Abstract: A process for preparing aldehydes from methanol includes introducing a feed stream comprising methanol and hydrogen gas into a reaction zone of a first reactor, converting the feed stream into an intermediate stream comprising C2 to C4 olefins in the reaction zone in the presence of a first catalyst, wherein the first catalyst is a microporous catalyst component, removing water and species C4 and heavier from the intermediate stream to form a lights stream, and converting the lights stream into a product stream comprising propionaldehyde in the presence of a second catalyst and carbon monoxide in a second reactor. The propionaldehyde can further be converted to methyl methacrylate via oxidative esterification.

Abstract: A process for preparing aldehydes from synthesis gas includes introducing a first feed stream comprising hydrogen gas and a carbon-containing gas comprising carbon monoxide into a reaction zone of a first reactor, converting the first feed stream into a first product stream comprising C2 to C4 hydrocarbons in the reaction zone in the presence of a first catalyst, wherein the first product stream further comprises carbon dioxide, removing water and C4 and higher hydrocarbons from the first product stream to form a second feed stream, and converting the second feed stream into a second product stream comprising propionaldehyde in the presence of a second catalyst in a second reactor. The propionaldehyde can further be converted to methyl methacrylate via oxidative esterification.

Abstract: A process for preparing C2 to C4 carboxylic acids from synthesis gas includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas comprising carbon monoxide into a reaction zone of a first reactor, converting the feed stream into an intermediate stream comprising C2 to C4 hydrocarbons in the reaction zone in the presence of a first catalyst, wherein the intermediate stream further comprises carbon dioxide and wherein the first catalyst is a composite catalyst comprising a metal oxide catalyst component and a microporous catalyst component, and converting the intermediate stream into a product stream comprising C2 to C4 carboxylic acids in the presence of a second catalyst in a second reactor. The second reactor can be configured for olefin oxidation or paraffin oxidation.

Abstract: A heterogeneous catalyst comprising a support and gold, wherein: (i) said support comprises alumina, (ii) said catalyst comprises from 0.1 to 5 wt % of gold, (iii) at least 90 wt % of the gold is in the outer 60% of catalyst volume, and (iv) particles of the catalyst have an average diameter from 200 microns to 30 mm; wherein weight percentages are based on weight of the catalyst.

Abstract: A catalyst comprising a noble metal disposed on a support. The noble metal is present in an amount ranging from 0.1 wt % to 10 wt % relative to the total weight of the catalyst. The support comprises at least 50 wt % silicon carbide relative to the total weight of the support. The silicon carbide has a surface area of at least 5 m2/g. A method for preparing methyl methacrylate from methacrolein and methanol using the catalyst is also disclosed.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The process comprises contacting in a reactor a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said catalyst has an average diameter of at least 200 microns, liquid and gaseous reactants flow downward in the reactor and wherein the continuous phase in the reactor is a gas which has no more than 7.5 mol % oxygen at reactor inlets.

Abstract: A catalyst comprising noble metal particles and titanium-containing particles. The noble metal particles and titanium-containing particles are disposed on an outer surface of a support. At least 20% by weight of the total weight of noble metal particles are adjacent to at least one titanium-containing particle. The noble metal particles have an average diameter of less than 15 nm, and the catalyst has an average diameter of at least 200 microns. A method for preparing methyl methacrylate from methacrolein and methanol using the catalyst is also disclosed.

Abstract: A heterogeneous catalyst comprising a support and a noble metal, wherein said support comprises silicon, and wherein said catalyst comprises from 0.1 to 40 mol % titanium and from 0.1 to 10 mol % of at least one noble metal.

Abstract: A heterogeneous catalyst comprising a support and gold, wherein: (i) said support comprises titanium, (ii) said catalyst comprises from 0.1 to 5 wt % of gold, (iii) at least 90 wt % of the gold is in the outer 60% of catalyst volume, and (iv) particles of the catalyst have an average diameter from 200 microns to 30 mm; wherein weight percentages are based on weight of the catalyst.

Abstract: A heterogeneous catalyst comprising a support and a noble metal. The catalyst has an average diameter of at least 200 microns and at least 90 wt % of the noble metal is in the outer 50% of catalyst volume.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The process comprises contacting in a reactor a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said catalyst has an average diameter of at least 200 microns, liquid and gaseous reactants flow downward in the reactor and wherein the continuous phase in the reactor is a gas which has no more than 7.5 mol % oxygen at reactor inlets.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol; said method comprising contacting a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said support comprises silicon, and wherein said catalyst comprises from 0.1 to 40 mol % titanium and from 0.1 to 10 mol % of at least one noble metal.

Abstract: A heterogeneous catalyst comprising a support and gold, wherein: (i) said support comprises alumina, (ii) said catalyst comprises from 0.1 to 5 wt % of gold, (iii) at least 90 wt % of the gold is in the outer 60% of catalyst volume, and (iv) particles of the catalyst have an average diameter from 200 microns to 30 mm; wherein weight percentages are based on weight of the catalyst.

Abstract: A heterogeneous catalyst comprising a support and gold, wherein: (i) said support comprises titanium, (ii) said catalyst comprises from 0.1 to 5 wt % of gold, (iii) at least 90 wt % of the gold is in the outer 60% of catalyst volume, and (iv) particles of the catalyst have an average diameter from 200 microns to 30 mm; wherein weight percentages are based on weight of the catalyst.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The method comprises contacting a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein oxygen concentration at a reactor outlet is from 1 to 7.5 mol % and wherein pH at a reactor outlet is no greater than 7.5.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The method comprises contacting a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said catalyst has an average diameter of at least 200 microns and average concentration of methacrolein is at least 15 wt %.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol; said method comprising contacting in a reactor a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein pH at the reactor outlet is from 3 to 6.7.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The method comprises contacting a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said catalyst has an average diameter of at least 200 microns and at least 90 wt % of the noble metal is in the outer 70% of catalyst volume, and wherein oxygen concentration at a reactor outlet is from 0.5 to 7.5 mol %.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The method comprises contacting in a reactor a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said catalyst has an average diameter of at least 200 microns, wherein oxygen concentration at a reactor outlet is from 0.5 to 7.5 mol % and wherein the reactor comprises a partition with the catalyst bed on a first side of the partition and with flow through the catalyst bed in a first direction and flow on a second side of the partition in an opposite direction.

Abstract: A method for preparing methyl methacrylate from methacrolein and methanol. The method comprises contacting a mixture comprising methacrolein, methanol and oxygen with a heterogeneous catalyst comprising a support and a noble metal, wherein said catalyst has an average diameter of at least 200 microns and at least 90 wt % of the noble metal is in the outer 50% of catalyst volume.