Vanadium-phosphorus-tin-mordenite oxidation catalysts

Claim 1

An oxidation catalyst described by the formula: V.sub.a P.sub.b Sn.sub.c O.sub.d X wherein X is mordenite, a is 0.10 to 1, b is 1, c is 0.001 to 0.30, and d is a number which satisfies the valence requirements of the other elements present.

Claim 12

A method of preparing a vanadium, phosphorus, tin, oxygen and mordenite, oxidation catalyst which comprises: (A) contacting a vanadium compound and a phosphorus compound with an acidic-aqueous medium and a divalent tin compound under reaction conditions which will produce vanadium having an average valence of from +3.50 to +4.95, to form a catalyst precursor; (B) mixing the catalyst precursor with mordenite, to form an impregnated mordenite; and (C) calcining the oxidation catalyst at temperatures in the range of from 400° F. to 1,200° F., for from 1/4 hour to 6 hours.

Claim 13

A method of preparing a vanadium, phosphorus, tin, oxygen and mordenite, oxidation catalyst which comprises: (A) contacting a vanadium compound and a phosphorus compound with an acidic-aqueous medium and a divalent tin compound under reaction conditions which will produce vanadium having an average valence of from +3.50 to +4.95, to form a catalyst precursor; (B) mixing the catalyst precursor with mordenite, to form an impregnated mordenite; and (C) calcining the oxidation catalyst at temperatures in the range of from 400° F. to 1,200° F., for from 1/4 hour to 6 hours.

Claim 25

A method of preparing a vanadium, phosphorus, tin, oxygen and mordenite oxidation catalyst which comprises: (A) contacting a pentavalent vanadium compound, a pentavalent phosphorus compound and a divalent tin compound, at an atomic ratio of from 0.10:1:0.001 to 1:1:0.30 with an acidic-aqueous medium at a temperature of from 100° F. to 220° F., and a pressure from atmospheric pressure to 50 p.s.i.g., to form a catalyst precursor and produce vanadium having an average valence of from +3.50 to +4.95; (B) mixing from 15 weight percent to 50 weight percent of said catalyst precursor with from 50 weight percent to 85 weight percent of mordenite to form an impregnated mordenite; and (C) calcining the oxidation catalyst at temperatures in the range of from 400° F. to 1,200° F., for 1/2 hour to 6 hours.

Claim 26

A method of preparing a vanadium, phosphorus, tin, oxygen and mordenite oxidation catalyst which comprises: (A) contacting a pentavalent vanadium compound, a pentavalent phosphorus compound and a divalent tin compound, at an atomic ratio of from 0.10:1:0.001 to 1:1:0.30 with an acidic-aqueous medium at a temperature of from 100° F. to 220° F., and a pressure from atmospheric pressure to 50 p.s.i.g., to form a catalyst precursor and produce vanadium having an average valence of from +3.50 to +4.95; (B) mixing from 15 weight percent to 50 weight percent of said catalyst precursor with from 50 weight percent to 85 weight percent of mordenite to form an impregnated mordenite; and (C) calcining the oxidation catalyst at temperatures in the range of from 400° F. to 1,200° F., for 1/2 hour to 6 hours.

Claim 35

A method of preparing a vanadium, phosphorus, tin, oxygen and mordenite, oxidation catalyst having a surface area of from 100 M 2 /g to 450 M 2 /g, a pore volume of from 0.10 cc/g to 0.80 cc/g, and a compacted bulk density of from 0.50 to 1.50, which comprises: (A) Contacting ammonium metavanadate, phosphoric acid and stannous chloride at an atomic ratio of from 0.10:1:0.001 to 1:1:0.30 with aqueous hydrochloric acid at a temperature of from 100° F. to 220° F., and a pressure of from atmospheric pressure to 50 p.s.i.g., to form a catalyst precursor, wherein the vanadium has an average valence of from +3.50 to +4.95; (B) mixing from 15 weight percent to 50 weight percent of said catalyst precursor and from 50 weight percent to 85 weight percent of mordenite with from about 0 to 10 weight percent of a binding agent selected from the group consisting of silica, methyl cellulose and alumina and mixtures thereof, and a solvent selected from the group consisting of ethanol, propanol, isopropanol, and butanol and mixtures thereof in a binding agent and solvent weight ratio of from 1:20 to 20:1 to form an impregnated mordenite; and (C) calcining the oxidation catalyst at a temperature in the range of from 400° F. to 1,200° F., for 1/2 hour to 6 hours.

Claim 36

A method of preparing a vanadium, phosphorus, tin, oxygen and mordenite, oxidation catalyst having a surface area of from 100 M 2 /g to 450 M 2 /g, a pore volume of from 0.10 cc/g to 0.80 cc/g, and a compacted bulk density of from 0.50 to 1.50, which comprises: (A) Contacting ammonium metavanadate, phosphoric acid and stannous chloride at an atomic ratio of from 0.10:1:0.001 to 1:1:0.30 with aqueous hydrochloric acid at a temperature of from 100° F. to 220° F., and a pressure of from atmospheric pressure to 50 p.s.i.g., to form a catalyst precursor, wherein the vanadium has an average valence of from +3.50 to +4.95; (B) mixing from 15 weight percent to 50 weight percent of said catalyst precursor and from 50 weight percent to 85 weight percent of mordenite with from about 0 to 10 weight percent of a binding agent selected from the group consisting of silica, methyl cellulose and alumina and mixtures thereof, and a solvent selected from the group consisting of ethanol, propanol, isopropanol, and butanol and mixtures thereof in a binding agent and solvent weight ratio of from 1:20 to 20:1 to form an impregnated mordenite; and (C) calcining the oxidation catalyst at a temperature in the range of from 400° F. to 1,200° F., for 1/2 hour to 6 hours.