Processes for aldehyde synthesis

1. A method for manufacturing aldehydes, comprising:

providing an aldehyde precursor stream and an air stream comprising an oxygen gas in a first concentration from about 19 vol. % to 23 vol. % and a nitrogen in a first concentration from 77 vol. % to about 81 vol. % to a reactor comprising a catalyst;

reacting the aldehyde precursor stream and the oxygen gas in the first concentration in the reactor; and

converting the air stream to an oxygen gas stream comprising an oxygen gas in a second concentration from about 90 vol. % to 100 vol. % and a second nitrogen concentration from about 10 vol. % to 0 vol. % when reacting the aldehyde precursor stream and the oxygen gas in the second concentration.

2. The method of claim 1 , wherein the aldehyde precursor stream comprises methanol, ethanol, and combinations thereof.

3. The method of claim 1 , wherein the catalyst is a material selected from the group consisting of molybdenum, molybdenum oxide, vanadium, vanadium oxide, iron oxide, silver, and combinations thereof.

4. The method of claim 3 , wherein the catalyst comprises molybdenum and iron oxide.

5. The method of claim 1 , wherein the air stream comprises an oxygen gas at a concentration of about 21 vol. %.

6. The method of claim 1 , wherein the oxygen gas stream comprises an oxygen gas at a concentration of about 99.5 vol. %.

7. A method for manufacturing aldehydes, comprising:

providing an aldehyde precursor stream and an air stream comprising an oxygen gas in a first concentration from about 19 vol. % to 23 vol. % and a nitrogen in a first concentration from 77 vol. % to about 81 vol. % to a reactor comprising a molybdenum and iron oxide catalyst;

producing an aldehyde and a first post-reaction gas stream comprising nitrogen gas, carbon monoxide, carbon dioxide, and organic compounds;

recycling, a first portion of the first post-reaction gas stream to the reactor;

providing an oxygen gas stream comprising an oxygen gas in a concentration from about 90 vol. % to 100 vol. % and a second nitrogen concentration from about 10 vol. % to 0 vol. % to the reactor with the first post-reaction gas stream;

eliminating the air stream to the reactor; and

producing aldehyde and a second post-reaction gas stream comprising carbon monoxide and organic compounds.

8. The method of claim 7 , wherein the aldehyde precursor stream comprises methanol, ethanol, and combinations thereof.

9. The method of claim 7 , wherein the air stream comprises an oxygen gas concentration of about 21 vol. %.

10. The method of claim 7 , wherein the oxygen gas stream comprises an oxygen gas concentration of about 99.5 vol. %.

11. The method of claim 7 , further comprising oxidizing a second portion of the post-reaction gas stream to carbon dioxide.

12. The method of claim 7 , wherein the recycling the first portion of the first post-reaction gas stream comprises recycling from about 62 vol. % to about 75 vol. %.

13. The method of claim 7 , wherein the second post-reaction gas stream is free of nitrogen gas.

14. The method of claim 7 , wherein the organic compounds comprise dimethyl ether and formic acid byproducts.

15. The method of claim 7 , wherein the aldehyde comprises formaldehyde.

16. A method for manufacturing aldehydes, comprising:

providing an aldehyde precursor stream and an air stream comprising an oxygen gas in a first concentration from about 19 vol. % to 23 vol % and a nitrogen in a first concentration from 77 vol. % to about 81 vol. % to a reactor comprising a catalyst;

producing an aldehyde and a first post-reaction gas stream comprising nitrogen gas, carbon monoxide, and organic compounds;

recycling a first portion of the first post-reaction gas stream to the reactor;

converting the air stream to an oxygen gas stream comprising an oxygen gas in a second concentration from about 90 vol. % to 100 vol. % and a second nitrogen concentration from about 10 vol. % to 0 vol. %;

producing aldehyde and a second post-reaction gas stream free of nitrogen gas; and

recycling a first portion of the second post-reaction gas stream to the reactor.