Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process includes the steps of contacting an alkanoic acid and an alkylenating agent over a catalyst composition under conditions effective to produce the acrylate product. The catalyst composition comprises a metal phosphate matrix containing vanadium and bismuth. Preferably, the catalyst comprises, in an active phase, vanadium to bismuth at a molar ratio of at least 0.02:1. Preferably, the catalyst composition is substantially free of titanium.

Abstract: The invention relates to a process for producing an acrylate product comprising the step of reacting a reaction gas mixture A comprising methanol and oxygen to form a product gas mixture A. The process may further comprise the step of combining at least a portion of the product gas mixture A and acetic acid to form a reaction gas mixture B. The process may further comprise the step of reacting at least a portion of the acetic acid in the reaction gas input mixture B with at least a portion of the formaldehyde in the reaction gas input mixture B to form a product gas mixture B. The process may further comprise the step of separating at least a portion of the product gas mixture B to form an alkylenating agent stream comprising at least 1 wt % alkylenating agent and an intermediate acrylate product stream comprising acrylate product.

Abstract: A process for producing a crude product stream including an acrylate product and an alkylenating agent and separating at least a portion of the crude product stream to form alkylenating agent and intermediate product streams. The alkylenating agent stream comprises at least 1 wt % alkylenating agent and the intermediate product stream comprises acrylate products in high concentration. The crude product stream is formed by contacting acetic acid and formaldehyde in the presence of at least one aldol condensation catalyst under conditions effective to form the stream. Catalysts which are particularly useful are multielement oxide active materials of the general formula V1PbFecX1dX2eOn.

Abstract: In one embodiment, the invention is to a catalyst composition, comprising vanadium and titanium. Preferably, the molar ratio of vanadium to titanium in an active phase of the catalyst composition is greater than 0.5:1.

Abstract: In one embodiment, the invention is to a catalyst composition comprising vanadium and titanium. The catalyst composition has a surface area of at least 22.6 m2/g and a plurality of pores, and the plurality of pores have a pore diameter of less than 11.9 nm.

Abstract: In one embodiment, the invention is directed to a process for producing an acrylate product. The process comprises the step of reacting in a reactor a reaction mixture comprising an alkanoic acid and a liquid alkylenating agent source comprising methanol in an amount less than 0.5 wt. % over a catalyst and under conditions effective to form a crude acrylate product comprising acrylate product and alkylenating agent. The process further comprises the step of separating at least a portion of the crude acrylate product to form at least one alkylenating agent stream and at least one purified acrylate product stream comprising acrylate product.

Abstract: In one embodiment, the invention is to a catalyst composition comprising vanadium and titanium. The catalyst composition further comprises ethylene glycol and citric acid. Preferably, the catalyst composition is substantially free of oxalic acid and lactic acid.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of reacting a reaction mixture comprising an alkanoic acid, an alkylenating agent, and oxygen over a catalyst and under conditions effective to form a crude acrylate product. Preferably, the reaction mixture comprises from 0.5 wt % to 10 wt % oxygen. The crude acrylate product comprises acrylate product and alkylenating agent. The process further comprises the step of separating at least a portion of the crude product to form at least one alkylenating agent stream and at least one purified acrylate product stream. The purified acrylate product stream comprises acrylate product.

Abstract: In one embodiment, the invention is to a catalyst composition, comprising vanadium and titanium. Preferably, the molar ratio of vanadium to titanium in an active phase of the catalyst composition is greater than 0.5:1.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of providing a crude product stream comprising the acrylate product and an alkylenating agent. The process further comprises the step of separating at least a portion of the crude product stream to form an alkylenating agent stream and an intermediate product stream. The alkylenating agent stream comprises at least 1 wt % alkylenating agent and the intermediate product stream comprises acrylate product.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of reacting an alkanoic acid and an alkylenating agent over a catalyst to produce a crude acrylate product stream, and to product a used catalyst. The used catalyst may then be contacted with a regenerating stream to form a regenerated catalyst. Alkanoic acid and alkylenating agent may then be reacted over the regenerated catalyst to product additional crude acrylate product stream.

Abstract: A process for producing an acrylate product from methanol and acetic acid, in which, in a reaction zone A, the methanol is partially oxidized to formaldehyde in a catalyzed gas phase reaction, the product gas mixture A obtained and an acetic acid source are combined to form a reaction gas input mixture B which comprises acetic acid in excess over formaldehyde, and the formaldehyde in reaction gas input mixture B is aldol-condensed to acrylic acid in the presence of a catalyst in a reaction zone B to form an acrylic acid-containing product gas mixture B from which an acrylate product stream may be separated. Suitable aldol condensation catalysts include vanadium-bismuth, vanadium-titanium-bismuth, vanadium-bismuth-tungsten, vanadium-titanium-tungsten, vanadium-titanium and vanadium-tungsten.

Abstract: The invention is to a process for producing an acrylate product. The process includes the steps of contacting an alkanoic acid and an alkylenating agent over a catalyst composition under conditions effective to produce the acrylate product. The catalyst composition comprises vanadium, titanium and tungsten. Preferably, the catalyst comprises vanadium to tungsten at a molar ratio of at least 0.02:1, in an active phase.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of reacting in a reactor a reaction mixture comprising alkanoic acid and an alkylenating agent under conditions effective to form a crude acrylate product. The process further comprises the step of separating at least a portion of the crude acrylate product to recover a finished acrylate product. The reaction is conducted at a reaction pressure less than 120 kPa.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of reacting an alkanoic acid and an alkylenating agent under conditions effective to produce a crude acrylate product. A molar ratio of alkylenating agent to alkanoic acid is maintained at a level of at least 1.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of providing a crude product stream comprising the acrylate product and an alkylenating agent. The process further comprises the step of separating at least a portion of the crude product stream to form an alkylenating agent stream and an intermediate product stream. The alkylenating agent stream comprises at least 1 wt % alkylenating agent and the intermediate product stream comprises acrylate product.

Abstract: In one embodiment, the invention is to a catalyst composition, comprising vanadium and titanium. Preferably, the molar ratio of vanadium to titanium in an active phase of the catalyst composition is greater than 0.5:1.

Abstract: In one embodiment, the invention is to a catalyst composition comprising vanadium, titanium; and at least one oxide additive. The at least one oxide additive is present in an amount of at least 0.1 wt % based on the total weight of the catalyst composition. The molar ratio of titanium to metal additive in an active phase of the catalyst composition is at least 0.05:1.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of providing a diluted crude acrylate stream comprising the acrylate product and an alkylenating agent. The process further comprises the step of separating at least a portion of the diluted crude acrylate stream to form an alkylenating agent stream and an intermediate product stream. The alkylenating agent stream comprises at least 1 wt. % alkylenating agent and the intermediate product stream comprises acrylate product.

Abstract: In one embodiment, the invention is to a process for producing an acrylate product. The process comprises the step of producing a crude product stream by reacting reactants comprising an alkanoic acid, an alkylenating agent and oxygen in the presence of a catalyst, wherein the oxygen concentration across the reactor is from 0.5 to 10 wt %. The oxygen may be fed to the reactor through a plurality of feeds. The invention is also directed to methods of monitoring the oxygen concentration for the reaction and adjusting the oxygen concentration and/or placement of oxygen feed(s). The process further comprises the step of separating at least a portion of the crude product stream to form an alkylenating agent stream and an intermediate product stream.