Catalysts for the production of maleic anhydride

Claim 2

A process for the manufacture of a phosphorus vanadium catalyst suitable for use in the manufacture of maleic anhydride from butane which process comprises reacting P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with an inorganic acid in the aliphatic alcohol to produce acidified alcohol and a vanadium ester and using these to produce a vanadium phosphorus oxide catalyst which is dissolved in the acidified alcohol.

Claim 3

The process of claim 1 wherein a second addition of P 2 O 5 is carried out after the soluble P/V mixed oxide catalyst is formed.

Claim 4

The process of claim 1 or claim 2 wherein the vanadium compound is vanadium pentoxide.

Claim 5

The process of claim 1 or claim 2 wherein the dissolved phosphorus vanadium oxide catalyst is solidified by the evaporation of the acidified alcohol.

Claim 6

The process of claim 4 wherein a second addition of P 2 O 5 is carried out after the soluble P/V metal mixed oxide catalyst is formed.

Claim 7

A process for the manufacture of phosphorus vanadium metal catalyst wherein the metal has a valence of at least two suitable for use in the manufacture of maleic anhydride from butane which comprises reacting P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with an inorganic acid and the metal in the aliphatic alcohol to produce acidified alcohol and a vanadium ester and reacting these to produce a vanadium phosphorus metal oxide catalyst which is dissolved in the acidified alcohol.

Claim 8

A process for the manufacture of phosphorus vanadium metal catalyst wherein the metal has a valence of at least two suitable for use in the manufacture of maleic anhydride from butane which comprises reacting P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with an inorganic acid and the metal in the aliphatic alcohol to produce acidified alcohol and a vanadium ester and reacting these to produce a vanadium phosphorus metal oxide catalyst which is dissolved in the acidified alcohol.

Claim 9

The process of claim 6 or claim 5 wherein the vanadium compound is vanadium pentoxide.

Claim 10

The process of claim 6 or claim 5 wherein the dissolved phosphorus vanadium metal oxide catalyst is solidified by the evaporation of the acidified alcohol.

Claim 11

A process for the manufacture of a phosphorus vanadium molybdenum oxide catalyst suitable for use in the manufacture of maleic anhydride from butane which process comprises reacting P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with molybdenum oxide and an inorganic acid in the aliphatic alcohol to produce an acidified alcohol and a vanadium ester and reacting these to produce a vanadium phosphorus molybdenum oxide catalyst dissolved in the acidified alcohol.

Claim 12

A process for the manufacture of a phosphorus vanadium molybdenum oxide catalyst suitable for use in the manufacture of maleic anhydride from butane which process comprises reacting P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with molybdenum oxide and an inorganic acid in the aliphatic alcohol to produce an acidified alcohol and a vanadium ester and reacting these to produce a vanadium phosphorus molybdenum oxide catalyst dissolved in the acidified alcohol.

Claim 13

The process of claim 9 wherein a second addition of P 2 O 5 is carried out after the soluble P/V/Mo mixed oxide catalyst is formed.

Claim 14

The process of claim 9 or claim 10 wherein the vanadium compound is vanadium pentoxide.

Claim 15

The process of claim 8 or claim 9 wherein the dissolved phosphorus vanadium molybdenum oxide catalyst is solidified by the evaporation of the acidified alcohol.

Claim 16

The process of claim 8 or claim 9 wherein the inorganic acid is HCl.

Claim 17

The process of claim 8 or claim 9 wherein the alcohol is methanol.

Claim 18

A process for the manufacture of phosphorus vanadium zinc catalyst suitable for use in the manufacture of maleic anhydride from butane which process comprises solvating P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with zinc and an inorganic acid in the aliphatic alcohol to produce an acidified alcohol and a vanadium ester and reacting these to produce a vanadium phosphorus molybdenum oxide catalyst dissolved in the acidified alcohol.

Claim 19

A process for the manufacture of phosphorus vanadium zinc catalyst suitable for use in the manufacture of maleic anhydride from butane which process comprises solvating P 2 O 5 in an aliphatic alcohol having about 1 to about 8 carbon atoms to produce mixed phosphate esters and reacting a vanadium compound with zinc and an inorganic acid in the aliphatic alcohol to produce an acidified alcohol and a vanadium ester and reacting these to produce a vanadium phosphorus molybdenum oxide catalyst dissolved in the acidified alcohol.

Claim 20

The process of claim 15 wherein a second addition of P 2 O 5 is carried out after the soluble P/V/Zn mixed oxide catalyst has formed.

Claim 21

The process of claim 16 or claim 17 wherein the vanadium compound is vanadium pentoxide.

Claim 22

The process of claim 15 or claim 16 wherein the dissolved phosphorus vanadium zinc oxide catalyst is solidified by evaporation of the acidified alcohol.

Claim 23

The process of claim 15 or claim 16 wherein the inorganic acid is HCl.

Claim 24

The process of claim 15 or claim 16 wherein the alcohol is methanol.

Claim 25

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 wherein the catalyst in the initial solid phase has a characteristic initial powder X-ray diffraction pattern, using copper K-alpha radiation as follows: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 26

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 wherein the catalyst in the initial solid phase has a characteristic initial powder X-ray diffraction pattern, using copper K-alpha radiation as follows: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 27

The catalyst of claim 19 wherein about 0.001 to about 0.4 atoms of the metal are present for each atom of vanadium.

Claim 28

The catalyst of claim 19 wherein the atomic ratio of vanadium to phosphorus is about 0.5:1 to about 1.1:1.

Claim 29

The catalyst of claim 21 wherein the atomic ratio of vanadium to phosphorus is about 0.5:1 to about 1.1:1.

Claim 30

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium divalent metal mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 and the total atomic ratio of the metal to vanadium being in the range of about 0.001:1 to about 0.4:1 wherein the catalyst in the initial solid phase has a characteristic initial powder X-ray diffraction pattern using copper K-alpha radiation as follows: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 31

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium divalent metal mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 and the total atomic ratio of the metal to vanadium being in the range of about 0.001:1 to about 0.4:1 wherein the catalyst in the initial solid phase has a characteristic initial powder X-ray diffraction pattern using copper K-alpha radiation as follows: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 32

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium zinc mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 and the total atomic ratio of zinc to vanadium being in the range of about 0.001:1 to about 0.4:1, wherein the catalyst in the initial solid phase has a characteristic powder X-ray diffraction pattern using copper K-alpha radiation as following: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 33

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium zinc mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 and the total atomic ratio of zinc to vanadium being in the range of about 0.001:1 to about 0.4:1, wherein the catalyst in the initial solid phase has a characteristic powder X-ray diffraction pattern using copper K-alpha radiation as following: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 34

The catalyst of claim 26 wherein the atomic ratio of vanadium to phosphorus is about 0.5:1 to about 1.1:1.

Claim 35

The catalyst of claim 26 wherein about 0.001 to about 0.4 atoms of zinc are present for each atom of vanadium.

Claim 36

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium molybdenum mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 and the total atomic ratio of molybdenum to vanadium being in the range of about 0.001:1 to about 0.4:1, wherein the catalyst in the initial solid phase has a characteristic powder X-ray diffraction pattern using copper K-alpha radiation as follows: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 37

A catalyst for the production of maleic anhydride by the oxidation of butane which catalyst comprises a phosphorus vanadium molybdenum mixed oxide, the atomic ratio of vanadium to phosphorus being in the range of about 0.5:1 to about 1.1:1 and the total atomic ratio of molybdenum to vanadium being in the range of about 0.001:1 to about 0.4:1, wherein the catalyst in the initial solid phase has a characteristic powder X-ray diffraction pattern using copper K-alpha radiation as follows: ______________________________________ Line Position d angstrom 2.θ Intensity ______________________________________ 8.75 10.1 38 5.7 15.2 23 4.5 19.4 24 3.7 24.0 21 3.3 26.8 32 3.1 28.3 24 2.9 30.3 100 ______________________________________

Claim 38

The catalyst of claim 29 wherein the atomic ratio of vanadium to phosphorus is about 0.5:1 to about 1.1:1.

Claim 39

The catalyst of claim 29 wherein about 0.001 to about 0.4 atoms of molybdenum are present for each atom of vanadium.