項1から8のいずれか1項に記載の不飽和カルボン酸製造用触媒。
- 成分Cが、SiO2、Al2O3、SiO2-Al2O3、ZrO2、ゼオライト類、活性炭からなる群から選択される少なくとも1種である請求項9に記載の不飽和カルボン酸製造用触媒。
- 成分Aと成分Bの質量比(A/B)が、0.0001~1000である請求項1から10のいずれか1項に記載の不飽和カルボン酸製造用触媒。
- 前記質量比(A/B)が0.1~300である、請求項11に記載の不飽和カルボン酸製造用触媒。
- Cr、MnおよびCo、並びにこれらの酸化物より選択される少なくとも一種からなる成分Aと、無機酸を含む成分Bを含んでなる、不飽和アルデヒドから不飽和カルボン酸を得るために用いる不飽和カルボン酸製造用触媒。
- 前記無機酸がH3BO3、H3PO4、H2SO4、HNO3およびヘテロポリ酸からなる群から選択される少なくとも一種を含む請求項13に記載の不飽和カルボン酸製造用触媒。
- 前記不飽和アルデヒドがメタクロレインであり、前記不飽和カルボン酸がメタクリル酸である請求項1から14のいずれか1項に記載のメタクリル酸製造用触媒。
- 請求項1から15のいずれか1項に記載の不飽和カルボン酸製造用触媒の存在下で、不飽和アルデヒドと分子状酸素または分子状酸素含有ガスを接触気相酸化する不飽和カルボン酸の製造方法。
- 請求項16に記載の不飽和カルボン酸の製造方法により製造された不飽和カルボン酸をエステル化する不飽和カルボン酸エステルの製造方法。
- 請求項1から15のいずれか1項に記載の不飽和カルボン酸製造用触媒の存在下で、不飽和アルデヒドと分子状酸素または分子状酸素含有ガスを接触気相酸化して不飽和カルボン酸を製造する工程と、該不飽和カルボン酸をエステル化する工程とを含む不飽和カルボン酸エステルの製造方法。
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