High efficiency ammoxidation process and mixed metal oxide catalysts

1. A process for the production of acrylonitrile, acetonitrile and hydrogen cyanide comprising contacting at an elevated temperature, propylene, ammonia and oxygen in the vapor phase in the presence of a catalyst, said catalyst comprising a complex of metal oxides wherein the relative ratios of the elements in said catalyst are represented by the following formula:

Mo 12 Bi a Fe b A c D d E e F f G g Ce h O x

wherein

A is at least one element selected from the group consisting of sodium, potassium, rubidium and cesium; and

D is at least one element selected from the group consisting of nickel, cobalt, manganese, zinc, magnesium, calcium, strontium, cadmium and barium;

E is at least one element selected from the group consisting of chromium, tungsten, boron, aluminum, gallium, indium, phosphorus, arsenic, antimony, vanadium and tellurium;

F is at least one element selected from the group consisting of a rare earth element, titanium, zirconium, hafnium, niobium, tantalum, aluminum, gallium, indium, thallium, silicon, germanium, and lead;

G is at least one element selected from the group consisting of silver, gold, ruthenium, rhodium, palladium, osmium, iridium, platinum and mercury; and

a is from 0.05 to 7,

b is from 0.1 to 7,

c is from 0.01 to 5,

d is from 0.1 to 12,

e is from 0 to 5,

f is from 0 to 5,

g is from 0 to 0.2,

h is from 0.01 to 5, and

x is the number of oxygen atoms required to satisfy the valence requirements of the other component elements present;

wherein the relative yields of acrylonitrile, acetonitrile and hydrogen cyanide from said process are defined by the following:

α=[(% AN+(3×% HCN)+(1.5×% ACN))÷% PC]×100

wherein % AN is the Acrylonitrile Yield and % AN≧81,

% HCN is the Hydrogen Cyanide Yield,

% ACN is the Acetonitrile Yield,

% PC is the Propylene Conversion, and

α is greater than 100.

2. The process of claim 1 wherein α is greater than 101.

3. The process of claim 1 wherein α is greater than 101.3.

4. The process of claim 1 , wherein 0.15≦(a+h)/d≦1.

5. The process of claim 1 , wherein 0.2≦(a+h)/d≦0.6.

6. The process of claim 1 , wherein 0.3≦(a+h)/d≦0.5.

7. The process of claim 1 , wherein 0.8≦h/b≦5.

8. The process of claim 1 , wherein 1≦h/b≦3.

9. The process of claim 1 , wherein 1.5≦h/b≦2.

10. The process of claim 1 , wherein the X-ray diffraction pattern of the catalyst has X-ray diffraction peaks at 2θ angle 28±0.3 degrees and 2θ angle 26.5±0.3 degrees, and wherein the ratio of the intensity of the most intense x-ray diffraction peak within 2θ angle 28±0.3 degrees to the intensity of most intense x-ray diffraction peak within 2θ angle 26.5±0.3 degrees is defined as X/Y, and wherein 0.3≦X/Y≦3.

11. The process of claim 10 , wherein 0.5≦X/Y≦2.

12. The process of claim 10 , wherein 0.8≦X/Y≦1.

13. The process of claim 1 , wherein the catalyst comprises a support selected from the group consisting of silica, alumina, zirconium, titania, or mixtures thereof.

14. The process of claim 13 , wherein the support comprises between 30 and 70 weight percent of the catalyst.

15. The process of claim 13 , wherein the support comprises silica having an average colloidal particle size in between about 8 nm and about 100 nm.

16. The process of claim 1 , wherein the catalyst has an Attrition of less than or equal to about 8.

17. A catalytic composition comprising a complex of metal oxides wherein the relative ratios of the elements in said catalyst composition are represented by the following formula:

Mo 12 Bi a Fe b A c D d E e F f G g Ce h O x

wherein

A is at least one element selected from the group consisting of sodium, potassium, rubidium and cesium; and

D is at least one element selected from the group consisting of nickel, cobalt, manganese, zinc, magnesium, calcium, strontium, cadmium and barium;

E is at least one element selected from the group consisting of chromium, tungsten, boron, aluminum, gallium, indium, phosphorus, arsenic, antimony, vanadium and tellurium;

F is at least one element selected from the group consisting of a rare earth element, titanium, zirconium, hafnium, niobium, tantalum, aluminum, gallium, indium, thallium, silicon, germanium, and lead;

G is at least one element selected from the group consisting of silver, gold, ruthenium, rhodium, palladium, osmium, iridium, platinum and mercury; and

a is from 0.05 to 7,

b is from 0.1 to 7,

c is from 0.01 to 5,

d is from 0.1 to 12,

e is from 0 to 5,

f is from 0 to 5,

g is from 0 to 0.2,

h is from 0.01 to 5, and

x is the number of oxygen atoms required to satisfy the valence requirements of the other component elements present;

wherein the catalytic composition when utilized for the production of acrylonitrile, acetonitrile and hydrogen cyanide in a process comprising contacting at an elevated temperature, propylene, ammonia and oxygen in the vapor phase in the presence of a catalyst, the relative yields of acrylonitrile, acetonitrile and hydrogen cyanide from said process are defined by the following:

α=[(% AN+(3×% HCN)+(1.5×% ACN))÷% PC]×100

wherein % AN is the Acrylonitrile Yield and % AN≧81,

% HCN is the Hydrogen Cyanide Yield,

% ACN is the Acetonitrile Yield,

% PC is the Propylene Conversion, and

α is greater than 100.

18. The catalyst composition of claim 17 , wherein 0.15≦(a+h)/d≦1 and 0.8≦h/b≦5.

19. The catalyst composition of claim 17 , wherein the X-ray diffraction pattern of the catalyst composition has X-ray diffraction peaks at 2θ angle 28 ±0.3 degrees and 2θ angle 26.5±0.3 degrees, and wherein the ratio of the intensity of the most intense x-ray diffraction peak within 2θ angle 28±0.3 degrees to the intensity of most intense x-ray diffraction peak within 2θ angle 26.5±0.3 degrees is defined as X/Y, and wherein 0.3≦X/Y≦3.

20. The catalyst composition of claim 17 , wherein the catalyst composition comprises a support selected from the group consisting of silica, alumina, zirconium, titania, or mixtures thereof.