US4562269A — Method of producing maleic anhydride

Claim 1

Independent Claim 44 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 hydrocarbon under reaction conditions, in contact with a catalyst comprising vanadium and phosphorus in combination with a microporous crystalline silica.

Claim 2

Independent Claim 44 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 hydrocarbon under reaction conditions, in contact with a catalyst comprising vanadium and phosphorus in combination with a microporous crystalline silica.

Claim 3

Dependent Claim 11 words

The method defined in claim 1, wherein the catalyst contains tin.

Claim 4

Dependent Claim 17 words

The method defined in claim 2, wherein the hydrocarbon is a C 4 to C 10 alkane.

Claim 5

Dependent Claim 37 words

The method defined in claim 3, wherein the C 4 to C 10 alkane is a member selected from the group consisting of butane, pentane, isopentane, cyclohexane, hexane, heptane, cycloheptane, octane, nonane and decane and mixtures thereof.

Claim 6

Dependent Claim 17 words

The method defined in claim 1, wherein the hydrocarbon is a C 4 to C 10 olefin.

Claim 7

Dependent Claim 40 words

The method defined in claim 5, wherein the C 4 to C 10 olefin is a member selected from the group consisting of butene, 1, 3, butadiene, pentene, cyclopentene, hexene, cyclohexene, heptene, cycloheptene, octene, nonene and decene and mixtures thereof.

Claim 8

Dependent Claim 25 words

The method defined in claim 1, wherein the gas is a member selected from the group consisting of air and mclecular oxygen and mixtures thereof.

Claim 9

Dependent Claim 31 words

The method defined in claim 1, wherein the feedstream comprises a gas containing molecular oxygen and from 0.1 to about 2.5 mole percent of a C 4 to C 10 hydrocarbon.

Claim 10

Dependent Claim 41 words

The method defined in claim 6, wherein the reaction conditions comprise a temperature from 500° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours.

Claim 11

Independent Claim 84 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 alkane in the vapor phase, under reaction conditions in contact with a catalyst having the following mole ratio: V.sub.a P.sub.b Sn.sub.c O.sub.d X wherein X is a microporous crystalline silica, a is 0.01 to 1, b is 1, c is 0.001 to 0.30 and d is a number which satisfies the valence requirements of the vanadium, phosphorus and tin present.

Claim 12

Independent Claim 84 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 alkane in the vapor phase, under reaction conditions in contact with a catalyst having the following mole ratio: V.sub.a P.sub.b Sn.sub.c O.sub.d X wherein X is a microporous crystalline silica, a is 0.01 to 1, b is 1, c is 0.001 to 0.30 and d is a number which satisfies the valence requirements of the vanadium, phosphorus and tin present.

Claim 13

Dependent Claim 34 words

The method defined in claim 10 wherein the C 4 to C 10 alkane is a member selected from the group consisting of butane, pentane, hexane, heptane, octane, nonane and decane and mixtures thereof.

Claim 14

Dependent Claim 24 words

The method defined in claim 10, wherein the gas is a member selected from the group consisting of air and oxygen and mixtures thereof.

Claim 15

Dependent Claim 30 words

The method defined in claim 10, wherein the feedstream comprises a gas containing molecular oxygen and from 0.1 to 2.5 mole percent of a C 4 to C 10 alkane.

Claim 16

Dependent Claim 41 words

The method defined in claim 10 wherein the reaction conditions comprise a temperature from 750° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours.

Claim 17

Independent Claim 84 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 olefin in the vapor phase, under reaction conditions in contact with a catalyst having the following mole ratio: V.sub.a P.sub.b Sn.sub.c O.sub.d X wherein X is a microporous crystalline silica, 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 vanadium, phosphorus and tin present.

Claim 18

Independent Claim 84 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 olefin in the vapor phase, under reaction conditions in contact with a catalyst having the following mole ratio: V.sub.a P.sub.b Sn.sub.c O.sub.d X wherein X is a microporous crystalline silica, 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 vanadium, phosphorus and tin present.

Claim 19

Dependent Claim 37 words

The method defined in claim 15, wherein the C 4 to C 10 olefin is a member selected from the group consisting of butene, 1, 3 butadiene, pentene, hexene, heptene, octene, nonene and decene and mixtures thereof.

Claim 20

Dependent Claim 24 words

The method defined in claim 15, wherein the gas is a member selected from the group consisting of air and oxygen and mixtures thereof.

Claim 21

Dependent Claim 30 words

The method defined in claim 15, wherein the feedstream comprises a gas containing molecular oxygen and from 0.1 to 2.5 mole percent of a C 4 to C 10 olefin.

Claim 22

Dependent Claim 42 words

The method defined in claim 15, wherein the reaction conditions comprise a temperature of from 500° F. to 900° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours.

Claim 23

Independent Claim 75 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 hydrocarbon in the vapor phase at a temperature of from 300° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus and tin in combination with silicalite.

Claim 24

Independent Claim 75 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 hydrocarbon in the vapor phase at a temperature of from 300° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus and tin in combination with silicalite.

Claim 25

Dependent Claim 17 words

The method defined in claim 20, wherein the hydrocarbon is a C 4 to C 10 alkane.

Claim 26

Dependent Claim 34 words

The method defined in claim 21, wherein the C 4 to C 10 alkane is a member selected from the group consisting of butane, pentane, hexane, heptane, octane, nonane and decane and mixtures thereof.

Claim 27

Dependent Claim 17 words

The method defined in claim 20, wherein the hydrocarbon is a C 4 to C 10 olefin.

Claim 28

Dependent Claim 38 words

The method defined in claim 23, wherein the C 4 to C 10 olefin is a member selected from the group consisting of butene, 1, 3 butadiene, pentene, hexene, heptene, octene, nonene or decene or a mixture thereof.

Claim 29

Dependent Claim 24 words

The method defined in claim 20, wherein the gas is a member selected from the group consisting of air and oxygen and mixtures thereof.

Claim 30

Dependent Claim 30 words

The method defined in claim 20 wherein the feedstream comprises a gas containing molecular oxygen and from 0.1 to 2.5 mole percent of a C 4 to C 10 hydrocarbon.

Claim 31

Independent Claim 75 words

A method for producing maleic anhydride, which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 alkane in the vapor phase at a temperature of from 750° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus and a crystalline silica molecular sieve.

Claim 32

Independent Claim 75 words

A method for producing maleic anhydride, which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 alkane in the vapor phase at a temperature of from 750° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus and a crystalline silica molecular sieve.

Claim 33

Dependent Claim 11 words

The method defined in claim 27 wherein the catalyst contains tin.

Claim 34

Dependent Claim 34 words

The method defined in claim 27 wherein the C 4 to C 10 alkane is a member selected from the group consisting of butane, pentane, hexane, heptane, octane, nonane and decane and mixtures thereof.

Claim 35

Dependent Claim 24 words

The method defined in claim 22 wherein the gas is a member selected from the group consisting of air and oxygen and mixtures thereof.

Claim 36

Dependent Claim 30 words

The method defined in claim 27 wherein the feedstream comprises a gas containing molecular oxygen and from 1.0 to 2.5 mole percent of a C 4 to C 10 alkane.

Claim 37

Independent Claim 75 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 olefin in the vapor phase, at a temperature of from 300° F. to 900° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours in contact with a catalyst comprising vanadium, phosphorus and a crystalline silica molecular sieve.

Claim 38

Independent Claim 75 words

A method for producing maleic anhydride which comprises reacting a feedstream comprising a gas containing molecular oxygen and a C 4 to C 10 olefin in the vapor phase, at a temperature of from 300° F. to 900° F., a pressure of from atmospheric pressure to 200 p.s.i.g., and a gas hourly space velocity of from 700 to 5,000 reciprocal hours in contact with a catalyst comprising vanadium, phosphorus and a crystalline silica molecular sieve.

Claim 39

Dependent Claim 11 words

The method defined in claim 32, wherein the catalyst contains tin.

Claim 40

Dependent Claim 37 words

The method defined in claim 32, wherein the C 4 to C 10 olefin is a member selected from the group consisting of butene, 1, 3 butadiene, pentene, hexene, heptene, octene, nonene and decene and mixtures thereof.

Claim 41

Dependent Claim 24 words

The method defined in claim 32, wherein the gas is a member selected from the group consisting of air and oxygen and mixtures thereof.

Claim 42

Dependent Claim 30 words

The method defined in claim 32, wherein the feedstream comprises a gas containing molecular oxygen and from 0.1 to 2.5 mole percent of a C 4 to C 10 olefin.

Claim 43

Independent Claim 69 words

A method for producing maleic anhydride, which comprises reacting a feedstream comprising air containing from 0.1 to 2.5 mole percent of butane in the vapor phase at a temperature of from 750° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g. and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus, tin and silicalite.

Claim 44

Independent Claim 69 words

A method for producing maleic anhydride, which comprises reacting a feedstream comprising air containing from 0.1 to 2.5 mole percent of butane in the vapor phase at a temperature of from 750° F. to 1,200° F., a pressure of from atmospheric pressure to 200 p.s.i.g. and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus, tin and silicalite.

Claim 45

Independent Claim 69 words

A method for producing maleic anhydride, which comprises reacting a feedstream comprising air containing from 0.1 to 2.5 mole percent of butene in the vapor phase at a temperature of from 300° F. to 900° F., a pressure of from atmospheric pressure to 200 p.s.i.g. and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus, tin and silicalite.

Claim 46

Independent Claim 69 words

A method for producing maleic anhydride, which comprises reacting a feedstream comprising air containing from 0.1 to 2.5 mole percent of butene in the vapor phase at a temperature of from 300° F. to 900° F., a pressure of from atmospheric pressure to 200 p.s.i.g. and a gas hourly space velocity of from 700 to 5,000 reciprocal hours, in contact with a catalyst comprising vanadium, phosphorus, tin and silicalite.

Claim 47

Dependent Claim 39 words

A process for oxidizing a hydrocarbon in the presence of an oxidation catalyst which comprises contacting a hydrocarbon in the gas phase with a catalyst comprising vanadium, phosphorus, and a microporous crystalline silica under oxidizing conditions producing maleic anhydride.

Claim 48

Dependent Claim 39 words

A process for oxidizing a hydrocarbon in the presence of an oxidation catalyst which comprises contacting a hydrocarbon in the gas phase with a catalyst comprising vanadium, phosphorus, and a microporous crystalline silica under oxidizing conditions producing maleic anhydride.

Claim 49

Dependent Claim 11 words

The process defined in claim 39 wherein the catalyst includes tin.

Claim 50

Dependent Claim 22 words

The process defined in claim 39 including contacting the hydrocarbon with the catalyst in the presence of a gas containing molecular oxygen.

Claim 51

Dependent Claim 38 words

A process for oxidizing a hydro-carbon with an oxidation catalyst which comprises contacting a C 4 to C 1O hydrocarbon with a catalyst comprising vanadium, phosphorus, tin and a microporous crystalline silica under oxidizing conditions producing maleic anhydride.

Claim 52

Dependent Claim 38 words

A process for oxidizing a hydro-carbon with an oxidation catalyst which comprises contacting a C 4 to C 1O hydrocarbon with a catalyst comprising vanadium, phosphorus, tin and a microporous crystalline silica under oxidizing conditions producing maleic anhydride.

Claim 53

Dependent Claim 22 words

The process defined in claim 42 including contacting the hydrocarbon with the catalyst in the presence of a gas containing molecular oxygen.

Claim 54

Dependent Claim 13 words

A method as defined in claim 1 wherein said crystalline silica comprises silicalite.

Claim 55

Dependent Claim 13 words

A method as defined in claim 5 wherein said crystalline silica comprises silicalite.

Claim 56

Dependent Claim 13 words

A process as defined in claim 39 wherein said crystalline silica comprises silicalite.

Claim 57

Dependent Claim 89 words

A method as defined in claim 1, 2, 10, 15, 20, 21, 23, 27, 28, 32, 33, 44, or 45 wherein said catalyst is prepared by a method comprising: (A) forming a catalyst precursor by reacting a vanadium compound and a phosphorus compound in an acidic aqueous solution with a divalent tin compound under reaction conditions which will provide vanadium having an average oxidation state of 3.50 to 4.90; (B) combining the catalyst precursor with a microporous crystalline silica; and (C) calcining the resultant material at an elevated temperature.

Claim 58

Dependent Claim 82 words

A process as defined in claim 39, 40, 41, 42, 43, or 46 wherein said catalyst is prepared by a method comprising: (A) forming a catalyst precursor by reacting a vanadium compound and a phosphorous compound in an acidic aqueous solution with a divalent tin compound under reaction conditions which will provide vanadium having an average oxidation state of 3.50 to 4.90; (B) combining the catalyst precursor with a microporous crystalline silica; and (C) calcining the resultant material at an elevated temperature.

Claim 59

Dependent Claim 34 words

A method as defined in claim 1, 2, 5, 15, 27, 32, 33, 38, 44, or 45 wherein said catalyst contains vanadium in an average valence state in the range of 3.5 to 4.9.

Claim 60

Dependent Claim 36 words

A method as defined in claim 49 wherein said catalyst has surface area from 100 to 450 M 2/ gm, and said vanadium is in an average valence state in the range of 4.1 to 4.7.

Claim 61

Dependent Claim 28 words

A process as defined in claim 39, 42, 43, or 46 wherein said catalyst contains vanadium in an average valence state in the range of 3.5 to 4.9.

Claim 62

Dependent Claim 36 words

A process as defined in claim 51 wherein said catalyst has surface area from 100 to 450 M 2/ gm, and said vanadium is in an average valence state in the range of 4.1 to 4.7.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-12-30	1989-07-01	1989-12-31	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-12-30	1993-07-01	1993-12-31	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-12-30	1997-07-01	1997-12-31	$7700.00	Window Closed / Lapsed

Method of producing maleic anhydride

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