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    • 专利摘要:
    CATALYTIC CONVERSION OF LACTIC ACID TO ACRYLIC ACID The catalytic dehydration of lactic acid to acrylic acid is presented in the present invention, which is characterized by a high conversion of lactic acid, a high selectivity of acrylic acid, a high yield of acrylic acid, and correspondingly, low selectivity and molar yields for unwanted by-products. This is achieved with a specific class of catalysts defined by a mixture of metal-containing phosphate salts which together provides the catalyst with a very high basic density and low acid density. Additionally, it is believed that the catalyst is stable and active for prolonged periods and has not yet been studied in the art by such dehydration processes.
    公开号:BR112014025347B1
    申请号:R112014025347-1
    申请日:2013-04-11
    公开日:2020-12-01
    发明作者:Janette Villalobos Lingoes；Dimitris Ioannis Collias
    申请人:The Procter & Gamble Company；
    IPC主号:
    专利说明:

    [0001] [0001] The description refers, in general, to the conversion of lactic acid into acrylic acid and the catalysts usable for it. More specifically, the description relates to the catalytic dehydration of lactic acid to acrylic acid and to catalysts capable of carrying out the same without significant conversion of lactic acid into unwanted by-products, such as, for example, acetic and propanoic acids.
    [0002] [0002] Acrylic acid has a variety of industrial uses, typically consumed in the form of a polymer. In turn, these polymers are commonly used in the manufacture of, among other things, adhesives, binders, coatings, paints, varnishes and superabsorbent polymers that are used in disposable absorbent articles including diapers and hygienic products, for example. Acrylic acid is commonly produced from petroleum derivatives. For example, acrylic acid has long been prepared by catalytic oxidation of propylene. These and other methods of preparing acrylic acid from petroleum derivatives are described in Kirk-Othmer Encyclopedia of Chemical Technology, Vol. 1, pages 342 to 369 (5th Ed., John Wiley & Sons, Inc., 2004).
    [0003] [0003] Increasingly, however, there is an interest in producing acrylic acid based on non-petroleum derivatives, such as lactic acid. US Patent Nos. 4,729,978 and 4,786,756 in general describe the conversion of lactic acid to acrylic acid. These patents teach that conversion can be achieved by contacting lactic acid and water with a metal oxide conductor impregnated with a phosphate salt, such as the monobasic or dibasic potassium phosphate salts KH2PO4 or K2HPO4, respectively, or aluminum phosphate. These impregnated conductors are acid catalysts and, at least the '978 patent, emphasizes that the number and intensity of acidic sites on the conductor's surface appear to influence selectivity and conversion to acrylic acid.
    [0004] [0004] Recent research has additionally focused on modifications of acid catalysts used to convert lactic acid into acrylic acid. This research included studies on acid catalysts (calcium and cupric sulfates) modified with potassium phosphate salts and the effect that reaction temperature and carrier gas feed selection have on conversion and selectivity to acrylic acid. See Lin et al. (2008) Can. J. Chem. Eng. 86: 1047 to 1053. The study reveals, however, that the best molar yield of acrylic acid that its researchers were able to obtain was 63.7% and that it was only with the aid of carbon dioxide as a carbon dioxide gas. drag and contact time (88 seconds) too high for any practical commercial manufacturing process. More recent research has revealed that the phosphate and nitrate salts may desirably change the surface acidity of acid catalysts to inhibit the decarbonization / decarboxylation of lactic acid to acetaldehyde, often an unwanted by-product of conversion. See Huang et al. (2010) Ind. Eng. Chem. Res. 49: 9082; see also, Weiji et al. (2011) ACS Catal. 1:32 to 41.
    [0005] [0005] Notwithstanding these teachings, however, the data from all this research still shows high amounts of unwanted by-products, such as acetaldehyde and propanoic acid. It is believed that the proximity of the alpha-hydroxyl group to the carboxylate group in lactic acid is responsible for these by-products, which may also include carbon monoxide, carbon dioxide, 2,3-pentanedione and lactic acid oligomers. By-products can be deposited on the catalyst resulting in premature and rapid fouling and deactivation of the catalyst, as indicated in the publication by Lin et al., For example. In addition, once deposited, these by-products can catalyze other undesired reactions in the process, such as polymerization reactions.
    [0006] [0006] In addition to being deposited on the catalysts, these by-products - even when present in only small quantities - mean additional costs when processing acrylic acid (when present in the effluent of the reaction product) in the manufacture of superabsorbent polymers, for example. And the literature on the manufacture of these polymers is replete with possible solutions — expensive as they can be — to remove impurities (like acetic acid and propanoic acid) when present among acrylic acid manufactured in merely small quantities. For example, US Patent No. 6,541,665 B1 describes the purification of acrylic acid containing propanoic acid, furans, water, acetic acid and aldehydes by crystallization, distillation and recycling. The '665 patent reports that a 5-stage crystallization (two purification stages and three extraction stages) was effective in obtaining 99.94% acrylic acid from a 99.48% acrylic acid mixture containing 2600 parts per million (based on weight) (ppm) of acetic acid and 358 ppm of propanoic acid, among others. Similarly, US patent application publication No. 2011/0257355 describes a method for removing propanoic acid in a single crystallization stage, from a crude reaction mixture (containing acrylic acid) derived from dehydration / oxidation of the glycerol to obtain 99% acrylic acid. These purification methods are necessary to obtain a highly pure acrylic acid needed for downstream uses in, for example, the manufacture of superabsorbent polymers. Thus, there is certainly value in removing impurities, if possible, just to be able to employ these purification methods.
    [0007] [0007] But, to date, the manufacture of acrylic acid from lactic acid by processes, such as those described in the recent literature noted above, results in significant amounts of unwanted by-products — in fact, very high amounts of by-products for even use the purification methods identified in the previous paragraph. Certainly, the low selectivity for acrylic acid in these processes also results in a loss of raw material, and, ultimately, results in increased production costs. As such, none of these processes for converting lactic acid to acrylic acid are commercially viable. SUMMARY OF THE INVENTION
    [0008] [0008] It has now been discovered that acrylic acid can be produced in a high molar yield of lactic acid without the deficiencies noted above. This production of acrylic acid is accompanied by a high conversion of lactic acid, a high selectivity of acrylic acid and a high yield of acrylic acid and, correspondingly, low selectivity and molar yield for unwanted by-products. This production is achieved with a specific class of catalysts and used under certain processing conditions. The result of the process, however, is an acrylic acid product sufficient for conventional industrial uses and one that may not require the complicated purification currently required in the art.
    [0009] [0009] Various types of suitable catalysts are disclosed in the present invention. One embodiment is a phosphate mixing catalyst that includes at least two different phosphate salts selected from the group consisting of Formulas (I), (II), (III) and (IV): ZH2PO4 (I) X2-aHPO4, (II) X3 (PO4) 2-b (III) X2 + cP2O7, (IV).
    [0010] [00010] In this modality, Z is a Group I metal. Additionally, in each of Formulas (II) to (IV), each X is independently a Group I or Group II metal. Countless conditions still define the phosphate mix catalyst. Specifically, in Formula (II), when X is a Group I metal, a is 0 and when X is a Group II metal, a is 1. Additionally, in Formula (III), when X is a Group I metal , b is 1 and when X is a Group II metal, b is 0. Also in Formula (IV), when X is a Group I metal, c is 2 and when X is a Group II metal, c is 0.
    [0011] [00011] Another embodiment of the phosphate mixing catalyst also includes at least two different phosphate salts. Here, however, a phosphate salt is a precipitation product of phosphoric acid (H3PO4) and a nitrate salt of Formula (V): X (NO3) 2-b (V).
    [0012] [00012] Another of the phosphate salts is selected from the group consisting of Formulas (I), (II), (III) and (IV), presented above. The variables X and b in Formula (V) are as defined above, with respect to Formula (III). More specifically, in each of Formulas (III) and (V), when X is a Group I metal, b is 1 and when X is a Group II metal, b is 0.
    [0013] [00013] In yet another embodiment, the phosphate mixing catalyst again includes at least two different phosphate salts. Here, however, the at least different phosphate salts are products of a coprecipitation of phosphoric acid (H3PO4) and two different nitrate salts of Formula (V), as defined above.
    [0014] [00014] These catalysts can be used in various ways of converting lactic acid into acrylic acid. According to one embodiment, a method for producing acrylic acid includes contact with a phosphate mixture catalyst and a gas mixture that includes water and lactic acid, under conditions sufficient to produce acrylic acid in a molar yield of at least 50% of the lactic acid. The phosphate mixture catalyst includes a mixture of at least different phosphate salts, and the phosphate mixture catalyst has a surface acid density of about 0.35 mmol / m2 or less and a surface basic density of at least about 2 mmol / m2.
    [0015] [00015] Alternative methods of producing acrylic acid include catalytic gas-phase dehydration of lactic acid by contact with a gas mixture that includes lactic acid and water with a phosphate mixture catalyst, which includes at least two different selected phosphate salts of the group consisting of Formulas (I), (II), (III) and (IV), as defined above. Another form of acrylic acid production includes the catalytic gas-phase dehydration of lactic acid by contact with a gas mixture that includes lactic acid and water, with a phosphate mixture catalyst that also includes at least two different phosphate salts. But here, at least one phosphate salt is a precipitation product of phosphoric acid (H3PO4) and a nitrate salt of Formula (V) defined above, and the other phosphate salt is selected from the group consisting of Formulas (I) , (II), (III) and (IV), as defined above. In yet another form of acrylic acid production, the method includes catalytic dehydration in the gas phase of lactic acid by contact with a gas mixture that includes lactic acid and water, with a phosphate mixture catalyst that again includes at least two salts different phosphate levels. Here, the phosphate mixture catalyst includes at least two different phosphate salts that are products of a phosphoric acid (H3PO4) coprecipitation and two different nitrate salts of Formula (V), as defined above.
    [0016] [00016] Additional features of the invention may be evident to those skilled in the art from an analysis of the detailed description below, taken in combination with the examples, the drawings of the Figures and the attached claims. BRIEF DESCRIPTION OF THE DRAWINGS
    [0017] [00017] For a more complete understanding of the description, reference should be made to the following detailed description and drawing of the Figure, which graphically illustrates the composition of the by-products and quantities of each of those present in the conversion of lactic acid to acrylic acid, according to the examples set out below. Although the catalysts and methods presented are susceptible to modalities in various forms, they are illustrated in the drawings (and from now on will be described) of the specific modalities of the invention, in the sense that the description is intended to be illustrative and is not intended to limit the invention to the specific modalities described and illustrated herein. DETAILED DESCRIPTION OF THE INVENTION
    [0018] [00018] Acrylic acid can be produced in a high molar yield from lactic acid, without the deficiencies prevalent in the technique. This production is accompanied by a high conversion of lactic acid, a high selectivity of acrylic acid, a high yield of acrylic acid, and correspondingly low selectivity and molar yield for unwanted by-products. This production is achieved with a specific class of catalysts and used under certain processing conditions. The result of the process, however, is an acrylic acid product sufficient for conventional industrial uses and one that cannot require the complicated purification currently required in the art. The catalyst
    [0019] [00019] The functional capabilities of the catalyst in the context of producing acrylic acid from lactic acid are discussed below. The catalyst is generally a phosphate mixture catalyst that has certain physical characteristics and is defined by a specific class of chemicals.
    [0020] [00020] A phosphate mix catalyst modality includes at least two different phosphate salts selected from the group consisting of Formulas (I), (II), (III) and (IV): ZH2PO4 (I) X2-aHPO4, (II) X3 (PO4) 2-b (III) X2 + cP2O7, (IV).
    [0021] [00021] In this modality, Z is a Group I metal. Additionally, in each of Formulas (II) to (IV), each X is independently a Group I or Group II metal. Countless conditions still define the mixed phosphate catalyst. Specifically, in Formula (II), when X is a Group I metal, a is 0 and when X is a Group II metal, a is 1. Additionally, in Formula (III), when X is a Group I metal , b is 1 and when X is a Group II metal, b is 0. Also in Formula (IV), when X is a Group I metal, c is 2 and when X is a Group II metal, c is 0.
    [0022] [00022] Certain embodiments of this catalyst include the phosphate salt of Formula (II), where X is potassium (K), the phosphate salt of Formula (III), where X is barium (Ba) and / or the salt phosphate of Formula (IV), where X is calcium (Ca). Consequently, the catalyst can include K2HPO4 and Ba3 (PO4) 2. Alternatively, the catalyst can include K2HPO4 and Ca2P2O7.
    [0023] [00023] In general, this phosphate mixture catalyst is prepared simply by physically mixing the at least two phosphate salts together and thereafter calcining the mixture and, optionally, sifting to form a suitable catalyst to be used in converting lactic acid into acrylic acid, as described in more detail below.
    [0024] [00024] Another embodiment of the phosphate mixing catalyst also includes at least two different phosphate salts. Here, however, a phosphate salt is a precipitation product of phosphoric acid (H3PO4) and a nitrate salt of Formula (V): X (NO3) 2-b (V).
    [0025] [00025] Another of the phosphate salts is selected from the group consisting of Formulas (I), (II), (III) and (IV), presented above. The variables X and b in Formula (V) are as defined, above with respect to Formula (III). More specifically, in each of Formulas (III) and (V), when X is a Group I metal, b is 1 and when X is a Group II metal, b is 0.
    [0026] [00026] Certain modalities of this catalyst include not only the precipitation product noted above, but also the phosphate salt of Formula (II), where X is potassium and / or the phosphate salt of Formula (III), where X it's barium. Consequently, the catalyst can include K2HPO4 and the precipitation product of phosphoric acid and Ba (NO3) 2. In general, this phosphate mixing catalyst is prepared by mixing an aqueous solution of nitrate salt with one or more of the phosphate salts and, thereafter, adding phosphoric acid and drying the combination of materials to repel nitric acid and result in a catalyst product mixture that contains at least two phosphate salts. After calcination and optional sieving, the phosphate mixing salt is suitable for use in converting lactic acid to acrylic acid, as described in more detail below.
    [0027] [00027] In yet another embodiment, the phosphate mixing catalyst again includes at least two different phosphate salts. Here, however, the at least different phosphate salts are products of a coprecipitation of phosphoric acid (H3PO4) and two different nitrate salts of Formula (V), as defined above.
    [0028] [00028] In general, this phosphate mix catalyst is prepared by mixing the two nitrate salts with water to form an aqueous solution of it and, after that, add phosphoric acid and dry the combination of materials to repel nitric acid and result in a catalyst product mixture that contains at least two phosphate salts. After calcination and optional sieving, the phosphate mixing salt is suitable for use in converting lactic acid to acrylic acid, as described in more detail below.
    [0029] [00029] In various embodiments of the phosphate mixture catalysts described above, the metals in the different phosphate salts can be the same. Alternatively, metals can also be different from each other, but when this is the case, then metals preferably have atomic radii that differ by 30 picometers (µm) or less. For example, when metals are different, then preferably they are selected from the group consisting of (a) potassium and calcium, (b) lithium (Li) and magnesium (Mg), (c) calcium and barium, (d) sodium (Na) and calcium, and (e) potassium and strontium (Sr).
    [0030] [00030] When the phosphate mixing catalyst includes two different phosphate salts, preferably the two metals are present in a ratio (molar) to the other of about 1: 9 to about 9: 1. For example, when the phosphate mix catalyst includes dibasic potassium phosphate (K2HPO4) and a phosphate salt that is a precipitation product of phosphoric acid (H3PO4) and barium nitrate (Ba (NO3) 2), potassium and barium are preferably present in a molar ratio, K: Ba, of about 2: 3.
    [0031] [00031] The phosphate mix catalyst can also include a conductor and support the different phosphate salts. Preferably, the conductor is selected from the group consisting of silica, silica sol, silica gel, alumina, alumina silicate, silicon carbide, diatomaceous earth, titanium dioxide, quartz, diamonds, carbon, zirconium oxide, oxide magnesium, cerium oxide, niobium oxide, and mixtures thereof. More preferably, the conductor is inert to the expected reaction mixture to come into contact with the catalyst. In the context of the reactions expressly described herein, therefore, the conductor is preferably a silica or zirconium oxide (for example, Zirblast). When present, the conductor is present in an amount of about 5% by weight to about 90% by weight, based on the total weight of the catalyst.
    [0032] [00032] The catalyst is preferably calcined at a temperature of about 250 ° C to about 450 ° C for about an hour to about four hours. Most preferably, the catalyst is calcined at 450 ° C for four hours (with an increase of 2 ° C per minute). The catalyst can be regenerated, as needed, under similar conditions. After calcination, the catalyst is preferably sieved to provide a more uniform product. Preferably, the catalyst is sieved at an average particle size of about 100 micrometers (µm) to about 200 µm. In addition, the particle size distribution of the catalyst particles preferably includes a particle polydispersion less than about 3, more preferably, less than about 2 and, most preferably, less than about 1.5. For use in the present invention, the term "average particle size" refers to the diameter of a particle below or above, in which 50% of the total particle volume is located. This average particle size is designated as Dv, 0.50. Although several methods and equipment are known to those skilled in the art for fractioning particles into different sizes, sieving is one of the easiest, least expensive and most common methods for measuring particle sizes and particle size distributions. An alternative way of determining the particle size distribution is light scattering. For use in the present invention, the term "particle polydispersity" refers to a statistical representation of a given particle sample and can be calculated as follows. First, the average particle size, Dv, 0.50, is calculated as described above. Then, using a similar method, the particle size that separates the particle sample in the 10% by volume fraction, Dv, 0.10, is determined, and then the particle size that separates the particle sample in the fraction 90 % by volume, Dv, 0.90, is determined. The particle polydispersity is then equal to (Dv, 0.90 - Dv, 0.10) / Dv, 0.50.
    [0033] [00033] Importantly, it has been found that the phosphate mixing catalysts described herein are, in functional terms, much more superior to anything else in the art in the context of acrylic acid production due to certain physical characteristics. Specifically, phosphate mixing catalysts preferably have a surface acid density of about 0.35 millimolar per square meter (mmol / m2) or less, more preferably about 0.001 mmol / m2 to about 0, 35 mmol / m2. The density of surface acidity is preferably measured by desorption at the programmed ammonia temperature (ammonia TPD) up to 400 ° C in mmol / g and converted to mmol / m2 using the catalyst surface area measured by BET (in m2 / g). In addition, phosphate mixing catalysts preferably have a surface basic density of at least about 2 mmol / m2, more preferably about 20 mmol / m2 to about 100 mmol / m2, and most preferably about 30 mmol / m2 to about 80 mmol / m2. Surface basic density is preferably measured by desorption at the program temperature of carbon dioxide (CO2 TPD) up to 400 ° C in mmol / g and converted to mmol / m2 using the surface area of the catalyst measured by BET (in m2 / g). Methods for producing acrylic acid
    [0034] [00034] Catalyst modalities described above can be used to produce acrylic acid from a reaction mixture containing lactic acid and water. A specific embodiment of this process includes contact with a phosphate mixture catalyst and a gas mixture that includes water and lactic acid under conditions sufficient to produce acrylic acid in a molar yield of at least 50% of the lactic acid. The phosphate mixture catalyst includes a mixture of at least different phosphate salts, and the phosphate mixture catalyst has a surface acid density of about 0.35 mmol / m2 or less, and a surface basic density of at least least about 2 mmol / m2. In preferred embodiments, the phosphate mixing catalyst has a surface basic density of about 20 mmol / m2 to about 100 mmol / m2, and most preferably about 30 mmol / m2 to about 80 mmol / m2. In preferred embodiments, the conditions are sufficient to produce acrylic acid in a molar yield of at least 50% of the lactic acid, more preferably at least about 70% and, most preferably, at least about 80%. In other preferred embodiments, the conditions are sufficient to result in an acrylic acid selectivity of at least about 65% of lactic acid, more preferably at least about 75% and, most preferably, at least about 90% .
    [0035] [00035] Without adhering to any theory, it is believed that phosphate mixture compounds result in a very high surface basicity (ie, a highly basic catalyst) compared to what a mixture rule may have predicted, based on in the values of density of superficial basicity of the pure phosphate salts, and a highly basic catalyst is responsible for the high yield of acrylic acid, high conversion of lactic acid, high selectivity of acrylic acid, and low selectivity of by-products of the common conversion in the art. This is because the reactive intermediates associated with the acidity-promoting process are avoided or minimized.
    [0036] [00036] The gas mixture which comes in contact with the catalyst preferably also includes an inert gas, that is, a gas otherwise inert to the reaction mixture and the catalyst under the conditions of the process. Inert gas is preferably selected from the group consisting of nitrogen, helium, neon, argon and mixtures thereof. Most preferably, the inert gas is selected from the group consisting of nitrogen, helium, neon, argon and mixtures thereof.
    [0037] [00037] In this way, the gas mixture in contact with the catalyst can comprise, upstream of the catalyst, separate the carrier gas feeds and a liquid that is made from an aqueous solution of lactic acid and in certain modalities derived from lactic acid , and one or more of lactide, lactic acid dimer, lactic acid salts, and alkyl lactates. Lactic acid derivatives include one or more of the lactic acid oligomers and lactic acid polymerization products. Preferably, however, the liquid includes lactic acid, based on the total weight of the liquid, from about 5% by weight to about 95% by weight, more preferably about 10% by weight to about 50% by weight, and even more preferably about 17% by weight to about 25% by weight. Furthermore, preferably, the liquid mixture contains less than about 30% by weight of the lactic acid derivatives, more preferably less than about 10% by weight, and more preferably even less than about 5%, by weight, lactic acid derivatives, based on the total weight of the liquid.
    [0038] [00038] The liquid is combined with the carrier gas at a temperature sufficient to form the gas mixture that contacts the catalyst. The conditions under which the gas mixture contacts the catalyst preferably include a temperature of about 250 ° C to about 450 ° C, more preferably about 300 ° C to about 375 ° C, and most preferably about from 325 ° C to about 350 ° C. The gas mixture preferably includes lactic acid in an amount of about 5 mol% or less, more preferably about 2.3 mol% to about 3.5 mol%, based on the total moles of the gas mixture. The amount of lactic acid can be controlled by the amount of carrier gas used. Specifically, by controlling the hourly space velocity of gas (GHSV), it is possible to control the amount of lactic acid in the gas mixture in contact with the catalyst. Thus, the conditions preferably include a GHSV of about 2200 per hour (h-1) to about 7900 h-1, more preferably about 3500 h-1.
    [0039] [00039] Preferably, the process is carried out in a reactor that contains an internal quartz surface. Alternatively, the process can be done in a stainless steel (SS) reactor or a reactor made from Hastelloy, inconel, borosilicate or manufactured sapphire. Preferably, the reactor has an aspect ratio (length / diameter) of about 50 to about 100, preferably about 75.
    [0040] [00040] Among the benefits obtained by the previously mentioned modalities are the low molar yield of by-products. For example, the conditions are sufficient to produce propanoic acid in a molar yield of less than about 6%, more preferably less than about 1%, of the lactic acid present in the gas mixture. Similarly, conditions are sufficient to produce each of acetic acid, pyruvate, 1,2-propanediol, and 2,3-pentanedione in a molar yield of less than about 2%, more preferably less than about 0, 5%, of lactic acid present in the gas mixture. Similarly, the conditions are sufficient to produce acetaldehyde in a molar yield of less than about 8%, more preferably less than about 4%, and even more preferably less than about 3%, of the lactic acid present in the mixture. gaseous These are yields that are believed to be inaccessibly low so far. Yet, these benefits are in fact possible as evidenced in the Examples set out below.
    [0041] [00041] Alternative methods of producing acrylic acid include catalytic gas-phase dehydration of lactic acid by contact with a gas mixture that includes lactic acid and water, with a phosphate mixture catalyst that includes at least two different selected phosphate salts of the group consisting of Formulas (I), (II), (III) and (IV), as defined above. Another embodiment of acrylic acid production includes catalytic gas-phase dehydration of lactic acid by contact with a gas mixture that includes lactic acid and water with a phosphate mixture catalyst that also includes at least two different phosphate salts. But here, at least one phosphate salt is a precipitation product of phosphoric acid (H3PO4) and a nitrate salt of Formula (V), defined above, and the other phosphate salt is selected from the group consisting of Formulas (I ), (II), (III) and (IV), as defined above. In yet another form of acrylic acid production, the method includes catalytic gas-phase dehydration of lactic acid by contact with a gas mixture that includes lactic acid and water with a phosphate mixture catalyst that again includes at least two salts of different phosphates. Here, the phosphate mixture catalyst includes at least two different phosphate salts that are products of a phosphoric acid (H3PO4) coprecipitation and two different nitrate salts of Formula (V), as defined above. Examples
    [0042] [00042] The following examples are provided to illustrate the invention, but are not intended to limit the scope of the invention. Examples 1 through 4 describe the preparation of five different phosphate mixing catalysts according to the various modalities described above. Example 5 describes the preparation of catalysts not according to the invention. Example 6 describes a laboratory-scale experiment of converting lactic acid to acrylic acid using the catalysts described in examples 1 through 5, and the results thereof. Example 7 describes an experiment to determine the activity of a catalyst according to the invention and reports the data obtained from that experiment. Example 8 describes a laboratory-scale experiment of converting lactic acid to acrylic acid using the catalysts described in example 1, the material of the reactor being different. Example 9 describes an experiment carried out without the catalyst present to demonstrate the stabilization of the feed in a quartz reactor (in relation to a stainless steel reactor. Example 1
    [0043] [00043] An aqueous solution of barium nitrate, Ba (NO3) 2 (85.36 milliliters (ml) of a stock solution with 0.08 grams per milliliter (g / ml), 0.026 mol, 99.999%, available from Aldrich # 202754), was added to the dibasic potassium phosphate, K2HPO4 (1.517 grams (g), 0.0087 mol, ≥98%, available from Aldrich # P3786), at room temperature to provide a white slurry containing the metals potassium (K, M1) and barium (Ba, M2) in an M1: M2 molar ratio of 40:60. Phosphoric acid H3PO4 (2.45 ml of 85% by weight, d = 1.684 g / ml, 0.036 mol, available from Acros # 295700010), was added by dripping to the slurry. The acid-containing slurry was then gradually dried at 50 ° C for 10 hours, then at 80 ° C for 10 hours (rise of 0.5 ° C / min) in a ventilated oven with air flow until complete precipitation catalyst has occurred. Heating continued at 120 ° C for 2 hours (rise of 0.5 ° C / min) followed by calcination at 450 ° C for 4 hours (rise of 2 ° C / min). After calcination, the catalyst was sieved from about 100 µm to about 200 µm. Two batches of this catalyst were prepared according to the previously mentioned procedure. The two batches of catalysts are referred to later in this document as "Catalyst 'A' and Catalyst 'B'". Example 2
    [0044] [00044] Sodium phosphate, Na3PO4 (85.68 g, 0.522 mol, 96% available from Aldrich, # 342483), was dissolved in 580 ml of deionized water and the pH adjusted to 7 with concentrated ammonium hydroxide (source general) as measured by a pH meter. Ba (NO3) 2 (121.07 g, 0.463 mol, 99.999% available from Aldrich # 202754) was dissolved in 1220 ml of deionized water to form a barium nitrate solution. Heating to 35 ° C with assisted dissolution. The barium nitrate solution was added by dripping to the Na3PO4 solution during stirring and heated to 60 ° C, forming a white slurry during the addition. The pH was continuously monitored and concentrated ammonium hydroxide added by dripping to maintain pH 7. Heating and stirring at 60 ° C continued for 60 minutes, at the time when the solid was filtered and washed completely with deionized water. The solid was suspended in 2 L of deionized water and filtered again and washed completely with deionized water. In a ventilated oven, the filter cake was dried at 120 ° C for 5 hours (elevation of 1 ° C / min), followed by calcination at 350 ° C for 4 hours (elevation of 2 ° C / min). After calcination, barium phosphate was sieved about 100 μm to about 200 μm. The fine solids were pressed and sieved again as needed.
    [0045] [00045] The prepared barium phosphate, Ba3 (PO4) 2 (13.104 g, 0.0218 mol), was mixed with dibasic potassium phosphate, K2HPO4 (1.896 g, 0.0109 mol, available from Fisher # P5240 / 53 ), which was previously sieved at about 100 μm to about 200 μm, to provide a mixture containing the metals potassium (M1) and barium (M2) in an M1: M2 molar ratio of 25:75. The solids were mixed and stirred manually in a closed jar, followed by heating in a ventilated oven at 50 ° C for 2 hours, at 80 ° C (rise of 0.5 ° C / min) for 2 hours, then at 120 ° C for 2 hours (0.5 ° C / min rise). After that, the catalyst was calcined at 450 ° C for 4 hours (rise of 0.2 ° C / min). After calcination, the catalyst was sieved again from about 100 μm to about 200 μm. This catalyst is referred to later in this document as "Catalyst 'C'". Example 3
    [0046] [00046] Calcium pyrophosphate (Ca2P2O7) was prepared according to the procedure described in Hong et al. Applied Catalysis A: General, 2011, 396, 194 to 200. An aqueous solution of calcium chloride hydrate, CaCl2.2H2O (39.46 g, 0.268 mol in 100 ml in deionized water), was slowly added (7 ml / min) to a solution of sodium pyrophosphate, Na4P2O7 (32.44 g, 0.122 mol, prepared in 250 ml of deionized water by heating to 50 ° C) with continuous stirring at room temperature for 1 hour. The resulting white slurry was filtered and dispersed in 350 ml of deionized water twice and filtered again to produce a pie. The cake was dried at 80 ° C in a ventilated oven with air flow for 6 hours, followed by calcination 500 ° C for 6 hours. The catalyst was sieved from about 100 μm to about 200 μm.
    [0047] [00047] The prepared calcium pyrophosphate, Ca2P2O7 (1.4738 g, 5.80 mmol), was mixed with monobasic potassium phosphate, KH2PO4 (0.5262 g, 3.87 mmol, available from Aldrich), which was previously sieved from about 100 µm to about 200 µm, to provide a mixture containing the metals potassium (M1) and calcium (M2) in an M1: M2 molar ratio of 25:75. The solids were mixed and stirred manually in a closed flask, followed by calcination according to the procedure described in Example 4. After calcination, the catalyst was sieved again from about 100 µm to about 200 µm. This catalyst is referred to later in this document as "Catalyst 'D'". Example 4 (Comparative)
    [0048] [00048] Numerous additional catalysts, mentioned in the present invention as "E", "F", and "G" Catalysts have been prepared and used for comparative purposes, and these catalysts have been described as follows:
    [0049] [00049] A barium phosphate catalyst (Catalyst "E"), not according to the invention, was prepared and used for comparative purposes. Sodium orthophosphate hydrate, Na3PO4.12H2O (19.4566 g, 0.0511 mol, ≥98%, available from Aldrich # 71911), was dissolved in 125 ml of deionized water and heated to 60 ° C with heated magnetic stirrer (IKA RCT). Ba (NO3) 2 (19.8866 g, 0.0761 mol, 99.999% available from Aldrich) was dissolved in 250 ml of deionized water to form a barium nitrate solution. Heating to 35 ° C with assisted dissolution. The barium nitrate solution was added by dripping to the Na3PO4 solution while stirring at 300 revolutions per minute (rpm) and heating at 60 ° C, forming a white slurry during the addition. The pH of the mixture was monitored using a pH meter. The pH was initially 12.68 and decreased to 11.82 after adding the barium nitrate solution. Heating and stirring at 60 ° C continued for 78 minutes, at which time the solid was filtered. The solid was suspended in 250 ml of deionized water and filtered again. This was repeated five times until the final pH was below 9 to obtain a filter cake. In a ventilated oven, the filter cake was dried at 95 ° C for 1 hour, and then at 120 ° C overnight, followed by calcination in a furnace at 450 ° C for 4 hours (rise of 2 ° C / min). After calcination, the catalyst was sieved from about 100 µm to about 200 µm. This catalyst is referred to later in this document as "Catalyst 'E'".
    [0050] [00050] Catalyst "F" was a phosphate mixture catalyst prepared according to Hong et al. Applied Catalysis A: General, 2011, 396, 194-200.
    [0051] [00051] Catalyst "G" was a potassium phosphate (K2HPO4), obtained from Sigma Aldrich, under the product designation "# P3786, ≥98%". Example 5
    [0052] [00052] Each of the "A" through "K" catalysts were used to convert a reaction mixture containing lactic acid and water to acrylic acid. Reactor and analytics
    [0053] [00053] Each of these conversions were performed in a flow reactor system with temperature and mass flow controllers, and supplied with a separate liquid and gas supply with a mixing section. Molecular nitrogen (N2) was fed into the reactor, along with helium (He), which was added as an internal standard for gas chromatography (GC) analysis. Aqueous lactic acid (20% by weight, L-lactic acid) was introduced to the top of the reactor while the pump pressure (~ 2.48 MPa) ((~ 360 psi)) to overcome any pressure drop from the catalyst bed was controlled. Stainless steel and, in some cases, quartz reactors with an aspect ratio (ie length / diameter) of 75 were used.
    [0054] [00054] Various catalyst beds and gas feed streams were used, resulting in a range of spatial velocities (reported in the present invention). The effluent from the reactor was also connected to another nitrogen dilution line, which diluted the effluent by a factor of two. The internal helium standard normalized any variation in this dilution for analytical purposes. The condensed products were collected by a liquid sampling system cooled to 6.5 ° C to 10 ° C while the gaseous products accumulated in the upper space of a collection flask. The gaseous products in the upper area were analyzed online using sampling valves and gas chromatography (GC).
    [0055] [00055] The food was balanced for 1 hour, after which the liquid sample was collected for 2.7 hours and analyzed offline at the end of the experiment by HPLC. During this time, the gaseous products were analyzed online twice by the CG and recorded as an average. The liquid products were analyzed by an Agilent 1200, HPLC series under the following analytical conditions: millimeter (mm) Supelcogel-H 250 column, isocratic eluent 0.005 M H2SO4 (aq.), Diode set and refractive index (IR) detectors , operating time: 30 minutes (min), flow: 0.2 ml / min, column temperature: 30 ° C, IR temperature: 30 ° C. Gaseous products were analyzed by an Interscience Compact gas chromatograph using three detectors (one FID and two thermal conductivity detectors "A" and "B" hereinafter referred to as "DCT-A" and "DCT-B", respectively). The gaseous products were recorded as an average determined by two sequential CG chromatograms.
    [0056] [00056] The DCT-A column was an Rt-Q Bond (Restek, Bellefonte, PA, USA), 26 m long and an I.D. 032 mm with a 10 μm thick film. There was a 2 m pre-column. The pressure was adjusted to 150 kPa, with a divided flow of 10 ml / min. The column oven temperature was adjusted to 100 ° C with a minimum oven temperature of 50 ° C. The flow was adjusted to 5.0 ml / min with a helium carrier gas. The DCT-B column was a Mol MS5A sieve (Restek, Bellefonte, PA, USA), with a length of 21 m and a film with a thickness of 10 μm. There was a 2 m pre-column. The pressure was adjusted to 200 kPa, with a divided flow of 10 ml / min. The column oven temperature was adjusted to 70 ° C with a minimum oven temperature of 50 ° C. The flow was adjusted to 2.0 ml / min with an argon carrier gas. The FID column was an RTx-624 (Restek, Bellefonte, PA, USA), with a length of 28 m and an internal diameter of 0.25 mm with a 14 mm thick film. There was a 2 m pre-column. The pressure was adjusted to 100 kPa, with a divided flow of 20 ml / min. The column oven temperature was adjusted to 45 ° C with a minimum oven temperature of 50 ° C.
    [0057] [00057] The gas phase calculations were performed on a carbon basis; Nml / min = flow rate at standard temperature and pressure; FR = response factor:
    [0058] [00058] CO production calculations based on data from the DCT-B thermal conductivity detector using He as an internal standard:
    [0059] [00059] CO emission (mmol / min) = [(DCT-B CO area / DCT-B He area) * (He penetration (Nml / min))] / 22.4
    [0060] [00060] CO2 production calculations based on DCT-A data using He as an internal standard:
    [0061] [00061] CO2 production (mmol / min) = [(DCT-A CO2 area / DCT-B He area) * (CO2 DCT-A RF) * (He penetration (Nml / min))] / 22.4
    [0062] [00062] Acetaldehyde (AcH) production was determined using the peak area of AcH measured in the FID column (FH AcH area), the He area measured in the DCT-B column (He area of the DCT-B) , a CH4-related response factor in FID to He in DCT-B (RF CH4 / He), a relative response factor in relation to AcH to CH4 both in the FID column (RRF AcH / CH4), the internal flow pattern of He by reactor (He penetration), the number of acetaldehyde carbons (2), and the ideal gas conversion factor (22.4):
    [0063] [00063] Production of acetaldehyde (AcH) GC (mmol / min) = [(FID AcH area / DCT-B He area) * (RF CH4 / He) * (RRF AcH / CH4) * (penetration of He (Nml / min)] / (2 * 22.4)
    [0064] [00064] Liquid phase calculations were performed using HPLC area:
    [0065] [00065] Product production (mol / min) = [(HPLC / HPLC RF area (g-1)) / HPLC collection time (min)] * [sample dilution / HPLC volume] * [weight of sample (g) / molecular weight of product (g / mol)]
    [0066] [00066] Net Mass Balance (%) = [weight of net product / weight of LA] * 100
    [0067] [00067] Total production was calculated based on total carbon:
    [0068] [00068] Total Production (mol / min): (2/3) * [C2H4 production (mol / min)] + (2/3) * [C2H6 emission (mol / min)] + [C3H6 production ( mol / min)] + [roduction of C3H8 (mol / min)] + (2/3) * [roduction of AcH (mol / min)] + (4/3) * [roduction of C4 (mol / min)] + [roduction of LA (mol / min)] + [roduction of Pyruvic Acid (mol / min)] + (2/3) * [roduction of Acetic Acid (mol / min)] + [roduction of 1,2-propanediol (mol / min)] + [PA production (mol / min)] + [AA production (mol / min)] + (5/3) * [2,3-pentanedione production (mol / min)] + (1/3) * [CO emission (mol / min)] + (1/3) * [CO2 production (mol / min)]
    [0069] [00069] Conversion (%) = [LA penetration (mol / min) - LA emission (mol / min)] / [LA penetration (mol / min)] * 100
    [0070] [00070] Yield (%) = [roduct production (mol / min) / LA penetration (mol / min)] * 100
    [0071] [00071] Balancing total molar mass or BMR (%) = [total production (mol / min) / LA penetration (mol / min)] * 100
    [0072] [00072] Note that the density of feed and product has been taken into account in the calculations of yield. The acrylic acid yield was corrected to account for variable flow. In most cases, this variation was ± 5%:
    [0073] [00073] The acrylic acid (AA) yield has been corrected for the TMB to consider slightly higher or lower flows in the reactor.
    [0074] [00074] AA yield corrected for TMB (%): [AA yield / total molar mass balance] * 100
    [0075] [00075] Selectivity (%) = [Yield / Conversion] * 100
    [0076] [00076] GHSV = [total gas flow rate / catalyst bed volume].
    [0077] [00077] The BET surface area was determined according to ASTM D 4820-99.
    [0078] [00078] Programmed thermal desorption (DTP) was performed on the AutoChem II 2920 Chemimeration Analyzer (Micromeritics, Norcross, GA, USA) to obtain the acidic and basic catalyst sites. The samples were pre-treated at 400 ° C for 30 minutes under He. CO2 adsorption was performed at 40 ° C for 30 minutes. ACO2 physesorption was performed at 40 ° C for 30 minutes. NH3 adsorption was carried out at 120 ° C for 30 minutes. The temperature rise by chemosorption of CO2 and NH3 at 400 ° C with 10 ° C / min and the sample maintained at 400 ° C for 30 minutes. Reactor power.
    [0079] [00079] A solution (113.6 g) of biomass-derived lactic acid (88% by weight, from Purac (Lincolnshire, IL, USA)) was dissolved in distilled water (386.4 g) to provide a solution with an expected concentration of lactic acid of 20% by weight. This solution was refluxed at 100 ° C for 30 hours. The resulting mixture was cooled and analyzed by HPLC (described above) against the weight standards known in the art. Experiment results
    [0080] [00080] Table 5 below sets out the GHSV under which the reaction proceeded with each catalyst. All of the reported yields are molar yields (except where indicated otherwise) and were determined after 222 minutes of reaction time. These reactions were carried out in the gas phase and, except where otherwise indicated, quartz reactors operating at 350 ° C, without support (load), were employed. In the Table, "AL" refers to lactic acid; "AA" refers to acrylic acid; "AA yield" refers to the molar yield of acrylic acid from lactic acid; "AP yield" refers to the molar yield of propanoic acid from lactic acid; and "ND" means that the value has not been determined.
    [0081] [00081] The experiment carried out with the "G" catalyst was carried out in a stainless steel reactor. The reactor temperature in the experiment performed with the "F" catalyst was 400 ° C. The data reported in the Table regarding the characteristics (BET, surface densities of basicity and acidity) for the "F" catalyst were obtained from Hong et al. Applied Catalysis A: General, 2011, 396, 194 to 200.
    [0082] [00082] The results in Table 5 provide a convenient comparison between converting lactic acid to acrylic acid using catalysts according to the invention (i.e., catalysts "A" through "D") and those not according to the invention ( that is, catalysts "E" through "G"). Among other things, under the same or similar reaction conditions, the catalysts according to the invention (ie "A" to "D" catalysts) converted more of the lactic acid to acrylic acid than any of the other catalysts (ie , "E" through "G" catalysts). In addition, under the same or similar reaction conditions, catalysts according to the invention resulted in a much higher selectivity for acrylic acid and much lower for propanoic acid than catalysts not according to the invention (that is, catalysts "E" to "G"). The selectivity is further illustrated in relation to other impurities in the exclusive drawing of the Figure. Catalysts "A" through "D" also performed better under these high spatial speeds, which are thought to be necessary for stabilizing the feed. The catalyst "G" or K2HPO4 had a lower selectivity than catalysts "A" to "D", demonstrating that the presence of both barium and potassium is necessary for the high selectivity of acrylic acid.
    [0083] [00083] Table 5 above, establishes characteristics of five catalysts and offers a convenient comparison between the surface area, surface basic density and the surface acid density of catalysts, according to the invention (i.e. "A" catalysts) and "B"), some not according to the invention (i.e., catalysts "E" through "G". The catalysts according to the invention have much higher density density values than catalyst "E" alone. similarly, catalysts "A" and "B", according to the invention, have surface acid density values similar to catalyst "E." But, the unexpectedly high increase in basicity of the catalysts in the phosphate mixture, According to the invention, in relation to the same densities for a single phosphate catalyst (for example, the "E" catalyst) is believed to have led to improved conversion of lactic acid and selectivity and yield of acrylic acid from lactic acid. Said otherwise, the data reflects that the catalyst with high surface density has performed better than those with lower density. Although the same selectivity was observed by the "A" and "B" catalysts, a difference in conversion was observed. This difference is believed to be a result of the number of basic sites per unit area, which was lower for catalyst "B". Example 6
    [0084] [00084] An experiment was carried out to determine the activity of a catalyst, according to the invention. Specifically, catalyst "B" was subjected to 21.6 hours of reaction time under the conditions presented in example 6. The data obtained are reported in Table 6, below, in which the acrylic acid yield and selectivity are corrected for TMB, and in the Table, "Conv." refers to conversion, and "Selet." refers to selectivity.
    [0085] [00085] The data show that the catalyst is stable for at least 21.6 hours as the catalyst, over time, does not appear to change significantly or adversely in relation to the yield and selectivity of acrylic acid and similarly does not it appears to deteriorate in relation to the selectivity of unwanted by-products, such as propanoic acid, acetic acid, acetaldehyde and carbon dioxide. Example No. 7
    [0086] [00086] Experiments were carried out to consider the effect of the reactor material on the conversion of lactic acid into acrylic acid. All tests were performed using the same reactor configuration but only varying conditions using a quartz reactor or a stainless steel reactor (316). No inert loads were used, the reactor temperature was maintained at 350 ° C, and the reactor was operated in each test at a GHSV of 3438 h-1.
    [0087] [00087] The data recorded in Table 7 above, demonstrate that the composition of the reactor can be important for the stabilization of the feed, although good yields were also observed using quartz or stainless steel. The data further demonstrate that the quartz reactors had better performance between the two types of reactor, in stabilizing the lactic acid feed, from the decomposition of products such as oligomerization, thus allowing superior performance of the catalyst. Although the same selectivity was observed for "A" and "B" catalysts using quartz, a difference in conversion was observed. Again, it is thought to be a result of the number of basic sites per unit area, which, for catalyst "B", led to an efficient decrease in catalyst loading. The difference in the performance of "A" and "B" catalysts in a stainless steel reactor may be due to variable feed decomposition. Example 8
    [0088] [00088] Experiments without the catalyst present also demonstrated the effect of stabilizing the feed in a quartz reactor. Empty reactors were compared with those loaded with fused silica (SiO2) (obtained from Sigma Aldrich (St. Louis, MO, USA) and Zirblast (obtained from Saint Gobain Zirpro (Le Pontet Cedex, France) in both steel reactors stainless and quartz.
    [0089] [00089] The data recorded in Table 8 above, reveal that at high spatial velocities, very few gaseous by-products were observed. Thus, it was found that the use of quartz reactors minimized two important side reactions: oligomerization and reduction of lactic acid to propanoic acid. This is important to assess the true activity of the catalysts, here "A" and "B" catalysts.
    [0090] [00090] The foregoing description is given only for the sake of clarity of understanding, and no unnecessary limitations should be interpreted from that, since modifications within the scope of the invention may be apparent to those normally skilled in the art. Experiment results
    [0091] [00091] Table 5 below sets out the GHSV under which the reaction proceeded with each catalyst. All of the reported yields are molar yields (except where indicated otherwise) and were determined after 222 minutes of reaction time. These reactions were carried out in the gas phase and, except where otherwise indicated, quartz reactors operating at 350 ° C, without support (load), were employed. In the Table, "AL" refers to lactic acid; "AA" refers to acrylic acid; "AA yield" refers to the molar yield of acrylic acid from lactic acid; "AP yield" refers to the molar yield of propanoic acid from lactic acid; and "ND" means that the value has not been determined.
    [0092] [00092] The experiment carried out with the "G" catalyst was carried out in a stainless steel reactor. The reactor temperature in the experiment performed with the "F" catalyst was 400 ° C. The data reported in the Table regarding the characteristics (BET, surface densities of basicity and acidity) for the catalyst "F" were obtained from Hong et al. Applied Catalysis A: General, 2011, 396, 194 to 200.
    [0093] [00093] The results in Table 5 provide a convenient comparison between the conversion of lactic acid to acrylic acid using catalysts according to the invention (i.e., catalysts "A" through "D") and those not according to the invention ( (ie, catalysts "E 'through" G "). Among other things, under the same or similar reaction conditions, the catalysts according to the invention (i.e. catalysts" A "through" D ") converted more of the acid lactic acid in acrylic than any of the other catalysts (ie catalysts "E" through "G"). Additionally, under the same or similar reaction conditions, the catalysts, according to the invention, resulted in a much higher selectivity by acrylic acid and much lower for propanoic acid than the catalysts not according to the invention (ie catalysts "E" to "G"). The selectivity is further illustrated in relation to other impurities in the exclusive drawing of the Figure. Catalysts "A" through "D" also had a m best performance under these high spatial speeds, which are thought to be necessary for the stabilization of food. The catalyst "G" or K2HPO4 had lower selectivity than catalysts "A" to "D", demonstrating that the presence of both barium and potassium is necessary for the high selectivity of acrylic acid.
    [0094] [00094] Table 5 above establishes characteristics of five catalysts, and offers a convenient comparison between the surface area, the density of surface basicity and the density of surface acidity of catalysts, according to the invention (i.e., catalysts " A "and" B ") some not according to the invention (i.e., catalysts" E "through" G ". The catalysts according to the invention have basic density values much higher than that of catalyst" E "alone. Similarly, catalysts "A" and "B", according to the invention, have surface acid density values similar to catalyst "E." But, the unexpectedly high increase in basicity of the phosphate mixture catalysts of According to the invention, in relation to the same densities for a single phosphate catalyst (for example, the "E" catalyst) it is believed that it has led to the improved conversion of lactic acid and selectivity and yield of acrylic acid from the acid l attic. In other words, the data reflect that the catalyst with a high basic density density performed better than those with a lower basic density. Although the same selectivity was observed for "A" and "B" catalysts, a difference in conversion was observed. This difference is believed to be a result of the number of basic sites per unit area, which was lower for catalyst "B". Example 6
    [0095] [00095] An experiment was carried out to determine the activity of a catalyst, according to the invention. Specifically, catalyst "B" was subjected to 21.6 hours of reaction time under the conditions presented in example 6. The data obtained are reported in Table 6, below, in which the acrylic acid yield and selectivity are corrected for TMB, and in the table, "Conv." refers to conversion, and "Selet." refers to selectivity.
    [0096] [00096] The data show that the catalyst is stable for at least 21.6 hours as the catalyst, over time, does not appear to change significantly or adversely in relation to acrylic acid yield and selectivity and similarly does not it appears to deteriorate in relation to the selectivity of unwanted by-products, such as propanoic acid, acetic acid, acetaldehyde, and carbon dioxide. Example 7
    [0097] [00097] Experiments were carried out to consider the effect of the reactor material on the conversion of lactic acid to acrylic acid. All tests were performed using the same reactor configuration but only varying conditions using a quartz reactor or a stainless steel reactor (316). No inert loads were used, the reactor temperature was maintained at 350 ° C, and the reactor was operated in each test at a GHSV of 3438 h-1.
    [0098] [00098] The data recorded in Table 7 above, demonstrate that the composition of the reactor may be important for the stabilization of the feed, although good yields were also observed using quartz or stainless steel. The data also demonstrate that the quartz reactors had better performance between the two types of reactor, in stabilizing the lactic acid feed from the decomposition of products such as oligomerization, thus allowing superior performance of the catalyst. Although the same selectivity has been observed for "A" and "B" catalysts using quartz, a difference in conversion has been observed. Again, it is thought to be a result of the number of basic sites per unit area, which, for catalyst "B", led to an efficient decrease in catalyst loading. The difference in the performance of "A" and "B" catalysts in a stainless steel reactor is thought to be due to variable feed decomposition. Example 8
    [0099] [00099] Experiments without the catalyst present also demonstrated the effect of stabilizing the feed in a quartz reactor. Empty reactors were compared to those loaded with fused silica (SiO2) (obtained from Sigma Aldrich (St. Louis, MO) and Zirblast (obtained from Saint Gobain Zirpro (Le Pontet Cedex, France) in both stainless steel and quartz reactors .
    [0100] [000100] The data recorded in Table 8 above, reveal that at high spatial speeds, very few gaseous by-products were observed. Thus, it was found that the use of quartz reactors minimized two important side reactions: oligomerization and reduction of lactic acid to propanoic acid. This is important to assess the true activity of the catalysts, here "A" and "B" catalysts.
    [0101] [000101] The foregoing description is given only for the sake of clarity of understanding, and no unnecessary limitations should be interpreted from that, since modifications within the scope of the invention may be apparent to those normally skilled in the art.
    [0102] [000102] The dimensions and values presented in the present invention should not be understood as being strictly limited to the exact numerical values mentioned. Instead, unless otherwise specified, each of these dimensions is intended to mean both the mentioned value and a range of functionally equivalent values around that value. For example, a dimension displayed as "40 mm" is intended to mean "about 40 mm".
    [0103] [000103] Each of the documents cited in the present invention, including any cross-reference, related patent or patent application, is hereby incorporated in its entirety, by way of reference, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art in relation to any invention presented or claimed in this document, or that it, alone or in any combination with any other reference or references, teaches, suggest or present any invention like that. In addition, if there is a conflict between any meaning or definition of a term mentioned in this document and any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document will take precedence.
    [0104] [000104] Although specific embodiments of the present invention have been illustrated and described, it should be obvious to those skilled in the art that various other changes and modifications can be made without departing from the character and scope of the invention. Therefore, it is intended to cover in the appended claims all such changes and modifications that fall within the scope of the present invention.
    权利要求:
    Claims (6)
    [0001]
    Phosphate mixture catalyst, characterized by the fact that it comprises at least two different phosphate salts, in which the at least two different phosphate salts comprise K2HPO4 and a precipitation product of phosphoric acid (H3PO4) and barium nitrate (Ba ( NO3) 2), where K2HPO4 potassium and barium from the phosphoric acid precipitation product (H3PO4) and barium nitrate (Ba (NO3) 2) are present in a molar ratio, K: Ba, of 2: 3 .
    [0002]
    Phosphate mixing catalyst according to claim 1, characterized in that the catalyst was calcined at a temperature of 250 ° C to 450 ° C for an hour to four hours.
    [0003]
    Phosphate mixing catalyst according to claim 1, characterized by the fact that it still comprises a conductor supporting the at least two different phosphate salts.
    [0004]
    Phosphate mixture catalyst according to claim 3, characterized by the fact that the conductor is selected from the group consisting of silica, silica sol, silica gel, alumina, alumina silicate, silicon carbide, diatomaceous earth, titanium dioxide, quartz, diamonds, and mixtures thereof.
    [0005]
    Phosphate mixture catalyst according to claim 1, characterized by the fact that it has a surface acid density of 0.35 mmol / m2 or less.
    [0006]
    Phosphate mixture catalyst according to claim 1, characterized by the fact that it has a surface basic density of at least 2 mmol / m2.
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    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-07-16| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-04-22| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2020-07-21| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-12-01| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/04/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
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