Oxidative dehydrogenation of paraffins to olefins provides a lower energy route to produce olefins. Oxidative dehydrogenation processes may be integrated with a number of processes in a chemical plant such as polymerization processes, manufacture of glycols, and carboxylic acids and esters. Additionally, oxidative dehydrogenation processes can be integrated with the back end separation process of a conventional steam cracker to increase capacity at reduced cost.

A process for producing a catalyst for the (amm)oxidation of alkanes comprises calcination of a crystalline mixed metal oxide catalyst partially or wholly in the presence of steam.

In the operation of an oxidative dehydrogenation (ODH) process, it is desirable to remove oxygen in the product stream for a number of reasons, including to reduce oxidation of the product. This may be achieved by having several pre-reactors upstream of the main reactor having a catalyst system containing labile oxygen. The feed passes through one or more reactors saturated with labile oxygen. When the labile oxygen is consumed through a valve system, the pre-reactor accepts product from the main reactor and complexes reactive oxygen in the product stream until the catalyst system is saturated with labile oxygen. Then the reactor becomes a pre-reactor and another pre-reactor becomes a scavenger.

Disclosed are methods for synthesizing an ester or a carboxylic acid from an organic alcohol. To form the ester one reacts, in the presence of oxygen gas, the alcohol with methanol or ethanol. This reaction occurs in the presence of a catalyst comprising palladium and a co-catalyst comprising bismuth, tellurium, lead, cerium, titanium, zinc and/or niobium (most preferably at least bismuth and tellurium). Alternatively that catalyst can be used to generate an acid from that alcohol, when water is also added to the reaction mix.

Oxidative dehydrogenation catalysts comprising MoVNbTeO having improved consistency of composition and a 25% conversion of ethylene at less than 420 C. and a selectivity to ethylene above 95% are prepared by treating the catalyst precursor with H.sub.2O.sub.2 in an amount equivalent to 0.30-2.8 mL H.sub.2O.sub.2 of a 30% solution per gram of catalyst precursor prior to calcining.

In the operation of an oxidative dehydrogenation (ODH) process, it is desirable to remove oxygen in the product stream for a number of reasons, including to reduce oxidation of the product. This may be achieved by having several pre-reactors upstream of the main reactor having a catalyst system containing labile oxygen. The feed passes through one or more reactors saturated with labile oxygen. When the labile oxygen is consumed through a valve system, the pre-reactor accepts product from the main reactor and complexes reactive oxygen in the product stream until the catalyst system is saturated with labile oxygen. Then the reactor becomes a pre-reactor and another pre-reactor becomes a scavenger.

Oxidative dehydrogenation of paraffins to olefins provides a lower energy route to produce olefins. Oxidative dehydrogenation processes may be integrated with a number of processes in a chemical plant such as polymerization processes, manufacture of glycols, and carboxylic acids and esters. Additionally, oxidative dehydrogenation processes can be integrated with the back end separation process of a conventional steam cracker to increase capacity at reduced cost.

Shaped catalyst compositions and methods for making and using the shaped catalyst compositions are provided. In an exemplary a catalyst active phase includes a MoVTeNbOx catalyst. The composition also includes a support phase, wherein the support phase includes fumed silica, and wherein the catalyst active phase and support phase form a heterogeneous mixture.

A catalyst, useful for oxidative dehydrogenation of ethane, comprising molybdenum, vanadium, tellurium, tantalum, and oxygen, prepared using a stage hydrothermal synthesis procedure, is provided. The catalyst comprises from 30 to 50 wt. % amorphous content and may be combined with a support/carrier material to form a catalyst material. The described catalysts and catalyst materials demonstrate high selectivity for ethylene at higher temperatures, show little to no decline in conversion and selectivity over time, and do not appear to be sensitive to low residual oxygen concentrations.

Methods are provided provides a method for preparing a catalyst for oxidative dehydrogenation. An exemplary method includes forming a slurry including oxides of molybdenum, tantalum oxide, and tellurium and adding VOSO4 to the slurry. Citric acid, oxalic acid, and ethylene glycol are added to the slurry. The slurry is transferred to an autoclave, and the autoclave is heated to form a catalyst precursor. The catalyst precursor formed in the autoclave is isolated and calcined to form the catalyst.