Acrylonitrile Catalysts

Polymerization Aliphatic, aromatic and oxygenated monomers Vinyl chloride Isoprene Acrylonitrile Catalyst activation... 

The structure of a highly active cerium-molybdenum-tellurium acrylonitrile catalyst(l ) has previously been described in terms of binary (Ce,Mo)0 and ternary (Ce,Mo,Te)0 phases( ). It was concluded that none of the constituent oxides (CeO, ... 

We have recently identified and characterized several new ternary oxides (Ce,Mo,Te)0( 3), after studying over 100 different compositions calcined in air at temperatures between 400 and 600 C. Combined with the knowledge of the (Te,Mo)0, (Ce,Mo)0, and (Ce,Te)0 chemistry, which was developed in the last decade, it is now possible to describe the complex solid-state relations of the ternary (Ce,Mo,Te)0 system. The results culminated in the identification of the active phase composition of a typical (Ce,Mo,Te)0 acrylonitrile catalyst. 

On the basis of the solid-state relationships of the (Ce,Mo,Te)0 system, it is now possible to derive the phase distribution of a typical unsupported (Ce,Mo,Te)0 acrylonitrile catalyst with the composition of Ref.(JJ ), as indicated in Table I. The results agree with previous conclusions with regard to the role of (Te,Mo)0 and (Te,Ce)O oxides in this system and the most likely composition of the active (Ce,Mo)0 phases ( /3-Ce2MOg0j g and a-Ce2Mo 0j ) ( ). XPS results (Ce(III) rather than Ce(IV) in the catalyst) favour the... 

Many MMA plants utilize the HCN by-product from acrylonitrile ammoxidation plants. MMA plants are often built in tandem with acrylonitrile units and sized to use the total quantity of HCN available. This is a convenient way to dispose of the HCN by-product This source, however, is declining because improved acrylonitrile catalysts produce less by-product. In addition, demand for methyl methacrylate has been growing faster than the demand for acrylonitrile and will therefore eventually exceed the availability of by-product HCN. 

GrasseUi, R.K. and Suresh, D.D. Aspects of structure and activity in uranium-antimony oxide acrylonitrile catalysts.,/ Catal 1972, 25, 273-291. 

The addition of active methylene compounds (ethyl malonate, ethyl aoeto-acetate, ethyl plienylacetate, nltromethane, acrylonitrile, etc.) to the aP-double bond of a conjugated unsaturated ketone, ester or nitrile In the presence of a basic catalyst (sodium ethoxide, piperidine, diethylamiiie, etc.) is known as the Michael reaction or Michael addition. The reaction may be illustrated by the addition of ethyl malonate to ethyl fumarate in the presence of sodium ethoxide hydrolysis and decarboxylation of the addendum (ethyl propane-1 1 2 3-tetracarboxylate) yields trlcarballylic acid ... 

Unsaturated nitriles are formed by the reaction of ethylene or propylene with Pd(CN)2[252]. The synthesis of unsaturated nitriles by a gas-phase reaction of alkenes. HCN, and oxygen was carried out by use of a Pd catalyst supported on active carbon. Acrylonitrile is formed from ethylene. Methacrylonitrile and crotononitrile are obtained from propylene[253]. Vinyl chloride is obtained in a high yield from ethylene and PdCl2 using highly polar solvents such as DMF. The reaction can be made catalytic by the use of chloranil[254]. 

An important nitrile is acrylonitrile H2C=CHCN It is prepared industrially from propene ammonia and oxygen m the presence of a special catalyst Polymers of acryl omtrile have many applications the most prominent being their use m the preparation of acrylic fibers... 

Processes have been developed whereby the oxygen is suppHed from the crystal lattice of a metal-oxide catalyst (5) (see Acrylonitrile Methacrylic acid AND derivatives). 

Addition of HCN to unsaturated compounds is often the easiest and most economical method of making organonitnles. An early synthesis of acrylonitrile involved the addition of HCN to acetylene. The addition of HCN to aldehydes and ketones is readily accompHshed with simple base catalysis, as is the addition of HCN to activated olefins (Michael addition). However, the addition of HCN to unactivated olefins and the regioselective addition to dienes is best accompHshed with a transition-metal catalyst, as illustrated by DuPont s adiponitrile process (6—9). 

Most, if not all, of the acetonitrile that was produced commercially in the United States in 1995 was isolated as a by-product from the manufacture of acrylonitrile by propylene ammoxidation. The amount of acetonitrile produced in an acrylonitrile plant depends on the ammoxidation catalyst that is used, but the ratio of acetonitrile acrylonitrile usually is ca 2—3 100. The acetonitrile is recovered as the water azeotrope, dried, and purified by distillation (28). U.S. capacity (1994) is ca 23,000 t/yr. 

In the presence of such catalysts as a solution of cuprous and ammonium chlorides, hydrogen cyanide adds to acetylene to give acrylonitrile... 

In 1957 Standard Oil of Ohio (Sohio) discovered bismuth molybdate catalysts capable of producing high yields of acrolein at high propylene conversions (>90%) and at low pressures (12). Over the next 30 years much industrial and academic research and development was devoted to improving these catalysts, which are used in the production processes for acrolein, acryUc acid, and acrylonitrile. AH commercial acrolein manufacturing processes known today are based on propylene oxidation and use bismuth molybdate based catalysts. 

Even ia 1960 a catalytic route was considered the answer to the pollution problem and the by-product sulfate, but nearly ten years elapsed before a process was developed that could be used commercially. Some of the eadier attempts iacluded hydrolysis of acrylonitrile on a sulfonic acid ion-exchange resia (69). Manganese dioxide showed some catalytic activity (70), and copper ions present ia two different valence states were described as catalyticaHy active (71), but copper metal by itself was not active. A variety of catalysts, such as Umshibara or I Jllmann copper and nickel, were used for the hydrolysis of aromatic nitriles, but aUphatic nitriles did not react usiag these catalysts (72). Beginning ia 1971 a series of patents were issued to The Dow Chemical Company (73) describiag the use of copper metal catalysis. Full-scale production was achieved the same year. A solution of acrylonitrile ia water was passed over a fixed bed of copper catalyst at 85°C, which produced a solution of acrylamide ia water with very high conversions and selectivities to acrylamide. 

Although acrylonitrile manufacture from propylene and ammonia was first patented in 1949 (30), it was not until 1959, when Sohio developed a catalyst capable of producing acrylonitrile with high selectivity, that commercial manufacture from propylene became economically viable (1). Production improvements over the past 30 years have stemmed largely from development of several generations of increasingly more efficient catalysts. These catalysts are multicomponent mixed metal oxides mostly based on bismuth—molybdenum oxide. Other types of catalysts that have been used commercially are based on iron—antimony oxide, uranium—antimony oxide, and tellurium-molybdenum oxide. 

Numerous patents have been issued disclosing catalysts and process schemes for manufacture of acrylonitrile from propane. These include the direct heterogeneously cataly2ed ammoxidation of propane to acrylonitrile using mixed metal oxide catalysts (61—64). 

The propylene-based process developed by Sohio was able to displace all other commercial production technologies because of its substantial advantage in overall production costs, primarily due to lower raw material costs. Raw material costs less by-product credits account for about 60% of the total acrylonitrile production cost for a world-scale plant. The process has remained economically advantaged over other process technologies since the first commercial plant in 1960 because of the higher acrylonitrile yields resulting from the introduction of improved commercial catalysts. Reported per-pass conversions of propylene to acrylonitrile have increased from about 65% to over 80% (28,68—70). 

Aminoalkoxy pentaerythritols are obtained by reduction of the cyanoethoxy species obtained from the reaction between acrylonitrile, pentaerythritol, and lithium hydroxide in aqueous solution. Hydrogen in toluene over a mthenium catalyst in the presence of ammonia is used (34). The corresponding aminophenoxyalkyl derivatives of pentaerythritol and trimethyl olpropane can also be prepared (35). 

Addition of Hydrogen Cyanide. At one time the predominant commercial route to acrylonitrile was the addition of hydrogen cyanide to acetylene. The reaction can be conducted in the Hquid (CuCl catalyst) or gas phase (basic catalyst at 400 to 600°C). This route has been completely replaced by the ammoxidation of propylene (SOHIO process) (see Acrylonitrile). 

Uses. Magnesium alkyls are used as polymerization catalysts for alpha-alkenes and dienes, such as the polymerization of ethylene (qv), and in combination with aluminum alkyls and the transition-metal haUdes (16—18). Magnesium alkyls have been used in conjunction with other compounds in the polymerization of alkene oxides, alkene sulfides, acrylonitrile (qv), and polar vinyl monomers (19—22). Magnesium alkyls can be used as a Hquid detergents (23). Also, magnesium alkyls have been used as fuel additives and for the suppression of soot in combustion of residual furnace oil (24). 

MAA and MMA may also be prepared via the ammoxidation of isobutylene to give meth acrylonitrile as the key intermediate. A mixture of isobutjiene, ammonia, and air are passed over a complex mixed metal oxide catalyst at elevated temperatures to give a 70—80% yield of methacrylonitrile. Suitable catalysts often include mixtures of molybdenum, bismuth, iron, and antimony, in addition to a noble metal (131—133). The meth acrylonitrile formed may then be hydrolyzed to methacrjiamide by treatment with one equivalent of sulfuric acid. The methacrjiamide can be esterified to MMA or hydrolyzed to MAA under conditions similar to those employed in the ACH process. The relatively modest yields obtainable in the ammoxidation reaction and the generation of a considerable acid waste stream combine to make this process economically less desirable than the ACH or C-4 oxidation to methacrolein processes. 

Oxidation Catalysis. The multiple oxidation states available in molybdenum oxide species make these exceUent catalysts in oxidation reactions. The oxidation of methanol (qv) to formaldehyde (qv) is generally carried out commercially on mixed ferric molybdate—molybdenum trioxide catalysts. The oxidation of propylene (qv) to acrolein (77) and the ammoxidation of propylene to acrylonitrile (qv) (78) are each carried out over bismuth—molybdenum oxide catalyst systems. The latter (Sohio) process produces in excess of 3.6 x 10 t/yr of acrylonitrile, which finds use in the production of fibers (qv), elastomers (qv), and water-soluble polymers. 

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