Preparation of fluidizable vanadium phosphorus oxide catalysts using a mixed phosphorus source

Claim 2

A process for the preparation of a fluid bed oxidation catalyst containing the mixed oxides of vanadium and phosphorus comprising (a) introducing at least one pentavalent vanadium compound into an organic liquid capable of reducing at least a portion of the vanadium to a valence state of +4; (b) effecting reduction of at least a portion of the vanadium to a valence state of +4; (c) contacting the vanadium with a mixed phosphorus component prior or subsequent to effecting said reduction, wherein said mixed phosphorus component comprises about 75-90 weight percent orthophosphoric acid and about 10-25 weight percent pyrophosphoric acid; (d) comminuting the catalyst precursor resulting from steps (a) through (c); (e) introducing the catalyst precursor into water prior or subsequent to said comminuting to form an aqueous slurry; and (f) spray drying said slurry to form microspheroidal catalyst particles.

Claim 3

A process as in claim 1, comprising the additional step of calcining the microspheroidal catalyst particles.

Claim 4

A process as in claim 1, wherein said mixed phosphorus component comprises about 80-90 weight percent orthophosphoric acid, about 10-20 weight percent pyrophosphoric acid and 0-3 weight percent triphosphoric acid.

Claim 5

A process as in claim 1, wherein said organic liquid is essentially anhydrous.

Claim 6

A process as in claim 1, wherein reduction of said vanadium is effected by heating the vanadium-containing liquid medium.

Claim 7

A process as in claim 1 wherein said mixed phosphorus source additionally comprises up to 5 weight percent triphosphoric acid.

Claim 8

A process as in claim 1 wherein said catalyst additionally contains promoter elements selected from the group consisting of U, Co, Mo, Fe, Zn, Hf, Zr and mixtures thereof.

Claim 9

A process as in claim 1, wherein said catalyst precursor is substantially dried prior to introducing the catalyst precursor into water.

Claim 10

A process as in claim 1, wherein a substantial portion of said catalyst precursor is comminuted to a particle size of less than about one micron average diameter.

Claim 11

A process as in claim 1, wherein said aqueous slurry has a solids content of about 25 to about 60 weight percent.

Claim 12

A process as in claim 1 wherein a substantial portion of said microspheroidal particles have a particle size of less than 300 microns.

Claim 13

A process as in claim 1 wherein a substantial portion of said microspheroidal particles have a particle size of about 20 microns to about 240 microns.

Claim 14

A process as in claim 1 wherein said reduction of vanadium is effected in the presence of the mixed phosphorus component.

Claim 15

A process as in claim 1 wherein said catalyst precursor is introduced into water prior to calcining the catalyst precursor.

Claim 16

A fluidizable oxidation catalyst, comprising the mixed oxides of vanadium and phosphorus characterized by an average valence state of vanadium from about +3.5 to about +4.6, and a phosphorus to vanadium ratio of about 0.5:1 to 3:1, wherein said catalyst is microspheroidal in form, prepared by the steps of: (a) introducing at least one pentavalent vanadium compound into an organic liquid capable of reducing at least a portion of the vanadium to a valence state of +4; (b) effecting reduction of at least a portion of the vanadium to a valence state of +4; (c) contacting the vanadium with a mixed phosphorus component prior or subsequent to effecting said reduction, wherein said mixed phosphorus component comprises about 75-90 weight percent orthophosphoric acid and about 10-25 weight percent pyrophosphoric acid; (d) comminuting the catalyst precursor resulting from steps (a) through (c); (e) introducing the catalyst precursor into water prior or subsequent to said comminuting to form an aqueous slurry; and (f) spray drying said slurry to form microspheroidal catalyst particles.

Claim 17

A fluidizable oxidation catalyst, comprising the mixed oxides of vanadium and phosphorus characterized by an average valence state of vanadium from about +3.5 to about +4.6, and a phosphorus to vanadium ratio of about 0.5:1 to 3:1, wherein said catalyst is microspheroidal in form, prepared by the steps of: (a) introducing at least one pentavalent vanadium compound into an organic liquid capable of reducing at least a portion of the vanadium to a valence state of +4; (b) effecting reduction of at least a portion of the vanadium to a valence state of +4; (c) contacting the vanadium with a mixed phosphorus component prior or subsequent to effecting said reduction, wherein said mixed phosphorus component comprises about 75-90 weight percent orthophosphoric acid and about 10-25 weight percent pyrophosphoric acid; (d) comminuting the catalyst precursor resulting from steps (a) through (c); (e) introducing the catalyst precursor into water prior or subsequent to said comminuting to form an aqueous slurry; and (f) spray drying said slurry to form microspheroidal catalyst particles.

Claim 18

A fluidizable oxidation catalyst, as set forth in claim 15, wherein said catalyst additionally comprises promoter elements selected from the group consisting of U, Co, Mo, Fe, Zn, Hf, Zr and mixtures thereof.

Claim 19

A fluidizable oxidation catalyst, as set forth in claim 15 wherein said catalyst precursor is prepared in an organic liquid slurry.

Claim 20

A fluidizable oxidation catalyst, as set forth in claim 15, wherein a substantial portion of said microspheroidal particles have an average diameter of less than 300 microns.