Abstract: Disclosed are methods for dehydrating a water containing source of formaldehyde in which water is separated from the water containing source of formaldehyde using a zeolite membrane. In certain aspects, the water containing source of formaldehyde includes a separation enhancer having a relative static permittivity ranging from 2.5 to 20, and the water containing source of formaldehyde may further include methanol. In certain aspects, (meth)acrylic acid alkyl ester may be produced using the dehydrated source of formaldehyde.

Abstract: A process of producing methacrylic acid and/or derivatives thereof including the following steps: (a) biologically converting isobutyryl-CoA into methacrylyl-CoA by the action of an oxidase; and (b) converting methacrylyl-CoA into methacrylic acid and/or derivatives thereof. The invention also extends to microorganisms adapted to conduct the steps of the process.

Abstract: A process of producing methacrylic acid and/or derivatives thereof including the following steps: (a) biologically converting isobutyryl-CoA into methacrylyl-CoA by the action of an oxidase; and (b) converting methacrylyl-CoA into methacrylic acid and/or derivatives thereof. The invention also extends to microorganisms adapted to conduct the steps of the process.

Abstract: A process for the production of an ethylenically unsaturated carboxylic acid ester, preferably an ?,ß ethylenically unsaturated carboxylic acid ester is described. The process takes place by the reaction of formaldehyde or a suitable source thereof with a carboxylic acid ester in the presence of a basic metal methyl carbonate co-reactant, wherein the process produces a second basic metal salt and wherein the process includes the step of contacting the second basic metal salt with: a) carbon dioxide (CO2) and optionally, methanol, and/or b) dimethyl carbonate, to regenerate the basic metal methyl carbonate co-reactant. The invention includes use of carbon dioxide and/or dimethyl carbonate to regenerate a basic metal methyl carbonate.

Abstract: The present invention relates to a process for the production of an ethylenically unsaturated carboxylic acid or ester, preferably ?,ß ethylenically unsaturated carboxylic acids or esters, by the liquid phase reaction of formaldehyde or a suitable source thereof with a non-cyclic carboxylic acid ester in the presence of a basic metal salt.

Abstract: A method of producing an ethylenically unsaturated carboxylic acid or ester, preferably an ?, ? ethylenically unsaturated carboxylic acid or ester. The method includes contacting formaldehyde or a suitable source thereof with a carboxylic acid or ester in the presence of a catalyst and optionally in the presence of an alcohol. The catalyst includes a nitrided metal oxide having at least two types of metal cations, M1 and M2, wherein M1 is selected from the metals of group 2, 3, 4, 13 (called also IIIA) or 14 (called also IVA) of the periodic table and M2 is selected from the metals of groups 5 or 15 (called also VA) of the periodic table.

Abstract: A process for regenerating a silica-supported depleted alkali metal catalyst is described. The level of alkali metal on the depleted catalyst is at least 0.5 mol % and the silica support is a zero-gel. The process comprises the steps of contacting the silica supported depleted alkali metal catalyst with a solution of a salt of the alkali metal in a solvent system that has a polar organic solvent as the majority component. A re-impregnated catalyst prepared by the process of the invention any comprising a silica zero-gel support and a catalytic metal selected from an alkali metal in the range 0.5-5 mol % on the catalyst, wherein the surface area of the silica support is <180 m2/g is also described. The invention is applicable to a process for preparing an ethylenically unsaturated acid or ester comprising contacting an alkanoic acid or ester of the formula R1—CH2—COOR3, with formaldehyde or a suitable source of formaldehyde.

Abstract: Disclosed are methods for dehydrating a water containing source of formaldehyde in which water is separated from the water containing source of formaldehyde using a zeolite membrane. In certain aspects, the water containing source of formaldehyde includes a separation enhancer having a relative static permittivity ranging from 2.5 to 20, and the water containing source of formaldehyde may further include methanol. In certain aspects, (meth)acrylic acid alkyl ester may be produced using the dehydrated source of formaldehyde.

Abstract: A method of extracting (meth)acrylic acid from an aqueous reaction medium into an organic phase in contact therewith is described. The aqueous reaction medium is formed from at least one base catalyst and at least one dicarboxylic acid selected from maleic, fumaric, malic, itaconic, citraconic, mesaconic, and citramalic acid or mixtures thereof in aqueous solution and contains the base catalyzed decarboxylation products of the base catalyzed reaction. The method includes either the addition of at least one of the said dicarboxylic acids and/or a pre-cursor thereof to the aqueous reaction medium to enhance the solvent extraction of the (meth)acrylic acid into the organic solvent or maintaining the level of base catalyst to dicarboxylic acid and/or pre-cursor at a sub-stoichiometric level during the extraction process. The method extends to a process of producing (meth)acrylic acid, its esters and polymers and copolymers thereof.

Abstract: A process for the reactivation of an acidic ion exchange resin is described. The invention relates to the treatment of an at least partially deactivated resin which has been deactivated by contact with an impure ethylenically unsaturated acid or ester containing target impurities. The reactivation includes the step of contacting the at least partially deactivated resin with an alcohol to thereby increase the activity thereof. The invention extends to reactivating a resin deactivated by contact with an impure ethylenically unsaturated acid, ester or nitrile containing target impurities by contacting the at least partially deactivated resin with an alcohol and a carboxylic acid to thereby increase the activity thereof. A reactivated resin and a process for preparing and purifying an ethylenically unsaturated acid or ester of the following formula: R1—C(?(CH2)m)—COOR2 are also described.

Abstract: The invention includes a process of producing methyl methacrylate or derivatives thereof is described. The process includes the steps of converting 2-butanone to methyl propionate using a Baeyer-Villiger monooxygenase, and treating the methyl propionate produced to obtain methyl methacrylate or derivatives thereof. A method of preparing polymers or copolymers of methyl methacrylate or its derivatives is also described.

Abstract: Novel bidentate ligands of general formula (I) are described. In formula (I), A and B each independently represent a linking group; and R represents a hydrocarbyl aromatic structure. The substituent(s) Yi on the aromatic structure together have a total number ?ti of atoms other than hydrogen such that ?ti is greater than or equal to 4, wherein ti represents the number of atoms other than hydrogen on a particular substituent Yi. i ranges from 1 to n; and n is the total number of substituent(s) Yi. The groups X1, X2, X3 and X4 are joined via tertiary carbon atoms to the respective atom Q2 or Q1. Q1 and Q2 each independently represent phosphorus, arsenic, or antimony. A catalyst system and a process for the carbonylation of ethylenically unsaturated compounds utilizing the catalyst system are also described.

Abstract: The present invention provides a catalyst system capable of catalyzing the carbonylation of an ethylenically unsaturated compound, which system is obtainable by combining: a) a metal of Group VIB or Group VIIIB or a compound thereof, b) a bidentate phosphine, arsine or stibine ligand, and c) an acid, wherein the ligand is present in at least a 2:1 molar excess compared to the metal or the metal in the metal compound, and that the acid is present in at least a 2:1 molar excess compared to the ligand, a process for the carbonylation of an ethylenically unsaturated compound, a reaction medium, and use of the system.

Abstract: A method of producing an ethylenically unsaturated carboxylic acid or ester such as (meth) acrylic acid or alkyl esters thereof, for example, methyl methacrylate is described. The process comprises the steps of contacting formaldehyde or a suitable source thereof with a carboxylic acid or ester, for example, propionic acid or alkyl esters thereof in the presence of a catalyst and optionally an alcohol. The catalyst comprises group II metal phosphate crystals having rod or needle like morphology or a suitable source thereof. The phosphate may be a hydroxyapatite, pyrophosphate, hydroxyphosphate, PO42? phosphate or mixtures thereof. The group II metal may be selected from Ca, Sr, Ba or mixtures thereof, for example, strontium hydroxyapatite and calcium hydroxyapatite. A catalyst system comprising a crystalline metal phosphate catalyst and a catalyst support is also described. The metal phosphate has rod/needle like morphology.

Abstract: A composition comprising a mixture of: (i) an aromatic polycarbonate; (ii) a graft copolymer including polyacrylonitrile; and, (iii) a non-crosslinked acrylic polymer having a weight average molecular weight (Mw) of less than or equal to 65,000 Daltons (Da).

Abstract: A process for regenerating a silica-supported depleted alkali metal catalyst is described. The level of alkali metal on the depleted catalyst is at least 0.5 mol % and the silica support is a zero-gel. The process comprises the steps of contacting the silica supported depleted alkali metal catalyst with a solution of a salt of the alkali metal in a solvent system that has a polar organic solvent as the majority component. A re-impregnated catalyst prepared by the process of the invention any comprising a silica zero-gel support and a catalytic metal selected from an alkali metal in the range 0.5-5 mol % on the catalyst, wherein the surface area of the silica support is <180 m2/g is also described. The invention is applicable to a process for preparing an ethylenically unsaturated acid or ester comprising contacting an alkanoic acid or ester of the formula R1—CH2—COOR3, with formaldehyde or a suitable source of formaldehyde.

Abstract: The invention relates to a method of producing an ethylenically unsaturated carboxylic acid or ester, preferably an ?, ? ethylenically unsaturated carboxylic acid or ester. The method includes contacting formaldehyde or a suitable source thereof with a carboxylic acid or ester in the presence of a catalyst and optionally in the presence of an alcohol. The catalyst comprises a nitrided metal oxide having at least two types of metal cations, M1 and M2, wherein M1 is selected from the metals of group 2, 3, 4, 13 (called also IIIA) or 14 (called also IVA) of the periodic table and M2 is selected from the metals of groups 5 or 15 (called also VA) of the periodic table. The invention extends to a catalyst system.

Abstract: A continuous process for the production of an alkyl ester product is described. The process includes the steps of carbonylating ethylene with carbon monoxide in the presence of C1-6 alkanol co-reactant to form the alkyl ester product. The carbonylation takes place in the presence of a catalyst system that includes (a) a bidentate ligand, (b) a catalytic metal selected from a group 8, 9 or 10 metal or a compound thereof, and (c) a sulphonic acid capable of forming an acid alkyl ester with the C1-6 alkanol. The process includes the step of separating the alkyl ester product from a carbonylated crude product stream by treatment effective to vaporizing the alkyl ester product in a single stage flash distillation column and providing a purified alkyl ester product stream separated from the bidentate ligand and catalytic metal.

Abstract: A novel bidentate ligand of general formula (I) is described together with a process for the carbonylation of ethylenically unsaturated compounds. The group X1 may be defined as a univalent hydrocarbyl radical of up to 30 atoms containing at least one nitrogen atom having a pKb in dilute aqueous solution at 18° C. of between 4 and 14 wherein the said at least one nitrogen atom is separated from the Q2 atom by between 1 and 3 carbon atoms. The group X2 is defined as X1, X3 or X4 or represents a univalent radical of up to 30 atoms having at least one primary, secondary or aromatic ring carbon atom wherein each said univalent radical is joined via said at least one primary, secondary or aromatic ring carbon atom(s) respectively to the respective atom Q2. Q1 and Q2 each independently represent phosphorus, arsenic or antimony.

Abstract: A method of producing an ethylenically unsaturated carboxylic acid or ester such as (meth) acrylic acid or alkyl esters thereof, for example, methyl methacrylate is described. The process comprises the steps of contacting formaldehyde or a suitable source thereof with a carboxylic acid or ester, for example, propionic acid or alkyl esters thereof in the presence of a catalyst and optionally an alcohol. The catalyst comprises group II metal phosphate crystals having rod or needle like morphology or a suitable source thereof. The phosphate may be a hydroxyapatite, pyrophosphate, hydroxyphosphate, PO42? phosphate or mixtures thereof. The group II metal may be selected from Ca, Sr, Ba or mixtures thereof, for example, strontium hydroxyapatite and calcium hydroxyapatite. A catalyst system comprising a crystalline metal phosphate catalyst and a catalyst support is also described. The metal phosphate has rod/needle like morphology.