Catalyst Design for Methacrolein Oxidation to Methacrylic Acid

Heteropoly compounds (HPCs) with the general formula CsMHPVMo₁₁O₄₀are prepared and tested as catalysts. The influence of elements entering the formula on the catalyst properties is studied: Cs defines the acidity and specific area, V controls the selectivity, and the transition metal M defines the mobility of oxygen in the bulk and the catalyst activity. The mechanism of methacrolein oxidation over HPCs is investigated. Using the response method and mass spectrometry of the reaction mixture, it is shown that only the catalyst oxygen atoms take part in the formation of methacrylic acid and that the transport of active oxygen to adsorbed methacrolein plays a key role in the oxidation process. A correlation between the HPC activity and the redox ability of the metal cation M ⁿ⁺ M ^{n+ i} (i= 1 or 2) is found. New catalysts for methacrolein oxidation to methacrylic acid are developed on the basis of this correlation. These are the salts of PVMo-poly acid with Cs, Cu, and the transition metal M as cations. These catalysts are more active (a conversion of up to 91%) and selective (up to 98%) compared to conventional catalysts for methacrolein oxidation to methacrylic acid.