Process for preparing methyl acrylate or mixtures thereof with acrylic acid

Claim 1

A method for preparing methyl acrylate or a mixture of methyl acrylate and acrylic acid by contacting with a catalyst a reacting gaseous flow comprising methanol, acrolein and oxygen, which comprises passing the said gaseous flow at a velocity of 5 to 50 cm/sec through a fluidized catalyst bed formed of regular spherical particles 15 to 100 microns in size, said particles comprising 10 to 80 Wt.% of a silica support, the remainder consisting of an active catalystic component chosen in the group of components defined by the general formulae: Mo.sub.a V.sub.b Me.sub.c O.sub.x Mo.sub.a W.sub.d Me.sub.c O.sub.y Mo.sub.a V.sub.b W.sub.d Me.sub.c O.sub.z wherein Me is an element chosen in the group consisting of chromium, manganese, iron, cobalt, nickel, copper, zinc, silver, cadmium, gold, mercury, sodium, barium, calcium, cerium, bismuth, thorium, uranium, lead, antimony, tin, phosphorus and boron; and wherein a, b, c, d, x, y, z are numbers varying respectively: a from 6 to 12, b from 1 to 6, c from 0 to 5, d from 1 to 6, x from 20.5 to 58.5, y from 21 to 61.5 and z from 23.5 to 76.5, said catalyst having been obtained by forming an ammoniacal aqueous solution of soluble silicate and of compounds of the elements other than oxygen present in the said active component, at a concentration of the said compounds up to 10-12 wt.% in the solution, spray-drying said solution with a gas at a temperature from 350° to 450° C. and maintaining the resulting particulate solid product in an air stream during 0.1 to 4 hours at a temperature from 150° to 350° C. and subsequently in an inert gas stream during 0.5 to 14 hours at a temperature from 350° to 480° C.

Claim 2

A method for preparing methyl acrylate or a mixture of methyl acrylate and acrylic acid by contacting with a catalyst a reacting gaseous flow comprising methanol, acrolein and oxygen, which comprises passing the said gaseous flow at a velocity of 5 to 50 cm/sec through a fluidized catalyst bed formed of regular spherical particles 15 to 100 microns in size, said particles comprising 10 to 80 Wt.% of a silica support, the remainder consisting of an active catalystic component chosen in the group of components defined by the general formulae: Mo.sub.a V.sub.b Me.sub.c O.sub.x Mo.sub.a W.sub.d Me.sub.c O.sub.y Mo.sub.a V.sub.b W.sub.d Me.sub.c O.sub.z wherein Me is an element chosen in the group consisting of chromium, manganese, iron, cobalt, nickel, copper, zinc, silver, cadmium, gold, mercury, sodium, barium, calcium, cerium, bismuth, thorium, uranium, lead, antimony, tin, phosphorus and boron; and wherein a, b, c, d, x, y, z are numbers varying respectively: a from 6 to 12, b from 1 to 6, c from 0 to 5, d from 1 to 6, x from 20.5 to 58.5, y from 21 to 61.5 and z from 23.5 to 76.5, said catalyst having been obtained by forming an ammoniacal aqueous solution of soluble silicate and of compounds of the elements other than oxygen present in the said active component, at a concentration of the said compounds up to 10-12 wt.% in the solution, spray-drying said solution with a gas at a temperature from 350° to 450° C. and maintaining the resulting particulate solid product in an air stream during 0.1 to 4 hours at a temperature from 150° to 350° C. and subsequently in an inert gas stream during 0.5 to 14 hours at a temperature from 350° to 480° C.

Claim 17

A method for preparing methyl acrylate or a mixture of methyl acrylate and acrylic acid by contacting with a catalyst a reacting gaseous flow comprising methanol, acrolein and oxygen, which comprises passing the said gaseous flow at a velocity of 5 to 50 cm/sec through a fluidized catalyst bed formed of regular spherical particles 15 to 100 microns in size, said particles comprising 10 to 80 wt.% of a silica support, the remainder consisting of an active catalytic component chosen in the group of components defined by the general formulae: Mo.sub.a V.sub.b Me.sub.c O.sub.x Mo.sub.a W.sub.d Me.sub.c O.sub.y Mo.sub.a V.sub.b W.sub.d Me.sub.c O.sub.z wherein Me is an element chosen in the group consisting of chromium, manganese, iron, cobalt, nickel, copper, zinc, silver, cadmium, gold, mercury, sodium, barium, calcium, cerium, bismuth, thorium, uranium, lead, antimony, tin, phosphorus and boron; and wherein a, b, c, d, x, y, z are numbers varying respectively: a from 6 to 12, b from 1 to 6, c from 0 to 5, d from 1 to 6, x from 20.5 to 58.5, y from 21 to 61.5 and z from 23.5 to 76.5, said catalyst having been obtained by impregnating silica particles 15 to 100 microns in size with an aqueous solution of compounds of the elements other than oxygen present in the said active component, drying said impregnated particles at a temperature up to 120° C. and treating the dried particles during 0.1 to 4 hours in an air stream at a temperature from 150° C. to 350° C. then during 0.5 to 14 hours in an inert gas stream at a temperature from 350° C. to 480° C.

Claim 18

A method for preparing methyl acrylate or a mixture of methyl acrylate and acrylic acid by contacting with a catalyst a reacting gaseous flow comprising methanol, acrolein and oxygen, which comprises passing the said gaseous flow at a velocity of 5 to 50 cm/sec through a fluidized catalyst bed formed of regular spherical particles 15 to 100 microns in size, said particles comprising 10 to 80 wt.% of a silica support, the remainder consisting of an active catalytic component chosen in the group of components defined by the general formulae: Mo.sub.a V.sub.b Me.sub.c O.sub.x Mo.sub.a W.sub.d Me.sub.c O.sub.y Mo.sub.a V.sub.b W.sub.d Me.sub.c O.sub.z wherein Me is an element chosen in the group consisting of chromium, manganese, iron, cobalt, nickel, copper, zinc, silver, cadmium, gold, mercury, sodium, barium, calcium, cerium, bismuth, thorium, uranium, lead, antimony, tin, phosphorus and boron; and wherein a, b, c, d, x, y, z are numbers varying respectively: a from 6 to 12, b from 1 to 6, c from 0 to 5, d from 1 to 6, x from 20.5 to 58.5, y from 21 to 61.5 and z from 23.5 to 76.5, said catalyst having been obtained by impregnating silica particles 15 to 100 microns in size with an aqueous solution of compounds of the elements other than oxygen present in the said active component, drying said impregnated particles at a temperature up to 120° C. and treating the dried particles during 0.1 to 4 hours in an air stream at a temperature from 150° C. to 350° C. then during 0.5 to 14 hours in an inert gas stream at a temperature from 350° C. to 480° C.