Method for producing catalyst and method for producing acrylic acid

Abstract

To provide a production method of a catalyst with which both of high raw material conversion and high product selectivity are achieved and which brings about an excellent yield of an unsaturated carboxylic acid when used as a catalyst for a vapor phase catalytic oxidation reaction to produce the unsaturated carboxylic acid such as acrylic acid, methacrylic acid or the like from an unsaturated aldehyde such as acrolein, methacrolein or the like.SOLUTION: A production method of a catalyst is a production method of a catalyst for synthesizing an unsaturated carboxylic acid comprising a molding step of molding powder including respective elements constituting the catalyst to obtain a catalyst precursor. In the molding step, the powder is molded with addition of a sulfur-containing inorganic compound.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a method for producing a catalyst used in producing an unsaturated carboxylic acid, such as acrylic acid or methacrylic acid, by vapor-phase catalytic oxidation of an unsaturated aldehyde, such as acrolein or methacrolein. The present invention also relates to a process for producing acrylic acid using the catalyst. [Background technology]

[0002] It is well known that catalysts containing molybdenum and vanadium are useful as catalysts used in the production of unsaturated carboxylic acids such as acrylic acid and methacrylic acid by gas-phase catalytic oxidation of unsaturated aldehydes such as acrolein and methacrolein, and these catalysts are widely used industrially.

[0003] As a prior art document relating to a method for producing a catalyst containing molybdenum and vanadium for synthesizing an unsaturated carboxylic acid, Patent Document 1 and the like are known. Patent Document 1 describes a method in which a liquid binder component and a catalytically active component containing molybdenum and vanadium and / or a precursor thereof are supplied to a tumbling granulator and granulated at a specific relative centrifugal acceleration to form a supported catalyst. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2015-96497 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, the catalysts for synthesizing unsaturated carboxylic acids obtained by the previously known methods do not satisfy the problems of both excellent raw material conversion and excellent product selectivity. As a result, even when unsaturated carboxylic acids are produced using the catalysts, the yield of unsaturated carboxylic acids is not satisfactory.

[0006] Therefore, an object of the present invention is to provide a catalyst which is used in a gas-phase catalytic oxidation reaction for producing an unsaturated carboxylic acid, such as acrylic acid or methacrylic acid, from an unsaturated aldehyde, such as acrolein or methacrolein, and which has high raw material conversion and product selectivity and is excellent in unsaturated carboxylic acid yield. [Means for solving the problem]

[0007] As a result of investigations, the present inventors have found that the above problems can be solved by using a specific molding aid, and have completed the present invention. That is, the present invention relates to the following.

[0008] [1] A method for producing a catalyst for synthesizing an unsaturated carboxylic acid, comprising a molding step of molding a powder containing each catalyst component element into a catalyst precursor, In the molding step, a sulfur-containing inorganic compound is added to the powder to mold it.

[0009] [2] The method for producing a catalyst according to [1], wherein the sulfur-containing inorganic compound does not contain the catalytic component element.

[0010] [3] The method for producing a catalyst according to [1] or [2], wherein the sulfur-containing inorganic compound is a sulfate.

[0011] [4] The method for producing a catalyst according to [3], wherein the sulfate is ammonium sulfate.

[0012] [5] The method for producing a catalyst according to any one of [1] to [4], wherein the amount of the sulfur-containing inorganic compound added is 1.0 part by weight or more and 15 parts by weight or less per 100 parts by weight of the powder.

[0013] [6] The method for producing a catalyst according to any one of [1] to [5], further comprising adding an organic compound to the molding step.

[0014] [7] The method for producing a catalyst according to [6], wherein the organic compound is glycerin.

[0015] [8] The method for producing a catalyst according to [6] or [7], wherein the amount of the organic compound added is 0.3 parts by weight or more and 15 parts by weight or less per 100 parts by weight of the powder.

[0016] [9] The method for producing a catalyst according to any one of [1] to [8], wherein the catalytic component elements contain molybdenum and vanadium.

[0017]

[10] The method for producing a catalyst according to any one of [1] to [9], wherein the molding step is a step of supporting the powder on a surface of a carrier and granulating the powder to obtain a catalyst precursor.

[0018]

[11] A method for producing acrylic acid, comprising the steps of: catalytically oxidizing acrolein with an oxygen-containing gas in the presence of a catalyst produced by the method for producing a catalyst according to any one of [1] to

[10] . Effect of the Invention

[0019] According to the present invention, it is possible to provide a catalyst which is used in a gas-phase catalytic oxidation reaction for synthesizing an unsaturated carboxylic acid, such as acrylic acid or methacrylic acid, from an unsaturated aldehyde, such as acrolein or methacrolein, and which has high raw material conversion and product selectivity and is excellent in unsaturated carboxylic acid yield. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Hereinafter, an embodiment of the method for producing a catalyst for synthesizing an unsaturated carboxylic acid of the present invention (hereinafter sometimes referred to as "the catalyst of the present invention") will be described in detail.

[0021] The catalyst of the present invention is a catalyst for synthesizing unsaturated carboxylic acids, such as acrylic acid and methacrylic acid, by gas-phase catalytic oxidation of unsaturated aldehydes, such as acrolein and methacrolein, as raw materials, with an oxygen-containing gas.

[0022] [Catalyst manufacturing method] The method for producing the catalyst of the present invention includes a molding step of molding a powder (hereinafter sometimes referred to as a "raw material powder") containing the constituent elements (hereinafter sometimes referred to as "catalyst component elements") that constitute the catalyst to form a catalyst precursor, and is characterized in that a specific molding aid is added in the molding step.

[0023] The raw material powder can be obtained, for example, through the following steps. A compound having a catalyst component element is used as a catalyst supply source compound (hereinafter referred to as "supply source compound"), and each supply source compound having the catalyst component element is added to a solvent or solution, integrated, and heated to obtain a preparation liquid (liquid preparation step), and then the preparation liquid is dried to obtain a raw material powder (drying step). The raw material powder is molded to obtain a catalyst precursor, which is then calcined (calcination step) to obtain the catalyst of the present invention.

[0024] [Liquid preparation process] The liquid preparation step is a step in which each source compound is combined, preferably in an aqueous system, and heated to obtain a prepared liquid.

[0025] "Aqueous integration" refers to integration by adding each supply source compound to an aqueous solvent or solution. The aqueous solvent is an aqueous medium for dissolving or suspending each supply source compound, and refers to water, or an organic solvent compatible with water such as methanol or ethanol, or a mixture thereof. The aqueous solution refers to a liquid in which one or more supply source compounds are dissolved, suspended, or integrated in an aqueous solvent.

[0026] The above-mentioned integration means mixing the aqueous solutions or dispersions of the respective supply source compounds all at once or stepwise, and heating as necessary.Specific examples of the integration include a method of mixing the respective supply source compounds all at once, a method of mixing the respective supply source compounds all at once and then heating, a method of mixing the respective supply source compounds stepwise, a method of repeatedly mixing and heating the respective supply source compounds stepwise, and a combination of these methods, all of which are included in the concept of integration of the respective supply source compounds.

[0027] The heating means stirring the mixed liquid or mixed dispersion obtained by the integration at a predetermined temperature for a predetermined time. This heating increases the viscosity of the mixed liquid or mixed dispersion, which in the case of a mixed dispersion, reduces the settling of solid components therein, and is particularly effective in suppressing the components from becoming non-uniform in the subsequent drying step, thereby improving the catalytic activity, such as the raw material conversion rate and product selectivity, of the catalyst, which is the final product obtained.

[0028] The heating temperature is preferably 60°C to 100°C, more preferably 60°C to 90°C, and even more preferably 70°C to 85°C. If the heating temperature is 60°C or higher, the effect of the heat treatment is sufficient, and good catalytic activity tends to be obtained. If the heating temperature is 100°C or lower, a pressure-resistant container is not required for the dissolution tank, and handling is also easy, which is preferable in terms of economy and operability. If the heating temperature is 90°C or lower, evaporation of water during the heat treatment is suppressed, and industrial implementation tends to be advantageous.

[0029] The heating time is preferably 2 to 12 hours, more preferably 3 to 8 hours. If the heating time is 2 hours or more, the activity and selectivity of the catalyst tend to be sufficiently expressed. If the heating time is too long, almost no improvement in the heating effect is obtained, so it is preferably 12 hours or less.

[0030] As the stirring method, any method can be adopted, for example, a method using a stirrer having stirring blades, a method using external circulation with a pump, etc.

[0031] [Source compound] The catalyst of the present invention preferably contains molybdenum (Mo) and vanadium (V) as catalytic component elements, and more preferably contains copper (Cu) as another catalytic component element. The catalyst of the present invention may further contain one or more of the following components: antimony (Sb), silicon (Si), carbon (C), niobium (Nb), tungsten (W), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), zinc (Zn), iron (Fe), cobalt (Co), nickel (Ni), bismuth (Bi), etc. Examples of the supply source compound of molybdenum (Mo) include ammonium paramolybdate, molybdenum trioxide, molybdic acid, ammonium phosphomolybdate, phosphomolybdic acid, etc. These may be used alone or in combination of two or more.

[0032] Examples of vanadium (V) supply source compounds include ammonium vanadate, ammonium metavanadate, vanadium pentoxide, vanadium oxalate, vanadium sulfate, etc. These may be used alone or in combination of two or more. The amount of vanadium added is preferably such that, as the atomic ratio of the catalyst component elements, when molybdenum atoms are taken as 12, it is more preferably from 0 to 12, more preferably from 0.1 to 6, even more preferably from 0.5 to 5, and particularly preferably from 1 to 3. By keeping the amount within this range, it is possible to obtain a catalyst that is excellent in raw material conversion and capable of producing an unsaturated carboxylic acid with high selectivity.

[0033] The supply source compound of niobium (Nb) includes niobium hydroxide, etc. These may be used alone or in combination of two or more. Examples of the tungsten (W) supply source compound include tungstic acid or a salt thereof, etc. These may be used alone or in combination of two or more. When at least one element selected from niobium and tungsten is used, the amount added is preferably such that the atomic ratio of the total catalyst component elements, when the molybdenum atoms are taken as 12, is 0 to 12, more preferably 0.1 to 6, and even more preferably 0.5 to 4. Within these ranges, a catalyst that is excellent in raw material conversion and capable of producing an unsaturated carboxylic acid with high selectivity can be obtained.

[0034] Examples of copper (Cu) source compounds include copper sulfate, copper nitrate, cuprous chloride, etc. These may be used alone or in combination of two or more. The amount of copper added is preferably added so that, as the atomic ratio of the catalyst component elements, when the molybdenum atoms are taken as 12, the amount is more preferably from 0 to 12, more preferably from 0.1 to 6, and even more preferably from 0.5 to 4. By being within this range, it is possible to obtain a catalyst that is excellent in raw material conversion and capable of producing an unsaturated carboxylic acid with high selectivity.

[0035] Examples of magnesium (Mg) source compounds include magnesium oxide, magnesium carbonate, magnesium sulfate, etc. These may be used alone or in combination of two or more. Examples of calcium (Ca) source compounds include calcium oxide, calcium carbonate, calcium hydroxide, etc. These may be used alone or in combination of two or more. These may be used alone or in combination of two or more. Examples of the source compound of strontium (Sr) include strontium oxide, strontium carbonate, strontium hydroxide, strontium nitrate, etc. These may be used alone or in combination of two or more. Examples of the supply source compound of barium (Ba) include barium oxide, barium carbonate, barium nitrate, barium acetate, barium sulfate, etc. These may be used alone or in combination of two or more. Examples of zinc (Zn) supply source compounds include zinc oxide, zinc carbonate, zinc hydroxide, zinc nitrate, etc. These may be used alone or in combination of two or more. When at least one element selected from the group consisting of magnesium, calcium, strontium, barium and zinc is used, the amount added is preferably such that the atomic ratio of the total catalyst component elements, when the molybdenum atoms are taken as 12, is 0 to 8, more preferably 0 to 6, and even more preferably 0 to 4. When the amount is within this range, a catalyst that is excellent in raw material conversion and can produce an unsaturated carboxylic acid with high selectivity can be obtained.

[0036] Examples of the antimony (Sb) supply source compound include trivalent antimony compounds such as antimony oxides (e.g., antimony trioxide, antimony pentoxide, etc.), antimony acetate, etc., and pentavalent antimony compounds. These may be used alone or in combination of two or more. When antimony is used, the amount of antimony added is preferably 0 to 500, more preferably 0.1 to 100, and even more preferably 0.2 to 50, in terms of the atomic ratio of the catalyst component elements, where molybdenum atoms are taken as 12. Within these ranges, a catalyst can be obtained that is excellent in raw material conversion and capable of producing an unsaturated carboxylic acid with high selectivity.

[0037] Examples of the iron (Fe) supply source compound include ferric nitrate, ferric sulfate, ferric chloride, ferric acetate, etc. These may be used alone or in combination of two or more. Examples of the cobalt (Co) supply source compound include cobalt nitrate, cobalt sulfate, cobalt chloride, cobalt carbonate, cobalt acetate, etc. These may be used alone or in combination of two or more. Examples of nickel (Ni) supply source compounds include nickel nitrate, nickel sulfate, nickel chloride, nickel carbonate, nickel acetate, etc. These may be used alone or in combination of two or more. Examples of the supply source compound of bismuth (Bi) include bismuth chloride, bismuth nitrate, bismuth oxide, bismuth subcarbonate, etc. These may be used alone or in combination of two or more. When at least one element selected from the group consisting of iron, cobalt, nickel and bismuth is used, the amount added is preferably such that the atomic ratio of the total catalyst component elements, when the molybdenum atoms are taken as 12, is 0 to 500, more preferably 0 to 400, and even more preferably 0 to 300. Within this range, a catalyst that is excellent in raw material conversion and capable of producing an unsaturated carboxylic acid with high selectivity can be obtained.

[0038] Examples of silicon (Si) source compounds include silica, granular silica, colloidal silica, and fumed silica. These may be used alone or in combination of two or more. Examples of silicon (Si) and carbon (C) source compounds include green silicon carbide and black silicon carbide. These may be used alone or in combination of two or more. When silicon is used, the amount of silicon added is preferably 0 to 500, more preferably 0 to 400, and even more preferably 0 to 300, in terms of the atomic ratio of the catalyst component elements, when the molybdenum atom is taken as 12. When the amount is within this range, a catalyst that is excellent in raw material conversion and can produce an unsaturated carboxylic acid with high selectivity can be obtained. When carbon is used, the amount of carbon added is preferably 0 to 500, more preferably 0 to 400, and even more preferably 0 to 300, in terms of the atomic ratio of the catalyst component elements, where molybdenum atoms are taken as 12. When the amount of carbon added is within this range, a catalyst can be obtained that is excellent in raw material conversion and capable of producing an unsaturated carboxylic acid with high selectivity.

[0039] [Method of adding source compound] In the above-mentioned solution preparation step, all of the source compounds may be prepared as one preparation solution, or each source compound may be prepared individually or in several groups as multiple preparation solutions, and the multiple preparation solutions may be mixed together or in sequence to prepare one preparation solution, or one or more preparation solutions may be dried and further calcined to form a solid, and the solid may be added to a preparation solution of the remaining source compounds to prepare a new preparation solution.

[0040] [Drying process] The resulting preparation liquid is dried in a drying step to obtain a raw material powder. The drying method in this drying step is not particularly limited, and examples thereof include methods using a conventional spray dryer, slurry dryer, drum dryer, etc.

[0041] The raw powder obtained by the drying treatment may be further subjected to a heat treatment, if necessary. This heat treatment is a treatment carried out in air for a short period of time at a temperature range of 200°C to 400°C, preferably 250°C to 350°C. There are no particular limitations on the method, and for example, the powder may be heated in a fixed state using a normal box-type heating furnace, a tunnel-type heating furnace, or the like, or the powder may be heated while being fluidized using a rotary kiln, or the like.

[0042] In addition, a powder obtained by further processing such as pulverization of a dried product obtained by the drying process is also included in the raw material powder of the present invention.

[0043] The raw material powder obtained by this drying process preferably contains molybdenum and vanadium, more preferably contains copper in addition, and among them, it is preferably a raw material powder having a composition represented by the following general formula (1).

[0044] Mo 12 V a X b Cu c Y d Sb e Z f Si g C h O i (1)

[0045] (In formula (1), X represents Nb and / or W, Y represents at least one element selected from the group consisting of Mg, Ca, Sr, Ba, and Zn, and Z represents at least one element selected from the group consisting of Fe, Co, Ni, and Bi. a to i represent the atomic ratios of the respective elements, and are in the ranges of 0 < a ≤ 12, 0 ≤ b ≤ 12, 0 < c ≤ 12, 0 ≤ d ≤ 8, 0 ≤ e ≤ 500, 0 ≤ f ≤ 500, 0 ≤ g ≤ 500, 0 ≤ h ≤ 500, and i is a value that satisfies the oxidation state of other elements.)

[0046] [Forming aid] In the method for producing the catalyst of the present invention, in the forming step described later, a sulfur-containing inorganic compound is added as a specific forming aid to the raw material powder and formed, which is a feature.

[0047] The sulfur-containing inorganic compound used in the present invention may be any inorganic compound containing sulfur and is not particularly limited, but it is preferably one that does not contain catalyst component elements because it is easy to control the composition of the catalyst to a suitable composition for the purpose.

[0048] As the sulfur-containing inorganic compound, from the viewpoint of obtaining a catalyst having a high raw material conversion rate and a good product selectivity, preferably, at least one compound selected from the group consisting of sulfates, sulfites, thiosulfates, and sulfamic acid is used. Among them, sulfates are preferred. As the sulfur-containing inorganic compound, from the viewpoint of obtaining a catalyst having a high raw material conversion rate and a good product selectivity, preferably, at least one compound selected from the group consisting of sodium-containing compounds, potassium-containing compounds, and ammonium-containing compounds is used. Among them, ammonium-containing compounds are preferred. Examples of the sulfate include sodium sulfate, potassium sulfate, and ammonium sulfate, and among these, ammonium sulfate is preferred. Examples of sulfites include sodium sulfite, potassium sulfite, and ammonium sulfite, and among these, ammonium sulfite is preferred. Examples of thiosulfates include sodium thiosulfate, potassium thiosulfate, and ammonium thiosulfate, and among these, ammonium thiosulfate is preferred. Examples of sulfamic acid include sodium sulfamate, potassium sulfamate, and ammonium sulfamate, and among these, ammonium sulfamate is preferred. These may be used alone or in combination of two or more.

[0049] Among these, from the viewpoint of obtaining a catalyst having a high raw material conversion rate and a good product selectivity, it is particularly preferable to use sulfates, and ammonium sulfate is preferable because it is easily decomposed during calcination.

[0050] The amount of sulfur-containing inorganic compound added is preferably 1.0 parts by weight or more and 15 parts by weight or less relative to 100 parts by weight of raw material powder. The lower limit of this amount is more preferably 2 parts by weight, even more preferably 3 parts by weight, and particularly preferably 4 parts by weight. The upper limit of the amount of sulfur-containing inorganic compound added is more preferably 14 parts by weight, even more preferably 13 parts by weight, and particularly preferably 12 parts by weight. By keeping the amount of sulfur-containing inorganic compound added within the above range, it is possible to reliably obtain a catalyst with high raw material conversion and good product selectivity.

[0051] The sulfur-containing inorganic compound is preferably added to the raw powder in the form of an aqueous solution, and in this case, the sulfur-containing inorganic compound concentration of the aqueous sulfur-containing inorganic compound solution is preferably 5% by weight or more and 40% by weight or less. The lower limit of the sulfur-containing inorganic compound concentration is more preferably 10% by weight, and the upper limit is more preferably 35% by weight. By having the sulfur-containing inorganic compound concentration in the above range, it becomes easy to uniformly add and disperse the sulfur-containing inorganic compound to the raw powder.

[0052] In the present invention, in the molding step, it is preferable to further add an organic compound as a molding aid to the raw material powder and then mold it, from the viewpoints of improving the strength of the resulting catalyst and obtaining a catalyst having a high raw material conversion rate and a good product selectivity.

[0053] Examples of organic compounds include ethylene glycol, glycerin, propionic acid, maleic acid, benzyl alcohol, propyl alcohol, butyl alcohol, cellulose, methyl cellulose, starch, polyvinyl alcohol, stearic acid, and phenol. These may be used alone or in combination of two or more. Among these organic compounds, glycerin is preferred because it can provide a catalyst with superior raw material conversion and product selectivity by adding it to the raw material powder together with the sulfur-containing inorganic compound.

[0054] When an organic compound is used, the amount of the organic compound added is preferably 0.3 parts by weight or more and 15 parts by weight or less relative to 100 parts by weight of the raw material powder. The lower limit of the amount of the organic compound added is more preferably 0.4 parts by weight, even more preferably 0.5 parts by weight, and particularly preferably 0.6 parts by weight, and the upper limit is more preferably 13 parts by weight, even more preferably 11 parts by weight, and particularly preferably 9 parts by weight. By keeping the amount of the organic compound added within the above range, it is possible to obtain a catalyst with a high raw material conversion rate and a good product selectivity.

[0055] The organic compound to be added is preferably in the form of an aqueous solution, and in this case, the organic compound concentration is preferably 2% by weight or more and 40% by weight or less. The lower limit of the organic compound concentration is more preferably 3% by weight, and the upper limit is more preferably 30% by weight. By having the organic compound concentration in the above range, the organic compound can be uniformly added and dispersed in the raw material powder.

[0056] In the catalyst manufacturing method of the present invention, in the molding step of the raw material powder, molding aids other than the above-mentioned sulfur-containing inorganic compounds and organic compounds may be added. Examples of molding aids other than the sulfur-containing inorganic compounds and organic compounds include silica, alumina, glass flakes (flake glass), glass fiber, silicon carbide, silicon nitride, graphite, etc. These other molding aids may be used alone or in combination of two or more. The strength of the obtained catalyst can be improved by adding these other molding aids. When these other molding aids are used, the amount of the additive is preferably 20 parts by weight or less, for example, 0.5 parts by weight or more and 20 parts by weight or less, relative to 100 parts by weight of the raw material powder.

[0057] [Molding process] The molding step is a step in which the above-mentioned molding aid is added to the raw material powder obtained in the above-mentioned drying step and molded to obtain a catalyst precursor.

[0058] The raw material powder may be molded by any conventional method. For example, the following two methods (1) and (2) can be mentioned. (1) A method in which a carrier that is inactive in an unsaturated carboxylic acid synthesis reaction is fluidized while the raw material powder is supplied to the fluidized carrier, the raw material powder is supported on the surface of the carrier, and the carrier is granulated to form a catalyst precursor (hereinafter sometimes referred to as the "tumbling granulation method"). (2) A method in which the raw material powder is placed in a mold and mechanically pressed to form a granule-molded catalyst precursor (hereinafter sometimes referred to as the "tabletting method"). Among these, the tumbling granulation method is preferred because it is easy to obtain a catalyst that is excellent in the yield of unsaturated carboxylic acid.

[0059] Examples of carriers used in the rolling granulation method include spherical or nearly spherical carriers made of silica, silicon carbide, alumina, mullite, alundum, etc., and having a diameter or major axis diameter of preferably 2.5 mm to 10 mm, more preferably 2.5 mm to 6 mm. These may be used alone or in combination of two or more kinds. The porosity of the support is preferably 20% to 60%, more preferably 30% to 57%, and further preferably 40% to 55%. The water absorption rate of the carrier is preferably 10% to 60%, more preferably 12% to 50%, and further preferably 15% to 40%. By setting the porosity and water absorption rate of the support within the above ranges, the raw material powder can be easily supported on the support.

[0060] The loading rate on the carrier (the ratio of the total weight of the supported raw material powder and molding aid to the weight of the carrier) is preferably 10% by weight or more and 90% by weight or less, and more preferably 20% by weight or more and 70% by weight or less.

[0061] The rolling granulation method is a method in which, for example, a fixed container has a flat or uneven disk at the bottom of the container, and the disk is rotated at high speed in a granulator, vigorously stirring the carrier inside the container through repeated rotation and revolution, and then raw material powder and molding aid are added to the container, causing the raw material powder and molding aid to be supported on the carrier. Examples of the method for adding a molding aid in the rolling granulation method include the following methods (1-1) to (1-5), etc. These methods may be used in combination of two or more kinds. (1-1) A method in which a raw material powder and a molding aid are mixed to prepare a homogeneous mixture, and the homogeneous mixture is then charged into a granulator and stirred. (1-2) A method in which the raw material powder and molding aid are simultaneously put into a granulator and stirred (1-3) A method in which the raw material powder is stirred in a granulator, a molding aid is added to the granulator, and further stirred. (1-4) A method in which a molding aid is added to the raw material powder to prepare a heterogeneous mixture, and the heterogeneous mixture is then put into a granulator and stirred. (1-5) A method in which the raw material powder and molding aid are separately mixed and then fed into the granulator simultaneously, alternately, or in random order while stirring.

[0062] Of the above-mentioned addition methods, in the method (1-5), it is preferable to suppress adhesion of the raw material powder and the like to the wall of the stirring vessel and aggregation of the raw material powder particles, and to adjust the addition rate using an autofeeder or the like so that a predetermined amount of the raw material powder particles is supported on the carrier.

[0063] In the catalyst manufacturing method of the present invention, at least a sulfur-containing inorganic compound is added and the raw material powder is molded by such a molding step. When the rolling granulation method is selected as the molding method, the above-mentioned methods (1-1) to (1-5) can be appropriately combined to "add a sulfur-containing inorganic compound and mold", but the method (1-5) is preferred because the shape of the catalyst is easily uniform. When tableting is selected, the method of "adding a sulfur-containing inorganic compound and molding" preferably involves adding the sulfur-containing inorganic compound to the raw material powder in advance to prepare a mixture, and then tableting the mixture.

[0064] [Firing process] In the method for producing a catalyst of the present invention, the catalyst precursor obtained in the above molding step is calcined at a temperature of preferably 300° C. to 500° C., more preferably 350° C. to 450° C., for about 1 hour to 16 hours. As the calcination method, the method used in the above-mentioned heat treatment can be adopted. The calcination atmosphere in this calcination step is preferably an atmosphere with an oxygen concentration of 10% by volume or less, from the viewpoint of improving the performance of the obtained catalyst.

[0065] In this manner, a catalyst which is highly active and has an excellent yield of the desired unsaturated carboxylic acid can be obtained.

[0066] The obtained catalyst preferably contains molybdenum and vanadium as catalytic component elements, and more preferably contains copper in addition to them, and particularly preferably has a composition represented by the above general formula (1).

[0067] The catalyst component elements are those contained in the powder, excluding the carrier and molding aid contained in the catalyst precursor or catalyst obtained by the production method of the present invention.

[0068] [Application] By using the catalyst produced by the production method of the present invention as a catalyst for synthesizing an unsaturated carboxylic acid, the catalytic performance such as the raw material conversion rate and the product selectivity can be further improved, and the corresponding unsaturated carboxylic acid such as acrylic acid or methacrylic acid can be produced in high yield by gas-phase catalytic oxidation of an unsaturated aldehyde such as acrolein or methacrolein with an oxygen-containing gas.

[0069] [Method of producing acrylic acid] The process for producing acrylic acid of the present invention is a process for producing acrylic acid by gas-phase catalytic oxidation of acrolein with an oxygen-containing gas in the presence of the catalyst of the present invention.

[0070] In this case, the type of reactor is not particularly limited, and for example, a fixed bed reactor or a fluidized bed reactor can be used, with a fixed bed reactor being preferred, and a fixed bed multi-tubular reactor being more preferred. The gas phase catalytic oxidation is carried out by contacting a mixed gas containing acrolein and molecular oxygen (hereinafter sometimes referred to as a "raw material gas") with a catalyst in a reactor.

[0071] When acrylic acid is produced by the gas-phase catalytic oxidation of acrolein using the catalyst of the present invention, the concentration of acrolein in the raw material gas can be changed in a wide range, but is preferably 1% by volume to 20% by volume, more preferably 3% by volume to 10% by volume. The raw material acrolein may contain small amounts of impurities such as water and lower saturated aldehydes that do not substantially affect the reaction.

[0072] The amount of molecular oxygen in the raw material gas is preferably 0.4 to 4 times by mol, more preferably 0.5 to 3 times by mol, that of acrolein. It is industrially advantageous to use air as the molecular oxygen source of the raw material gas, but air enriched with pure oxygen can also be used as necessary. It is also preferable that the raw material gas is diluted with an inert gas such as nitrogen or carbon dioxide gas, or with water vapor.

[0073] The reaction pressure in the gas-phase catalytic oxidation reaction is preferably from atmospheric pressure to several atmospheres. The reaction is preferably carried out in a fixed bed. The reaction temperature is preferably from 200° C. to 450° C., more preferably from 250° C. to 400° C. The contact time between the raw material gas and the catalyst is preferably from 1.5 seconds to 15 seconds, more preferably from 2 seconds to 7 seconds. EXAMPLES

[0074] The present invention will be described in more detail below with reference to examples. However, the present invention is not limited to the following examples in any way as long as the gist of the present invention is not exceeded.

[0075] [Examples 1 to 5, Comparative Examples 1 and 2] <Preparation of catalyst> 76 g of ammonium metavanadate was added to 2281 mL of warm water and dissolved therein. Then, 568 g of ammonium molybdate was further added and dissolved therein to obtain a solution (hereinafter referred to as "Solution A"). Solution B, prepared by dissolving 80 g of copper sulfate in 115 mL of warm water, was added to solution A and mixed uniformly. 52 g of niobium hydroxide and 16 g of antimony trioxide were then added and mixed to obtain a starting material mixture.

[0076] The starting material mixture was spray-dried at 150° C., and the spray-dried product was then heat-treated in air at a heating temperature of 300° C. for 1 hour to obtain a dried product. The dried product was pulverized using a mixing blade type pulverizer to a particle size of 200 μm or less to obtain a pulverized product. This pulverized material is the raw material powder to be molded.

[0077] To 100 parts by weight of the raw material powder, 1.5 parts by weight of glass flakes were added and mixed uniformly to obtain a mixture. 100 g of a spherical inert carrier having a diameter of 4.9 mm and mainly composed of alumina-silica was placed in a pan-type granulator, and the mixture and the molding aid shown in Table 1 were added alternately to the inert carrier in the amounts shown in Table 1 to support the carrier at a support rate of 40% by weight, thereby obtaining a catalyst precursor in the form of a granulated molded body. The catalyst precursor was calcined at 390° C. for 3 hours in an atmosphere of 2% by volume of oxygen obtained by diluting air with nitrogen to obtain a catalyst. The composition ratio of the catalyst was as follows: Mo 12 V 2.4 Cu 1.2 Nb 1 Sb 0.4

[0078] <Gas-phase catalytic oxidation of acrolein> Using the catalysts obtained in each of the Examples and Comparative Examples, a gas-phase catalytic oxidation reaction of acrolein was carried out under the conditions described below, and the acrolein conversion, acrylic acid selectivity and acrylic acid yield were investigated. The results are shown in Table 1. A jacketed reaction tube (inner diameter 21 mm) containing niter as a heat medium was filled with 33 mL of the catalyst, the reaction tube was heated, and raw material gas (acrolein 6 vol%, oxygen 8 vol%, steam 22 vol%, nitrogen 64 vol%) was introduced to carry out a gas-phase catalytic oxidation reaction of acrolein at SV (space velocity; flow rate of raw material gas per unit time / apparent volume of filled catalyst) of 1550 / hr. The heat medium temperature was 250°C.

[0079] The acrolein conversion, the selectivity to acrylic acid, and the yield of acrylic acid are defined as shown in the following formulas (1) to (3). (1) Acrolein conversion rate (mol%) = 100 × (moles of acrolein reacted) / (moles of acrolein supplied) (2) Acrylic acid selectivity (mol%)=100×(moles of acrylic acid produced) / (moles of acrolein converted) (3) Acrylic acid yield (mol%)=100×(moles of acrylic acid produced) / (moles of acrolein supplied)

[0080] [Table 1]

[0081] From the above, it is clear that according to the present invention, by molding a raw material powder using a sulfur-containing inorganic compound, a catalyst can be produced which has high raw material conversion and product selectivity and provides an excellent acrylic acid yield.

Claims

1. A method for producing a catalyst for synthesizing acrylic acid, comprising a molding step of molding a powder containing each catalyst component element into a catalyst precursor, The powder has a composition represented by the following general formula (1): In the molding step, a sulfur-containing inorganic compound is added to the powder to mold it. *] １２ . ａ ︸ ｂ u ｃ ﹹ ｄ 3) ｅ : ｆ 3) ｇ 4 ｈ . ｉ () (In formula (1), X represents Nb, Y represents at least one element selected from the group consisting of Mg, Ca, Sr, Ba, and Zn, and Z represents at least one element selected from the group consisting of Fe, Co, Ni, and Bi. a to i represent atomic ratios of each element and are in the ranges of 0<a≦3, 0.1≦b≦4, 0<c≦4, 0≦d≦4, 0.1≦e≦50, 0≦f≦300, 0≦g≦300, and 0≦h≦300, and i is a value that satisfies the oxidation state of other elements.)

2. 2. The method for producing a catalyst according to claim 1, wherein the sulfur-containing inorganic compound does not contain the catalyst component element.

3. 3. The method for producing a catalyst according to claim 1, wherein the sulfur-containing inorganic compound is a sulfate.

4. 4. The method for producing a catalyst according to claim 3, wherein the sulfate is ammonium sulfate.

5. 5. The method for producing a catalyst according to claim 1, wherein the amount of the sulfur-containing inorganic compound added is 1.0 part by weight or more and 15 parts by weight or less based on 100 parts by weight of the powder.

6. The method for producing a catalyst according to claim 1 , wherein in the molding step, an organic compound is further added and then molded.

7. The method for producing a catalyst according to claim 6, wherein the organic compound is glycerin.

8. 8. The method for producing a catalyst according to claim 6, wherein the amount of the organic compound added is 0.3 parts by weight or more and 15 parts by weight or less based on 100 parts by weight of the powder.

9. The method for producing a catalyst according to any one of claims 1 to 8, wherein the molding step comprises supporting the powder on a surface of a carrier and granulating the powder to obtain a catalyst precursor.

10. A method for producing acrylic acid, comprising the step of subjecting acrolein to gas-phase catalytic oxidation with an oxygen-containing gas in the presence of a catalyst produced by the method for producing a catalyst according to any one of claims 1 to 9.

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