Process for producing methacrolein

Abstract

A process for producing methacrolein by oxidizing isobutylene or tertiary butanol with molecular oxygen, characterized by contacting a gaseous mixture of isobutylene or tertiary butanol, air or oxygen and optionally steam and an inert gas with a catalyst having the general composition:Mo.sub.12 Fe.sub.a Ni.sub.b Te.sub.c X.sub.d Z.sub.f Y.sub.g O.sub.hwherein a, b, c, d, f and g represent the numbers of atoms of the respective elements per 12 molybdenum atoms; X is Tl, Rb or Cs; Z is In or Ti; Y represents at least one element selected from the group consisting of Cu, Nd, Sm and Pb; a is a value of 0.2-6; b is a value of 0.2-6; a+b is a value of 1-10; c is a value of 0.1-4; d is a value of 0.1-3; f is a value of 0.1-3; g is a value of 0-5; and h is the number of oxygen atoms for satisfying the valencies of the existing elements. The use of this catalyst enables the selectivity for methacrolein to be improved to 90 or more and the yield based on the starting material to be increased to 89-91%. In addition, the high activity of said catalyst and high selectivity are stably maintained for a long period of time.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to process for producing methacrolein in a high yield by oxidizing isobutylene or tertiary butanol with molecular oxygen with a specific catalyst.

2. Description of the Prior Art

Hitherto, many catalysts have been proposed for the gas phase catalytic oxidation of isobutylene or tertiary butanol. From the industrial point of view, however, there are yet many points to be improved.

For example, in the production of methacrolein, the yield of the product, methacrolein, based on the starting material (isobutylene or tertiary butanol) is still so low that the selectivity based on isobutylene is at most about 82-86% even with a catalyst which has hitherto been called an excellent catalyst. Therefore, a catalyst system capable of giving a much higher selectivity is desired. Some of the catalysts containing molybdenum as a main component and additionally containing tellurium exhibit a considerably high yield in the early stage of the reaction. However, their activities drop markedly owing to structural change and scattering of tellurium, and there has been found substantially no catalyst enabling methacrolein to be obtained in a high yield for a long period of time.

When it is intended to use the resulting methacrolein as a starting material for producing an unsaturated ester directly from an unsaturated aldehyde, it is desired that the amount of by-products such as methacrylic acid and acetic acid is as small as possible. Thus, the use as an industrial catalyst involves a number of problems. The present inventors have conducted earnest and detailed studies with the aim of solving the above-mentioned problems. As a result, this invention has been accomplished.

SUMMARY OF THE INVENTION

According to this invention, there is provided a process for producing methacrolein by oxidizing isobutylene or tertiary butanol with molecular oxygen, characterized by using a catalyst having the general composition:

Mo.sub.12 Fe.sub.a Ni.sub.b Te.sub.c X.sub.d Z.sub.f Y.sub.g O.sub.h wherein a, b, c, d, f and g represent the numbers of atoms of the respective elements per 12 molybdenum atoms; X is Tl, Rb or Cs; Z is In or Ti; Y represents at least one element selected from the group consisting of Cu, Nd, Sm and Pb; a is a value of 0.2-6; b is a value of 0.2-6; a+b is a value of 1-10; c is a value of 0.1-4; d is a value of 0.1-3; f is a value of 0.1-3; g is a value of 0-5; and h is the number of oxygen atoms for satisfying the valencies of the existing elements.

DETAILED DESCRIPTION OF THE INVENTION

The characteristic feature of this invention consists in that, by the use of said catalyst, the selectivity for methacrolein is as high as 90% or more and methacrolein is obtained from isobutylene or tertiary butanol with a high selectivity. Accordingly, the amounts of methacrylic acid, acetic acid, acetone, carbon monoxide and carbon dioxide, which are by-products, are small. Further, said catalyst exhibits only a very small drop in activity and has an ability to maintain a high activity and a high selectivity for a long period of time.

In the catalyst of this invention, molybdenum is an essential component. A system having the catalyst composition from which molybdenum has been excluded has so low an activity that no improvement in yield of methacrolein is expected.

Tellurium is used as a promotor. Tellurium as a promoter has hitherto been used for improving the catalyst activity and selectivity. However, catalysts containing tellurium have hitherto been regarded as impractical because their activity decreases rapidly, even though they are excellent in initial activity and selectivity.

In this invention, for the purpose of preventing the decrease in catalytic activity which is one of the faluts of catalysts in which tellurium is used as a promotor and imparting a high acitivity, indium or titanium is contained together with iron and nickel in the catalyst system of this invention.

The decrease in catalytic activity is fatal to an industrial catalyst, but can be prevented by using appropriate quantities of indium or titanium and iron and nickel. The above-mentioned effects of indium or titanium and iron and nickel are lost when any one of them is omitted. Moreover, when the contents of iron and nickel are such that the total amount of iron and nickel are larger than the amount of molybdenum, the function of the molybdenum as main catalyst is affected, and this is not desirable.

The addition of indium or titanium brings about not only the above-mentioned effects, but also the effect that the amount of water-soluble acids (acetic acid and methacrylic acid) formed as by-products is particularly made small. Accordingly, the amount of waste water to be treated becomes small, and equippment for treating waste water can be made small, though there has hitherto been required an operation for removing the water-soluble acids and the like from the reaction product gas by means of a quenching tower or the like. Furthermore, when said catalyst is used in the process for producing methacrolein which is a starting material for preparing an unsaturated ester, for example, methyl methacrylate, directly from methacrolein, the amount of methacrylic acid formed as by-product is very small, and therefore, the yield of methacrolein becomes high and the cost for treating the methacrylic acid becomes very low.

As a carrier for the catalyst of this invention, known carriers such as silica, silicon carbide, alumina and the like may be used, among which silica sol and silica gel are particularly excellent. The catalyst of this invention can be prepared, for example, in the following manner: Water-soluble compounds of iron, nickel and the X component, a compound of indium or titanium and a water-soluble Y component compound are added to an aqueous solution of ammonium molybdate, and an oxide or an acid of tellurium is added to the resulting mixture. Furthermore, silica sol is added thereto as a carrier. The mixture is evaporated to dryness on a water bath, preliminarily calcined in the presence of air or oxygen and subsequently subjected to main calcination. Usually, the preliminary calcination is carried out at a temperature of 100.degree.-500.degree. C., preferably 200.degree.-400.degree. C. The main calcination is usually carried out at a temperature of 400.degree.-1,000.degree. C., preferably 500.degree.-700.degree. C., more preferably 500.degree.-650.degree. C.

As the starting materials of the respective elements used in the preparation of the catalyst of this invention, there may be used not only oxides but also any substances so far as they constitute the catalyst of this invention upon being calcined. Examples of said substances include ammonium salts, inorganic acid salts such as nitrate, carbonate and the like and organic acid salts such as acetate and the like, of the above-mentioned elements. The catalyst may be used either in the form of powder, or in a granular form, or as tablet.

As the reactor, either fixed bed or fluidized bed may be used. The reaction of this invention is carried out at a temperature ranging from 200.degree. C. to 550.degree. C., preferably from 250.degree. C. to 450.degree. C. at a pressure of 0.5-10 atmospheres, preferably a pressure ranging from atmospheric pressure to 2 atmospheres.

The contact time between said catalyst and the starting gaseous mixture comprising isobutylene or tertiary butanol, air (or oxygen), steam and an inert gas is 0.1 to 15 seconds, preferably 0.2 to 10 seconds, in the case of atmospheric pressure. The flow rate of the starting gas fed to the catalyst is generally a space velocity of 100 to 5,000 hr.sup.-1, preferably 200 to 2,000 hr.sup.-1.

The gaseous mixture comprises 0.5 to 4 moles, preferably 1.4 to 2.5 moles, of oxygen per mole of isobutylene or tertiary butanol. Though steam is not essential, it is advantageous in the aspect of yield to add steam in an amount of 1 to 30 moles, preferably 2 to 15 moles, per mole of isobutylene or tertiary butanol. Moreover, the addition of an inert gas, such as N.sub.2, He, Ar, CO.sub.2 or the like, may be varied depending upon the variation of the composition of other components.

By using the catalyst of this invention described above in detail, the selectivity for methacrolein reaches even 90-94%. A catalyst capable of giving such a high selectivity and maintaining its activity stably for a long period of time is very epoch-making.

DESCRIPTION OF PREFERRED EMBODIMENTS

This invention is further explained in more detail below referring to Examples, which are merely by way of illustration and not be way of limitation.

EXAMPLE 1

In 200 ml of distilled water was dissolved 21.2 g of ammonium paramolybdate, and 0.80 g of thallium nitrate was further dissolved therein. The resulting solution is hereinafter referred to as "Solution A". On the other hand, 2.9 g of nickel nitrate was dissolved in 200 ml of distilled water, and in the resulting solution were discolved 4.04 g of ferric nitrate, 6.6 g of lead nitrate, 3.55 g of indium nitrate and 4.55 g of telluric acid. The resulting solution was mixed with Solution A, to which 52.43 g of silica sol (Snowtex N 30) was added.

Then, this mixture was evaporated to dryness on a water bath, after which the residue was preliminarily calcined in the presence of air at 250.degree. C. for 2 hours, and the calcined product was pulverized to 10-28 meshes and then calcined in the presence of air at 650.degree. C. for 4 hours. The catalyst thus obtained had the following composition:

Mo.sub.12 Pb.sub.2 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 In.sub.1 Te.sub.2 O.sub.h.

EXAMPLE 2

A Pyrex reaction tube having an inner diameter of 5 mm was packed with 5 g of the catalyst prepared in Example 1, and reaction was carried out at a reaction temperature of 360.degree. C.-440.degree. C. The starting gas had a molar ratio of isobutylene/O.sub.2 /H.sub.2 O/He=3/6/20/71. The contact time was 2.5 seconds. The analysis was carried out with Shimazu 6APrTF Gas Chromatograph, using the Chromosorb 101 column. The results are shown in Table 1.

EXAMPLE 3

Using a catalyst having the composition Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Ni.sub.1 Fe.sub.1 In.sub.0.3 Te.sub.2 O.sub.h prepared under the same preparative conditions as in Example 1, reaction was carried out under the same reaction conditions as in Example 2. The results are shown in Table 1.

Comparative Example 1

Using a catalyst having the composition Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 Te.sub.2 O.sub.h prepared under the same preparative conditions as in Example 1, reaction was carried out under the same reaction conditions as in Example 3. The results are shown in Table 1.

EXAMPLE 4

Using a catalyst having the composition Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Ni.sub.1 Fe.sub.1 In.sub.1 Te.sub.2 O.sub.h prepared under the same preparative conditions as in Example 1, reaction was carried out under the same reaction conditions as in Example 2. The results are shown in Table 1.

TABLE 1__________________________________________________________________________ Conversion Selectivity Selectivity of for for acetic Temperature isobutylene methacrolein acid plus MAANo. Composition of catalyst (.degree.C.) (%) (%) (%)__________________________________________________________________________Example Mo.sub.12 Pb.sub.2 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 In.sub.1 Te.sub.2 O.sub.h 400 93.2 93.0 0.6Example Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 380 94.3 91.5 0.83Example Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.1 Te.sub.2 O.sub.h 380 96.4 91.0 0.74Compar- Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 Te.sub.2 O.sub.h 420 65.8 88.0 2.3ativeExample1__________________________________________________________________________

EXAMPLES 5-23

Using catalysts having the compositions shown in Table 2 which had been prepared under the same preparative conditions as in Example 1, reactions were carried out under the same reaction conditions as in Example 2. The results are shown in Table 2.

TABLE 2__________________________________________________________________________ Conversion Selectivity of forExample Temperature isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________5 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 In.sub.0.5 Te.sub.2 O.sub.h 380 95.2 91.46 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 420 92.2 92.77 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 410 94.3 91.08 Mo.sub.12 Fe.sub.2 Ni.sub.2 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 400 95.0 91.29 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 380 95.8 91.510 Mo.sub.12 Fe.sub.1 Ni.sub.1 Cs.sub.0.3 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 96.2 91.011 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 97.2 90.912 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 97.4 90.713 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 400 91.0 91.314 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 380 96.5 91.515 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 400 92.8 92.316 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 90.9 92.017 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 90.4 92.518 Mo.sub.12 Fe.sub.4 Ni.sub.4 Tl.sub.0.3 Cu.sub.l In.sub.0.5 Te.sub.2 O.sub.h 420 91.4 92.019 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.4 O.sub.h 380 96.2 92.320 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.1 O.sub.h 410 94.4 90.821 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 In.sub.3 Te.sub.2 O.sub.h 420 96.1 90.922 Mo.sub.12 Fe.sub.1 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 In.sub.1 Te.sub.2 O.sub.h 370 97.1 90.323 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 Cu.sub.1 In.sub.0.2 Te.sub.2 O.sub.h 380 96.4 92.0__________________________________________________________________________

Comparative Examples 2-9

Using catalysts having the compositions shown in Table 3 which had been prepared under the same preparative conditions as in Example 1, reactions were carried out under the same reaction conditions as in Example 2. The results are shown in Table 3.

TABLE 3__________________________________________________________________________Compar- Conversion Selectivityative of forExample Temperature isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________2 Mo.sub.12 Fe.sub.1 Ni.sub.1 Te.sub.2 Cu.sub.1 In.sub.0.3 O.sub.h 400 97.2 81.23 Mo.sub.12 Fe.sub.1 Ni.sub.1 Te.sub.2 Cu.sub.1 In.sub.0.3 Na.sub.0.3 O.sub.h 400 95.1 82.34 Mo.sub.12 Fe.sub.0.2 Ni.sub.0.2 Te.sub.2 Cu.sub.1 In.sub.0.3 Tl.sub.0.3 O.sub.h 420 67.3 86.75 Mo.sub.12 Fe.sub.1 Te.sub.2 Cu.sub.1 In.sub.0.3 Tl.sub.0.3 O.sub.h 400 53.0 85.06 Mo.sub.12 Fe.sub.9 Ni.sub.4 Te.sub.2 Cu.sub.1 In.sub.0.3 Tl.sub.0.3 O.sub.h 400 61.4 80.47 Mo.sub.12 Fe.sub.1 Ni.sub.1 Te.sub.6 Cu.sub.1 In.sub.0.3 Tl.sub.0.3 O.sub.h 400 91.0 86.58 Mo.sub.12 Fe.sub.1 Ni.sub.1 Te.sub.2 Cu.sub.1 In.sub.6 Tl.sub.0.3 O.sub.h 420 62.3 81.79 Fe.sub.1 Ni.sub.1 Te.sub.4 Cu.sub.1 In.sub.0.3 Tl.sub.0.3 O.sub.h 420 12.1 47.2__________________________________________________________________________

EXAMPLES 24-26

Using the same catalysts as used in Examples 2-4, reactions were carried out continuously for 100 hours under the same conditions as in the respective Examples. The results are shown in Table 4.

TABLE 4__________________________________________________________________________ At the start of measurement After 100 hours Conversion Selectivity Conversion Selectivity of for of forExample Temperature isobutylene methacrolein isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%) (%) (%)__________________________________________________________________________24 Mo.sub.12 Pb.sub.2 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.1 Te.sub.2 O.sub.h 400 93.2 93.0 93.2 93.025 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 380 94.3 91.5 94.4 91.326 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.1 Te.sub.2 O.sub.h 380 96.4 91.0 96.4 91.1__________________________________________________________________________

EXAMPLES 27-29

A Pyrex reaction tube having an inner diameter of 5 mm was packed with 5 g of each of the catalysts having the compositions shown in Table 5 which had been prepared under the same preparative conditions as in Example 1, and reactions were carried out at a reaction temperature of 380.degree.-440.degree. C.

The starting gas had a molar ratio of tertiary butanol/O.sub.2 /H.sub.2 O/He=3/6/20/71. The contact time was 2.5 seconds. The results are shown in Table 5.

Comparative Example 10

Using a catalyst having the composition shown in Table 5 which had been prepared under the same preparative conditions as in Example 1, reaction was carried out under the same reaction conditions as in Examples 27-29. The results are shown in Table 5.

TABLE 5__________________________________________________________________________ Conversion Selectivity Selectivity for of for acetic acid plus Temperature isobutylene methacrolein methacrylic acidNo. Composition of catalyst (.degree.C.) (%) (%) (%)__________________________________________________________________________Example Mo.sub.12 Fe.sub.1 Ni.sub.1 Pb.sub.2 Tl.sub.0.3 In.sub.1 Te.sub.2 O.sub.h 400 93.0 93.0 0.727Example Mo.sub.12 Fe.sub.1 Ni.sub.1 Cu.sub.1 Tl.sub.0.3 In.sub.0.3 Te.sub.2 O.sub.h 380 94.3 91.6 0.828Example Mo.sub.12 Fe.sub.1 Ni.sub.1 Cu.sub.1 Tl.sub.0.3 In.sub.1 Te.sub.2 O.sub.h 380 96.3 91.0 0.729Compar- Mo.sub.12 Fe.sub.1 Ni.sub.1 Cu.sub.1 Tl.sub.0.3 Te.sub.2 O.sub.h 380 65.8 87.8 2.6ativeExample10__________________________________________________________________________

EXAMPLES 30-48

Using catalysts having the compositions shown in Table 6 which had been prepared under the same preparative conditions as in Example 1, reactions were carried out under the same reaction conditions as in Examples 27-29. The results are shown in Table 6.

TABLE 6__________________________________________________________________________ Conversion Selectivity of forExample Temperature isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________30 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 In.sub.0.5 Te.sub.2 O.sub.h 380 95.0 91.531 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 420 92.2 92.532 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 410 94.4 90.833 Mo.sub.12 Fe.sub.2 Ni.sub.2 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 400 94.8 91.334 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 380 95.7 91.535 Mo.sub.12 Fe.sub.1 Ni.sub.1 Cs.sub.0.3 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 96.1 91.036 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 97.0 90.637 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 97.3 90.838 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 400 91.0 91.439 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 380 96.3 91.040 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 400 92.7 92.341 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 90.7 92.142 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 Pb.sub.2 In.sub.0.5 Te.sub.2 O.sub.h 400 90.5 92.443 Mo.sub.12 Fe.sub.4 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.2 O.sub.h 420 91.0 92.144 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.4 O.sub.h 380 96.1 92.545 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.5 Te.sub.1 O.sub.h 410 94.1 90.046 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.3 Te.sub.2 O.sub.h 420 95.7 90.947 Mo.sub.12 Fe.sub.1 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 In.sub.1 Te.sub.2 O.sub.h 370 97.0 90.148 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 Cu.sub.1 In.sub.0.2 Te.sub.2 O.sub.h 380 96.4 91.8__________________________________________________________________________

Comparative Examples 11-17

Using catalysts having the compositions shown in Table 7 which had been prepared under the same preparative conditions as in Example 1, reactions were carried out under the same reaction conditions as in Examples 27-29. The results are shown in Table 7.

TABLE 7__________________________________________________________________________Compar- Conversion Selectivityative of forExample Temperature t-BuOH methacroleinNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________11 Mo.sub.12 Fe.sub.1 Ni.sub.1 Cu.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 400 97.0 81.312 Mo.sub.12 Fe.sub.1 Ni.sub.1 Cu.sub.1 In.sub.0.3 Na.sub.0.3 Te.sub.2 O.sub.h 400 95.1 82.013 Mo.sub.12 Fe.sub.0.2 Ni.sub.0.2 Tl.sub.0.5 Cu.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 420 67.2 87.614 Mo.sub.12 Fe.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 400 53.0 85.115 Mo.sub.12 Fe.sub.9 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 400 61.0 80.316 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 400 90.6 86.617 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 In.sub.6 Te.sub.2 O.sub.h 420 62.3 82.0__________________________________________________________________________

EXAMPLES 49-51

Using the same catalysts as in Examples 2-4, reactions were carried out continuously for 100 hours under the same conditions as in the respective Examples. The results are shown in Table 8.

TABLE 8__________________________________________________________________________ At the start of measurement After 100 hours Conversion Selectivity Conversion Selectivity of for of forExample Temperature isobutylene methacrolein isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%) (%) (%)__________________________________________________________________________49 Mo.sub.12 Pb.sub.2 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.1 Te.sub.2 O.sub.h 400 93.0 93.0 93.1 93.050 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.0.3 Te.sub.2 O.sub.h 380 94.3 91.6 94.3 91.451 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 In.sub.1 Te.sub.2 O.sub.h 380 96.3 91.0 96.3 91.0__________________________________________________________________________

EXAMPLE 52

In 200 ml of distilled water was dissolved 21.2 g of ammonium paramolybdate, and 0.80 g of thallium nitrate was then dissolved in the resulting solution. The resulting solution is hereinafter referred to as "Solution A". On the other hand, 2.9 g of nickel nitrate was dissolved in 200 ml of distilled water, and in the resulting solution were dissolved 4.04 g of ferric nitrate, 6.6 g of lead nitrate, 1.54 g of titanium trichloride and 4.55 g of telluric acid. The resulting solution was mixed with Solution A, to which 52.43 g of silica sol (Snowtex) was added thereto.

Then, this mixture was evaporated to dryness on a water bath, and the residue was preliminarily calcined in the presence of air at 250.degree. C. for 2 hours. The calcined product was pulverized to 10-28 meshes and then calcined in the presence of air at 650.degree. C. for 4 hours. The catalyst thus obtained had the following composition:

Mo.sub.12 Pb.sub.2 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.1 Te.sub.2 O.sub.h.

EXAMPLE 53

A Pyrex reaction tube having an inner diameter of 5 mm was packed with 5 g of the catalyst prepared in Example 52, and reaction was carried out therein at a reaction temperature of 400.degree. C. The starting gas had a molar ratio of isobutylene/O.sub.2 /H.sub.2 O/He=3/6/20/71. The contact time was 2.5 seconds. The analysis was carried out with Shimazu 6APrTF Gas Chromatograph, using a Chromosorb 101 column. The results are shown in Table 9.

EXAMPLES 54-55

Using catalysts having the compositions shown in Table 9 which had been prepared under the same preparative conditions as in Example 52, reactions were carried out under the same reaction conditions as in Example 53. The results are shown in Table 9.

TABLE 9__________________________________________________________________________ Selectivity Conversion Selectivity for acetic of for acid plusExample Temperature isobutylene methacrolein methacrylicNo. Composition of catalyst (.degree.C.) (%) (%) acid (%)__________________________________________________________________________53 Mo.sub.12 Pb.sub.2 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.1 Te.sub.2 O.sub.h 400 93.5 92.8 0.754 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Te.sub.2 O.sub.h 380 94.8 91.4 0.755 Mo.sub.12 Cu.sub.1 Fe.sub.1 Ni.sub.1 Ti.sub.1 Tl.sub.0.3 Te.sub.2 O.sub.h 380 96.7 90.9 0.8__________________________________________________________________________

EXAMPLES 56-74

Using catalysts having the compositions shown in Table 10 which had been prepared under the same preparative conditions as in Example 52, reactions were carried out under the same reaction conditions as in Example 53. The results are shown in Table 10.

TABLE 10__________________________________________________________________________ Conversion Selectivity of forExample Temperature isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________56 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.0.5 Te.sub.2 O.sub.h 380 96.0 90.957 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 420 93.1 92.058 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 410 94.8 90.559 Mo.sub.12 Fe.sub.2 Ni.sub.2 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 95.8 91.060 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 380 96.2 91.161 Mo.sub.12 Fe.sub.1 Ni.sub.1 Cs.sub.0.3 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 96.8 90.862 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 98.0 90.163 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.1 Pb.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 97.7 90.564 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 92.2 91.065 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 380 97.0 90.966 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 Te.sub.0.3 Te.sub.2 O.sub.h 400 93.3 92.067 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 92.0 91.168 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 91.6 92.069 Mo.sub.12 Fe.sub.4 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 420 93.2 90.970 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.4 O.sub.h 380 96.5 91.871 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.1 O.sub.h 410 95.3 90.572 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.3 Te.sub.2 O.sub.h 420 96.6 90.273 Mo.sub.12 Fe.sub.1 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 Ti.sub.1 Te.sub.2 O.sub.h 370 97.6 90.174 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 Cu.sub.1 Ti.sub.0.2 Te.sub.2 O.sub.h 380 96.6 91.5__________________________________________________________________________

Comparative Examples 18-25

Using catalysts having the compositions shown in Table 11 which had been prepared under the same preparative conditions as in Example 52, reactions were carried out under the same reaction conditions as in Example 53. The results are shown in Table 11.

TABLE 11__________________________________________________________________________Compar- Conversion Selectivityative of forExample Temperature isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________18 Mo.sub.12 Fe.sub.1 Ni.sub.1 Te.sub.2 Cu.sub.1 Ti.sub.0.3 O.sub.h 400 97.4 81.019 Mo.sub.12 Fe.sub.1 Ni.sub.1 Na.sub.0.3 Te.sub.2 Cu.sub.1 Ti.sub.0.3 O.sub.h 400 95.3 82.220 Mo.sub.12 Fe.sub.0.2 Ni.sub.0.2 Tl.sub.0.3 Te.sub.2 Cu.sub.1 Ti.sub.0.3 O.sub.h 420 67.3 86.721 Mo.sub.12 Fe.sub.1 Tl.sub.0.3 Te.sub.2 Cu.sub.1 Ti.sub.0.3 O.sub.h 400 53.5 85.222 Mo.sub.12 Fe.sub.9 Ni.sub.4 Tl.sub.0.3 Te.sub.2 Cu.sub.1 Ti.sub.0.3 O.sub.h 400 61.4 79.923 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Te.sub.6 Cu.sub.1 Ti.sub.0.3 O.sub.h 400 91.5 86.324 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Te.sub.2 Cu.sub.1 Ti.sub.6 O.sub.h 420 62.8 81.325 Fe.sub.1 Ni.sub.1 Te.sub.4 Cu.sub.1 Ti.sub.0.3 Tl.sub.0.3 O.sub.h 420 12.9 46.0__________________________________________________________________________

EXAMPLES 75-77

Using the same catalysts as used in Examples 53-54, reactions were carried out continuously for 100 hours under the same reaction conditions as in the respective Examples. The results are shown Table 12.

TABLE 12__________________________________________________________________________ At the start of measurement After 100 hours Conversion Selectivity Conversion Selectivity of for of forExample Temperature isobutylene methacrolein isobutylene methacroleinNo. Composition of catalyst (.degree.C.) (%) (%) (%) (%)__________________________________________________________________________75 Mo.sub.12 Pb.sub.2 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 Ti.sub.1 Te.sub.2 O.sub.h 400 93.5 92.8 93.4 92.876 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 Ti.sub.0.3 Te.sub.2 O.sub.h 380 94.8 91.4 94.9 91.477 Mo.sub.12 Cu.sub.1 Tl.sub.0.3 Fe.sub.1 Ni.sub.1 Ti.sub.1 Te.sub.2 O.sub.h 380 96.7 90.9 96.7 90.9__________________________________________________________________________

EXAMPLES 78-80

A Pyrex reaction tube having an inner diameter of 5 mm was packed with 5 g of each of the catalysts having the compositions shown in Table 13 which had been prepared under the same preparative conditions as in Example 52, and reactions were carried out at a reaction temperature of 380.degree.-440.degree. C.

The starting gas had a molar ratio of tertiary butanol/O.sub.2 /H.sub.2 O/He=3/6/20/71. The contact time was 2.5 seconds. The results are shown in Table 13.

TABLE 13__________________________________________________________________________ Selectivity Selectivity for acetic Conversion for acid plusExample Temperature of t-BuOH methacrolein methacrylicNo. Composition of catalyst (.degree.C.) (%) (%) acid (%)__________________________________________________________________________78 Mo.sub.12 Pb.sub.2 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.1 Te.sub.2 O.sub.h 400 93.3 92.8 0.879 Mo.sub.12 Cu.sub.1 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.0.3 Te.sub.2 O.sub.h 380 94.5 91.6 0.880 Mo.sub.12 Cu.sub.1 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.1 Te.sub.2 O.sub.h 380 96.7 90.9 0.9__________________________________________________________________________

EXAMPLES 81-99

Using catalysts having the compositions shown in Table 14 which had been prepared under the same preparative conditions as in Example 52, reactions were carried out under the same reaction conditions as in Examples 78-80. The results are shown in Table 14.

TABLE 14__________________________________________________________________________ Selectivity Conversion for methacrylicExample Temperature of t-BuOH acidNo. Composition of catalyst (.degree.C.) (%) (%)__________________________________________________________________________81 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Ti.sub.0.5 Te.sub.2 O.sub.h 380 95.8 90.982 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 420 93.1 91.883 Mo.sub.12 Fe.sub.4 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 410 94.5 90.684 Mo.sub.12 Fe.sub.2 Ni.sub.2 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 95.5 91.185 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 380 96.0 91.386 Mo.sub.12 Fe.sub.1 Ni.sub.1 Cs.sub.0.3 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 96.6 90.787 Mo.sub.12 Fe.sub.1 Ni.sub.1 Rb.sub.0.3 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 97.8 90.388 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.1 Pb.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 97.6 90.589 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 92.2 91.090 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 380 96.9 90.891 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 Ti.sub.0.5 Te.sub.2 O.sub.h 400 93.1 92.092 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Nd.sub.1 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 92.1 91.093 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Sm.sub.1 Pb.sub.2 Ti.sub.0.5 Te.sub.2 O.sub.h 400 91.5 92.094 Mo.sub.12 Fe.sub.4 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 Tl.sub.0.5 Te.sub.2 O.sub.h 420 93.1 90.995 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.4 O.sub.h 380 96.3 91.796 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.0.5 Te.sub.1 O.sub.h 410 95.4 90.597 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Cu.sub.1 Ti.sub.3 Te.sub.2 O.sub.h 420 96.1 90.198 Mo.sub.12 Fe.sub.1 Ni.sub.4 Tl.sub.0.3 Cu.sub.1 Ti.sub.1 Te.sub.2 O.sub.h 370 97.6 90.199 Mo.sub.12 Fe.sub.1 Ni.sub.1 Tl.sub.0.3 Pb.sub.2 Cu.sub.1 Ti.sub.0.2 Te.sub.2 O.sub.h 380 96.5 91.6__________________________________________________________________________

Claims

1. A process for producing methacrolein by oxidizing isobutylene or tertiary butanol with molecular oxygen in the presence of a catalyst, characterized in that the oxidation is conducted at a temperature of 200.degree. to 550.degree. C. at a pressure of 9.5 to 10 atm at a space velocity of 100 to 5,000 hr.sup.-1 for a contact time of 0.1 to 15 sec and the catalyst has the general composition:

Mo.sub.12 Fe.sub.a Ni.sub.b Te.sub.c X.sub.d Z.sub.f Y.sub.g O.sub.h

wherein a, b, c, d, f and g represent the numbers of atoms of the respective elements per 12 molybdenum atoms; X is Tl, Rb or Cs; Z is In or Ti; Y represents at least one element selected from the group consisting of Cu, Nd, Sm and Pb; a is a value of 0.2-6; b is a value of 0.2-6; a+b is a value of 1-10; c is a value of 0.1-4; d is a value of 0.1-3; f is a value of 0.1-3; g is a value of 0-5; and h is the number of oxygen atoms for satisfying the valencies of the existing elements.

2. A process according to claim 1, wherein said catalyst is supported on a carrier.

3. A process according to claim 2, wherein said carrier is silica, silicon carbide or alumina.

4. A process according to any one of claims 1-3, wherein the reaction is carried out at a temperature of 250.degree.-450.degree. C. at a pressure ranging from normal pressure to 2 atmospheres.

5. A process according to any one of claims 1-3, wherein a gaseous mixture comprising isobutylene or tertiary butanol, air or oxygen, steam and an inert gas is contacted with said catalyst under normal pressure.