Ammoxidation catalyst for the production of acrylonitrile from propylene and process for producing the same

Claim 2

A catalyst for producing acrylonitrile by the catalytic ammoxidation of propylene, said catalyst comprising an oxide composition of the empirical formula (I): Mo.sub.a Co.sub.b Ni.sub.c Fe.sub.d Bi.sub.e V.sub.f Ca.sub.g K.sub.h X.sub.i Si.sub.j O.sub.k (I) wherein X represents at least one element selected from the group consisting of zirconium and chromium, the subscripts a, b, c, d, e, f, g, h, i and j respectively denote the number of the respective atoms of the elements, and the ratio a:b:c:d:e:f:g:h:i:j is in a range of 10:0 to 8:0 to 8:0.3 to 7:0.01 to 3:0.01 to 2:0.01 to 5:0.05 to 0.5:0 to 2:10 to 50, the ratio a:(b+c) being in a range of 10:2 to 10, and the subscript k denotes the number of oxygen atoms which satisfies the average valency of the elements other than oxygen, the ratio a:k being in a range of 10:30 to 80, and said catalyst is prepared by (a) mixing an aqueous liquid with (1) a molybdenum-containing compound, (2) at least one member selected from cobalt- and nickel-containing compounds, (3) an iron-containing compound, (4) a bismuth-containing compound, (5) a vanadium-containing compound, (6) a calcium-containing compound, (7) a potassium-containing compound, (8) at least one member selected from zirconium- and chromium-containing compounds, and (9) a silicon-containing compound, each in an amount sufficient to satisfy the abovespecified atomic ratio of the elements in the empirical formula (I), to prepare an aqueous slurry, said aqueous slurry containing not more than 15% of the sum of the respective element-containing compounds, which are in the form of solid particles having a size of 2 microns or less, based on the entire weight of said aqueous slurry, and having a pH of 1.0 or less; (b) spray drying said aqueous slurry to form a dried solid precursor catalyst, and (c) calcining said precursor catalyst at a temperature of from 500° to 750° C. to prepare an activated catalyst.

Claim 3

A catalyst as claimed in claim 1, wherein the ratio a:b:c:d:e:f:g:h:i:j is in a range of 10:0 to 8:0 to 8:0.5 to 5:0.03 to 2:0.01 to 1:0.05 to 4:0.07 to 0.4:0.1 to 1.9:15 to 45 and the ratio a:(b+c) is in a range of 10:3 to 9.

Claim 4

A catalyst as claimed in claim 1, wherein said catalyst is in the form of fine particles having a size of from 20 to 150 microns.

Claim 5

A process for producing an ammoxidation catalyst comprising an oxide composition of the empirical formula (I): Mo.sub.a Co.sub.b Ni.sub.c Fe.sub.d Bi.sub.e V.sub.f Ca.sub.g K.sub.h X.sub.i Si.sub.j O.sub.k (I) wherein X represents at least one element selected from the group consisting of zirconium and chromium, the subscripts a, b, c, d, e, f, g, h, i and j respectively denote the number of the respective atoms of the elements, and the ratio a:b:c:d:e:f:g:h:i:j is in a range of 10:0 to 8:0 to 8:0.3 to 7:0.01 to 3:0.01 to 2:0.01 to 5:0.05 to 0.5:0 to 2:10 to 50, the ratio a:(b+c) being in a range of 10:2 to 10, and the subscript k denotes the number of oxygen atoms which satisfies the average valency of the elements other than oxygen, the ratio a:k being in a range of 10:30 to 80, which process comprises the steps of: (a) mixing an aqueous liquid with (1) a molybdenum-containing compound, with (2) at least one member selected from the group consisting of cobalt- and nickel-containing compounds, an (3) iron-containing compound, (4) a bismuth-containing compound, (5) a vanadium-containing compound, (6) a calcium-containing compound, (7) a potassium-containing compound, (8) at least one member selected from the group consisting of zirconium- and chromium-containing compounds, and (9) a silicon-containing compound, each in an amount sufficient to satisfy the above-specified atomic ratio of the elements in the empirical formula (I), to prepare an aqueous slurry, said aqueous slurry containing not more than 15% of the sum of the respective element-containing compounds which are in the form of solid particles having a size of 2 microns or less, based on the entire weight of said aqueous slurry, and having a pH of 1.0 or less; (b) spray drying said aqueous slurry to form a dried solid precursor catalyst, and (c) calcining said precursor catalyst at a temperature of from 500° to 750° C. to prepare an activated catalyst.

Claim 6

A process for producing an ammoxidation catalyst comprising an oxide composition of the empirical formula (I): Mo.sub.a Co.sub.b Ni.sub.c Fe.sub.d Bi.sub.e V.sub.f Ca.sub.g K.sub.h X.sub.i Si.sub.j O.sub.k (I) wherein X represents at least one element selected from the group consisting of zirconium and chromium, the subscripts a, b, c, d, e, f, g, h, i and j respectively denote the number of the respective atoms of the elements, and the ratio a:b:c:d:e:f:g:h:i:j is in a range of 10:0 to 8:0 to 8:0.3 to 7:0.01 to 3:0.01 to 2:0.01 to 5:0.05 to 0.5:0 to 2:10 to 50, the ratio a:(b+c) being in a range of 10:2 to 10, and the subscript k denotes the number of oxygen atoms which satisfies the average valency of the elements other than oxygen, the ratio a:k being in a range of 10:30 to 80, which process comprises the steps of: (a) mixing an aqueous liquid with (1) a molybdenum-containing compound, with (2) at least one member selected from the group consisting of cobalt- and nickel-containing compounds, an (3) iron-containing compound, (4) a bismuth-containing compound, (5) a vanadium-containing compound, (6) a calcium-containing compound, (7) a potassium-containing compound, (8) at least one member selected from the group consisting of zirconium- and chromium-containing compounds, and (9) a silicon-containing compound, each in an amount sufficient to satisfy the above-specified atomic ratio of the elements in the empirical formula (I), to prepare an aqueous slurry, said aqueous slurry containing not more than 15% of the sum of the respective element-containing compounds which are in the form of solid particles having a size of 2 microns or less, based on the entire weight of said aqueous slurry, and having a pH of 1.0 or less; (b) spray drying said aqueous slurry to form a dried solid precursor catalyst, and (c) calcining said precursor catalyst at a temperature of from 500° to 750° C. to prepare an activated catalyst.

Claim 7

A process as claimed in claim 4, wherein said precursor catalyst is shaped into a desired form before said calcining.

Claim 8

A process as claimed in claim 4, wherein said aqueous liquid is selected from the group consisting of water and nitric acid aqueous solutions.

Claim 9

A process as claimed in claim 4, wherein said aqueous slurry has a temperature of 60° C. or less.

Claim 10

A process as claimed in claim 4, wherein the amount of said solid particles in said aqueous slurry is in a range of from 5 to 12% based on the entire weight of said aqueous slurry.