Method for producing methacrolein

Details Method for producing methacrolein Method for producing methacrolein

1996-08-26

1998-03-17

Geist, Gary

Organic compounds -- part of the class 532-570 series

Organic compounds

Oxygen containing

502305, 502317, 502314, 502321, C07C 4534

Patent

active

057288941

DESCRIPTION:

BRIEF SUMMARY
This is the U.S. National Stage Application of PCT/JP95/01234 filed Jun. 21, 1995 now WO/95/35273 published Dec. 28, 1995.


BACKGROUND OF THE INVENTION

1. Technical field
The present invention relates to a method for producing methacrolein. More particularly, the present invention is concerned with a method for producing methacrolein, which comprises subjecting at least one member selected from the group consisting of isobutylene and tert-butanol to gas phase catalytic oxidation with a molecular oxygen-containing gas in the presence of an oxide catalyst composition which has a specific, relatively simple structural composition and therefore can be easily prepared, and which has not only a prolonged catalyst life due to the excellent thermal stability and reduction resistance, but also excellent selectivity for methacrolein, wherein the catalyst composition contains bismuth, cerium, iron and potassium in specific amounts and in a specific relative amount ratio, and without such elements as have conventionally been necessarily used to achieve high catalytic performances despite the accompanying environmental pollution and toxicity problems, and also without the need for using, as raw materials for the preparation thereof, compounds having low solubility in water, such as a tungstate, an antimony compound and a niobium compound, which have frequently been used in order to achieve desired catalytic performances, but the use of which is disadvantageous because of difficulties in obtaining uniform catalyst compositions.
2. Prior art
Heretofore, various proposals have been made with respect to catalysts which can be used for production of methacrolein by gas phase catalytic oxidation of at least one member selected from the group consisting of isobutylene and tert-butanol. Most of such conventional techniques are directed to the choice of elements to be contained in the catalyst composition and atomic ratios of the elements. For example, there has been known a technique in which cerium is used as a component for a catalyst composition to thereby improve catalytic activities, especially, yield of methacrolein. However, the conventional catalysts proposed for producing methacrolein are still unsatisfactory with respect to other requirements for a catalyst than the yield of methacrolein, such as catalyst life, ease and safety in the preparation thereof, and freedom from the detrimental influence of the catalyst on the environment. Thus, there has been a strong demand for a catalyst for producing methacrolein, which is satisfactory in respect of the above-mentioned various requirements.
As examples of prior art patent documents, the working examples of which disclose the use of catalysts containing Ce, there can be mentioned German Patent No. 2035517 (corresponding to Examined Japanese Patent Application Publication No. 43-13987), Unexamined Japanese Patent Application Laid-Open Specification No. 60-161932, Unexamined Japanese Patent Application Laid-Open Specification No. 60-163830, Unexamined Japanese Patent Application Laid-Open Specification No. 63-107745, Unexamined Japanese Patent Application Laid-Open Specification No. 63-122641, European Patent No. 0 267 556 (corresponding to Unexamined Japanese Patent Application Laid-Open Specification No. 63-122642), Unexamined Japanese Patent Application Laid-Open Specification No. 2-227140, European Patent No. 0 420 048 (corresponding to Unexamined Japanese Patent Application Laid-Open Specification No. 3-109943), European Patent No. 0 523 727 (corresponding to Unexamined Japanese Patent Application Laid-Open Specification No. 5-23596), Unexamined Japanese Patent Application Laid-Open Specification No. 6-192144, Unexamined Japanese patent Application Laid-Open Specification No. 52-111505, European Patent No. 0 102 641 (corresponding to Examined Japanese Patent Application Publication No. 62-36740), U.S. Pat. No. 4,537,874 (corresponding to Examined Japanese patent Application publication No. 2-32017), European Patent No. 0 279 374 (corresponding to Unexamined Japanese

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