Liquid-phase (AMM)oxidation process

Abstract

A process for oxidizing a hydrocarbon, which comprises subjecting the hydrocarbon to a liquid phase catalytic oxidation reaction in the presence of at least one oxidation catalyst to form an oxidized product.

Description

Claims

1. A process for oxidizing a hydrocarbon, which comprises subjecting the hydrocarbon to a liquid phase catalytic oxidation reaction in the presence of at least one oxidation catalyst to form an oxidized product, wherein said liquid phase comprises a solvent having a boiling point of at least 25° C. and Hildebrand solubility parameter no greater than 7 cal1/2cm−3/2(14 MPa1/2).

2. The process of claim 1 in which the oxidation catalyst is a mixed metal oxide having the empirical formula AaMbNcXdZeOf wherein A is at least one element selected from the group consisting of Mo and W; M is at least one element selected from the group consisting of V and Ce; N is at least one element selected from the group consisting of Te, Sb and Se; X is at least one element selected from the group consisting of Nb, Ta, Ti, Al, Zr, Cr, Mn, Fe, Ru, Co, Rh, Ni, Pt, Sb, Bi, B, In, As, Ge, Sn, Li, Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Ba, Ra, Hf, Pb, P, Pm, Eu, Gd, Dy, Ho, Er, Tm, Yb and Lu; and Z is at least one element selected from the group consisting of Zn, Ga, Ir, Sm, Pd, Au, Ag, Cu, Sc, Y, Pr, Nd and Tb; and wherein, when a=1, b=0.01 to 1.0, c=0.01 to 1.0, d=0.01 to 1.0, e=0 to 0.1, and f is dependent on the oxidation state of the other elements.

3. The process of claim 2 in which the hydrocarbon is an acyclic C3-C8 alkane and the oxidized product is an unsaturated carboxylic acid.

4. The process of claim 1 in which the solvent has a Hildebrand solubility parameter no greater than 6 cal1/2cm−3/2 (12 MPa1/2).

5. The process of claim 4 in which the solvent is a perfluoroalkane or perfluoroether.

6. The process of claim 1 in which oxidized product is recovered from the solvent after a phase separation.

7. The process of claim 6 in which additional oxidized product is separated from the solvent as a solution in an extractant; said extractant having less than 1% solubility in the solvent.

8. The process of claim 2 in which the oxidized product is an unsaturated nitrile, the hydrocarbon is an acyclic C3-C8 alkane and ammonia is present in the liquid phase catalytic oxidation reaction.

9. The process of claim 1 in which the oxidized product is an unsaturated aldehyde, the hydrocarbon is an acyclic C3-C8 alkene, and said at least one oxidation catalyst comprises a mixed metal oxide catalyst comprising at least one atom of a group VIB element, at least one atom of a group VA element, and at least two group VIII atoms.

10. The process of claim 1 in which the oxidized product is an unsaturated nitrile, the hydrocarbon is an acyclic C3-C8 alkene, ammonia is present in the liquid phase catalytic oxidation reaction, and said at least one oxidation catalyst comprises a mixed metal oxide catalyst comprising at least one atom of a group VIB element, at least one atom of a group VA element, and at least two group VIII atoms.