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1. (WO2005063674) PROCEDE POUR PRODUIRE UN ALDEHYDE INSATURE ET/OU UN ACIDE INSATURE
Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

Claims
1. A method for producing unsaturated aldehydes from olefins by means of fixed-bed catalytic partial oxidation in a shell-and-tube reactor, characterized in that the reactor includes a reaction zone for producing unsaturated aldehydes comprising two or more catalytic layers, each of the catalytic layers being packed with a formed product of catalyst as secondary particles, wherein the secondary particles in each catalytic layer are formed of primary particles of a catalytically active component having a different particle size, and the particle size of primary particles of the catalytically active component is controlled so that it decreases from an inlet of the reactor to an outlet of the reactor.

2. The method according to claim 1, wherein the catalytically active component is a compound represented by the following formula 1:
[formula 1]
MoaAbBcCdDeEfFgOh
wherein Mo is molybdenum;
A is at least one element selected from the group consisting of Bi and Cr;
B is at least one element selected from the group consisting of Fe, Zn, Mn, Nb and Te;
C is at least one element selected from the group consisting of Co, Rh and Ni;
D is at least one element selected from the group consisting of W, Si, Al, Zr, Ti, Cr, Ag and Sn;
E is at least one element selected from the group consisting of P, Te, As, B, Sb, Sn, Nb, Cr, Mn, Zn, Ce and Pb;

F is at least one element selected from the group consisting of Na, K, Li, Rb, Cs, Ta, Ca, Mg, Sr, Ba and MgO; and
each of a, b, c, d, e, f and g represents the atomic ratio of each element, with the proviso that when a=10, b is a number of between 0.01 and 10, c is a number of between 0.01 and 10, d is a number of between 0 and 10, e is a number of between 0 and 10, f is a number of between 0 and 20, g is a number of between 0 and 10, and h is a number defined depending on the oxidation state of each of the above elements.

3. A method for producing unsaturated acids from unsaturated aldehydes by means of fixed-bed catalytic partial oxidation in a shell-and-tube reactor, characterized in that the reactor includes a reaction zone for producing unsaturated acids comprising two or more catalytic layers, each of the catalytic layers being packed with a formed product of catalyst as secondary particles, wherein the secondary particles in each catalytic layer are formed of primary particles of a catalytically active component having a different particle size, and the particle size of primary particles of the catalytically active component is controlled so that it decreases from an inlet of the reactor to an outlet of the reactor.

4. The method according to claim 3, wherein the catalytically active component is a compound represented by the following formula 2:
[formula 2]
MoaWbVcAdBeCfOx
wherein Mo is molybdenum;

W is tungsten;
V is vanadium;
A is at least one element selected from the group consisting of iron (Fe) , copper (Cu) , bismuth (Bi) , chrome (Cr) , cobalt (Co) and manganese (Mn) ;
B is at least one element selected from the group consisting of tin (Sn) , antimony (Sb) , nickel (Ni) , cesium (Cs) and thallium (Tl) ;
C is at least one element selected from the group consisting of alkali metals and alkaline earth metals;
0 is an oxygen atom; and
each of a, b, c, d, e and x represents the atomic ratio of Mo, W, V, A, B and 0 atoms, with the proviso that when a=10, 0.5 <b < 4, 0.5 c ≤ 5, 0 <d ≤ 5, 0 <e < 2, 0 ≤f ≤ 2, and x is a number defined depending on the oxidation state of each of the above elements.

5. The method according to claim 1 or 3, wherein the formed product of catalyst is a formed catalyst obtained by binding a plurality of primary particles formed of a catalytically active component and forming them into a desired shape, or a supported catalyst obtained by supporting a plurality of primary particles formed of a catalytically active component on an inactive carrier having a desired shape.

6. The method according to claim 1 or 3, wherein the catalytic layer having the largest size of primary particles of catalytically active component includes a hot spot whose temperature is the highest, and the size of the primary particles ranges from 10 to 150 microns.

7. A shell-and-tube reactor that may be used in a method for producing unsaturated aldehydes and/or unsaturated acids from olefins by means of fixed-bed catalytic partial oxidation, characterized in that the reactor includes at least one reaction zone of a first-step reaction zone for producing unsaturated aldehydes as a main product and a second-step reaction zone for producing unsaturated acids as a main product, and at least one reaction zone of the reaction zones comprises two or more catalytic layers, each of the catalytic layers being packed with a formed product of catalyst as secondary particles, wherein the secondary particles in each catalytic layer are formed of primary particles of a catalytically active component having a different particle size, and the particle size of primary particles of the catalytically active component is controlled so that it decreases from an inlet of the reactor to an outlet of the reactor.

8. The reactor according to claim 7, wherein the catalytically active component is obtained by agitating and mixing a solution of salts of metals forming a metal oxide to form an aqueous catalyst solution or suspension; and carrying out a pulverization step during or after the formation of the aqueous catalyst solution or suspension in order to control the primary particle size of the catalytically active component.

9. The reactor according to claim 7, wherein the catalytically active component is obtained by agitating and mixing a solution of salts of metals forming a metal oxide to form an aqueous catalyst solution or suspension; and drying the aqueous catalyst solution or suspension to obtain powder and pulverizing the powder to control the primary particle size of the catalytically active component.

10. The reactor according to claim 7, wherein the formed product of catalyst is a formed catalyst obtained by binding a plurality of primary particles formed of a catalytically active component and forming them into a desired shape, or a supported catalyst obtained by supporting a plurality of primary particles formed of a catalytically active component on an inactive carrier having a desired shape.

11. The reactor according to claim 7, wherein the catalytic bed is packed in two catalytic layers, including a first layer having a catalytically active component with a primary particle size of 10-150 microns and a second layer having a catalytically active component with a primary particle size of 10 microns or less.

12. The reactor according to claim 7, wherein the catalytic bed is packed in th-ree catalytic layers, including a first layer having a catalytically active component with a primary particle size of 10-150 microns, a second layer having a catalytically active component with a primary particle size of 1-10 microns, and a third layer having a catalytically active component with a primary particle size of 1 micron or less.