Abstract: An integrated facility is disclosed for simultaneous production of butanal and methacrylic acid products where the facility utilizes a mixed methacrolein and isobutanal stream to make methacrylic acid. The facility is also designed to utilize downstream n-butanal products such as n-butanol and/or 2-ethyl-hexanol to make butyl-methacrylates and 2-ethyl-hexyl-methacrylate. A method is also disclosed which integrates the production of butanal derived products and methacrylic acid derived products.

Abstract: Methods for making unsaturated acids using catalysts for oxidation of unsaturated and/or Saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo) and phosphorus (P), where the catalyst has a pore size distribution including at least 50% medium pores and if bismuth is present, a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12.

Abstract: A catalyst for oxidation of unsaturated and/or saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo), phosphorus (P), vanadium (V), bismuth (Bi), and a first component selected from the group consisting of potassium (K), rubidium (Rb), cesium (Cs), thallium (Tl), or mixtures or combinations thereof, where the catalyst has at least 57% medium pores and a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12. Methods for making and using such catalysts are also disclosed.

Abstract: An integrated facility is disclosed for simultaneous production of butanal and methacrylic acid products where the facility utilizes a mixed methacrolein and isobutanal stream to make methacrylic acid. The facility is also designed to utilize downstream n-butanal products such as n-butanol and/or 2-ethyl-hexanol to make butyl-methacrylates and 2-ethyl-hexyl-methacrylate. A method is also disclosed which integrates the production of butanal derived products and methacrylic acid derived products.

Abstract: A heteropolyacid catalyst for oxidation of isobutyraldehyde, methacrolein or mixtures or combinations thereof to methacrylic acid is disclosed where the heteropolyacid catalyst includes at least molybdenum (Mo), phosphorus (P), vanadium (V), and a first component including bismuth (Bi) and/or boron (B). The heteropolyacid catalyst can also optionally include a second component including potassium (K), rubidium (Rb), cesium (Cs), and/or thallium (Tl) and optionally a third component including antimony (Sb), cerium (Ce), niobium (Nb), indium (In), iron (Fe), chromium (Cr), cobalt (Co), nickel (Ni), manganese (Mn), arsenic (As), silver (Ag), zinc (Zn), germanium (Ge), gallium (Ga), zirconium (Zr), magnesium (Mg), barium (Ba), lead (Pb), tin (Sn), titanium (Ti), aluminum (Al), silicon (Si), tantalum (Ta), tungsten (W), and/or lanthanum (La). The heteropolyacid catalyst can also include an ammonium-containing compound designed to increase a value of medium pores in the final heteropolyacid catalyst.

Abstract: A catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, contains oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals. The catalyst has a certain relative amount ratio of cesium to bismuth, a certain relative amount ratio of iron to bismuth and a certain relative amount ratio of bismuth, iron, cesium and certain other metals to molybdenum and, optionally, tungsten. For a catalyst of the formula: Mo12BiaWbFecCodNieSbfCsgMghZniPjOx wherein a is 0.1 to 1.5, b is 0 to 4, c is 0.2 to 5.0, d is 0 to 9, e is 0 to 9, f is 0 to 2.0, g is from 0.4 to 1.5, h is 0 to 1.5, i is 0 to 2.0, j is 0 to 0.5 and x is determined by the valences of the other components, c:g=3.3-5.0, c:a=2.0-6.0 and (3a+3c+2d+2e+g+2h+2i)/(2×12+2b)=0.95-1.10.

Abstract: The present invention is for a process for making a heteropoly acid compound catalyst for oxidation of unsaturated aldehydes, such as methacrolein, to unsaturated carboxylic acids, such as methacrylic acid, said catalyst containing oxides of molybdenum, phosphorus, and M?, wherein M? is cesium, potassium, rubidium, or sodium, and bismuth. The process is a synthesis of the catalyst with specific process conditions for addition of the bismuth compound as an aqueous slurry without nitric acid. A catalyst precursor is formed by removing the water and drying the solid particles. The heteropoly acid compound catalyst is formed by calcination of the catalyst precursor.

Abstract: The invention is a supported or bound heteropoly acid catalyst composition, a method of making the catalyst composition and a process for the oxidation of saturated and/or unsaturated aldehydes to unsaturated carboxylic acids using the catalyst composition. The catalyst composition has a heteropoly acid component containing molybdenum, vanadium, phosphorus and cesium and support/binder having a surface area of about 0.1 m2/g to about 1.0 m2/g. The catalyst is made by dissolving compounds of the components of each of the heteropoly acid compounds in a solution, precipitating the heteropoly acid compounds, contacting the heteropoly acid compounds to form a catalyst precursor and calcining the catalyst precursor to form a heteropoly acid compound catalyst. Unsaturated aldehydes, such as methacrolein, may be oxidized in the presence of the heteropoly acid compound catalyst to produce an unsaturated carboxylic acid, such as methacrylic acid.

Abstract: A catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, contains oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals. The catalyst has a certain relative amount ratio of cesium to bismuth, a certain relative amount ratio of iron to bismuth and a certain relative amount ratio of bismuth, iron, cesium and certain other metals to molybdenum and, optionally, tungsten. For a catalyst of the formula: Mo12BiaWbFecCodNieSbfCsgMghZniPjOx wherein a is 0.1 to 1.5, b is 0 to 4, c is 0.2 to 5.0, d is 0 to 9, e is 0 to 9, f is 0 to 2.0, g is from 0.4 to 1.5, h is 0 to 1.5, i is 0 to 2.0, j is 0 to 0.5 and x is determined by the valences of the other components, c:g=3.3-5.0, c:a=2.0-6.0 and (3a+3c+2d+2e+g+2h+2i)/(2×12+2b)=0.95-1.10.

Abstract: A catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, contains oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals. The catalyst has a certain relative amount ratio of cesium to bismuth, a certain relative amount ratio of iron to bismuth and a certain relative amount ratio of bismuth, iron, cesium and certain other metals to molybdenum and, optionally, tungsten. For a catalyst of the formula: Mo12BiaWbFecCodNieSbfCsgMghZniPjOx wherein a is 0.1 to 1.5, b is 0 to 4, c is 0.2 to 5.0, d is 0 to 9, e is 0 to 9, f is 0 to 2.0, g is from 0.4 to 1.5, h is 0 to 1.5, i is 0 to 2.0, j is 0 to 0.5 and x is determined by the valences of the other components, c:g=3.3-5.0, c:a=2.0-6.0 and (3a+3c+2d+2e+g+2h+2i)/(2×12+2b)=0.95-1.10.

Abstract: A catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, contains oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals. The catalyst has a certain relative amount ratio of cesium to bismuth, a certain relative amount ratio of iron to bismuth and a certain relative amount ratio of bismuth, iron, cesium and certain other metals to molybdenum and, optionally, tungsten. For a catalyst of the formula: Mo12BiaWbFecCodNieSbfCsgMghZniPjOx wherein a is 0.1 to 1.5, b is 0 to 4, c is 0.2 to 5.0, d is 0 to 9, e is 0 to 9, f is 0 to 2.0, g is from 0.4 to 1.5, h is 0 to 1.5, i is 0 to 2.0, j is 0 to 0.5 and x is determined by the valences of the other components, c:g=3.3-5.0, c:a=2.0-6.0 and (3a+3c+2d+2e+g+2h+2i)/(2×12+2b)=0.95-1.10.

Abstract: The invention is a supported or bound heteropoly acid catalyst composition, a method of making the catalyst composition and a process for the oxidation of saturated and/or unsaturated aldehydes to unsaturated carboxylic acids using the catalyst composition. The catalyst composition has an active heteropoly acid component containing molybdenum, vanadium, phosphorus and cesium and an inert heteropoly acid component containing molybdenum, phosphorus and cesium, potassium, rubidium or sodium at a relative molybdenum:cesium/potassium/rubidium/sodium molar ratio of above about 12:2. The catalyst is made by dissolving compounds of the components of each of the heteropoly acid compounds in a solution, precipitating the heteropoly acid compounds, contacting the heteropoly acid compounds to form a catalyst precursor and calcining the catalyst precursor to form a heteropoly acid compound catalyst.

Abstract: The invention is a supported or bound heteropoly acid catalyst composition, a method of making the catalyst composition and a process for the oxidation of saturated and/or unsaturated aldehydes to unsaturated carboxylic acids using the catalyst composition. The catalyst composition has an active heteropoly acid component containing molybdenum, vanadium, phosphorus and cesium and an inert heteropoly acid component containing molybdenum, phosphorus and cesium, potassium, rubidium or sodium at a relative molybdenum:cesium/potassium/rubidium/sodium molar ratio of above about 12:2. The catalyst is made by dissolving compounds of the components of each of the heteropoly acid compounds in a solution, precipitating the heteropoly acid compounds, contacting the heteropoly acid compounds to form a catalyst precursor and calcining the catalyst precursor to form a heteropoly acid compound catalyst.

Abstract: The present invention is for a process for making a heteropoly acid compound catalyst for oxidation of unsaturated aldehydes, such as methacrolein, to unsaturated carboxylic acids, such as methacrylic acid, said catalyst containing oxides of molybdenum, phosphorus, and M?, wherein M? is cesium, potassium, rubidium, or sodium, and bismuth. The process is a synthesis of the catalyst with specific process conditions for addition of the bismuth compound as an aqueous slurry without nitric acid. A catalyst precursor is formed by removing the water and drying the solid particles. The heteropoly acid compound catalyst is formed by calcination of the catalyst precursor.

Abstract: A catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, contains oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals. The catalyst has a certain relative amount ratio of cesium to bismuth, a certain relative amount ratio of iron to bismuth and a certain relative amount ratio of bismuth, iron, cesium and certain other metals to molybdenum and, optionally, tungsten. For a catalyst of the formula: Mo12BiaWbFecCodNieSbfCsgMghZniPjOx wherein a is 0.1 to 1.5, b is 0 to 4, c is 0.2 to 5.0, d is 0 to 9, e is 0 to 9, f is 0 to 2.0, g is from 0.4 to 1.5, h is 0 to 1.5, i is 0 to 2.0, j is 0 to 0.5 and x is determined by the valences of the other components, c:g=3.3–5.0, c:a=2.0–6.0 and (3a+3c+2d+2e+g+2h+2i)/(2×12+2b)=0.95–1.10.

Abstract: An integrated facility is disclosed for simultaneous production of butanal and methacrylic acid products where the facility utilizes a mixed methacrolein and isobutanal stream to make methacrylic acid. The facility is also designed to utilize downstream n-butanal products such as n-butanol and/or 2-ethyl-hexanol to make butyl-methacrylates and 2-ethyl-hexyl-methacrylate. A method is also disclosed which integrates the production of butanal derived products and methacrylic acid derived products.

Abstract: A catalyst for oxidation of unsaturated and/or saturated aldehydes to unsaturated acids is disclosed where the catalyst includes at least molybdenum (Mo), phosphorus (P), vanadium (V), bismuth (Bi), and a first component selected from the group consisting of potassium (K), rubidium (Rb), cesium (Cs), thallium (Tl), or mixtures or combinations thereof, where the bismuth component was dissolved in an organic acid solution prior to adding the bismuth containing solution to a solution of the other components. Methods for making and using the catalysts are also disclosed.

Abstract: A heteropolyacid catalyst for oxidation of isobutyraldehyde, methacrolein or mixtures or combinations thereof to methacrylic acid is disclosed where the heteropolyacid catalyst includes at least molybdenum (Mo), phosphorus (P), vanadium (V), and a first component including bismuth (Bi) and/or boron (B). The heteropolyacid catalyst can also optionally include a second component including potassium (K), rubidium (Rb), cesium (Cs), and/or thallium (Tl) and optionally a third component including antimony (Sb), cerium (Ce), niobium (Nb), indium (In), iron (Fe), chromium (Cr), cobalt (Co), nickel (Ni), manganese (Mn), arsenic (As), silver (Ag), zinc (Zn), germanium (Ge), gallium (Ga), zirconium (Zr), magnesium (Mg), barium (Ba), lead (Pb), tin (Sn), titanium (Ti), aluminum (Al), silicon (Si), tantalum (Ta), tungsten (W), and/or lanthanum (La). The heteropolyacid catalyst can also include an ammonium-containing compound designed to increase a value of medium pores in the final heteropolyacid catalyst.

Abstract: A catalyst for oxidation of unsaturated and/or saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo), phosphorus (P), vanadium (V), bismuth (Bi), and a first component selected from the group consisting of potassium (K), rubidium (Rb), cesium (Cs), thallium (Ti), or mixtures or combinations thereof, where the catalyst has at least 57% medium pores and a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12. Methods for making and using such catalysts are also disclosed.

Abstract: A process for making a catalyst containing oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals, such as tungsten, cobalt, nickel, antimony, magnesium, zinc, phosphorus, potassium, rubidium, thallium, manganese, barium, chromium, boron, sulfur, silicon, aluminum, titanium, cerium, tellurium, tin, vanadium, zirconium, lead, cadmium, copper and niobium wherein metal compounds are dissolved and then precipitated as a catalyst precursor which is calcined to form a mixed metal oxide catalyst. The process of the present invention uses an organic acid, such as acetic acid, instead of nitric acid to dissolve the bismuth compound and, optionally, other metal compounds. The catalyst synthesized by this process may be used for the production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene.