Selenium catalyzed decomposition of peroxide intermediates resulting from the autoxidation of acrolein and methacrolein

Claim 2

A process for the preparation of acrylic acid or methacrylic acid which comprises catalytically decomposing at a temperature in the range of from about 0° C. to about 100° C. in the presence of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof, the corresponding peracrylic acid and acrolein monoperacrylate or permethacrylic acid and methacrolein monopermethacrylate intermediate peroxide compounds formed during the liquid phase autoxidation of acrolein or methacrolein, or contained in an oxidate solution derived from and after said liquid phase autoxidation, and recovering the acrylic or methacrylic acid.

Claim 3

A process according to claim 1 wherein the peroxide compounds are decomposed in situ during the liquid phase autoxidation of acrolein or methacrolein at a temperature in the range of about 0° C. to about 100° C. in the presence of from about 0.0001 to about 0.1 mole of a selenium catalyst per mole of acrolein or methacrolein being oxidized.

Claim 4

A process according to claim 2 wherein the process is carried out at a temperature between about 65° C. and 75° C. in the presence of from about 0.001 to 0.01 mole of a selenium catalyst per mole of acrolein or methacrolein being oxidized.

Claim 5

A process according to claim 2 wherein an inert organic solvent is employed at concentrations of from about 10 to 95 weight percent of the solvent-aldehyde mixture and is selected from the group consisting of aliphatic, cycloaliphatic or aromatic hydrocarbons, halogenated hydrocarbon, carboxylic acids, ethers, esters, amides and alcohols or mixtures thereof.

Claim 6

A process according to claim 4 wherein the solvent is selected from n-hexane, carbon tetrachloride, benzene or mixtures of cyclohexane and ethyl alcohol, pentane, and n-hexane and ethyl alcohol.

Claim 7

A process according to claim 1 wherein the peroxide compounds are contained in an oxidate reaction mixture derived from the liquid phase autoxidation of acrolein or methacrolein, said peroxide compounds in said oxidate solution being decomposed at a temperature of from about ambient to about 100° C. in the presence of from about 0.001 to about 10 percent by weight of the oxidate reaction solution of a selenium catalyst.

Claim 8

A process according to claim 6 wherein the process is carried out at a temperature between about 30° and 60° C. in the presence of from about 0.01 to about 1.0 percent by weight of a selenium catalyst based on the oxidate reaction solution.

Claim 9

A process according to claim 6 wherein an inert organic solvent is employed in the oxidate solution at concentrations of from about 10 to about 95 weight percent of the solvent-oxidate mixture and is selected from the group consisting of aliphatic, cycloaliphatic or aromatic hydrocarbons, halogenated hydrocarbon, carboxylic acids, ethers, esters, amides and alcohols or mixtures thereof.

Claim 10

A process according to claim 8 wherein the solvent is selected form n-hexane, n-dodecane, carbon tetrachloride, cyclohexane, benzene, dioxane or mixtures of n-hexane and t-butyl alcohol, n-hexane and ethyl alcohol, cyclohexane and carbon tetrachloride, n-hexane and dioxane and benzene and acetic acid.

Claim 11

A process according to claim 1 wherein the selenium catalyst is selected from selenium per se, selenium dioxide, selenium bromide, selenium trioxide, selenium chloride, diethyl selenite, diphenyl selenide and selenious acid or mixtures thereof.

Claim 12

A process according to claim 1 wherein the selenium catalyst is supported.

Claim 13

A process for the preparation of acrylic acid which comprises the steps of: oxidizing acrolein with oxygen or an oxygen-containing gas in the liquid phase to produce a reaction product oxidate containing unreacted acrolein, peracrylic acid, acrolein monoperacrylate, acrylic acid and other by-products; adding from about 20 to 80 weight percent of an aliphatic, cycloaliphatic or aromatic hydrocarbon, halogenated hydrocarbon, carboxylic acid, ether, ester, alcohol or amide solvent or mixture thereof to said oxidate to form a solvent-oxidate mixture; subjecting the solvent-oxidate mixture to a temperature in the range of from about 30° to 60° C. in the presence of from about 0.01 to 1.0 percent by weight of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof to catalytically decompose peracrylic acid and acrolein monoperacrylate to acrylic acid; and recovering said acrylic acid produced by said oxidation and catalytic decomposition.

Claim 14

A process for the preparation of acrylic acid which comprises the steps of: oxidizing acrolein with oxygen or an oxygen-containing gas in the liquid phase to produce a reaction product oxidate containing unreacted acrolein, peracrylic acid, acrolein monoperacrylate, acrylic acid and other by-products; adding from about 20 to 80 weight percent of an aliphatic, cycloaliphatic or aromatic hydrocarbon, halogenated hydrocarbon, carboxylic acid, ether, ester, alcohol or amide solvent or mixture thereof to said oxidate to form a solvent-oxidate mixture; subjecting the solvent-oxidate mixture to a temperature in the range of from about 30° to 60° C. in the presence of from about 0.01 to 1.0 percent by weight of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof to catalytically decompose peracrylic acid and acrolein monoperacrylate to acrylic acid; and recovering said acrylic acid produced by said oxidation and catalytic decomposition.

Claim 15

A process according to claim 12 wherein the unreacted acrolein or solvent in the reaction product oxidate is removed by distillation prior to or during the decomposition step.

Claim 16

A process for the preparation of methacrylic acid which comprises the steps of: oxidizing methacrolein with oxygen or an oxygencontaining gas in the liquid phase to produce a reaction product oxidate containing unreacted methacrolein, permethacrylic acid, methacrolein monopermethacrylate, methacrylic acid and other by-products; adding from about 20 to 80 weight percent of an aliphatic, cycloaliphatic or aromatic hydrocarbon, halogenated hydrocarbon, carboxylic acid, ether, ester, alcohol or amide solvent or mixture thereof to said oxidate to form a solvent-oxidate mixture; subjecting the solvent-oxidate mixture to a temperature in the range of from about 30° to 60° C. in the presence of from about 0.01 to 1.0 percent by weight of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof to catalytically decompose permethacrylic acid and methacrolein monopermethacrylate to methacrylic acid; and recovering said methacrylic acid produced by said oxidation and catalytic decomposition.

Claim 17

A process for the preparation of methacrylic acid which comprises the steps of: oxidizing methacrolein with oxygen or an oxygencontaining gas in the liquid phase to produce a reaction product oxidate containing unreacted methacrolein, permethacrylic acid, methacrolein monopermethacrylate, methacrylic acid and other by-products; adding from about 20 to 80 weight percent of an aliphatic, cycloaliphatic or aromatic hydrocarbon, halogenated hydrocarbon, carboxylic acid, ether, ester, alcohol or amide solvent or mixture thereof to said oxidate to form a solvent-oxidate mixture; subjecting the solvent-oxidate mixture to a temperature in the range of from about 30° to 60° C. in the presence of from about 0.01 to 1.0 percent by weight of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof to catalytically decompose permethacrylic acid and methacrolein monopermethacrylate to methacrylic acid; and recovering said methacrylic acid produced by said oxidation and catalytic decomposition.

Claim 18

A process according to claim 14 wherein the unreacted methacrolein or solvent in the reaction product oxidate is removed and recovered by distillation prior to or during the decomposition step.

Claim 19

A process for the preparation of acrylic acid which comprises contacting an inert solvent solution of acrolein with oxygen or an oxygen-containing gas at a temperature of from about 20° to 80° C. and a pressure of between about 50 psig and 500 psig in the presence of from about 0.001 to 0.01 mole of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride, and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, deithylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof per mole of acrolein to effect a catalytic in situ decomposition of intermediate peracrylic acid and acrolein monoperacrylate formed during oxidation of the acrolein to acrylic acid.

Claim 20

A process for the preparation of acrylic acid which comprises contacting an inert solvent solution of acrolein with oxygen or an oxygen-containing gas at a temperature of from about 20° to 80° C. and a pressure of between about 50 psig and 500 psig in the presence of from about 0.001 to 0.01 mole of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride, and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, deithylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof per mole of acrolein to effect a catalytic in situ decomposition of intermediate peracrylic acid and acrolein monoperacrylate formed during oxidation of the acrolein to acrylic acid.

Claim 21

A process for the preparation of methacrylic acid which comprises contacting an inert solvent solution of methacrolein with oxygen or an oxygen-containing gas at a temperature of from about 20° to 80° C. and a pressure of between about 50 psig and 500 psig in the presence of from about 0.001 to 0.01 mole of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof per mole of methacrolein to effect a catalytic in situ decomposition of intermediate permethacrylic acid and methacrolein monopermethacrylate formed during oxidation of the methacrolein to methacrylic acid.

Claim 22

A process for the preparation of methacrylic acid which comprises contacting an inert solvent solution of methacrolein with oxygen or an oxygen-containing gas at a temperature of from about 20° to 80° C. and a pressure of between about 50 psig and 500 psig in the presence of from about 0.001 to 0.01 mole of a selenium catalyst selected from the group consisting of elemental selenium, selenium dioxide, trioxide, sulfide, disulfide, chloride, oxychloride and bromide, selenious acid, selenic acid, aluminum selenide, sodium selenide, sodium selenite, sodium selenate, diethylselenite, diethyldiselenide, dioctylselenide, dioctyldiselenide, diphenylselenide, diphenyldiselenide and phenylseleninic acid, or mixtures thereof per mole of methacrolein to effect a catalytic in situ decomposition of intermediate permethacrylic acid and methacrolein monopermethacrylate formed during oxidation of the methacrolein to methacrylic acid.