WO2021141134A1 - 触媒、それを用いた化合物の製造方法及び化合物 - Google Patents
触媒、それを用いた化合物の製造方法及び化合物 Download PDFInfo
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- WO2021141134A1 WO2021141134A1 PCT/JP2021/000588 JP2021000588W WO2021141134A1 WO 2021141134 A1 WO2021141134 A1 WO 2021141134A1 JP 2021000588 W JP2021000588 W JP 2021000588W WO 2021141134 A1 WO2021141134 A1 WO 2021141134A1
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- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
- C07C2523/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper
- C07C2523/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36
- C07C2523/78—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36 with alkali- or alkaline earth metals or beryllium
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
- C07C2523/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper
- C07C2523/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36
- C07C2523/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
Definitions
- the present invention relates to a catalyst, a method for producing a compound using the catalyst, and a compound.
- the activity of the oxide catalyst does not increase with time in the reaction. Moreover, it is described that unsaturated aldehyde can be produced in a high yield.
- the catalytic activity affects the reaction bath temperature when producing the target product, and when a catalyst having low activity is used, the reaction bath temperature must be raised in order to maintain the yield of the target product. Then, the catalyst is subjected to thermal stress, the selectivity and the yield are lowered, and the catalyst life may be shortened. In particular, regarding the catalyst life, the relationship between the physical properties of the catalyst or its change over time and the life of the catalyst was unclear. When producing unsaturated aldehydes, unsaturated carboxylic acids or conjugated diene using catalysts while maintaining high yield and / or high selectivity, what characteristics of catalysts are used and what indicators are used for control. It was not clear whether it should be done.
- the present invention provides a method for producing the corresponding unsaturated aldehyde and unsaturated carboxylic acid using propylene, isobutylene, t-butyl alcohol, etc. as raw materials, and a vapor-phase catalytic oxidation method for producing 1,3-butadiene from butenes. It proposes a catalyst to be used, which has a high catalytic activity and a high selectivity of a target product. By using the catalyst of the present invention, it is possible to safely, stably, and inexpensively operate the vapor-phase catalytic oxidation method for a long period of time.
- a decrease in selectivity during a reaction may be a problem depending on the type of catalyst, and the reason has been unknown.
- the present invention relates to the following 1) to 11).
- 1) Regarding the peak intensity of 2 ⁇ 25.3 ⁇ 0.2 ° in the X-ray diffraction pattern obtained by containing molybdenum, bismuth, and cobalt as essential components and using CuK ⁇ ray as an X-ray source, the following equations (1) to (4) ),
- the rate of change (Q1) per 1000 hours of reaction time is 16 or less.
- Q1 ⁇ (U1 / F1-1) x 100 ⁇ / T x 1000 ...
- At least one element selected from, Y is at least one element selected from sodium, potassium, cesium, rubidium, and tarium, Z belongs to groups 1 to 16 of the periodic table, and Mo, Bi, Ni, It means at least one element selected from elements other than Co, Fe, X, and Y, where a1, b1, c1, d1, e1, f1, g1, h1, and i1 are molybdenum, bismuth, nickel, cobalt, respectively.
- the catalyst of the present invention maintains a high selectivity and is effective in improving the yield in the vapor phase catalytic oxidation reaction or the vapor phase catalytic oxidation dehydrogenation reaction.
- it is useful when producing the corresponding unsaturated aldehyde or unsaturated carboxylic acid from propylene, isobutylene, t-butyl alcohol or the like as a raw material.
- FIG. 1 It is a figure which shows the X-ray diffraction pattern of the catalyst (catalyst 3-1) of Example 3. It is a figure which shows the X-ray diffraction pattern of the catalyst (catalyst 3-2) of Example 3.
- FIG. It is a figure which shows the X-ray diffraction pattern of the catalyst (catalyst 4-1) of Comparative Example 1. It is a figure which shows the X-ray diffraction pattern of the catalyst (catalyst 4-2) of the comparative example 1.
- the vapor phase catalytic oxidation reaction and the vapor phase catalytic oxidation / dehydrogenation reaction may be collectively referred to as an oxidation reaction.
- Q1 ⁇ (U1 / F1-1) x 100 ⁇ / T x 1000 ...
- the rate of change (Q1) of the peak intensity of the phase per 1000 hours of reaction time due to the oxidation reaction is stable in a high selectivity state when it is below a certain level, specifically when it is 16 or less. It is due to that.
- the range of Q1 is 16 or less as described above, but more preferable values as the upper limit values are 15, 10, 7.0, 5.0, 2.2, 2.0, 1.5, and 1. It is 2, 1.0, 0.70, 0.50, more preferably 0.0, still more preferably -5.0, and most preferably -7.0.
- the lower limit value does not have to be set, but the preferable values are -100, -80, -60, -40, and -20, more preferably -15, and further preferably -10, which are the most preferable values. It is preferably ⁇ 8.0. That is, a more preferable range of the rate of change (Q1) of the peak intensity per 1000 hours of reaction time is set by the above upper and lower limits, for example, -40 or more and 15 or less, and most preferably -8.0 or more and -7. It is 0 or less.
- the X-ray diffraction angle (2 ⁇ ) may be measured under the condition of a measurement speed of 10 ° / min, but the present invention is not limited to this as long as the measurement principle is not deviated.
- the peak intensity of the present embodiment is performed after removing the background and halo patterns described in Patent Document 3 in the X-ray diffraction pattern before the calculation.
- each of the above-mentioned peaks does not have a clear maximum value within the corresponding range of 2 ⁇ or does not have a peak shape, or when it is not judged to be a clear peak with too much noise.
- the peak intensity is assumed to be 0.
- the lower limit value does not have to be set, but the preferable values are -100, -80, -60, and -40 in order, more preferably -20, further preferably -15, and most preferably -. 14. That is, a more preferable range as the rate of change of peak intensity (Q2) is set by the above upper and lower limits, for example, -40 or more and 4.0 or less, and most preferably -14 or more and -10 or less.
- the lower limit value does not have to be set, but the preferable values are -100, -80, -60, -40, -20, and -10 in order, more preferably -5.0, and further preferably -1. It is 0.0, most preferably 0.0. That is, a more preferable range as the rate of change of peak intensity (Q3) is set by the above upper and lower limits, for example, -40 or more and 8.0 or less, and most preferably 0.0 or more and 0.3 or less.
- the amount of change (D1) per 1000 hours of reaction time is preferably 4.1 or less.
- D1 (U1-F1) / T ⁇ 1000 ... (5)
- the range of D1 is preferably 4.1 or less as described above, but more preferable values as the upper limit values are 3.0, 2.0, 1.9, 1.5, 1.0, and 0, respectively. It is 50, 0.30, 0.20, 0.10, more preferably 0.0, still more preferably -1.0, and most preferably -1.3. Further, the lower limit value does not have to be set, but the preferable values are -17, -15, -10, more preferably -5.0, still more preferably -2.0, and most preferably. Is -1.5.
- a more preferable range as the amount of change (D1) of the peak intensity per 1000 hours of reaction time is set by the above upper and lower limits, for example, -10 or more and 3.0 or less, and most preferably -1.5 or more-. It is 1.3 or less.
- the lower limit does not have to be set, but the preferred values are -8.7, -8.0, and -5.0, more preferably -3.0, and even more preferably -2.0, in that order.
- Most preferably -1.2 that is, a more preferable range for the amount of change in peak intensity (D2) is set by the above upper and lower limits, for example, -5.0 or more and 0.50 or less, and most preferably -1.2 or more and -1.0 or less. Is.
- the lower limit does not have to be set, but the preferred values are -9.6, -9.0, -7.0, -5.0, -3.0, and -2.0, which are more preferable. It is ⁇ 1.0, more preferably 0.0, and most preferably 0.010. That is, a more preferable range as the amount of change in peak intensity (D3) is set by the above upper and lower limits, for example, ⁇ 2.0 or more and 1.0 or less, and most preferably 0.010 or more and 0.050 or less. ..
- the oxidation reaction time T (hr) in the present embodiment is determined by a specific time of 300 hours or more and 30,000 hours or less, but is preferably 800 hours or more and 3000 hours or less, and more preferably 1000 hours or more and 1500 hours or less. , Most preferably 1300 hours.
- Q1 is 16 or less at an arbitrary time of 300 hours or more and 30,000 hours or less.
- the effect of the catalyst can be clarified by evaluating and comparing the catalyst before the oxidation reaction and the catalyst after the oxidation reaction under the same evaluation conditions.
- Any condition may be used for the evaluation, but it is preferable to evaluate under a condition where the propylene space velocity is as large as 300 hr -1 or more because it is easy to find a difference before and after the oxidation reaction.
- When changing the reactor when removing the catalyst from the reaction tube to obtain the catalyst after the oxidation reaction, divide the reaction tube into three or more sections in the length direction and sample equal amounts from each position. , It is good to evaluate after mixing.
- the catalytically active component contained in the catalyst of the present embodiment preferably has a composition represented by the following formula (A). Mo a1 Bi b1 Ni c1 Co d1 Fe e1 X f1 Y g1 Z h1 O i1 ... (A) (In the formula, Mo, Bi, Ni, Co and Fe represent molybdenum, bismuth, nickel, cobalt and iron, respectively, and X represents tungsten, antimony, tin, zinc, chromium, manganese, magnesium, silicon, aluminum, cerium and titanium, respectively.
- At least one element selected from, Y is at least one element selected from sodium, potassium, cesium, rubidium, and tarium
- Z belongs to groups 1 to 16 of the periodic table, and Mo, Bi, Ni, It means at least one element selected from elements other than Co, Fe, X, and Y, and a1, b1, c1, d1, e1, f1, g1, h1 and i1 are molybdenum, bismuth, nickel, cobalt, and iron, respectively.
- the preferable ranges of b1 to i1 are as follows.
- the lower limit of b1 is 0.2, 0.5, 0.7, 0.8 in the desired order, most preferably 0.9, and the upper limit of b1 is 5, 3, 2, 1.6 in the desired order. , 1.4, 1.2, most preferably 1.1. That is, the most preferable range of b1 is 0.9 ⁇ b1 ⁇ 1.1.
- the lower limit of c1 is 1, 2, 2.5, 2.8, 3.0 in the desired order, the most desirable is 3.1, and the upper limit of c1 is 5, 4, 3.8, 3 in the desired order. It is .6, 3.4, and most preferably 3.2.
- the most preferable range of c1 is 3.1 ⁇ c1 ⁇ 3.2.
- the lower limit of d1 is 3, 4, 5, 5.3, 5.5, 5.7 in the desired order, the most desirable is 5.8, and the upper limit of d1 is 8, 7, 6.5 in the desired order. , 6.3, 6.1, most preferably 6.0. That is, the most preferable range of d1 is 5.8 ⁇ d1 ⁇ 6.0.
- the lower limit of e1 is 0.5, 1, 1.2, 1.4 in the desired order, most preferably 1.5, and the upper limit of e1 is 4, 3, 2.5, 2, 1 in the desired order. It is 0.8, most preferably 1.7.
- the most preferable range of e1 is 1.5 ⁇ e1 ⁇ 1.7.
- the upper limit of f1 is 8, 7, 6, and 5 in the desired order.
- the most preferable range of f1 is 0 ⁇ f1 ⁇ 5.
- the lower limit of g1 is 0, 0.02, 0.04, 0.06 in the desired order, most preferably 0.07, and the upper limit of g1 is 1.5, 1, 0.5, 0 in the desired order. It is .2, 0.15, and most preferably 0.10. That is, the most preferable range of g1 is 0.07 ⁇ g1 ⁇ 0.10.
- the upper limit of h1 is 8, 7, 6, and 5 in the desired order. That is, the most preferable range of h1 is 0 ⁇ h1 ⁇ 5. It is preferable that two or less types of Y are contained, and one type is particularly preferable. Further, it is a particularly preferable embodiment that f1 and h1 are 0.
- a catalyst in which a pre-baked powder obtained by pre-firing after preparation of the catalytically active component is supported on an inert carrier is particularly effective as the catalyst of the present embodiment.
- the material of the inert carrier known materials such as alumina, silica, titania, zirconia, niobia, silica alumina, silicon carbide, carbides, and mixtures thereof can be used, and further, the particle size, water absorption rate, mechanical strength, and the like.
- the degree of crystallization and mixing ratio of the crystal phase are not particularly limited, and an appropriate range should be selected in consideration of the final catalyst performance, moldability, production efficiency, and the like.
- the mixing ratio of the carrier and the pre-baked powder is calculated as the loading ratio from the following formula based on the charged mass of each raw material.
- Support rate (mass%) (mass of pre-baked powder used for molding) / ⁇ (mass of pre-baked powder used for molding) + (mass of carrier used for molding) ⁇ ⁇ 100
- the preferable upper limit of the carrying ratio is 80% by mass, and more preferably 60% by mass.
- the lower limit is preferably 20% by mass, more preferably 30% by mass. That is, the most preferable range as the loading ratio is 30% by mass or more and 60% by mass or less.
- the inert carrier silica and / or alumina are preferable, and a mixture of silica and alumina is particularly preferable.
- a binder for supporting.
- binders that can be used include water, ethanol, methanol, propanol, polyhydric alcohol, polyvinyl alcohol of polymer binder, silica sol aqueous solution of inorganic binder, and the like, but ethanol, methanol, propanol, and polyhydric.
- Alcohol is preferable, diol such as ethylene glycol and triol such as glycerin are preferable, and an aqueous solution having a concentration of glycerin of 5% by mass or more is preferable.
- the amount of these binders used is usually 2 to 60 parts by mass with respect to 100 parts by mass of the pre-baked powder, but is preferably 10 to 30 parts by mass in the case of an aqueous glycerin solution.
- the binder and the pre-baked powder may be supplied to the molding machine alternately or at the same time.
- control can be performed by changing each condition in each manufacturing process described later, but for example, (I) the catalyst composition is changed. (II) Method of changing firing conditions, (III) Method of changing temperature lowering conditions after firing, (IV) Control not to add mechanical strength to the catalyst and its precursor in all steps of catalyst production. (V) A method using a high-purity raw material, another method (VI) to (XI), and a method of combining (I) to (XI). The details of the other method (VI) to the method (XI) will be described later.
- d1 / (b1 + c1 + e1) is adjusted to a specific range, and the upper limit is 1.25, preferably 1.20, and more preferably 1.10.
- the lower limit is 0.10, 0.30, 0.50, 0.70, 0.80, 0.90, 1.00 in the desired order. That is, the most preferable range is 1.00 or more and 1.10 or less.
- the upper limit of e1 / b1 is 1.90, preferably 1.80, and the lower limit of e1 / b1 is 0.10, 0.50, 1.00, 1.40, 1.50 in the desired order, and d1.
- the upper limit of / b1 is 9.0, 8.0, 7.0, 6.0 in the desired order
- the lower limit of d1 / b1 is 2.0, 3.0, 4.0, 5.0 in the desired order. 5.5, 4.0, 3.0, 2.5 in the order desired as the upper limit of c1 / e1, 1.5, 1.7, 1.9 in the order desired as the lower limit of c1 / e1
- the upper limit of c1 / d1 is 2.0, 1.0, 0.8 in the desired order
- the lower limit of c1 / d1 is 0.4, 0.5 in the desired order
- the lower limit of c1 + d1 + e1 is 7.0, 7.5, 8.0, 8.5, 9.0, 9.5 in the desired order
- the upper limit of c1 + d1 + e1 is 13. 0, 12.5, 12.0, 11.5, 11.0, 10.5
- the lower limit of b1 + c1 + d1 + e1 is 8.0, 8.5, 9.0, 9.5, 10.0, in the desired order. It is 10.5 and 11.0
- the upper limit of b1 + c1 + d1 + e1 is 14.0, 13.5, 13.0, 12.5, 12.0, and 11.5 in the desired order.
- the temperature is 200 ° C. or higher and 600 ° C. or lower, preferably 300 ° C. or higher and 550 ° C. or lower, more preferably 460 ° C. or higher and 550 ° C. or lower, and 0. 5 hours or more, preferably 1 hour or more and 40 hours or less, more preferably 2 hours or more and 15 hours or less, most preferably 2 hours or more and 9 hours or less, and the atmosphere is such that the oxygen concentration is 0% by volume or more and 40% by volume or less. It preferably has 5% by volume or more and 30% by volume or less, more preferably 10% to 25%, and most preferably an air atmosphere.
- the temperature of the catalyst surface from the maximum temperature reached during the firing step (pre-baking temperature or main firing temperature) to the temperature lowered to room temperature.
- the rate of decrease (temperature lowering rate) is 1 ° C./min or more and 200 ° C./min or less, preferably 5 ° C./min or more and 150 ° C./min or less, more preferably 10 ° C./min or more and 120 ° C./min or less, most preferably 50.
- the temperature is °C / min or more and 100 °C / min or less.
- the temperature lowering method generally used industrially to achieve the above-mentioned temperature lowering rate range, for example, the method of exposing the catalyst after firing taken out from the firing furnace to an inert atmosphere or mist with an inert solvent, or sufficient cooling in advance. All techniques for rapidly moving the fired catalyst into the chamber are within the scope of the present invention.
- the method (IV) is a method of controlling the catalyst precursor and / or the granules formed in each step so as not to apply mechanical impact, shear stress, etc., which will be described later.
- the preferred range of shear stress and the like is controlled to 100 kgf or less, preferably 50 kgf or less, more preferably 20 kgf or less, still more preferably 10 kgf or less, and most preferably 5 kgf or less.
- the details of the method (V) are not limited as long as it uses a reagent-grade high-purity raw material, and for example, the content of sulfur and its compounds, lithium, halogen and its compounds, and lead is 10,000 mass ppm or less. It is preferably 1000 mass ppm or less, more preferably 100 mass ppm or less, and most preferably 10 mass ppm or less.
- the method (VII) is a method in which the cobalt raw material and the nickel raw material are controlled so as to shorten the mixing, reaction, slurrying, and residence time in the blending kettle in the catalyst blending step described later, which is more specific.
- There is no metal salt raw material other than molybdenum and alkali metal in the compounding pot and the method of shortening the residence time in the presence of cobalt raw material and nickel raw material, or the pH in the compounding pot takes a specific range.
- This is a method for shortening the residence time in the presence of a cobalt raw material and a nickel raw material.
- the residence time is preferably 24 hours, more preferably 1 hour, further preferably 30 minutes, and most preferably 10 minutes.
- the pH range is 1 or more and 14 or less, preferably 2 or more and 10 or less, more preferably 2 or more and 8 or less, and most preferably 3 or more and 7 or less.
- the required amount is not charged at one time, but is divided into two or more times. It is preferable to leave a certain interval between the addition of the divided raw materials once and the next addition of the raw materials, and the time is preferably 5 seconds or more and 1 hour or less, more preferably 30 seconds or more and 45 minutes or less, further preferably. Is 1 minute or less and 30 minutes or less, most preferably 3 minutes or more and 15 minutes or less.
- the number of divisions of one raw material is preferably 2 times or more, more preferably 3 times or more, still more preferably 4 times or more, and most preferably 5 times or more.
- the addition time of two or more aqueous solutions used for mixing is preferably 1. It will be carried out within seconds or more and 30 minutes, more preferably 10 seconds or more and 20 minutes or less, further preferably 30 seconds or more and 5 minutes or less, and most preferably 1 minute or more and 5 minutes or less.
- the transfer time from preparing the suspended slurry in the final state to moving to the drying step of the next step is preferably 10 seconds or more and 1 hour or less. It is preferably 30 seconds or more and 10 minutes or less, and most preferably 1 minute or more and 5 minutes or less.
- the method (XI) is a method of adding an organic substance either before or after adding each raw material in the catalyst preparation step described later, and is preferably 0.001 mol% or more as the lower limit of the addition amount to the molybdenum raw material. , More preferably 0.01 mol% or more, further preferably 0.1 mol% or more, most preferably 1 mol% or more, and the upper limit of the addition amount is preferably 100 mol% or less, more preferably 90 mol% or less. , More preferably 80 mol% or less, and most preferably 60 mol% or less.
- Carboxylic acid and alcohol are preferable as organic substances to be added, and examples thereof include acetic acid, propionic acid, lactic acid, citric acid, stearic acid, oleic acid, ethylenediamine tetraacetic acid, methanol, ethanol, propanol, ethylene glycol, and glycerin. ..
- (XII) a method of controlling the hot spot temperature of the catalyst layer
- (XIII) a method of controlling the oxygen concentration at the outlet of the reaction tube
- (XIV) a method of controlling the steam concentration at the inlet of the reaction tube
- (XV) examples thereof include a method of controlling the temperature lowering rate when some temperature lowering treatment is performed during the reaction, a method of suppressing the mechanical impact applied to the (XVI) catalyst, and a method of combining the method (XII) to the method (XVI).
- the hot spot temperature of the catalyst layer when producing an unsaturated aldehyde compound, an unsaturated carboxylic acid compound, and / or a conjugated diene is controlled at 427 ° C. or lower, and the upper limit is 420 in the desired order. ° C. or lower, 410 ° C. or lower, 400 ° C. or lower, 390 ° C. or lower, 380 ° C. or lower. That is, it is most preferably 380 ° C. or lower.
- the time for controlling the hotspot temperature is 500 hours or less, preferably 300 hours or less, more preferably 200 hours or less, still more preferably 100 hours or less, and most preferably 50 hours or less.
- the method (XIII) is a method of controlling the oxygen concentration at the outlet of the reaction tube when producing an unsaturated aldehyde compound, an unsaturated carboxylic acid compound, and / or a conjugated diene at 4.0% by volume or more, as a lower limit. It is preferably 4.3% by volume or more, more preferably 4.5% by volume or more, and most preferably 4.7% by volume or more.
- the steam concentration at the inlet of the reaction tube when producing an unsaturated aldehyde compound, an unsaturated carboxylic acid compound, and / or a conjugated diene is controlled at 30% by volume or less, and the upper limit is in the desired order. It is 25% by volume or less, 20% by volume or less, 15% by volume or less, 10% by volume or less, and 9% by volume or less. That is, it is most preferably 9% by volume or less.
- the rate of decrease (temperature lowering rate) until the temperature of the catalyst itself decreases from the reaction bath temperature to 100 ° C. or less is 1 ° C./min or more and 200 ° C./min or less, preferably 5 ° C./min. It is 150 ° C./min or less, more preferably 10 ° C./min or more and 120 ° C./min or less, and most preferably 50 ° C./min or more and 100 ° C./min or less. All generally industrially used temperature-lowering techniques to achieve the temperature-lowering rate range described above fall within the scope of the present invention.
- the method (XVI) is a method for controlling the catalyst itself so as not to apply mechanical impact and shear stress in any step from filling the catalyst to during the reaction, and the mechanical impact and shear stress, etc.
- the preferred range of the above is 100 kgf or less, preferably 50 kgf or less, more preferably 20 kgf or less, still more preferably 10 kgf or less, and most preferably 5 kgf or less.
- the starting material for each element constituting the catalyst of the present embodiment and its pre-fired powder is not particularly limited, but for example, the raw material for the molybdate component includes molybdate oxide such as molybdenum trioxide, molybdic acid, and the like. Molybdic acid or a salt thereof such as ammonium paramolybdate and ammonium metamolybdate, and a heteropolyacid or a salt thereof containing molybdate such as phosphomolybdic acid and silicate molybdate can be used.
- molybdate oxide such as molybdenum trioxide, molybdic acid, and the like.
- Molybdic acid or a salt thereof such as ammonium paramolybdate and ammonium metamolybdate
- a heteropolyacid or a salt thereof containing molybdate such as phosphomolybdic acid and silicate molybdate
- bismuth nitrate bismuth carbonate, bismuth sulfate, bismuth salt such as bismuth acetate, bismuth trioxide, metal bismuth and the like
- bismuth salt such as bismuth acetate, bismuth trioxide, metal bismuth and the like
- These raw materials can be used as a solid or as a slurry of an aqueous solution, a nitric acid solution, or a bismuth compound produced from the aqueous solution, but it is preferable to use nitrate, a solution thereof, or a slurry produced from the solution.
- Heteropolyacids, heteropolyacid salts, sulfates, hydroxides, organic acid salts, oxides or mixtures thereof may be used in combination, but ammonium salts and nitrates are preferably used.
- the compounds containing these active ingredients may be used alone or in combination of two or more.
- the slurry liquid can be obtained by uniformly mixing each active ingredient-containing compound and water.
- the amount of water used in the slurry liquid is not particularly limited as long as the total amount of the compound used can be completely dissolved or uniformly mixed.
- the amount of water used may be appropriately determined in consideration of the drying method and drying conditions.
- the amount of normal water used is 100 parts by mass or more and 2000 parts by mass or less with respect to 100 parts by mass of the total mass of the compound for preparing the slurry.
- the amount of water may be large, but if it is too large, the energy cost of the drying process will be high, and there are many disadvantages such as the case where the water cannot be completely dried.
- the slurry liquid of the source compound of each component element is a method of (a) mixing the above source compounds collectively, (b) a method of collectively mixing and then aging treatment, and (c) stepwise. It is preferable to prepare by a method of mixing, (d) a method of repeating the mixing and aging treatment stepwise, and a method of combining (a) to (d).
- the above-mentioned aging means "processing an industrial raw material or a semi-finished product under specific conditions such as a certain period of time and a certain temperature to acquire, increase, or increase the required physical properties and chemical properties, or the progress of a predetermined reaction. It means "operation to measure such things”.
- the above-mentioned constant time means a range of 5 minutes or more and 24 hours or less
- the above-mentioned constant temperature means a range of an aqueous solution or an aqueous dispersion above room temperature and below the boiling point.
- the method of (c) stepwise mixing is preferable in terms of the activity and yield of the catalyst finally obtained, and more preferably, each raw material to be mixed stepwise with the mother liquor is a completely dissolved solution.
- the most preferable method is to mix various mixed solutions of alkali metal solution and nitrate with the mother liquor made of molybdenum raw material as a mixed solution or slurry.
- the shape of the stirring blade of the stirrer used when mixing the essential active ingredients is not particularly limited, and the propeller blade, the turbine blade, the paddle blade, the inclined paddle blade, the screw blade, the anchor blade, the ribbon blade, and the large size are not particularly limited. Any stirring blade such as a lattice blade can be used in one stage, or the same blade or different types of blades can be used in two or more stages in the vertical direction.
- a baffle may be installed in the reaction tank as needed.
- the drying method is not particularly limited as long as the slurry liquid can be completely dried, and examples thereof include drum drying, freeze drying, spray drying, and evaporation drying. Of these, in the present embodiment, spray drying, which can dry the slurry liquid into powder or granules in a short time, is particularly preferable.
- the drying temperature of spray drying varies depending on the concentration of the slurry liquid, the liquid feeding rate, and the like, but the temperature at the outlet of the dryer is generally 70 ° C. or higher and 150 ° C. or lower.
- a supported molding method of supporting on a carrier such as silica or a non-supported molding method using no carrier can be adopted.
- Specific molding methods include, for example, tableting molding, press molding, extrusion molding, granulation molding and the like.
- the shape of the molded product for example, a columnar shape, a ring shape, a spherical shape, or the like can be appropriately selected in consideration of operating conditions, and the catalytically active component is supported on a spherical carrier, particularly an inert carrier such as silica or alumina.
- a supported catalyst having an average particle size of 3.0 mm or more and 10.0 mm or less, preferably an average particle size of 3.0 mm or more and 8.0 mm or less is preferable.
- a rolling granulation method As the supporting method, a rolling granulation method, a method using a centrifugal flow coating device, a wash coating method and the like are widely known, and the method is not particularly limited as long as the pre-baked powder can be uniformly supported on the carrier, but the catalyst.
- the rolling granulation method is preferable in consideration of the production efficiency of the above. Specifically, in a device having a flat or uneven disk at the bottom of a fixed cylindrical container, the carrier charged in the container is rotated and revolved by rotating the disk at high speed. This is a method in which the powder component is supported on a carrier by vigorously stirring by repeating the exercise and adding a pre-baked powder to the stirring. In addition, it is preferable to use a binder for supporting.
- binders that can be used include water, ethanol, methanol, propanol, polyhydric alcohol, polyvinyl alcohol of polymer binder, silica sol aqueous solution of inorganic binder, and the like, but ethanol, methanol, propanol, and polyhydric.
- Alcohol is preferable, diol such as ethylene glycol and triol such as glycerin are more preferable, and an aqueous solution having a concentration of glycerin of 5% by mass or more is further preferable.
- the amount of these binders used is usually 2 to 60 parts by mass with respect to 100 parts by mass of the pre-baked powder, but 15 to 50 parts by mass is preferable in the case of an aqueous glycerin solution.
- the binder and the pre-baked powder may be supplied to the molding machine alternately or at the same time. Further, at the time of molding, a small amount of known additives such as graphite and talc may be added.
- the molding aid, pore-forming agent, and carrier added in molding are all constituent elements of the active ingredient in the present embodiment regardless of whether or not they are active in the sense of converting the raw material into some other product. It shall not be considered as.
- the pre-firing method, pre-firing conditions, main firing method, and main firing conditions are not particularly limited, and known processing methods and conditions can be applied.
- Preliminary firing and main firing are usually performed at 200 ° C. or higher and 600 ° C. or lower, preferably 300 ° C. or higher and 550 ° C. or lower, for 0.5 hours or longer, preferably under the flow of an oxygen-containing gas such as air or an inert gas. Perform in 1 hour or more and 40 hours or less.
- the inert gas refers to a gas that does not reduce the reaction activity of the catalyst, and specific examples thereof include nitrogen, carbon dioxide, helium, and argon.
- the optimum conditions in the main firing differ depending on the reaction conditions when producing the unsaturated aldehyde and / or the unsaturated carboxylic acid using the catalyst, and the process parameters of the main firing step, that is, in the atmosphere. Since it is known to those skilled in the art to change the oxygen content, the maximum temperature reached, the firing time, etc., it falls within the scope of the present invention. Further, the main firing step shall be performed after the above-mentioned pre-baking step, and the maximum reached temperature (main firing temperature) in the main firing step is higher than the maximum reached temperature (pre-baking temperature) in the above-mentioned pre-baking step. It shall be expensive.
- the firing method is not particularly limited to a fluidized bed, rotary kiln, muffle furnace, tunnel firing furnace, etc., and an appropriate range should be selected in consideration of the final catalyst performance, mechanical strength, moldability, production efficiency, etc. Is.
- the catalyst of the present embodiment is preferably used as a catalyst for producing an unsaturated aldehyde compound, an unsaturated carboxylic acid compound, or a conjugated diene compound, and more preferably as a catalyst for producing an unsaturated aldehyde compound. It is more preferably used, and particularly preferably used as a catalyst for producing acrolein from propylene.
- the catalyst itself is prevented from deteriorating due to the heat generated by the reaction. It is known to those skilled in the art that different catalyst species are filled in multiple layers so that the activity increases toward the outlet side of the reaction tube.
- the catalyst of the present embodiment can be used on any of the catalyst layers on the inlet side of the reaction tube, the outlet side of the reaction tube, and the catalyst layer in between, but for example, the highest side of the reaction tube, that is, the highest of all catalyst layers in the reaction tube. Most preferably it is used as an active catalyst. In the multi-layer filling, two-layer or three-layer filling is a particularly preferable embodiment.
- the oxidation reaction of the second stage can be carried out to obtain an unsaturated carboxylic acid compound. ..
- the catalyst of the embodiment of the present application can also be used, but a catalyst containing a catalytically active component represented by the following formula (B) is preferable. Mo 12 V a2 W b2 Cu c2 Sb d2 X2 e2 Y2 f2 Z2 g2 Oh2 ...
- A2, b2, c2, d2, e2, f2, g2 and h2 represent the atomic ratio of each element, and a2 is 0 ⁇ for molybdenum atom 12.
- a2 ⁇ 10 b2 is 0 ⁇ b2 ⁇ 10
- c2 is 0 ⁇ c2 ⁇ 6
- d2 is 0 ⁇ d2 ⁇ 10
- e2 is 0 ⁇ e2 ⁇ 1
- g2 is 0 ⁇ It represents g2 ⁇ 6, and h2 is the number of oxygen atoms required to satisfy the atomic value of each component.
- a method generally known as a method for preparing a catalyst of this type for example, an oxide catalyst, a heteropolyacid or a catalyst having a salt structure thereof.
- the raw materials that can be used in producing the catalyst are not particularly limited, and various materials can be used.
- molybdenum oxides such as molybdenum trioxide, molybdates, molybdates such as ammonium molybdate or salts thereof
- heteropolyacids containing molybdenum such as phosphomolybdic acid and silicate molybdate or salts thereof may be used. it can.
- the raw material for the antimony component is not particularly limited, but antimony trioxide or antimony acetate is preferable.
- the compounds containing these active ingredients may be used alone or in combination of two or more.
- the slurry liquid obtained above is dried to obtain a solid catalytically active ingredient.
- the drying method is not particularly limited as long as the slurry liquid can be completely dried, and examples thereof include drum drying, freeze drying, spray drying, and evaporative drying, and the slurry liquid is dried into powder or granules in a short time. Spray drying that can be done is preferred.
- the drying temperature of spray drying varies depending on the concentration of the slurry liquid, the liquid feeding rate, and the like, but the temperature at the outlet of the dryer is generally 70 to 150 ° C. Further, it is preferable to dry the slurry liquid dried product obtained at this time so that the average particle size is 10 to 700 ⁇ m.
- the catalyst-active component solid of the second stage obtained as described above can be used as it is in the coating mixture, but it is preferable because the moldability may be improved by firing.
- the firing method and firing conditions are not particularly limited, and known processing methods and conditions can be applied. The optimum firing conditions vary depending on the catalyst raw material used, the catalyst composition, the preparation method, and the like, but the firing temperature is usually 100 to 350 ° C., preferably 150 to 300 ° C., and the firing time is 1 to 20 hours.
- the firing is usually carried out in an air atmosphere, but may be carried out in an inert gas atmosphere such as nitrogen, carbon dioxide, helium, or argon, or further after firing in an inert gas atmosphere, if necessary.
- the firing may be performed in an air atmosphere.
- the calcined solid thus obtained is preferably pulverized before molding.
- the crushing method is not particularly limited, but it is preferable to use a ball mill.
- the compound containing the active ingredient in preparing the slurry of the second stage does not necessarily have to contain all the active ingredients, and some of the components may be used before the following molding step. ..
- the shape of the catalyst in the second stage is not particularly limited, and it is molded into a columnar shape, a tablet, a ring shape, a spherical shape, or the like in order to reduce the pressure loss of the reaction gas in the oxidation reaction.
- it is particularly preferable to support the catalytically active component solid on an inert carrier and use it as a supported catalyst.
- the rolling granulation method described below is preferable for this support. In this method, for example, in a device having a flat or uneven disk at the bottom of a fixed container, the carrier in the container is vigorously agitated by repeating rotation and revolution by rotating the disk at high speed.
- the method of adding the binder is as follows: 1) the carrier mixture is mixed in advance, 2) the carrier mixture is added at the same time as being added into the fixed container, and 3) the carrier mixture is added after being added into the fixed container. 4) Addition of the supporting mixture before adding it into the fixed container, 5) Dividing the supporting mixture and the binder, and adding the total amount of 2) to 4) in appropriate combinations can be arbitrarily adopted. ..
- the addition rate is adjusted by using an auto feeder or the like so that the supporting mixture does not adhere to the wall of the fixed container and the supporting mixture does not aggregate with each other and a predetermined amount is supported on the carrier.
- the binder include water, ethanol, polyhydric alcohol, polyvinyl alcohol as a high molecular weight binder, celluloses such as crystalline cellulose, methyl cellulose and ethyl cellulose, and an aqueous solution of silica sol as an inorganic binder, such as celluloses and ethylene glycol.
- Diol, triol such as glycerin, and the like are preferable, and an aqueous solution having a concentration of glycerin of 5% by mass or more is particularly preferable.
- the amount of these binders used is usually 2 to 60 parts by mass, preferably 10 to 50 parts by mass with respect to 100 parts by mass of the supporting mixture.
- the carrier in the above-mentioned carrier include spherical carriers having a diameter of 1 to 15 mm, preferably 2.5 to 10 mm, such as silicon carbide, alumina, silica alumina, mullite, and arandom. These carriers are usually used having a porosity of 10 to 70%.
- the ratio of the carrier to the supporting mixture is usually 10 to 75% by mass, preferably 15 to 60% by mass of the supporting mixture / (supporting mixture + carrier). When the proportion of the supporting mixture is large, the reaction activity of the supporting catalyst is large, but the mechanical strength tends to be small. On the contrary, when the proportion of the supporting mixture is small, the mechanical strength tends to be large, but the reaction activity tends to be small.
- examples of the molding aid used as necessary include silica gel, diatomaceous earth, and alumina powder.
- the amount of the molding aid used is usually 1 to 60 parts by mass with respect to 100 parts by mass of the catalytically active component solid.
- using a catalyst active component solid and an inorganic fiber (for example, ceramic fiber or whiskers) inactive with respect to the reaction gas as a strength improver is useful for improving the mechanical strength of the catalyst. Glass fiber is preferred.
- the amount of these fibers used is usually 1 to 30 parts by mass with respect to 100 parts by mass of the catalytically active component solid.
- the molding aid, the pore forming agent, and the carrier added may or may not be active in the sense of converting the raw material into some other product. It shall not be considered as a constituent element of the active ingredient in this embodiment.
- the supported catalyst obtained as described above can be used as it is as a catalyst for the vapor phase catalytic oxidation reaction, but it is preferable because the catalytic activity may be improved by firing.
- the firing method and firing conditions are not particularly limited, and known processing methods and conditions can be applied. The optimum firing conditions vary depending on the catalyst raw material used, the catalyst composition, the preparation method, and the like, but the firing temperature is usually 100 to 450 ° C., preferably 270 to 420 ° C., and the firing time is 1 to 20 hours.
- the firing is usually carried out in an air atmosphere, but may be carried out in an inert gas atmosphere such as nitrogen, carbon dioxide, helium, or argon, or further after firing in an inert gas atmosphere, if necessary.
- the firing may be performed in an air atmosphere.
- the catalytic activity can be improved and the yield can be improved, which greatly improves the price competitiveness of the product as compared with known methods. It is effective for.
- the effect of improving the process stability of the partial oxidation reaction accompanied by heat generation such as reduction of the hotspot temperature can be expected.
- the catalyst of the present embodiment is also effective in reducing by-products that adversely affect the environment and the quality of the final product, such as carbon monoxide (CO), carbon dioxide (CO 2 ), acetaldehyde, acetic acid, and formaldehyde. ..
- the catalyst of the present embodiment thus obtained can be used, for example, in producing acrolein and / or acrylic acid by vapor-phase catalytic oxidation of propylene with a molecular oxygen-containing gas.
- the distribution method of the raw material gas may be an ordinary single distribution method or a recycling method, and can be carried out under generally used conditions, and is not particularly limited.
- propylene as a starting material is 1 to 10% by volume, preferably 4 to 9% by volume
- molecular oxygen is 3 to 20% by volume, preferably 4 to 18% by volume
- water vapor is 0 to 60% by volume at room temperature.
- reaction is carried out by introducing at a space speed of 300 to 5000 h-1 at a pressure of about 450 ° C. and a pressure of normal pressure to 10 atm.
- the improvement of the catalytic activity means that the raw material conversion rate is high when the catalytic reaction is carried out at the same reaction bath temperature and the comparison is made unless otherwise specified.
- the high yield in the present invention means that when an oxidation reaction is carried out using propylene, isobutylene, t-butyl alcohol or the like as a raw material, the corresponding unsaturated aldehyde and / or unsaturated carboxylic acid is used. Indicates that the total yield of is high. Unless otherwise specified, the yield refers to the effective yield described later.
- the constituent elements of the catalyst active component refer to all the elements used in the catalyst manufacturing process unless otherwise specified, but the raw materials that disappear, sublimate, volatilize, and burn at the maximum temperature or less in the firing process. And its constituent elements shall not be included in the constituent elements of the active component of the catalyst. Further, the elements constituting the molding aid and the carrier in the molding process and other inorganic materials are not included as the constituent elements of the active ingredient of the catalyst.
- the hot spot temperature is the maximum temperature of the temperature distribution in the catalyst packed bed measured by installing a thermocouple in the long axis direction in the multi-tube reaction tube, and the reaction bath temperature is the heat generation of the reaction tube. It is the set temperature of the heat medium used for the purpose of cooling.
- the number of points for measuring the temperature distribution is not particularly limited, but for example, the catalyst filling length is evenly divided from 10 to 1000.
- a temperature sheath is installed in the long axis direction of the reaction tube and the thermocouple is installed therein for the purpose of stabilizing the measurement by the thermocouple.
- the outer diameter of the temperature sheath is not limited, but is preferably 7 mm or less, more preferably 6 mm or less, still more preferably 3.5 mm or less, and the outer diameter of the thermocouple is also not limited, but is, for example, 6 mm or less. Is preferable, more preferably 4 mm or less, still more preferably 3 mm or less.
- the unsaturated aldehyde and the unsaturated aldehyde compound are organic compounds having at least one double bond and at least one aldehyde in the molecule, and are, for example, acrolein and methacrolein.
- the unsaturated carboxylic acid and the unsaturated carboxylic acid compound are organic compounds having at least one double bond and at least one carboxy group in the molecule, or an ester group thereof, for example, acrylic acid, methacrylic acid, and the like. It is methyl methacrylate.
- the conjugated diene is a diene in which a double bond is separated by one single bond and chemically conjugated, for example, 1,3-butadiene.
- the catalyst of the present invention also has the advantages of (i) reducing the hotspot temperature and (ii) stabilizing the activity even when the reaction bath temperature is low.
- raw material conversion rate (%) (number of moles of reacted propylene, t-butyl alcohol, isobutylene or butene) / (number of moles of supplied propylene, t-butyl alcohol, isobutylene or butene) x 100
- Effective selectivity (%) (total number of moles of acrolein and acrylic acid produced, or total number of moles of methacrolein and methacrylic acid produced) / (number of moles of reacted propylene, t-butyl alcohol or isobutylene) x 100
- Butadiene selectivity (%) (total number of moles of butadiene produced) / (number of moles of reacted butene) x 100 Support rate
- the firing time described in each of the following examples means the holding time from the time when each firing temperature is reached, in which the temperature raising time and the temperature lowering time are not included.
- the aging treatment described later means that a reaction tube having a specified thickness is filled with a catalyst, propylene is flowed at a specified flow rate, and an oxidation reaction is carried out for a specified period.
- the temperature of the reaction bath at this time is an arbitrary temperature, but the lower limit is 300 ° C., and the upper limit is the temperature at which the temperature of the catalyst layer in the reaction tube is 450 ° C. or lower.
- Example 1 100 parts by mass of ammonium heptamolybdate was completely dissolved in 380 parts by mass of pure water heated to 60 ° C. (mother solution 1). Next, 0.37 parts by mass of potassium nitrate was dissolved in 3.3 parts by mass of pure water and added to the mother liquor 1. Next, 31 parts by mass of ferric nitrate, 81 parts by mass of cobalt nitrate and 44 parts by mass of nickel nitrate were dissolved in 83 parts by mass of pure water heated to 60 ° C. and added dropwise to the mother liquor 1.
- the catalyst 1-1 was filled in a stainless steel reaction tube having an inner diameter of 25 mm, and subjected to 1300 hr aging treatment under the conditions of a propylene concentration of 8% by volume and a propylene space velocity of 160 hr-1 with respect to all the catalysts in the reaction tube.
- the maximum temperature of the catalyst layer in the reaction tube during the aging treatment was 444 ° C., and the minimum oxygen concentration of the gas at the outlet of the reaction tube was 4.8% by volume. After that, it was taken out from the reaction tube to obtain catalyst 1-2.
- the X-ray diffraction angle (2 ⁇ ) of the catalyst 1-2 was measured.
- Example 2 100 parts by mass of ammonium heptamolybdate was completely dissolved in 380 parts by mass of pure water heated to 60 ° C. (mother solution 1). Next, 0.17 parts by mass of potassium nitrate was dissolved in 1.5 parts by mass of pure water and added to the mother liquor 1. Next, 38 parts by mass of ferric nitrate, 89 parts by mass of cobalt nitrate and 33 parts by mass of nickel nitrate were dissolved in 85 parts by mass of pure water heated to 60 ° C. and added dropwise to the mother liquor 1.
- the catalyst 2-1 was filled in a stainless steel reaction tube having an inner diameter of 25 mm, and subjected to a 26000 hr aging treatment under the conditions of a propylene concentration of 8% by volume and a propylene space velocity of 95 hr-1 with respect to all the catalysts in the reaction tube.
- the maximum temperature of the catalyst layer in the reaction tube during the aging treatment was 384 ° C., and the minimum oxygen concentration of the gas at the outlet of the reaction tube was 3.9% by volume. Then, it was taken out from the reaction tube to obtain a catalyst 2-2.
- the X-ray diffraction angle (2 ⁇ ) of the catalyst 2-2 was measured.
- Example 3 100 parts by mass of ammonium heptamolybdate was completely dissolved in 380 parts by mass of pure water heated to 60 ° C. (mother solution 1). Next, 0.44 parts by mass of potassium nitrate was dissolved in 4.0 parts by mass of pure water and added to the mother liquor 1. Next, 34 parts by mass of ferric nitrate, 71 parts by mass of cobalt nitrate and 38 parts by mass of nickel nitrate were dissolved in 76 parts by mass of pure water heated to 60 ° C. and added to the mother liquor 1.
- FIG. 1 is a diagram showing an X-ray diffraction pattern of the catalyst 3-1.
- S3 was 12.0.
- the catalyst 3-1 was filled in a stainless steel reaction tube having an inner diameter of 27 mm, and subjected to a 24000 hr aging treatment under the conditions of a propylene concentration of 8% by volume and a propylene space velocity of 100 hr-1 with respect to all the catalysts in the reaction tube. Then, it was taken out from the reaction tube to obtain a catalyst 3-2.
- the X-ray diffraction angle (2 ⁇ ) of the catalyst 3-2 was measured.
- FIG. 2 is a diagram showing an X-ray diffraction pattern of the catalyst 3-2.
- FIG. 3 is a diagram showing an X-ray diffraction pattern of the catalyst (catalyst 4-1) of Comparative Example 1. S3 was 13.5.
- the catalyst 4-1 was filled in a stainless steel reaction tube having an inner diameter of 25 mm, and subjected to 1300 hr aging treatment under the conditions of a propylene concentration of 8% by volume and a propylene space velocity of 160 hr-1 with respect to all the catalysts in the reaction tube.
- the maximum temperature of the catalyst layer in the reaction tube during the aging treatment was 444 ° C., and the minimum oxygen concentration of the gas at the outlet of the reaction tube was 4.8% by volume. Then, it was taken out from the reaction tube to obtain a catalyst 4-2.
- the X-ray diffraction angle (2 ⁇ ) of the catalyst 4-2 was measured.
- FIG. 4 is a diagram showing an X-ray diffraction pattern of the catalyst 4-2.
- the reaction tube outlet gas was analyzed between 100 hr and 150 hr from the start of introduction of propylene.
- Table 1 shows the reaction bath temperatures, raw material conversion rate, effective selectivity and XRD measurement results for catalyst 1-1, catalyst 2-1 and catalyst 3-1 and catalyst 1-4. 2.
- Table 2 shows the reaction bath temperatures up to the catalysts 3-2 and 4-2, the raw material conversion rate, the effective selectivity, and the results of the XRD measurement.
- Table 3 shows the amount of decrease in effective selectivity per 1000 hours of reaction time, Q1, Q2, Q3, D1, D2, and D3, taking into account the reaction time T (hr) in which the oxidation reaction was performed.
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Abstract
Description
特に、プロピレン、イソブチレン、t-ブチルアルコール等を原料にして対応する不飽和アルデヒド、不飽和カルボン酸を製造する方法に関しては、その収率の向上や触媒活性を改善する手段として多くの報告がなされている(例えば特許文献1等)。
特許文献3には、触媒活性成分のCu-Kα線を用いたX線回折分析によって測定される2θ=5°以上90°以下の範囲の結晶化度Tを4%以上18%以下の範囲に制御することにより、触媒活性、選択率等の触媒性能を向上させることが出来ると記載されている。
さらに特許文献4には、2θ=26.4°±0.2°の位置に現れるCoMoO4相の回折ピーク(c)の強度Pcに対する、2θ=27.4°±0.2°に現れるBi10Mo3O24相の回折ピーク(a)の強度Paの比Ri=Pa/Pcが0.2≦Ri≦1.0である、酸化物触媒において、反応における経時的な活性上昇が少なく、且つ不飽和アルデヒドを高収率で生成できると記載されている。
特に触媒寿命に関しては、触媒の物性またはその経時的な変化と触媒の寿命との関係が不明確であった。触媒を使用し不飽和アルデヒド、不飽和カルボン酸又は共役ジエンを高収率及び/または高選択率を維持して製造する際、どのような特性を有する触媒を用い、またどのような指標により管理すべきなのか明確であるとは言えない状況であった。
1)
モリブデン、ビスマス、およびコバルトを必須成分として含有し、CuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(1)~(4)で表される反応時間1000時間当たりの変化率(Q1)が16以下である、触媒。
Q1={(U1/F1-1)×100}/T×1000・・・(1)
F1=(酸化反応前の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(2)
U1=(酸化反応後の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応後の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(3)
T=酸化反応を行った時間(hr)・・・(4)
2)
CuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(5)および前記式(2)~(4)で表される反応時間1000時間当たりの変化量(D1)が4.1以下である、1)に記載の触媒。
D1=(U1-F1)/T×1000 ・・・(5)
3)
触媒活性成分の組成が下記式(A)で表される、1)又は2)に記載の触媒。
Moa1Bib1Nic1Cod1Fee1Xf1Yg1Zh1Oi1・・・(A)
(式中、Mo、Bi、Ni、CoおよびFeはそれぞれモリブデン、ビスマス、ニッケル、コバルトおよび鉄を表し、Xはタングステン、アンチモン、錫、亜鉛、クロム、マンガン、マグネシウム、シリカ、アルミニウム、セリウムおよびチタンから選ばれる少なくとも一種の元素、Yはナトリウム、カリウム、セシウム、ルビジウム、およびタリウムから選ばれる少なくとも一種の元素、Zは周期表の第1族から第16族に属し、上記Mo、Bi、Ni、Co、Fe、X、およびY以外の元素から選ばれる少なくとも一種の元素を意味し、a1、b1、c1、d1、e1、f1、g1、h1、およびi1はそれぞれモリブデン、ビスマス、ニッケル、コバルト、鉄、X、Y、Zおよび酸素の原子数を表し、a1=12としたとき、0<b1≦7、0≦c1≦10、0<d1≦10、0<c1+d1≦20、0≦e1≦5、0≦f1≦2、0≦g1≦3、0≦h1≦5、およびi1=各元素の酸化状態によって決まる値である。)
4)
不活性担体に触媒活性成分が担持された触媒である、1)から3)のいずれか一項に記載の触媒。
5)
前記不活性担体がシリカ、アルミナまたはそれらの混合物である、4)に記載の触媒。
6)
不飽和アルデヒド化合物、不飽和カルボン酸化合物、及び共役ジエンの少なくとも1種の製造用の触媒である、1)から5)のいずれか一項に記載の触媒。
7)
1)から6)のいずれか一項に記載の触媒を用いた不飽和アルデヒド化合物、不飽和カルボン酸化合物、及び共役ジエンの少なくとも1種の製造方法。
8)
前記不飽和アルデヒド化合物がアクロレインであり、前記不飽和カルボン酸化合物がアクリル酸であり、前記共役ジエンが1,3-ブタジエンである、7)に記載の製造方法。
9)
1)から6)のいずれか一項に記載の触媒を用いて製造された不飽和アルデヒド化合物、不飽和カルボン酸化合物、又は共役ジエン。
10)
モリブデン、ビスマス、およびコバルトを必須成分として含有する触媒を用い、当該触媒のCuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(14)~(17)で表される反応時間1000時間当たりの変化率(Q4)が、16以下である不飽和アルデヒド化合物、不飽和カルボン酸化合物、及び共役ジエンの少なくとも1種の製造方法。
Q4={(U4/F4-1)×100}/T×1000・・・(14)
U4=(酸化反応後の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応後の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(15)
F4=(酸化反応前の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(16)
T=酸化反応を行った時間(hr)・・・(17)
11)
下記式(18)で表される反応時間1000時間当たりの変化量(D4)が4.1以下である10)に記載の不飽和アルデヒド化合物、不飽和カルボン酸化合物、及び共役ジエンの少なくとも1種の製造方法。
D4=(U4-F4)/T×1000 ・・・(18)
本実施形態の触媒は、CuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(1)~(4)で表される反応時間1000時間当たりの変化率(Q1)に特徴を有する。
Q1={(U1/F1-1)×100}/T×1000・・・(1)
F1=(酸化反応前の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(2)
U1=(酸化反応後の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応後の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(3)
T=酸化反応を行った時間(hr)・・・(4)
α-CoMoO4に帰属されるX線回折ピークは他にも存在する。触媒のCuKα線をX線源として得られるX線回折パターンにおける2θ=32.7±0.2°の範囲内にみられるピーク強度について、下記式(6)~(8)および前述の式(4)で表される反応時間1000時間当たりの変化率(Q2)が、4.8以下であると好ましい。なお、変化率(Q2)ではU2をF2で割るため、実質的に(酸化反応後の触媒の2θ=32.7±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=32.7±0.2°のピーク強度値)にて求まる値に基づいて算出される。
Q2={(U2/F2-1)×100}/T×1000・・・(6)
F2=(酸化反応前の触媒の2θ=32.7±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(7)
U2=(酸化反応後の触媒の2θ=32.7±0.2°のピーク強度値)÷(酸化反応後の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(8)
Q3={(U3/F3-1)×100}/T×1000・・・(9)
F3=(酸化反応前の触媒の2θ=47.4±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(10)
U3=(酸化反応後の触媒の2θ=47.4±0.2°のピーク強度値)÷(酸化反応後の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(11)
本実施形態の触媒は、CuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(5)および上記式(2)~(4)で表される反応時間1000時間当たりの変化量(D1)が4.1以下であると好ましい。
D1=(U1-F1)/T×1000 ・・・(5)
後述するように、触媒の組成や製法によりα-CoMoO4の結晶相は変化し、またその安定性も変化する。このことは特に2θ=25.3±0.2°のピーク強度の反応時間1000時間当たりの変化量(D1)に着目することで確認することができる。D1の範囲は、上記の通り4.1以下であると好ましいが、その上限値としてさらに好ましい値は、順に3.0、2.0、1.9、1.5、1.0、0.50、0.30、0.20、0.10であり、より好ましくは0.0であり、更に好ましくは-1.0であり、最も好ましくは-1.3である。また下限値は設定しなくても良いが、好ましい値は順に-17、-15、-10、であり、より好ましくは-5.0であり、更に好ましくは-2.0であり、最も好ましくは-1.5である。すなわち、ピーク強度の反応時間1000時間当たりの変化量(D1)としてより好ましい範囲は、上記上下限によって設定され、例えば-10以上3.0以下等であり、最も好ましくは-1.5以上-1.3以下である。
α-CoMoO4に帰属されるX線回折ピークは他にもあるが、触媒のCuKα線をX線源として得られるX線回折パターンにおける2θ=32.7±0.2°の範囲内にみられるピーク強度について、下記式(12)ならびに前述の式(4)、(7)および(8)で表される反応時間1000時間当たりのピーク強度の変化量(D2)が0.80以下であると好ましい。
D2=(U2-F2)/T×1000・・・(12)
D3=(U3-F3)/T×1000・・・(13)
本実施形態における酸化反応時間T(hr)は、300時間以上30000時間以下の特定の時間で判断するが、好ましくは800時間以上3000時間以下であり、更に好ましくは1000時間以上1500時間以下であり、最も好ましくは1300時間で判断する。
ただし、本実施形態の触媒の特性として、上記300時間以上30000時間以内の任意の時間においてQ1が16以下である場合が特に好ましい態様である。なお上記計算式に代入する際は有効数字2桁で計算すると良い。
S3=(2θ=27.4±0.2°のピーク強度値)÷(2θ=26.5±0.2°のピーク強度値)×100
プロピレン空間速度300hr-1以上の条件で評価する際はスケールの小さい反応器を使用すると容易に評価でき好ましい。反応器を変更するにあたり、酸化反応後の触媒を得るために反応管から触媒を抜き出す際は、反応管を長さ方向に3つ以上の区画に等分し、それぞれの位置から等量サンプリングし、混合してから評価を行うと良い。
本実施形態の触媒に含まれる触媒活性成分は、下記式(A)で表される組成を有する場合が好ましい。
Moa1Bib1Nic1Cod1Fee1Xf1Yg1Zh1Oi1・・・(A)
(式中、Mo、Bi、Ni、CoおよびFeはそれぞれモリブデン、ビスマス、ニッケル、コバルトおよび鉄を表し、Xはタングステン、アンチモン、錫、亜鉛、クロム、マンガン、マグネシウム、ケイ素、アルミニウム、セリウムおよびチタンから選ばれる少なくとも一種の元素、Yはナトリウム、カリウム、セシウム、ルビジウム、およびタリウムから選ばれる少なくとも一種の元素、Zは周期表の第1族から第16族に属し、上記Mo、Bi、Ni、Co、Fe、X、およびY以外の元素から選ばれる少なくとも一種の元素を意味し、a1、b1、c1、d1、e1、f1、g1、h1およびi1はそれぞれモリブデン、ビスマス、ニッケル、コバルト、鉄、X、Y、Zおよび酸素の原子数を表し、a1=12としたとき、0<b1≦7、0≦c1≦10、0<d1≦10、0<c1+d1≦20、0≦e1≦5、0≦g1≦2、0≦f1≦3、0≦h1≦5、およびi1=各元素の酸化状態によって決まる値である。)
b1の下限は望ましい順に、0.2、0.5、0.7、0.8であり、最も望ましくは0.9であり、b1の上限は望ましい順に、5、3、2、1.6、1.4、1.2であり、最も望ましくは1.1である。すなわちb1の最も好ましい範囲は、0.9≦b1≦1.1である。
c1の下限は望ましい順に、1、2、2.5、2.8、3.0であり、最も望ましくは3.1であり、c1の上限は望ましい順に、5、4、3.8、3.6、3.4であり、最も望ましくは3.2である。すなわちc1の最も好ましい範囲は、3.1≦c1≦3.2である。
d1の下限は望ましい順に、3、4、5、5.3、5.5、5.7であり、最も望ましくは5.8であり、d1の上限は望ましい順に、8、7、6.5、6.3、6.1であり、最も望ましくは6.0である。すなわちd1の最も好ましい範囲は、5.8≦d1≦6.0である。
e1の下限は望ましい順に、0.5、1、1.2、1.4であり、最も望ましくは1.5であり、e1の上限は望ましい順に、4、3、2.5、2、1.8であり、最も望ましくは1.7である。すなわちe1の最も好ましい範囲は、1.5≦e1≦1.7である。
f1の上限は望ましい順に、8、7、6、5である。f1の最も好ましい範囲は、0≦f1≦5である。
g1の下限は望ましい順に、0、0.02、0.04、0.06であり、最も望ましくは0.07であり、g1の上限は望ましい順に、1.5、1、0.5、0.2、0.15であり、最も望ましくは0.10である。すなわちg1の最も好ましい範囲は、0.07≦g1≦0.10である。
h1の上限は望ましい順に、8、7、6、5である。すなわちh1の最も好ましい範囲は、0≦h1≦5である。
なお、Yは2種以下含有される場合が好ましく、1種類である場合が特に好ましい態様である。また、f1とh1は0である場合が特に好ましい態様である。
触媒活性成分の調製後に予備焼成を行った予備焼成粉体を不活性担体に担持させた触媒は、本実施形態の触媒として特に効果の優れたものである。
不活性担体の材質としてはアルミナ、シリカ、チタニア、ジルコニア、ニオビア、シリカアルミナ、炭化ケイ素、炭化物、およびこれらの混合物など公知の物を使用でき、さらにその粒径、吸水率、機械的強度、各結晶相の結晶化度や混合割合なども特に制限はなく、最終的な触媒の性能、成形性や生産効率等を考慮して適切な範囲を選択されるべきである。担体と予備焼成粉体の混合の割合は、各原料の仕込み質量により、下記式より担持率として算出される。
担持率(質量%)=(成形に使用した予備焼成粉体の質量)/{(成形に使用した予備焼成粉体の質量)+(成形に使用した担体の質量)}×100
上記担持率としての好ましい上限は、80質量%であり、さらに好ましくは60質量%である。
また好ましい下限は、20質量%であり、さらに好ましくは30質量%である。すなわち担持率として最も好ましい範囲は、30質量%以上60質量%以下である。
なお不活性担体としては、シリカ及び/又はアルミナが好ましく、シリカとアルミナの混合物が特に好ましい。
なお、担持に際して、バインダーを使用するのが好ましい。使用できるバインダーの具体例としては、水やエタノール、メタノール、プロパノール、多価アルコール、高分子系バインダーのポリビニールアルコール、無機系バインダーのシリカゾル水溶液等が挙げられるが、エタノール、メタノール、プロパノール、多価アルコールが好ましく、エチレングリコール等のジオールやグリセリン等のトリオール等が好ましく、グリセリンの濃度5質量%以上の水溶液が好ましい。グリセリン水溶液を適量使用することにより成形性が良好となり、機械的強度の高い、高性能な触媒が得られる。これらバインダーの使用量は、予備焼成粉末100質量部に対して通常2~60質量部であるが、グリセリン水溶液の場合は10~30質量部が好ましい。担持に際してバインダーと予備焼成粉末は成形機に交互に供給しても、同時に供給してもよい。
また、e1/b1の上限として1.90、好ましくは1.80、e1/b1の下限は望ましい順に、0.10、0.50、1.00、1.40、1.50であり、d1/b1の上限として望ましい順に、9.0、8.0、7.0、6.0であり、d1/b1の下限として望ましい順に、2.0、3.0、4.0、5.0、5.5であり、c1/e1の上限として望ましい順に、4.0、3.0、2.5であり、c1/e1の下限として望ましい順に、1.5、1.7、1.9であり、c1/d1の上限として望ましい順に、2.0、1.0、0.8であり、c1/d1の下限として望ましい順に、0.4、0.5であり、g1/d1の上限として望ましい順に、0.20、0.19、0.18、0.17、0.16、0.15、0.14、0.10であり、g1/d1の下限として望ましい順に、0.01、0.02、0.03、0.04、0.05であり、g1/c1の上限として望ましい順に、0.041、0.039、0.037、0.035、0.033、0.031、0.029、0.025、0.023であり、g1/c1の下限として望ましい順に、0.017、0.019、0.021である。さらに上記組成式(A)において、c1+d1+e1の下限は望ましい順に7.0、7.5、8.0、8.5、9.0、9.5であり、c1+d1+e1の上限は望ましい順に、13.0、12.5、12.0、11.5、11.0、10.5であり、b1+c1+d1+e1の下限は望ましい順に8.0、8.5、9.0、9.5、10.0、10.5、11.0であり、b1+c1+d1+e1の上限は望ましい順に14.0、13.5、13.0、12.5、12.0、11.5である。
本実施形態の触媒やその予備焼成粉体を構成する各元素の出発原料としては特に制限されるものではないが、例えばモリブデン成分の原料としては三酸化モリブデンのようなモリブデン酸化物、モリブデン酸、パラモリブデン酸アンモニウム、メタモリブデン酸アンモニウムのようなモリブデン酸またはその塩、リンモリブデン酸、ケイモリブデン酸のようなモリブデンを含むヘテロポリ酸またはその塩などを用いることができる。
本実施形態の触媒を、第一段目の触媒、すなわち不飽和アルデヒド化合物を製造する為の触媒として用いた場合、第二段目の酸化反応を行い、不飽和カルボン酸化合物を得ることができる。
この場合、第二段目の触媒としては、本願実施形態の触媒も用いることもできるが、好ましくは下記式(B)で表される触媒活性成分を含む触媒である。
Mo12Va2Wb2Cuc2Sbd2X2e2Y2f2Z2g2Oh2・・・(B)
(式中、Mo、V、W、Cu、SbおよびOはそれぞれ、モリブデン、バナジウム、タングステン、銅、アンチモンおよび酸素を示し、X2はアルカリ金属、およびタリウムからなる群より選ばれた少なくとも一種の元素を、Y2はマグネシウム、カルシウム、ストロンチウム、バリウムおよび亜鉛からなる群より選ばれた少なくとも一種の元素を、Zはニオブ、セリウム、すず、クロム、マンガン、鉄、コバルト、サマリウム、ゲルマニウム、チタンおよび砒素からなる群より選ばれた少なくとも一種の元素をそれぞれ示す。またa2、b2、c2、d2、e2、f2、g2およびh2は各元素の原子比を表し、モリブデン原子12に対して、a2は0<a2≦10、b2は0≦b2≦10、c2は0<c2≦6、d2は0<d2≦10、e2は0≦e2≦0.5、f2は0≦f2≦1、g2は0≦g2<6を表す。また、h2は前記各成分の原子価を満足するのに必要な酸素原子数である。)。
本発明において収率が高いとは、特に断りがない限り、プロピレン、イソブチレン、t-ブチルアルコール等を原料にして酸化反応を行った場合には、対応する不飽和アルデヒドおよび/または不飽和カルボン酸の合計収率が高いことを指す。また、特に断りがない限り、収率とは後述する有効収率を指す。
本発明において触媒活性成分の構成元素とは、特に断りがない限り、上記触媒製造工程において使用するすべての元素を指すが、本焼成工程の最高温度以下にて消失、昇華、揮発、燃焼する原料およびその構成元素は、触媒の活性成分の構成元素に含めないものとする。また、成形工程における成形助剤や担体に含まれるケイ素およびその他の無機材料を構成する元素も、触媒の活性成分の構成元素として含まれないものとする。
本発明においてホットスポット温度とは、多管式反応管内の長軸方向に熱電対を設置し、測定される触媒充填層内の温度分布の最高温度であり、反応浴温度とは反応管の発熱を冷却する目的で使用される熱媒の設定温度である。上記温度分布の測定の点数には特に制限はないが、例えば触媒充填長を均等に10から1000に分割する。またホットスポット温度の測定には、上記熱電対による測定を安定にする目的で、反応管長軸方向に温度鞘を設置し、この中に熱電対を設置することも当業者にとって公知である。この温度鞘の外径に制限はないが、たとえば7mm以下が好ましく、より好ましくは6mm以下、さらに好ましくは3.5mm以下であり、上記熱電対の外径にも制限はないが、たとえば6mm以下が好ましく、より好ましくは4mm以下、さらに好ましくは3mm以下である。
本発明において不飽和アルデヒドおよび不飽和アルデヒド化合物とは、分子内に少なくとも一つの二重結合と少なくとも一つのアルデヒドを有する有機化合物であり、たとえばアクロレイン、メタクロレインである。本発明において不飽和カルボン酸および不飽和カルボン酸化合物とは、分子内に少なくとも一つの二重結合と少なくとも一つのカルボキシ基、またはそのエステル基を有する有機化合物であり、たとえばアクリル酸、メタクリル酸、メタクリル酸メチルである。本発明において共役ジエンとは、1つの単結合によって二重結合が隔てられ化学的に共役したジエンであり、たとえば1,3-ブタジエンである。
本発明の触媒は、(i)ホットスポット温度の低減および(ii)反応浴温度が低温の場合でも活性が安定するという利点も有する。
原料転化率(%)=(反応したプロピレン、t-ブチルアルコール、イソブチレンまたはブテンのモル数)/(供給したプロピレン、t-ブチルアルコール、イソブチレンまたはブテンのモル数)×100
有効選択率(%)=(生成したアクロレインおよびアクリル酸の合算モル数、または生成したメタクロレインおよびメタクリル酸の合算モル数)/(反応したプロピレン、t-ブチルアルコールまたはイソブチレンのモル数)×100
ブタジエン選択率(%)=(生成したブタジエンの合算モル数)/(反応したブテンのモル数)×100
担持率(質量%)=(成形に使用した予備焼成粉体の質量)/{(成形に使用した予備焼成粉体の質量)+(成形に使用した担体の質量)}×100
出口酸素濃度(体積%)=(反応管出口の酸素モル数)/(水蒸気を含む反応管出口の全ガスのモル数)×100
加えて、後述するエージング処理とは指定の太さの反応管に触媒を充填し、指定の流量でプロピレンを流し、指定の期間酸化反応を行う事を意味する。この時の反応浴の温度は任意の温度であるが下限が300℃であり、上限は反応管内の触媒層の温度が450℃以下となる温度である。
ヘプタモリブデン酸アンモニウム100質量部を60℃に加温した純水380質量部に完全溶解させた(母液1)。次に、硝酸カリウム0.37質量部を純水3.3質量部に溶解させて、母液1に加えた。次に、硝酸第二鉄31質量部、硝酸コバルト81質量部及び硝酸ニッケル44質量部を60℃に加温した純水83質量部に溶解させ、母液1に滴下して加えた。続いて硝酸ビスマス23質量部を60℃に加温した純水24質量部に硝酸(60質量%)5.8質量部を加えて調製した硝酸水溶液に溶解させ母液1に滴下して加えた。この母液1をスプレードライ法にて乾燥し、得られた乾燥粉体を440℃、4時間の条件で予備焼成した。こうして得られた予備焼成粉体(仕込み原料から計算される原子比はMo:Bi:Fe:Co:Ni:K=12:1.0:1.6:5.9:3.2:0.080)に対して5質量%分の結晶性セルロースを添加し、十分混合した後、転動造粒法にてバインダーとして33質量%グリセリン溶液を用いて、不活性の担体に担持率が50質量%となるように球状に担持成形した。こうして得られた粒径5.3mmの球状成形品について、510℃、4時間の条件で本焼成を行い、触媒1-1を得た。触媒1-1のX線回折角度(2θ)の測定を行った。なおS3は12.3であった。
ヘプタモリブデン酸アンモニウム100質量部を60℃に加温した純水380質量部に完全溶解させた(母液1)。次に、硝酸カリウム0.17質量部を純水1.5質量部に溶解させて、母液1に加えた。次に、硝酸第二鉄38質量部、硝酸コバルト89質量部及び硝酸ニッケル33質量部を60℃に加温した純水85質量部に溶解させ、母液1に滴下して加えた。続いて硝酸ビスマス21質量部を60℃に加温した純水23質量部に硝酸(60質量%)5.4質量部を加えて調製した硝酸水溶液に溶解させ母液1に滴下して加えた。この母液1をスプレードライ法にて乾燥し、得られた乾燥粉体を440℃、4時間の条件で予備焼成した。こうして得られた予備焼成粉体(仕込み原料から計算される原子比はMo:Bi:Fe:Co:Ni:K=12:0.93:2.0:6.5:2.4:0.040)に対して5質量%分の結晶性セルロースを添加し、十分混合した後、転動造粒法にてバインダーとして33質量%グリセリン溶液を用いて、不活性の担体に担持率が50質量%となるように球状に担持成形した。こうして得られた粒径5.3mmの球状成形品について、550℃、4時間の条件で本焼成を行い、触媒2-1を得た。触媒2-1のX線回折角度(2θ)の測定を行った。なおS3は11.3であった。
ヘプタモリブデン酸アンモニウム100質量部を60℃に加温した純水380質量部に完全溶解させた(母液1)。次に、硝酸カリウム0.44質量部を純水4.0質量部に溶解させて、母液1に加えた。次に、硝酸第二鉄34質量部、硝酸コバルト71質量部及び硝酸ニッケル38質量部を60℃に加温した純水76質量部に溶解させ、母液1に加えた。続いて硝酸ビスマス38質量部を60℃に加温した純水41質量部に硝酸(60質量%)9.9質量部を加えて調製した硝酸水溶液に溶解させ母液1に加えた。この母液1をスプレードライ法にて乾燥し、得られた乾燥粉体を440℃、4時間の条件で予備焼成した。こうして得られた予備焼成粉体(仕込み原料から計算される原子比はMo:Bi:Fe:Co:Ni:K=12:1.7:1.8:5.2:2.8:0.095)に対して5質量%分の結晶性セルロースを添加し、十分混合した後、転動造粒法にてバインダーとして33質量%グリセリン溶液を用いて、不活性の担体に担持率が50質量%となるように球状に担持成形した。こうして得られた粒径5.3mmの球状成形品について、530℃、4時間の条件で本焼成を行い、触媒3-1を得た。触媒3-1のX線回折角度(2θ)の測定を行った。図1は、触媒3-1のX線回折パターンを示す図である。なおS3は12.0であった。
ヘプタモリブデン酸アンモニウム100質量部を60℃に加温した純水380質量部に完全溶解させた(母液1)。次に、硝酸カリウム0.46質量部を純水4.1質量部に溶解させて、母液1に加えた。次に、硝酸第二鉄38質量部、硝酸コバルト89質量部及び硝酸ニッケル33質量部を60℃に加温した純水85質量部に溶解させ、母液1に加えた。続いて硝酸ビスマス16質量部を60℃に加温した純水17質量部に硝酸(60質量%)4.1質量部を加えて調製した硝酸水溶液に溶解させ母液1に加えた。この母液1をスプレードライ法にて乾燥し、得られた乾燥粉体を440℃、4時間の条件で予備焼成した。こうして得られた予備焼成粉体(仕込み原料から計算される原子比はMo:Bi:Fe:Co:Ni:K=12:0.7:2.0:6.5:2.4:0.10)に対して5質量%分の結晶性セルロースを添加し、十分混合した後、転動造粒法にてバインダーとして33質量%グリセリン溶液を用いて、不活性の担体に担持率が50質量%となるように球状に担持成形した。こうして得られた粒径5.3mmの球状成形品について、540℃、4時間の条件で本焼成を行い、触媒4-1を得た。触媒4-1のX線回折角度(2θ)の測定を行った。図3は、比較例1の触媒(触媒4-1)のX線回折パターンを示す図である。なおS3は13.5であった。
なお、本願は、2020年1月10日付で出願された日本国特許出願(特願2020-002508)に基づいており、その全体が引用により援用される。また、ここに引用されるすべての参照は全体として取り込まれる。
Claims (9)
- モリブデン、ビスマス、およびコバルトを必須成分として含有し、CuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(1)~(4)で表される反応時間1000時間当たりの変化率(Q1)が16以下である、触媒。
Q1={(U1/F1-1)×100}/T×1000・・・(1)
F1=(酸化反応前の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応前の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(2)
U1=(酸化反応後の触媒の2θ=25.3±0.2°のピーク強度値)÷(酸化反応後の触媒の2θ=26.5±0.2°のピーク強度値)×100・・・(3)
T=酸化反応を行った時間(hr)・・・(4)
- CuKα線をX線源として得られるX線回折パターンにおける2θ=25.3±0.2°のピーク強度について、下記式(5)および前記式(2)~(4)で表される反応時間1000時間当たりの変化量(D1)が4.1以下である、請求項1に記載の触媒。
D1=(U1-F1)/T×1000 ・・・(5)
- 触媒活性成分の組成が下記式(A)で表される、請求項1又は2に記載の触媒。
Moa1Bib1Nic1Cod1Fee1Xf1Yg1Zh1Oi1・・・(A)
(式中、Mo、Bi、Ni、CoおよびFeはそれぞれモリブデン、ビスマス、ニッケル、コバルトおよび鉄を表し、Xはタングステン、アンチモン、錫、亜鉛、クロム、マンガン、マグネシウム、シリカ、アルミニウム、セリウムおよびチタンから選ばれる少なくとも一種の元素、Yはナトリウム、カリウム、セシウム、ルビジウム、およびタリウムから選ばれる少なくとも一種の元素、Zは周期表の第1族から第16族に属し、上記Mo、Bi、Ni、Co、Fe、X、およびY以外の元素から選ばれる少なくとも一種の元素を意味し、a1、b1、c1、d1、e1、f1、g1、h1、およびi1はそれぞれモリブデン、ビスマス、ニッケル、コバルト、鉄、X、Y、Zおよび酸素の原子数を表し、a1=12としたとき、0<b1≦7、0≦c1≦10、0<d1≦10、0<c1+d1≦20、0≦e1≦5、0≦f1≦2、0≦g1≦3、0≦h1≦5、およびi1=各元素の酸化状態によって決まる値である。) - 不活性担体に触媒活性成分が担持された触媒である、請求項1から3のいずれか一項に記載の触媒。
- 前記不活性担体がシリカ、アルミナまたはそれらの混合物である、請求項4に記載の触媒。
- 不飽和アルデヒド化合物、不飽和カルボン酸化合物、及び共役ジエンの少なくとも1種の製造用の触媒である、請求項1から5のいずれか一項に記載の触媒。
- 請求項1から6のいずれか一項に記載の触媒を用いた不飽和アルデヒド化合物、不飽和カルボン酸化合物、及び共役ジエンの少なくとも1種の製造方法。
- 前記不飽和アルデヒド化合物がアクロレインであり、前記不飽和カルボン酸化合物がアクリル酸であり、前記共役ジエンが1,3-ブタジエンである、請求項7に記載の製造方法。
- 請求項1から6のいずれか一項に記載の触媒を用いて製造された不飽和アルデヒド化合物、不飽和カルボン酸化合物、又は共役ジエン。
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