Title of Invention

A METHOD AND APPARATUS FOR PRODUCING (METH) ACRYCLIC ACID

Abstract The acrylic acid-containing solution in the absorption column is decided by the amount of acrylic acid and the amount of a solvent to be supplied therein. To prepare the acrylic acid-containing solution of a high concentration, therefore, it suffices to lower the amount of the solvent. An attempt to obtain bottom liquid which have an acrylic acid concentration of not less than 70 wt. %, however, is not easily carried out because the loss of acrylic acid through the top of the absorption column increases when the amount of the solvent for absorbing acrylic acid supplying to the absorption column is decreased. The present inventors have pursued a study in search of conditions which permit preparation of an acrylic acid-containing solution of high concentration while lowering the loss of acrylic acid. They have perfected this invention as a result. Specifically, they have found that when the amount of the water contained in the raw material is decreased, the amount of the water introduced into the reactor can be decreased and the (meth) acrylic acid solution of high concentration is obtained while the loss of (meth) acrylic acid is allayed, and that while part of the gas emanating from the absorption column is recycled to the reactor, the (meth)acrylic acid solution of high concentration is obtained as suppressing the loss of (meth) acrylic acid by decreasing the amount of a condensable substance in the recycled gas being introduced via the reactor in the form of a gas again into the absorption column excluding no change in the amount of the condensable substance in the waste gas discharged from the system. This invention has been perfected based on this knowledge. Accordingly, the instant invention provides a method for producing (meth)acrylic acid by a procedure comprising the steps of subjecting raw material such as herein described of (meth)acrylic acid to a reaction of catalytic gas phase oxidation, absorbing (meth)acrylic acid, separating a gas discharged from the absorbing step into a recycle gas such as herein described and a waste gas, cooling said recycle gas and circulating the recycle gas to a reactor and discarding the waste gas to outside of the system, wherein the concentration of a condensable substance such as herein described contained in the recycle gas is lower than the concentration of a condensable substance contained in the waste gas, and said cooling step induces condensation of at least part of a condensable substance contained therein in the form of a condensate and consequently lowers the concentration of the condensable substance contained in said gas, and removes water content or acid content or both from the recycle gas.
Full Text BACKGROUND OF THE. INVENTION
Field of the Invention:
This invention relates to a method for producing
(meth)acrylic acid performing a step of discarding part of
the exhaust gas of an absorption column and recycling the
remainder to a reactor and a step of separating a condensable
substance exclusively from the recycling gas, and/or a method
for producing (meth)acrylic acid comprising a step of
decreasing the water content entrained in a molecular
oxygen-containing gas supplied to the reactor, thereby
enhancing an absorption efficiency of (meth)acrylic acid.
Description of the Related Art:
Commercial production of acrylic acid generally resorts
to the method of propylene oxidation which consists in
subjecting propylene and/or acrolein to catalytic gas phase
oxidation. When acrylic acid is produced by this method of
propylene oxidation, the step of propylene oxidation gives
rise to such impurities as water, acids like propionic acid,
acetic acid, and maleic acid, and aldehydes like acrolein,
furfural, and formaldehyde and ketoses like acetone, in the
form of by-products. The gas containing these by-products
is absorbed as an acrylic acid-containing solution generally
via contact with an absorption solvent. This solution is
subsequently purified by separating the absorption solvent
by such a means as distillation and further separating low
boiling substances and high boiling substances. The minute
amount of such impurities as aldehydes which cannot be easily
separated by distillation is possibly purified by a chemical
treatment or a process of crystallization. The purification

to a high degree necessitates many steps and complicates
equipment and operation and forms one cause for degrading
the yield of acrylic acid.
One known method, for example, produces acrylic acid
of high purity by absorbing an acrylic acid-containing gas
resulting from catalytic gas phase oxidation with a high
boiling solvent, distilling the solvent now entraining the
gas thereby separating it into the solvent and crude acrylic
acid, and subsequently subjecting the crude acrylic acid to
a process of crystallization (JP-A-1997-227445) . This
method, however, forms a complicated procedure which
comprises a step of cooling an acrylic acid-containing gas
with a venturi, then subjecting the cooled gas to a step of
absorption and subsequently to a step of removing low boiling
substances, thereafter a step of separating the residue in
a distillation column into a high boiling substance and a
medium boiling substance, and a step of extracting crude
acrylic acid from the intermediate stage of the column.
If an acrylic acid solution having a high concentration
is successfully treated at the step of acrylic acidproduction,
this treatment will prove efficient in allowing a decrease
in the amount of treatment at the subsequent purifying step.
Thus, a method has been proposed which comprises supplying
a reaction composition containing more than 7 vol% of propylene,
molecular oxygen, steam, and the balance of an inert gas to
a reactor having disposed therein numerous reaction tubes
each packed with a catalyst and furnished with two reaction
zones thereby allowing utility of a propylene reactant of
a high concentration (JP-A-2000-103761). In one example 1
cited in this official gazette, the absorption with water
obtained an acrylic acid solution having an average
concentration of 69.5 wt%.

Another method has been disclosed which comprises
introducing an acrylic acid-containing gas into the
absorption column, introducing a recovery water containing
acetic acid emanating from the bottom liquid of a solvent
recovering column at the purifying step into the top of the
absorption column thereby effecting absorption of acrylic
acid therein, and producing as the bottom liquid of the
absorption column an acrylic acid-containing solution
composed of 50 - 80 wt% of acrylic acid, 2-5 wt% of acetic
acid, and the balance of water (JP-A-1993-246941) . This
method obtains purified acrylic acid by sub j ect ing the acrylic
acid-containing solution to azeotropic dehydration using a
mixed solution of two or more azeotropic solvents and
subsequently passing the product of dehydration through such
steps as the removal of high boiling substance.
Still another method has been disclosed which, in the
absorption with water of an acrylic acid-containing gas
resulting from a reaction of catalytic gas phase oxidation,
comprises supplying the recovery water emanating from the
step of azeotropic dehydration to the absorption column,
supplying the resultant acrylic acid-containing solution to
a stripping column, and obtaining an acrylic acid solution
composed of 70.9 wt. % of acrylic acid, 25.6 wt. % of water,
and 2.0 wt. % of acetic acid via the bottom of the stripping
column (JP-A-2001-199931). This method obtains purified
acrylic acid by performing azeotropic dehydration of the
acrylic acid-containing solution and subsequently subjecting
the product of dehydration to the step of crystallization.
The methods published in the official gazettes mentioned
above, however, necessitate a stripping column for the purpose
of obtaining an aqueous solution containing acrylic acid at
a high concentration and, when an organic solvent is used

as an absorption solvent, subsequently necessitate a step
of solvent separation. Further, they have such a complicated
procedure as adjusting anew the conditions of the reaction
of catalytic gas phase oxidation. In spite of these measures,
the acrylic acid-containing solutions they produce have
concentrations which hardly deserve to be called fully
satisfactory. In JP-A-1997-117445 mentioned above, for
example, since the high boiling solvent used therein has a
lower absorbing power than water, the acrylic acid
concentration of the solution obtained at the step of
absorption is about 20 wt. % at the most.
When the acrylic acid concentration is low in the acrylic
acid-containing solution obtained from the step of absorption,
this low concentration results in adding to the impurities
to be separated at the subsequent steps and requiring the
equipment for the separation to be enlarged and inevitably
entailing an increase in the amount of necessary utilities.
An attempt to heighten the acrylic acid concentration in the
acrylic acid-containing solution obtained at the step of
absorption is actually infeasible commercially because it
increases the loss of acrylic acid at the step of absorption.
In the inventions of JP-A-2000-103761, JP-A-1993-246941, and
JP-A-2001-199931, the acrylic acid concentrations in the
solutions obtained at the step of absorption are 80 wt. %
at the most and the losses of acrylic acid, therefore, are
presumed to be high.
SUMMARY OF THE INVENTION
The acrylic acid-containing solution in the absorption
column is decided by the amount of acrylic acid and the amount
of a solvent to be supplied therein. To prepare the acrylic
acid-containing solution of a high concentration, therefore,

it suffices to lower the amount of the solvent. An attempt
to obtain bottom liquid which have an acrylic acid
concentration of not less than 70 wt. %, however, is not easily
carried out because the loss of acrylic acid through the top
of the absorption column increases when the amount of the
solvent for absorbing acrylic acid supplying to the absorption
column is decreased. The present inventors have pursued a
study in search of conditions which permit preparation of
an acrylic acid-containing solution of high concentration
while lowering the loss of acrylic acid. They have perfected
this invention as a result. Specifically, they have found
that when the amount of the water contained in the raw material
is decreased, the amount of the water introduced into the
reactor can be decreased and the (meth) acrylic acid solution
of high concentration is obtained while the loss of
(meth) acrylic acid is allayed, and that while part of the
gas emanating from the absorption column is recycled to the
reactor, the (meth)acrylic acid solution of high
concentration is obtained as suppressing the loss of
(meth) acrylic acid by decreasing the amount of a condensable
substance in the recycled gas being introduced via the reactor
in the form of a gas again into the absorption column excluding
no change in the amount of the condensable substance in the
waste gas discharged from the system. This invention has been
perfected based on this knowledge.
Accordingly, the instant invention provides a method for
producing (meth)acrylic acid by a procedure comprising the
steps of subjecting raw material such as herein described of
(meth)acrylic acid to a reaction of catalytic gas phase
oxidation, absorbing (meth)acrylic acid, separating a gas

discharged from the absorbing step into a recycle gas such as
herein described and a waste gas, cooling said recycle gas
and circulating the recycle gas to a reactor and discarding
the waste gas to outside of the system, wherein the
concentration of a condensable substance such as herein
described contained in the recycle gas is lower than the
concentration of a condensable substance contained in the
waste gas, and said cooling step induces condensation of at
least part of a condensable substance contained therein in
the form of a condensate and consequently lowers the
concentration of the condensable substance contained in said
gas, and removes water content or acid content or both from
the recycle gas.
This invention is also directed toward providing a method
for producing (meth)acrylic acid by a procedure comprising
a step of supplying the raw material of (meth)acrylic acid
and a molecular oxygen-containing gas to a reactor for
catalytic gas phase oxidation thereby obtaining a
(meth)acrylic acid-containing gas and a step of absorbing
(meth)acrylic acid contained in the gas, characterized by
removing the water contained in the molecular
oxygen-containing gas prior to the introduction of the gas
into the reactor. The use of the molecular oxygen-containing
gas which has been dehumidified in advance results in
decreasing the amount of water introduced into the reactor
and permitting absorption of the (meth) acrylic acid of high
concentration at a high yield.
The instant invention also provides an apparatus for the
production of (meth)acrylic acid, comprising a reactor for
subjecting raw material of (meth)acrylic acid to catalytic

gas phase oxidation, a (meth)acrylic acid absorption column
for absorbing (meth)acrylic acid obtained by catalytic gas
phase oxidation, and a piping for discharging a residual gas
from the top of said absorption column after said absorption
and said circulation of the discharged gas as a recycle gas
to said reactor, wherein said piping is furnished with a
branch for discarding part of the discharged gas as a waste
gas to the out side of system and is provided between said
branch and the reactor with a device for removing condensable
substances contained in said recycle gas.
According to this invention, by cooling exclusively part
of the gas discharged from the (meth) acrylic acid absorption
column as circulating a part of the discharged gas to the
reactor, it is made possible to decrease the amount of water
contained in the recycle gas and enhance the absorption
efficiency of (meth) acrylic acid. Further, by decreasing the
acid content in the recycle gas, it is made possible to prevent
the catalyst from deterioration.
The decrease of the water content is also attained by
dehumidifying the air to be supplied to the reactor in advance
of the supply. Consequently, the absorption efficiency of
(meth)acrylic acid can be enhanced as well.
According to this invention, the (meth)acrylic
acid-containing solution can be obtained in high
concentration. As a result, the containedwater can be removed
in the subsequent step without requiring use of an azeotropic
solvent and the step of azeotropic dehydration can be omitted

and, owing to the absence of survival of the azeotropic solvent,
the step of separation of the solvent can be eliminated, with
the result that the process of production will be simplified.
Now, the invention will be described in detail below.
BRIEF DESCRIPTION OF THE DRAWING
Figure is a process diagram illustrating one example
of the preferred mode of embodying this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The first aspect of this invention is directed toward
providing a method for producing (meth)acrylic acid by a
procedure comprising a step of subjecting raw material of
(meth) acrylic acid to a reaction of catalytic gas phase
oxidation, a step of absorbing (meth) acrylic acid, and a step
of circulating part of a gas discharged from the absorbing
step as a recycle gas to a reactor and discarding the remainder
of the discharged gas as waste gas to the out side of system,
wherein the concentration of a condensable substance
contained in the recycle gas is lower than the concentration
of a condensable substance contained in the waste gas (i),
and a method for producing (meth) acrylic acid by a procedure
comprising a step of supplying the raw material of
(meth) acrylic acid and a molecular oxygen-containing gas to
a reactor for the reaction of catalytic gas phase oxidation
thereby obtaining a (meth)acrylic acid-containing gas and
a step of absorbing (meth) acrylic acid contained in said gas,
wherein said molecular oxygen-containing gas is introduced
into said reactor after the water component contained in said
gas has been removed (ii).
For the purpose of obtaining a (meth)acrylic
acid-containing solution of high concentration, it is

necessary either to decrease the amount of water introduced
into the system or to increase the amount of water discarded
to the out side of system. Heretofore, it has been customary
to recycle the gas discharged from the absorption column to
the reactor without cooling the gas in the meantime. The
present invention obtains the (meth)acrylic acid solution
of high concentration by cooling the recycle gas thereby
decreasing the amount of water contained therein and
consequently decreasing the amount of water recycled to the
reactor and/or by dehumidifying the air supplied as an
oxidizing gas to the reactor prior to the supply to the reactor
thereby decreasing the amount of water introduced into the
absorption column. When the whole amount of the discharged
gas from the absorption column is cooled and the amount of
water discarded to the out side of system is consequently
decreased, the amount of water in the recycle gas is indeed
decreased but the absorption efficiency of (meth) acrylic acid
is not heightened and rather lowered widely than when the
cooling is omitted. This invention, therefore, effects
condensation of not merely the water component but also the
acid component in the part of the gas discharged from the
(meth)acrylic acid absorption column which is recycled as
the so-called recycle gas to the reactor to enhance the
absorption efficiency of (meth)acrylic acid and further
prevent the catalyst from deterioration. The decrease of the
concentration of a condensable substance contained in the
recycle gas (i) and the removal of the water component from
the air mentioned above (ii) may be carried out either singly
or in combination.
As used in this specification, the term "(meth) acrylic
acid" refers to acrylic acid or methacrylic acid and the term
"condensable substance" to a substance which assumes a liquid

state at 20°C under an atmospheric pressure. Now, one example
of the preferred embodiment this invention in the production
of acrylic acid from propylene and/or acrolein as the raw
material gas will be described below based on The Figure.
First, such a molecular oxygen-containing gas as air
3 having the amount of water decreased with a dehumidifying
device not shown in the diagram, the raw material of acrylic
acid such as propylene and/or acrolein 1, and a diluting gas
5 are mixed together. At this step, a recycle gas 34 which
has undergone the acrylic acid absorbing step and subsequently
discharged through the top of the absorption column may be
mixed with the air, propylene and/or acrolein, and diluting
gas. In this case, the recycle gas 34 maybe used as a diluting
gas. This mixed gas (hereinafter referred to occasionally
as "the raw material gas") is supplied to a reactor 20 packed
with a catalyst 10 for catalytic gas phase oxidation and
subjected therein to a reaction of catalytic gas phase
oxidation to obtain an acrylic acid-containing gas 25. The
gas 25 is supplied to the absorption column 30 via the bottom
thereof and an aqueous solution absorbent 33 is supplied to
the absorption column 30 via the top thereof, with the result
that the acrylic acid-containing gas 25 and the aqueous
solution absorbent 33 will be brought into mutual contact.
In this specification, the part of a discharged gas 32 from
the top of the absorption column 30, namely the discharge
gas circulated to the reactor will be referred to as "a recycle
gas" and the part thereof, namely the gas discharged to the
out side of system will be referred to as "a waste gas." In
this invention, the recycle gas 34 alone is introduced into
a cooling column 36, cooled therein by gas-liquid contact
with an absorbing water 33' newly supplied into the system,
condensed a condensable substance contained in the recycle

gas, and subsequently circulated to the reactor 20. The
resultant condensed liquid may be mixed with the absorbing
water 33' mentioned above and supplied as the aqueous solution
absorbent 33 to the absorption column 30. Thus, by adjusting
the temperature of the top of the absorption column with a
cooling device 37 disposed in the absorption column, it is
made possible to obtain a solution 35 containing acrylic acid
in high concentration via the bottom of the absorption column.
The steps following the absorbing step do not need to
be particularly restricted. For the sake of efficiently
purifying the acrylic acid-containing solution of high
concentration, this invention contemplates a procedure which
comprises supplying the acrylic acid-containing solution 35
to a first distillation column 40 and causing a low boiling
substance contained therein to remove and consequently
obtaining crude acrylic acid 41. Acrylic acid 60 as a finished
product is obtained by supplying the crude acrylic acid 41
to a crystallizing column 50. The bottom liquid of the
absorption column, depending on the composition thereof, may
be directly supplied to the crystallizing column 50 without
using the first distillation column 40. Since the high boiling
substance contained in the bottom liquid 43 of the first
distillation column 40 contains acrylic acid dimer, the bottom
liquid is supplied to a second distillation column 70 furnished
on the bottom thereof with a thin film distilling device 73
so as to concentrate the acrylic acid dimer. Subsequently,
the dimer is retained in a dimmer decomposing tank 75 so as
to be thermally decomposed into acrylic acid. This acrylic
acid may be circulated via the second distillation column
70 to the first distillation column 40 and/or the absorption
column 30 so as to be recovered as the finished product. The
term "low boiling substance" refers to a substance which has

a lower boiling point than (meth)acrylic acid in the normal
state and the term "high boiling substance" refers to a
substance which has a higher boiling point than (meth) acrylic
acid in the normal state.
In this invention, propylene and/or acrolein can be used
as the raw material gas of acrylic acid. While the reactor
20 does not need to be particularly restricted but is only
required to be capable of performing a reaction of catalytic
gas phase oxidation. The shell-and-tube type reactor can be
used advantageously in respect that it excels in the efficiency
of reaction. By packing the reactor 20 with the well-known
catalyst 10 for catalytic gas phase oxidation and then bringing
the raw material gas into contact with such a molecular
oxygen-containing gas as oxygen or air, it is made possible
to effect the oxidation of the raw material gas. When
propylene is used as the raw material gas, the propylene
concentration is in the range of 7 - 15 vol% and the molecular
oxygen concentration is such that the ratio of propylene :
molecular oxygen (by volume) falls in the range of 1 : 1.0
- 2.0. Air may be used as the source of supply of molecular
oxygen. When the air contains a water component, it is
preferred to be dehumidified prior to the supply thereof to
the reactor. The dehumidification is preferred because it
is capable of decreasing the amount of water introduced into
the reactor and consequently decreasing the amount of water
introduced to the absorption column. It is permissible to
use an oxygen-enriched air or purified oxygen in the place
of air. As concrete examples of the diluting gas 5, nitrogen,
carbon dioxide, and other inert gases may be cited.
In this invention, the recycle gas may be introduced
into the reactor after it has been cooled to induce condensation
of a condensable substance. When the recycle gas is used in

this manner, the recycle gas is deprived of the water component
in advance so that the water concentration in the raw material
gas supplied to the reactor falls in the range of 0 - 10 vol%,
preferably in the range of 0 - 7 vol%, and particularly in
the range of 0 - 6 vol% . When the molecular oxygen-containing
gas is deprived of the water component without using the recycle
gas, the concentration of the water component in the raw
material gas supplied to te reactor is so adjusted as to fall
in the range of 0 - 5 vol%, more preferably in the range of
0-3 vol%, and particularly preferably in the range of 0
- 1 vol%. If the concentration exceeds 10 vol%, the excess
will possibly result in causing the water component supplied
via the reactor to the absorption column to increase the acrylic
acid loss ratio. The total acid concentration is so adjusted
at to fall in the range of 0 - 0.2 vol% and more preferably
in the range of 0 - 0.1 vol%. If the total acid concentration
exceeds 0.2 vol%, the excess will possibly result in
accelerating the deterioration of the catalyst by oxidation.
The recycle gas contains unaltered propylene and acrolien,
oxygen, diluting gas, etc. in addition to the water component
and the acid component. The propylene, oxygen, water
component concentration, and total acid concentration
mentioned above can be easily adjusted by computing the amount
of the water component contained in the recycle gas and the
amount thereof to be incorporated in the raw material gas
so as to enable the water component concentration and the
total acid concentration in the raw material gas to fall in
the optimum ranges mentioned above and computing the propylene
concentration and the oxygen concentration in the recycle
gas thereby deciding the amount of propylene and the amount
of air to be newly supplied to the reactor. The term "total
acid" as used herein refers to compounds having a carboxyl

group. The recycle gas contains acrylic acid, formic acid,
and acetic acid as compounds answering the description.
The reaction of catalytic gas phase oxidation performed
by using propylene as the raw material is generally carried
out in two stages by the use of two kinds of catalyst 10 for
catalytic gas phase oxidation. The catalyst for the first
stage of this reaction is capable of forming acrolein mainly
by the gas phase oxidation of the raw material gas containing
propylene in a gas phase and the catalyst for the second stage
of the reaction is capable of forming acrylic acid mainly
by the gas phase oxidation of the raw material containing
acrolein. As the catalyst for the first stage of the reaction,
a complex oxide containing iron, molybdenum, and bismuth may
be cited. As the catalyst for the second stage of the reaction,
a catalyst having vanadium as an essential component may be
cited.
The Figure depicts the mode of performing the two-stage
reaction mentioned above with a single reactor. Optionally,
this reaction may be performed in a tandem system having two
different reactors connected to each other. The acrylic
acid-containing gas 25 which is obtained by the reaction of
catalytic gas phase oxidation contains 5-14 vol% of acrylic
acid, 0.1 - 2.5 vol% of acetic acid, 0.5-3 vol% of molecular
oxygen, and 5-36 vol% of water and other components which
are by-products of reaction such as the unaltered component
of the raw material gas, propionic acid, maleic acid, acetone,
acrolein, furfural, formaldehyde and COx.
In the acrylic acid absorption column 30, any of the
known methods of contact may be used for establishing contact
between the acrylic acid-containing gas and the aqueous
solution absorbent. As concrete examples of such methods of
contact, crossflow contact devices using a bubble-cap tray,

a perforated tray, a jet tray, a valve tray; and counter current
contact devices using a dual flow tray, a ripple tray,
structured packings of gauze type, sheet type, and grid type
and random packings may be cited.
As the aqueous solution absorbent 33 to be used in this
invention, a wide variety of aqueous solutions which are
capable of absorbing acrylic acid are available. The
condensate resulting from cooling the recycle gas may be used
as the aqueous solution absorbent. Since the condensate often
contains acrylic acid, it is preferred to be reused as the
aqueous solution absorbent. The temperature of the aqueous
solution absorbent at the time of introduction falls in the
range of 0 - 50°C and preferably in the range of 10 - 40°C.
The flow rate ratio of mass of the absorbing water (which
excludes the condensate from the recycle gas and corresponds
to the absorbing water 33' shown in The Figure) to the acrylic
acid-containing gas maybe properly selected to suit the target
acrylic acid concentration. The absorption of acrylic acid
is effected by counter current contact using a mass flow rate
of the absorbing water of 0.1 - 1.5 times, preferably 0.1
- 1.0 times, and particularly 0.15 - 0.8 times to the mass
flow rate of acrylic acid contained in the acrylic
acid-containing gas. If the mass flow rate ratio falls short
of the level of 0.1 times, the shortage will possibly induce
an extreme decrease of the efficiency of the acrylic acid
absorption column. Conversely, if it exceeds the level of
1. 5 times, the excess will render the acquisition of an acrylic
acid-containing solution of high concentration difficult.
Incidentally, the absorbing water may contain therein for
the purpose of preventing such polymerizing substances as
acrylic acid from succumbing to polymerization one or more
compounds selected from the group consisting of N-oxyl

compounds, phenol compounds, manganese salts such as
manganese acetate, copper salts of dialkyl-dithiocarbamic
acid such as copper dibutylthiocarbamate, nitroso compounds,
amine compounds, and phenothiazine which are cited as in the
official gazettes of JP-A-2001-348360, 2001-348358, and
2001-348359.
The acrylic acid absorption column is generally operated
above normal pressure. In this invention, the column top
pressure (gauge pressure) is set in the range of 0 - 0.4 MPa,
preferably in the range of 0 - 0.1 MPa, and particularly in
the range of 0 - 0.03 MPa. If this pressure falls short of
0 MPa (gauge pressure), the shortage will necessitate a
pressure decreasing device and consequently add to the cost
of equipment and the cost of utilities. Conversely, if the
pressure exceeds 0.4 MPa (gauge pressure), the excess will
possibly require the temperature of the absorption column
to be elevated considerably for the purpose of discharging
a low boiling substance from the column top and consequently
degrade the absorption efficiency. The column top
temperature falls generally in the range of 30 - 85°C and
particularly in the range of 40 - 80°C. In this invention,
the acrylic acid-containing solution 35 comprising 70 - 98
wt. % of acrylic acid, 1 - 29 wt. % of water, and 1 - 10 wt. %
of impurities (such as acids like acetic acid, maleic acid,
and propionic acid, aldehydes like furfural and formaldehyde)
is obtained under the conditions of absorption mentioned
above.
This invention is characterized by the fact that when
part of the gas discharged through the top of the absorption
column 30 is recycled to the reactor 20 and the remainder
thereof is discarded, the concentration of the condensable
substance contained in the recycle gas is made lower than

the concentration of the condensable substance contained in
the waste gas. Water, acrylic acid, and acetic acid are
condensable substances. The reason for decreasing their
concentrations and consequently decreasing their amount for
circulation to the absorption column resides in enhancing
the absorption efficiency of acrylic acid. The gas discharged
from the absorption column may be given any of such treatments
as increase of pressure, elevation of temperature, and
combustion before the gas is separated into the cycle gas
and the waste gas. To lower the concentrations of such
condensable substances, it is only necessary that the recycle
gas alone be cooled so as to condense such condensable
substances as water and acrylic acid, etc. and decrease the
amount of the water component and the amount of acrylic acid,
etc. When the discharged gas is cooled, the recycle gas must
be cooler than the waste gas. This limitation is necessary
because the concentrations of condensable substances could
not be otherwise differentiated between the recycle gas and
the waste gas. Specifically, as demonstrated in the working
examples cited herein below, when the whole amount of the
gas discharged from the absorption column is cooled to lower
the concentrations of the condensable substances contained
in the recycle gas, the acrylic acid loss ratio is rather
suffered to increase to a greater level than when then the
recycle gas is not cooled at all. Though this phenomenon
remains yet to be clarified, it may be logically explained
by a postulate that since the amount of the water component
contained in the discharged gas is increased in accordance
as the temperature of this gas is heightened, the cooling
effected also on the waste gas possibly obstruct the efficient
waste of the water component to the out side of system. In
any event, when the whole amount of the discharged gas is

cooled and reused in the absorption column, the efficiency
of the absorption with the aqueous solution absorbent is
degraded consequently. As a result, the concentration of
acrylic acid in the gas discharged from the absorption column
increases with the elapse of time, the amount of acrylic acid
discarded as the waste gas from the system increases, and
the acrylic acid loss ratio eventually increases. When part
of the piping for circulating the gas discharged via the top
of the absorption column as the recycle gas to the reactor
is furnished with a branch for discarding the waste gas,
therefore, it is advisable to interpose a cooling device
between the branch and the reactor to cool exclusively the
recycle gas.
The method for cooling the recycle gas does not need
to be particularly restricted. It is only required to resort
to a device which is capable of condensing the condensable
substances contained in the recycle gas . As concrete examples
of the device answering the description, the shell-and-tube
type heat exchanger, fin tube type heat exchanger, air cooled
heat exchanger, double pipe heat exchanger, coil type heat
exchanger, direct contact type heat exchanger, and plate type
heat exchanger may be cited. Since the condensate more often
than not contains such polymerizable substances as acrylic
acid, however, the method of cooling which resorts to the
combination of the cooling column 36 and such a cooling device
39 as illustrated in The Figure is commendable in respect
that it permits easy supply of a polymerization inhibitor.
The cooling temperature of the recycle gas does not need
to be particularly restricted. The total amount of the raw
material gas supplied to the reactor is so cooled till
condensation that the concentration of the water component
therein falls in the range of 0 - 10 vol%, preferably in the

range of 0 - 7 vol%, and particularly in the range of 0 -
6 vol% and further the concentration of the total acid falls
in the range of 0 - 0.2 vol%, preferably in the range of 0
0.1 vol%. When air is used as the molecular
oxygen-containing gas, the air contains a water component.
The amount of the water component which exists after the recycle
gas is cooled is computed from the amount of the air supplied,
the aforementioned preferred concentration of the water
component in the raw material gas and the amount of the raw
material gas supplied and the cooling is carried out till
the concentration of the water component found by the
computation is reached. In this invention, the recycle gas
is cooled to a temperature which is 1 - 50°C, preferably 2
- 40°C, and particularly preferably 3- 30°C lower than the
temperature of the waste gas.
The condensate resulting from the condensation caused
by cooling may be returned to the absorption column or may
be withdrawn from the system instead of being so returned.
Though the acrylic acid loss ratio is not changed very much
between these two choices, the return to the absorption column
is at an advantage in obviating the necessity for treating
waste liquid. The recycle gas which has been cooled may be
supplied without changing the temperature existing during
the cooling to the reactor or may be heated with the object
of preventing the deposition of acrylic acid on the inner
wall of the piping extending from the cooling device to the
reactor. In this invention, the method for decreasing the
condensable substances in the recycle gas does not need to
be limited to the cooling of the recycle gas.
In this invention, since the absorption column produces
bottom liquid which have an extremely high acrylic acid
concentration of 70 - 98 wt. %, the subsequent step of

purification can be carried out easily. Though the method
of purifying the acrylic acid-containing solution to such
a high concentration as mentioned above does not need to be
restricted, the method which comprises removing such low
boiling substances as water contained in the solution and
subsequently purifying the remaining solution by
crystallization may be cited. For example, the acrylic
acid-containing solution 35 is supplied to the first
distillation column 40 and crude acrylic acid containing
substantially no water is separated as a bottom column flow
and/or a side column flow.
The first distillation column 40 does not need to be
particularly restricted but is only required to be capable
of separating acrylic acid. A packed column, a plate column
(tray column), etc. are available.
The first distillation column 40 can execute expected
distillation under the conditions that enable such low boiling
substances as water and acetic acid to be separated. This
distillation does not require use of an azeotropic solvent.
This is because the absorbing step produces an acrylic
acid-containing solution of high concentration and, as a
result, such low boiling substances as water and acetic acid
which are contained in the solution are efficiently separated
as a distillate from the top of the first distillation column
40 without using use of an azeotropic solvent. Since no
azeotropic solvent is used, the distillate mentioned above
can be used as an acetic acid-containing aqueous solution
without requiring oil-water separation. The conditions of
the distillation may be properly selected, depending on the
concentration of acrylic acid in the acrylic acid-containing
solution 35 to be introduced and the purity of the crude acrylic
acid aimed at. Commendably, the column top pressure (absolute

pressure) is set in the range of 20 - 400 hPa, preferably
in the range of 30 hPa - 300 hPa, and particularly in the
range of 30 - 200 hPa. If this pressure falls short of 20
hPa (absolute pressure), the shortage will be at a disadvantage
in requiring the column, condenser, and vacuum device to be
enlarged and the cost of equipment to be unduly increased.
Conversely, if the pressure exceeds 400 hPa (absolute
pressure), the excess will be at a disadvantage in heightening
the temperature inside the distillation column 40 and adding
to the possibility of polymerization. The column top
temperature falls generally in the range of 30 - 70°C and
particularly in the range of 40 - 60°C. Then, the column bottom
temperature falls generally in the range of 70 - 120°C and
particularly in the range of 80 - 110°C. The distillation
performed under these conditions produces crude acrylic acid
containing substantially no water and having an acetic acid
content in the range of 0 - 1.0 wt. % as a column side stream
of the distillation column.
In this invention, the purification of this crude acrylic
acid may be executed by utilizing a step of azeotropic
dehydration, a step of separating low boiling substances
subsequent to the dehydrating step mentioned above, a step
of separating high boiling substances, and other steps of
purification which are disclosed in the official gazettes
of JP-A-2000-290221, 2001-226320, 2001-348360, and
2001-348358 in addition to a distillation column illustrated
as the first distillation column 40 in The Figure. This
invention, however, is characterized by preparing an acrylic
acid-containing solution of high concentration and purifying
this solution and, as a result, enabling such low boiling
substances as water and acetic acid to be removed from the
solution without requiring use of an azeotropic solvent and

avoiding installation of a solvent recovering column and an
oil-water separating device for separating a solvent and a
recovered water. Incidentally, the step of purifying acrylic
acid does not need to be limited to purification by distillation.
Optionally, the purification of acrylic acid may be effected
by properly combining stripping, crystallization, extraction,
absorption, and partial condensation.
This invention obtains the purified acrylic acid 60 by
supplying the crude acrylic acid 41 to the crystallizing column
50. The crystallization is an operation for precipitating
crystals from the liquid phase and the gas phase. This mode
of operation can be performed by following the procedure
disclosed in JP-A-2001-199931 with necessary modifications.
The bottom liquid of the second distillation column 70
have high viscosity. The distillation column 70, therefore,
is preferred to be provided additionally on the column bottom
side with the thin layer evaporator 73. Commendably, the
second distillation column 70 executes the expected
distillation with a number of theoretical plate in the range
of 1 - 5 under a reduced pressure in the range of 10 - 150
hPa (absolute pressure) at a column bottom temperature of
not higher than 120°C. The high boiling substances contained
in the bottom liquid of the first distillation column 40 include
acrylic acid dimer, maleic acid, and polymerization inhibitor,
for example.
In this invention, acrylic acid may be distilled from
the top of the second distillation column and part of the
distillate may be supplied to any of the crystallizing device
50, the first distillation column 40, and the absorption column
30.
The liquid formed in the thin layer evaporator 73
mentioned above is supplied to the dimmer decomposing tank

75. In this dimmer decomposing tank 75, the acrylic acid dimer
is decomposed at a temperature in the range of 120 - 220°C.
The hold up time (the liquid amount in of the dimmer decomposing
tank/amount of waste oil), though variable with the
temperature of thermal decomposition, generally falls in the
range of 20 - 50 hours. After the acrylic acid dimer is
decomposed into acrylic acid, th acrylic acid can be
effectively utilized by circulating the acrylic acid to the
thin layer evaporator 73 and supplying the distillate from
the top of the second distillation column to the first
distillation column 40. In this invention, the acrylic
acid-containing solution of high concentration can be
prepared in the acrylic acid absorption column 30, which
solution can be prevented from polymerization by the addition
of a polymerization inhibitor. At the step of absorption and
the step of purification, polymerization inhibitors
conforming to relevant acrylic acid concentrations are used.
In this invention, these polymerization inhibitors are
expelled out of the system as a waste liquid of the dimmer
decomposing tank 75 to allow manufacture of acrylic acid 60
of high concentration as a finished product.
Incidentally, the residual mother liquid recovered from
the crystallizing device 50 may be supplied in the whole amount
to any of the absorption column 30, the first distillation
column 40, the second distillation column 70, the thin layer
evaporator 73, and the dimmer decomposing tank 75. Otherwise,
part of the mother liquid may be discharged as waste oil to
the out side of system. When the whole amount of the residual
liquid mentioned above is supplied to the acrylic acid dimer
decomposing step, part of the acrylic acid recovered from
the acrylic acid dimer decomposing step may be discharged
to the out side of system for the purpose of avoiding

concentration of low boiling substances. Otherwise, the
acrylic acid may be subjected to a chemical pretreatment for
the purpose of converting aldehydes and maleic acid to high
boiling substances before it is supplied to the acrylic acid
dimer decomposing step. As a result, the concentration of
impurities in the acrylic acid to be recovered by the acrylic
acid dimer decomposing step can be decreased. This mode of
operation may be carried out by following the procedure
disclosed in JP-A-2001-199931 with necessary modifications.
The method for producing acrylic acid has been described
hitherto. Methacrylic acid may be produced by using at least
one compound selected from the group consisting of
methacrolein, isobutyl aldehyde, isobutyric acid, and
isobutane in the place of propylene and/or acrolein and also
using a catalyst containing at least the oxides of phosphorus,
molybdenum, vanadium, iron, copper, and antimony and used
for the production of methacrylic acid as disclosed in
JP-A-1987-161739, a catalyst containing at least the oxides
of phosphorus and molybdenum and used for the production of
methacrylic acid as disclosed in JP-A-1992-90853, a
multicomponent type catalyst containing phosphorus,
molybdenum, vanadium, and copper and used for the production
of methacrylic acid as disclosed in JP-A-1993-96172, a
catalyst containing at least the oxides of phosphorus,
molybdenum, vanadium, and arsenic and used for the production
of methacrylic acid as disclosed in JP-A-1994-86932, or a
catalyst containing at least the oxides of molybdenum,
phosphorus, vanadium, antimony, rhenium and used for the
production of methacrylic acid as disclosed in
JP-A-1995-163883. The purification of a methacrylic
acid-containing solution having a concentration in the range
of 70 - 95 wt. % may be effected by following the process

illustrated in The Figure with necessary modification or by
adopting the hitherto known method for the production of
methacrylic acid.
The second aspect of this invention is directed toward
an apparatus for the production of (meth)acrylic acid,
comprising a reactor for subjecting the raw material of
(meth)acrylic acid to catalytic gas phase oxidation, a
(meth)acrylic acid absorption column for absorbing
(meth)acrylic acid obtained by the catalytic gas phase
oxidation, and a piping for discharging residual gas from
the top of the absorption column and circulating the discharged
gas as a recycle gas to the reactor, wherein the piping is
furnished with a branch for discarding part of the waste gas
to the out side of system and a device for removing condensable
substances contained in the recycle gas is interposed between
the branch and the reactor.
The use of this apparatus enables the condensable
substances exclusively in the part of the discharged gas from
the absorption column which is recycled to the reactor to
remove or decrease and consequently allows the amounts of
water, acrylic acid, and acetic acid contained in the recycle
gas to decrease. As a result, the absorption efficiency of
(meth) acrylic acid can be exalted. Further, the catalyst can
be prevented from deterioration because the amounts of acid
component contained in the recycle gas to the reactor are
decreased.
As a means to remove such condensable substances, a device
for cooling a gas is available. As concrete examples of the
gas cooling device, the combination of a cooling column and
a cooling device illustrated in The Figure and the
shell-and-tube heat exchanger, fin tube type heat exchanger,
air-cooled type heat exchanger, double pipe type heat

exchanger, coil type heat exchanger, direct contact type heat
exchanger, and plate type heat exchanger enumerated above
may be cited.
The third aspect of this invention is directed to an
apparatus for the production of (meth)acrylic acid,
comprising an introduction line for introducing the raw
material of (meth)acrylic acid and a molecular
oxygen-containing gas to a reactor, the reactor used for
catalytic gas phase oxidation and connected to the line, and
a (meth)acrylic acid absorption column for absorbing the
(meth) acrylic acid obtained by the catalytic gas phase
oxidation, wherein the molecular oxygen-containing gas
introducing line is furnished with a device for removing a
water component.
The reaction of catalytic gas phase oxidation uses a
molecular oxygen-containing gas. Air is used in most cases
as the gas mentioned above. Generally, air contains a water
component. When the apparatus is used even where air is
supplied to the reactor, the water component contained in
the air can be removed with the water component removing device
before the air is introduced into the reactor. Thus, the
amount of the water component supplied to the reactor can
be decreased and the amount of the water component in the
acrylic acid-containing gas introduced into the absorption
column can be decreased as well. As a result, the absorption
efficiency of acrylic acid can be exalted as described above
and the acrylic acid-containing solution of high
concentration can be manufactured. Moreover, according to
the apparatus, the amount of acrylic acid discharged via the
top of the absorption column can be decreased. When the
discharged gas is recycled to the reactor, therefore, the
deterioration of the catalyst with acids can be prevented

because the amounts of acid components such as acrylic acid
which are circulated to the reactor can be decreased.
As concrete examples of the water component removing
device, various devices which are capable of effecting
dehumidification by cooling, absorption, adsorption, and
compression may be cited.
Examples
Now, this invention will be specifically described below
with reference to working examples.
(Example of catalyst production)
A molybdenum-bismuth type catalyst was prepared by
following the procedure of Example 1 cited in JP-A-2000-325795.
This was labeled as "catalyst (I)." A molybdenum-vanadium
type catalyst was prepared by following the procedure of
example 1 cited in JP-A-1996-206504. This was labeled as
"catalyst (11)."
(Formula of calculation)
In the following working examples and comparative
examples, the numerical values of the conversion of propylene,
the yield of acrolein, the yield of acrylic acid, the recycle
ratio, and the acrylic acid loss ratio were calculated in
accordance with the following formulas.
Conversion of propylene (%) = [(Number of mols of
propylene reacted)/(Number of mols of propylene
supplied)] X 100
Yield of acrolein (%) = [(Number of mols of acrolein
formed)/(Number of mols of propylene supplied)]

X 100
Yield of acrylic acid(%)= [(Number of mols of acrylic
acid formed) / (Number of mols of propylene
supplied)] X 100
Recycle ratio (%) = [(Number of mols of gas (before
cooling) recycled to the reactor) / (Number of mols
of gas discharged via the top of the absorption
column)] X 100
Acrylic acid loss ratio(%) = [(Amount of acrylic acid
in waste gas and waste liquid) / (Amount of acrylic
acid formed in the reactor)] X 100
(Example 1)
Acrylic acid was produced by using the apparatus
illustrated in The Figure.
A reactor furnished on the outer periphery thereof with
a jacket for circulating a heat medium, containing therein
reaction tubes 25 mm in inside diameter and 7, 000 mm in length,
and provided at a position of 3,500 mm from the lower part
of the jacket with a perforated tube sheet dividing the heat
medium jacket into two halves, an upper one and a lower one,
was used. The lower part (the first reaction zone) and the
upper part (the second reaction zone) of the reactor had their
temperatures controlled by circulation of their respective
heat media. The reactor was packed with (1) ceramic balls
having an average diameter of 5 mm, (2) a mixture of catalyst
(I) and ceramic balls of an average diameter of 5 mm at a
volume ratio of 70 : 30, (3) catalyst (I), (4) raschig rings
made of stainless steel andmeasuring 5 mm in outside diameter,

4.5 mm in inside diameter, and 6 mm in length, (5) a mixture
of catalyst (II) and ceramic balls of an average diameter
of 5 mm at a volume ratio of 75 : 25, and (6) catalyst (II)
placed sequentially from the lower part toward the upper part
of the reactor in respective bed lengths of 250 mm, 700 mm,
2,300 mm, 500 mm, 600 mm, and 1,900 mm.
To the first reaction zone of the reactor, propylene,
air (the concentration of water component 2 wt. %), and part
of the discharged gas (recycle gas) from the absorption column
were circulated to supply 8.0 vol% of propylene, 14.4 vol%
of O2, and 5.0 vol% of H2O (the remainder comprising N2, propane,
COx, acrylic acid, and acetic acid, etc.) with the respective
flow rates and the cooling temperature of the recycle gas
so adjusted as to set the space velocity in the first reaction
zone at 1,250 hr-1 (STP).
The heat medium temperatures of the first reaction zone
and the second reaction zone were so adjusted as to set the
conversion of propylene at 97 ± 0.5 mol% and the yield of
acrolein at 1 ± 0.5 mol% under the outlet pressure, 0.15 MPa
(absolute pressure), of the second reaction zone to obtain
an acrylic acid-containing gas.
The acrylic acid-containing gas thus obtained was
introduced at a temperature of 170°C into an acrylic acid
absorption column having a number of theoretical plate of
23 found by calculation to absorb acrylic acid with water
containing hydroquinone in an amount corresponding to 200
mass ppm relative to the amount of acrylic acid in the acrylic
acid-containing gas introduced into the absorption column.
When the amount of the absorbing water was adjusted with
the column top temperature of the acrylic acid absorption
column set at 67°C and the top pressure thereof set at 0.11
MPa (absolute pressure), the absorption column produced

bottom liquid having an acrylic acid concentration of 90 wt. %.
The gas discharged via the top of the absorption column
except the recycle gas was discharged as waste gas to the
out side of system. The recycle gas was introduced into a
cooling column to induce partial condensation of low boiling
substances by cooling and then circulated to the reactor.
The whole amount of the condensate and the absorbing water
were mixed and returned to the absorption column. The cooling
temperature was set at a level at which the H2O concentration
in the first reaction zone reached the prescribed value.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the cooling temperature of the recycle gas was found to be
56.9°C, the recycle ratio 24.2%, the acid concentration at
the inlet to the first reaction zone (the sum of the amounts
of acrylic acid and acetic acid in mol ppm at the inlet to
the first reaction zone) 150 ppm, and the yield of acrylic
acid 86.8% and the acrylic acid loss ratio 2.80%. The outlined
procedures of working examples and comparative examples and
the results thereof are shown in Table 1 and Table 2.
(Example 2)
An operation was performed with the same apparatus under
the same conditions as in Example 1 with the exception of
adjusting the flow rates of relevant gases and the cooling
temperature of the recycle gas so as to set the H20 concentration
at the inlet of the first reaction zone at 2. 5 vol% and adjusting
the amount of the absorbing water so as to set the acrylic
acid concentration in the bottom liquid of the absorption
column at 90 wt. %.
Under the stabilized conditions acquired after the

elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the cooling temperature of the recycle gas was found to be
34.1°C, the recycle ratio 24.3%, the acid concentration at
the inlet to the first reaction zone 30 ppm, the yield of
acrylic acid 86.5% and the acrylic acid loss ratio 1.96%.
(Example 3)
An operation was performed with the same apparatus under
the same conditions as in Example 1 with the exception of
discarding the whole amount of the condensate formed by cooling
and adjusting the amount of the absorbing water so as to set
the acrylic acid concentration in the bottom liquid of the
absorption column at 90 wt. %.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the cooling temperature of the recycle gas was found to be
56.9°C, the recycle ratio 24.2%, the acid concentration at
the inlet to the first reaction zone 100 ppm, the yield of
acrylic acid 86.9%, and the acrylic acid loss ratio 2.86%.
Since the condensate was discarded, waste water occurred in
an amount corresponding to 9 wt. % relative to the bottom
liquid of the absorption column.
(Comparative Example 1)
An operation was performed with the same apparatus under
the same conditions as in Example 1 with the exception of
supplying the recycle gas to the first reaction zone without
being cooled meanwhile, adjusting the relevant flow rates
so as to set the concentrations of propylene and O2 respectively
at 8 vol% and 14.4 vol%, and adjusting the amount of the

absorbing water so as to set the acrylic acid concentration
in the bottom liquid of the absorption column at 90 wt. %.
The concentration of H2O introduced into the first reaction
zone was 7.0 vol%.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the recycle ratio was found to be 23. 7%, the acid concentration
at the inlet to the first reaction zone 1,130 ppm, the yield
of acrylic acid 86.3%, and the acrylic acid loss ratio 3.52%.
(Comparative Example 2)
An operation was performed with the same apparatus under
the same conditions as in Example 1 with the exception of
changing the place of installation of the cooling device from
the recycle gas line to the line for discharging the gas via
the top of the absorption column, adjusting the flow rates
of relevant gases and the cooling temperatures so as to set
the concentrations of propylene, O2, and H2O respectively at
8 vol%, 14.4 vol%, and 5.0 vol%, and adjusting the amount
of the absorbing water so as to set the acrylic acid
concentration in the bottom liquid of the absorption column
at 90 wt. %.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the cooling temperature of the discharged gas from the top
of the column was found to be 57.8 °C, the recycle ratio 25.1%,
the acid concentration at the inlet to the first reaction
zone2, 420ppm, the yield of acrylic acid 84. 6%, and the acrylic
acid loss ratio 8.91%.

(Example 4)
An operation was performed with the same apparatus under
the same conditions as in Example 1 with the exception of
changing the number of theoretical plate of the acrylic acid
absorption column (found by calculation) to 10, setting the
top temperature of the absorption column at 63°C, adjusting
the relevant flow rates and the cooling temperatures so as
to set the concentrations of propylene, O2, and H2O respectively
at 8 vol%, 14.4 vol%, and 4.0 vol%, and adjusting the amount
of the absorbing water so as to set the acrylic acid
concentration in the bottom liquid of the absorption column
at 75 wt. %.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the cooling temperature of the recycle gas was found to be
50.2°C, the recycle ratio 25.2%, the acid concentration at
the inlet to the first reaction zone 50 ppm, the yield of
acrylic acid 86.7%, and the acrylic acid loss ratio 1.59%.
(Comparative Example 3)
An operation was performed under the same conditions
as in Example 1 with the exception of using the same apparatus
as in Example 4, supplying the recycle gas to the first reaction
zone without being cooled meanwhile, adjusting the flow rates
of relevant gases so as to set the concentrations of propylene
and 02 respectively at 8 vol% and 14.4 vol%, and adjusting
the amount of the absorbing water so as to set the acrylic
acid concentration in the bottom liquid of the absorption
column at 75 wt. %. The concentration of H20 introduced into
the first reaction zone was 6.2 vol%.
Under the stabilized conditions acquired after the

elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the recycle ratio was found to be 25. 0%, the acid concentration
at the inlet to the first reaction zone 4 60 ppm, the yield
of acrylic acid 86.7%, and the acrylic acid loss ratio 1. 93%.
(Example 5)
An operation was performed with the same apparatus under
the same conditions as in Comparative Example 1 with the
exception of disposing a dehumidifying device in the raw
material air line to dehumidify the air introduced into the
first reaction zone, supplying the recycle gas to the first
reaction zone without being cooled meanwhile, adjusting the
flow rates of relevant gases so as to set the concentrations
of propylene and O2 respectively at 8 vol% and 14.4 vol%, and
adjusting the amount of the absorbing water so as to set the
acrylic acid concentration in the bottom liquid of the
absorption column at 90 wt. %. The concentration of H2O
introduced into the first reaction zone was 6.5 vol%.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the recycle ratio was found to be 24.4%, the acid
concentration at the inlet to the first reaction zone 960
ppm, the yield of acrylic acid 86.3%, and the acrylic acid
loss ratio 2.95%.
(Example 6)
An operation was performed with the same apparatus under
the same conditions as in Example 2 with the exception of
disposing a dehumidifying device in the raw material air line
to dehumidify the air introduced into the first reaction zone,

cooling the recycle gas to the same temperature of 34.1°C as
in Example 2 and supplying the cooled recycle gas to the first
reaction zone, adjusting the flow rates of relevant gases
so as to set the concentrations of propylene, O2, and-
H2O respectively at 8 vol%, 14.4. vol%, and 4.0 vol%, and
adjusting the amount of the absorbing water so as to set the
acrylic acid concentration in the bottom liquid of the
absorption column at 90 wt. %. The concentration of H20
introduced into the first reaction zone at 18 vol%.
Under the stabilized conditions acquired after the
elapse of about 100 hours following the start of the reaction,
the operation was analyzed to collect data. Consequently,
the recycle ratio was found to be 24. 9%, the acid concentration
at the inlet to the first reaction zone 20 ppm, the yield
of acrylic acid 8 6.8%, and the acrylic acid loss ratio 1.70%.



(Results)
(1) In working examples and comparative examples, the
recycle ratios were invariably in the neighborhood of 25 vol%
and the amounts of discarded gas showed no change. It is,
therefore, evident that the variation of the acrylic acid

loss ratio correlated with the concentrations of acrylic acid
contained in the discarded gas.
(2) Comparison of Example 1 and Comparative Example 1
reveals that in Example 1, since the amount of a water component
contained in the recycle gas was decreased by cooling the
recycle gas, the acrylic acid loss ratio could be decreased
when the acrylic acid-containing solution of a fixed
concentration was prepared.
(3) Example 1 and Comparative Example 1 were equal in
the top temperature of the absorption column, the number of
theoretical plate, acrylic acid concentration in the
absorption column, recycle gas cooling temperature, and
amount of water component in the gas supplied to the reactor
and were different in respect that the recycle gas was
exclusively cooled in the former case and the discharged gas
was wholly cooled in the latter case. Since the acrylic acid
loss ratio was in proportion to the concentration of acrylic
acid contained in the discharged gas from the absorption column
as mentioned above, Comparative Example 2 produced higher
acrylic acid concentrations in gas phase in both the acids
at the inlet of the reactor and the discharged gas from the
absorption column than Example 1. Since the acrylic acid
concentrations of the bottom liquid of the absorption column
were invariably 90 wt. %, the amount of acrylic acid not
absorbed with the aqueous absorbent was large, namely the
ratio of absorption of acrylic acid was low in Comparative
Example 2, The ratio of reaction of acrylic acid was 86.8%
in Example 1 and it was 84.6% in Comparative Example 1,
indicating a decrease in the latter case. The cooling of the
whole amount of the discharged gas from the absorption column
resulted in changing the acid concentration at the inlet to
the reactor and lowering the ratio of reaction of acrylic

acid. Example 1 cooled the recycle gas exclusively and
Comparative Example 1 cooled both the recycle gas and the
waste gas. Thus, Example 1 enjoyed a decrease in the utilities
required for cooling.
(4) Example 2 which decreased the amount of water
component in the recycle gas by cooling the gas to a lower
temperature than in Example 1 enjoyed a further decrease of
the amount of water component introduced into the reactor
and a further decrease of the acrylic acid loss ratio.
(5) Example 3 which did not circulate the condensate
to the absorption column equaled Example 1 in the acrylic
acid loss ratio and in the ratio of reaction of acrylic acid.
(6) Comparison of Example 4 which cooled the recycle
gas and controlled the concentration of acrylic acid in the
bottom liquid of the absorption column to 75 wt. % and
Comparative Example 3 which did not cool the recycle gas reveals
that Comparative Example 3 had a higher acrylic acid loss
ratio than Example 4. The effect of this cooling on the acrylic
acid loss ratio showed the same tendency to the effect of
the presence or absence of the cooling of the recycle gas
on the production of the acrylic acid of a concentration of
90 wt. % in the bottom liquid of the column.

(7) Example 5 which introduced the air dehumidified in
advance with the object of lowering the amount of water
component introduced into the first reaction zone attained
the acrylic acid loss ratio lower than Comparative Example
1 which did not perform a treatment of dehumidification.
(8) Example 6 which cooled the recycle gas and introduced
the air dehumidified in advance enjoyed the lowest
concentration of acid at the inlet to the reactor and the
lowest acrylic acid loss ratio in all the samples having an
acrylic acid concentration of 90 wt. % in the bottom liquid

of the column.

WE CLAIM:
1. A method for producing (meth)acrylic acid by a procedure
comprising the steps of subjecting raw material such as
herein described of (meth)acrylic acid to a reaction of
catalytic gas phase oxidation, absorbing (meth)acrylic
acid, separating a gas discharged from the absorbing step
into a recycle gas such as herein described and a waste
gas, cooling said recycle gas and circulating the recycle
gas to a reactor and discarding the waste gas to outside of
the system, wherein the concentration of a condensable
substance such as herein described contained in the recycle
gas is lower than the concentration of a condensable
substance contained in the waste gas, and said cooling step
induces condensation of at least part of a condensable
substance contained therein in the form of a condensate and
consequently lowers the concentration of the condensable
substance contained in said gas, and removes water content
or acid content or both from the recycle gas.
2. A method as claimed in claim 1, wherein said cooling
step lowers the temperature of said recycle gas to a level
1-50°c. lower than the temperature of said waste gas.
3. A method as claimed in claim 1, wherein the condensate
obtained by said cooling step is reused as an absorbent.
4. A method as claimed in claim 1, wherein the total acid

concentration in raw material gas introduced into said
reactor is in the range of 0-0.2 vol %.
5. A method as claimed in claim 1, wherein said absorbing
step uses an aqueous solution as an absorbent.
6. A method as claimed in claim 1, wherein the (meth)
acrylic acid concentration in a bottom liquid of an
absorption column used in said absorbing step is in the
range of 70-98 wt. %.
7. A method as claimed in claim 1, wherein the water
component concentration in raw material gas supplied to
said reactor is in the range of 0-10 vol %.
8. A method as claimed in claim 2, wherein the condensate
obtained by said cooling step is reused as an absorbent.
9. The method as claimed in claim 1 wherein the water
component concentration in raw material gas supplied to
said reactor is in the range of 0-3 vol %.
10. The method as claimed in claim 1 wherein said cooling
step includes providing a cooler in a recycle gas line
receiving said gas discharged from said absorbing step.
11. An apparatus for the production of (meth)acrylic acid,

Comprising a reactor for subjecting raw material of (meth)
acrylic acid to catalytic gas phase oxidation, a (meth)
acrylic acid absorption column for absorbing (meth)acrylic
acid obtained by catalytic gas phase oxidation, and a
piping for discharging a residual gas from the top of said
absorption column after said absorption and said
circulation of the discharged gas as a recycle gas to said
reactor, wherein said piping is furnished with a branch for
discarding part of the discharged gas as a waste gas to
the out side of system and is provided between said branch
and the reactor with a device for removing condensable
substances contained in said recycle gas.
12. A method for the production of (meth) acrylic acid,
substantially as herein described, particularly with
reference to the accompanying drawings.
13. An apparatus for the production of (meth)acrylic acid,
substantially as herein described, particularly with
reference to the accompanying drawings.

The acrylic acid-containing solution in the absorption
column is decided by the amount of acrylic acid and the amount
of a solvent to be supplied therein. To prepare the acrylic
acid-containing solution of a high concentration, therefore,

it suffices to lower the amount of the solvent. An attempt
to obtain bottom liquid which have an acrylic acid
concentration of not less than 70 wt. %, however, is not easily
carried out because the loss of acrylic acid through the top
of the absorption column increases when the amount of the
solvent for absorbing acrylic acid supplying to the absorption
column is decreased. The present inventors have pursued a
study in search of conditions which permit preparation of
an acrylic acid-containing solution of high concentration
while lowering the loss of acrylic acid. They have perfected
this invention as a result. Specifically, they have found
that when the amount of the water contained in the raw material
is decreased, the amount of the water introduced into the
reactor can be decreased and the (meth) acrylic acid solution
of high concentration is obtained while the loss of
(meth) acrylic acid is allayed, and that while part of the
gas emanating from the absorption column is recycled to the
reactor, the (meth)acrylic acid solution of high
concentration is obtained as suppressing the loss of
(meth) acrylic acid by decreasing the amount of a condensable
substance in the recycled gas being introduced via the reactor
in the form of a gas again into the absorption column excluding
no change in the amount of the condensable substance in the
waste gas discharged from the system. This invention has been
perfected based on this knowledge.
Accordingly, the instant invention provides a method for
producing (meth)acrylic acid by a procedure comprising the
steps of subjecting raw material such as herein described of
(meth)acrylic acid to a reaction of catalytic gas phase
oxidation, absorbing (meth)acrylic acid, separating a gas

discharged from the absorbing step into a recycle gas such as
herein described and a waste gas, cooling said recycle gas
and circulating the recycle gas to a reactor and discarding
the waste gas to outside of the system, wherein the
concentration of a condensable substance such as herein
described contained in the recycle gas is lower than the
concentration of a condensable substance contained in the
waste gas, and said cooling step induces condensation of at
least part of a condensable substance contained therein in
the form of a condensate and consequently lowers the
concentration of the condensable substance contained in said
gas, and removes water content or acid content or both from
the recycle gas.

Documents:

285-KOL-2004-CORRESPONDENCE 1.1.pdf

285-KOL-2004-CORRESPONDENCE.pdf

285-KOL-2004-FORM 27 1.1.pdf

285-KOL-2004-FORM 27.pdf

285-KOL-2004-FORM-27.pdf

285-kol-2004-granted-abstract.pdf

285-kol-2004-granted-assignment.pdf

285-kol-2004-granted-claims.pdf

285-kol-2004-granted-correspondence.pdf

285-kol-2004-granted-description (complete).pdf

285-kol-2004-granted-drawings.pdf

285-kol-2004-granted-examination report.pdf

285-kol-2004-granted-form 1.pdf

285-kol-2004-granted-form 13.pdf

285-kol-2004-granted-form 18.pdf

285-kol-2004-granted-form 2.pdf

285-kol-2004-granted-form 3.pdf

285-kol-2004-granted-form 5.pdf

285-kol-2004-granted-gpa.pdf

285-kol-2004-granted-priority document.pdf

285-kol-2004-granted-reply to examination report.pdf

285-kol-2004-granted-specification.pdf

285-kol-2004-granted-translated copy of priority document.pdf


Patent Number 227273
Indian Patent Application Number 285/KOL/2004
PG Journal Number 02/2009
Publication Date 09-Jan-2009
Grant Date 05-Jan-2009
Date of Filing 31-May-2004
Name of Patentee NIPPON SHOKUBAI CO. ,LTD.
Applicant Address 1-1 KORAIBASHI 4-CHOME, CHUO-KU, OSAKA-SHI, OSAKA
Inventors:
# Inventor's Name Inventor's Address
1 HIRAO HARUNORI 448-2, WAKU, ABOSHI-KU, HIMEJI-SHI, HYOGO, 671-1227
2 UENO KOUJI 706-12, YORO, KATSUHARA-KU, HIMEJI-SHI, HYOGO 671-1203
3 SERATA NAOKI 931-11, HAMADA, ABOSHI-KU, HIMEJI-SHI, HYOGO 671-1242
4 YOKOGOSHIYA TAKESHI 931-11, HAMADA, ABOSHI-KU, HIMEJI-SHI, HYOGO, 671-1242
PCT International Classification Number B01D 53/14
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-160767 2003-06-05 Japan