METHOD AND REACTOR FOR OXIDATIVE COUPLING OF METHANE

A method of autothermal oxidative coupling of methane (OCM) utilizes introducing a methane-containing feedstock and an oxygen-gas-containing feedstock into a reactor (10) as a flowing mixture (18) with a space time of 500 ms or less. The reactor (10) contains a catalyst bed (20) of an OCM catalyst that contacts the flowing mixture and wherein the catalyst bed (20) has a heat Peclet number (Peh) of from 5 or less, a mass Peclet number (Pem) of from 5 or more, and a transverse Peclet number (P) of from 1 or less while contacting the flowing mixture. The methane and oxygen of the feedstocks are allowed to react within the reactor (10) to form methane oxidative coupling reaction products. A reactor (10) for carrying out the OCM reaction is also disclosed.

Catalysts made with manganese tungsten oxide for the oxidative coupling of methane

Disclosed is a supported catalyst and methods to prepare and use the supported catalyst in an oxidative coupling of methane (OCM) reaction. The supported catalyst can contain MnWO4 or MnWO4 nanostructures that are in contact with the surface of a sodium containing silicon dioxide support material. The supported MnWO4 catalyst can have an active MnWO4 crystal phase.

Oxidative Methankupplung mit La-Ce Katalysatoren

Ein Metalloxid-Katalysator, der zum Katalysieren einer oxidativen Methankupplungsreaktion in der Lage ist, wird beschrieben. Der Metalloxid-Katalysator schließt ein Lanthan(La)/Cer(Ce)-Metalloxid ein und schließt ferner eine kristalline Lanthanhydroxid(La(OH)3)-Phase ein. Der Katalysator ist zum Katalysieren der Herstellung von C2+ Kohlenwasserstoffen aus Methan und Sauerstoff in der Lage. Verfahren und Systeme unter Verwendung des Metalloxid-Katalysators zur Herstellung von C2+ Kohlenwasserstoffen aus einem Reaktantengas werden auch beschrieben.

KATALYSATOREN, HERGESTELLT MIT MANGANWOLFRAMOXID, FÜR DIE OXIDATIVE KUPPLUNG VON METHAN

Offenbart werden ein Trägerkatalysator und Verfahren zur Herstellung und Verwendung des Trägerkatalysators in einer oxidative Methankupplung (OCM)-Reaktion. Der Trägerkatalysator kann MnWOoder MnWO-Nanostrukturen, die in Kontakt mit der Oberfläche eines natriumhaltigen Siliciumdioxid-Trägermaterials sind, enthalten. Der MnWO-Trägerkatalysator kann eine aktive MnWO-Kristallphase aufweisen.

METHOD AND REACTOR FOR OXIDATIVE COUPLING OF METHANE

A method of autothermal oxidative coupling of methane (OCM) utilizes introducing a methane-containing feedstock and an oxygen-gas-containing feedstock into a reactor (10) as a flowing mixture (18) with a space time of 500 ms or less. The reactor (10) contains a catalyst bed (20) of an OCM catalyst that contacts the flowing mixture and wherein the catalyst bed (20) has a heat Peclet number (Peh) of from 5 or less, a mass Peclet number (Pem) of from 5 or more, and a transverse Peclet number (P) of from 1 or less while contacting the flowing mixture. The methane and oxygen of the feedstocks are allowed to react within the reactor (10) to form methane oxidative coupling reaction products. A reactor (10) for carrying out the OCM reaction is also disclosed.

CATALYST FOR THE OXIDATIVE COUPLING OF METHANE WITH LOW FEED TEMPERATURES

A catalytic material for oxidative coupling of methane includes: a catalyst with the formula A a B b C c O x , wherein: A is selected from alkaline earth metals; B and C are selected from rare earth metals, and wherein B and C are different rare earth metals; and the oxide of at least A, B, and C has basic, redox, or both basic and redox properties, and wherein the elements A, B, and C are selected to create a synergistic effect whereby the catalytic material provides an oxygen conversion of greater than or equal to 50% and a C 2 + selectivity of greater than or equal to 70%, and wherein the catalyst provides the oxygen conversion and selectivity at a temperature of 797° F. (425° C.) or greater. The catalyst can be used in an oxidative coupling of methane reactor at lower feed temperatures compared to other catalysts.

Method and reactor for oxidative coupling of methane

A method of autothermal oxidative coupling of methane (OCM) utilizes introducing a methane-containing feedstock and an oxygen-gas-containing feedstock into a reactor (10) as a flowing mixture (18) with a space time of 500 ms or less. The reactor (10) contains a catalyst bed (20) of an OCM catalyst that contacts the flowing mixture and wherein the catalyst bed (20) has a heat Peclet number (Peh) of from 5 or less, a mass Peclet number (Pem) of from 5 or more, and a transverse Peclet number (P) of from 1 or less while contacting the flowing mixture. The methane and oxygen of the feedstocks are allowed to react within the reactor (10) to form methane oxidative coupling reaction products. A reactor (10) for carrying out the OCM reaction is also disclosed.

Mischoxidkatalysator für oxidative Kopplung von Methan

Ein Mischoxidkatalysator für die oxidative Kopplung von Methan kann einen Katalysator mit der Formel ABCDOaufweisen, wobei: das Element A aus Erdalkalimetallen ausgewählt ist; die Elemente B und C aus Seltenerdmetallen ausgewählt sind, und wobei die Elemente B und C unterschiedliche Seltenerdmetalle sind; das Oxid von mindestens einem der Elemente A, B, C und D basische Eigenschaften aufweist; das Oxid von mindestens einem der Elemente A, B, C und D Redox-Eigenschaften hat; und die Elemente A, B, C und D ausgewählt sind, um einen synergistischen Effekt zu erzeugen, wodurch das katalytische Material eine Methanumwandlung von mehr als oder gleich 15 % und eine C-Selektivität von mehr als oder gleich 70 % vorsieht. Systeme und Verfahren können das Kontaktieren des Katalysators mit Methan und Sauerstoff und das Reinigen oder Sammeln von C-Produkten beinhalten.

MIXED OXIDE CATALYST FOR THE OXIDATIVE COUPLING OF METHANE

A mixed oxide catalyst for the oxidative coupling of methane can include a catalyst with the formula ABCDO, wherein: element A is selected from alkaline earth metals; elements B and C are selected from rare earth metals, and wherein elements B and C are different rare earth metals; the oxide of at least one of A, B, C, and D has basic properties; the oxide of at least one of A, B, C, and D has redox properties; and elements A, B, C, and D are selected to create a synergistic effect whereby the catalytic material provides a methane conversion of greater than or equal to 15% and a C selectivity of greater than or equal to 70%. Systems and methods can include contacting the catalyst with methane and oxygen and purifying or collecting C products. 1. A catalytic material for oxidative coupling of methane comprising:{'sub': a', 'b', 'c', 'd', 'x, 'claim-text': element A is selected from alkaline earth metals;', 'elements B and C are selected from rare earth metals, and wherein elements B and C are different rare earth metals;', 'the oxide of at least one of A, B, C, and D has basic properties;', 'the oxide of at least one of A, B, C, and D has redox properties; and', {'sub': '2', 'sup': '−', 'elements A, B, C, and D are selected to create a synergistic effect whereby the catalytic material provides a methane conversion of greater than or equal to 15% and a C selectivity of greater than or equal to 70%.'}], 'a catalyst with the formula ABCDO, wherein2. The catalytic material according to claim 1 , wherein: =1.0; claim 1 , claim 1 , and are each in the range from about 0.01 to about 10; and is a number selected to balance the oxidation state of D.3. The catalytic material according to claim 1 , wherein element A is selected from the group consisting of magnesium claim 1 , calcium claim 1 , strontium claim 1 , and barium.4. The catalytic material according to claim 1 , wherein elements B and C are selected from the group consisting of cerium claim 1 , ytterbium claim 1 , ...

METHOD FOR CONVERTING METHANE TO ETHYLENE AND IN SITU TRANSFER OF EXOTHERMIC HEAT

Disclosed is a method for production of ethylene by an oxidative coupling of methane process in the presence of a catalytic material. Heat generated from the oxidative coupling of methane can be transferred to an inert material in an amount sufficient to reduce thermal deactivation of the catalytic material. 1. A method of producing ethylene from a reactant mixture comprising methane (CH) and oxygen (O) , the method comprising:{'sub': '4', 'contacting the reactant mixture with a catalytic material to produce a product stream comprising ethylene, wherein the ethylene is obtained from oxidative coupling of CH,'}{'sub': '4', 'wherein heat produced by the oxidative coupling of CHis transferred to an inert material in an amount sufficient to reduce thermal deactivation of the catalytic material.'}2. The method of claim 1 , wherein the method occurs in a continuous flow reactor.3. The method of claim 2 , wherein the continuous flow reactor is a fixed-bed reactor or a fluidized reactor.4. The method of claim 1 , wherein the catalytic material is positioned upstream from the inert material.5. The method of claim 1 , wherein heat is transferred from the inert to a cooling fluid or medium.6. The method of claim 1 , wherein the catalytic material and the inert material are configured in multiple alternating layers claim 1 , and wherein the total number of layers of the catalytic material is equal to x claim 1 , and the total number of layers of the inert material is equal to x−1 claim 1 , x+1 claim 1 , or x.7. The method of claim 6 , wherein the total number of layers of the catalytic material ranges from 3 to 50 claim 6 , 3 to 25 claim 6 , or 3 to 5.8. The method of claim 6 , wherein the inert layer has a thickness that is greater than the thickness of the catalytic material layer.9. The method of claim 1 , further comprising at least a second catalytic material and at least a second inert material claim 1 , wherein the second catalytic material is positioned downstream from ...

OXIDATIVE COUPLING OF METHANE AT NEAR AMBIENT FEED TEMPERATURE

Methods of performing a startup of an oxidative coupling of methane reaction to produce C+ hydrocarbons are described. The methods can include incrementally varying startup parameters of the oxidative methane reactor and using the feed gas as a coolant such that high C+ hydrocarbon selectivity is achieved. 112-. (canceled)13. A startup method for an oxidative coupling of methane reaction to produce C+ hydrocarbons , the method comprising the steps of:(a) preheating a catalyst bed of an adiabatic reactor with a heat source, wherein the catalyst bed comprises an oxidative coupling of methane catalyst;{'sub': 4', '2', '4', '2, '(b) introducing a gaseous feed stream comprising methane (CH) and oxygen (O) having a temperature of less than 350° C. and an initial CH:Omolar ratio to the adiabatic reactor;'}(c) igniting the oxidative coupling of methane reaction; and{'sub': 4', '2', '4', '2, '(d) incrementally reducing the initial CH:Omolar ratio of the gaseous feed stream introduced into the reactor to a final CH:Omolar ratio of 9:1 to 3:1 over steps (a) through (c).'}14. The method of claim 13 , wherein the initial CH:Omolar ratio is 5:1 to 40:1 and the final CH:Omolar ratio is 9:1 to 3:1 after incremental reduction.15. The method of claim 13 , wherein the temperature of the gaseous feed stream introduced into the reactor is 150° C. or less and the catalyst bed is preheated to 400° C. to 700° C.16. The method of claim 13 , wherein the catalyst bed is preheated to at least the ignition temperature of the oxidative coupling of methane reaction at the initial CH:Omolar ratio and the reactor is in an ignited condition.17. The method of claim 16 , wherein ignited conditions comprise a Zeldovich number (B) of greater than or equal to four and the product of a Damköhler number (Da) and Zeldovich number (B×Da) of greater than or equal to one.18. The method of claim 13 , wherein the heat source is removed in any one of steps (a)-(d) after the catalyst bed has been preheated.19. The ...

SMALL CHANNEL SHORT FIXED BED ADIABATIC REACTOR FOR OXIDATIVE COUPLING OF METHANE

Disclosed herein are systems and processes for the conversion of a methane feedstock to C hydrocarbons. 1. A reactor system for an oxidative conversion of methane comprising:a reactor vessel having a reactant inlet and a product outlet;a pre-heating component disposed within the reactor vessel configured to receive feedstock from the reactant inlet; andone or more reactor bodies configured to receive the feedstock from the reactant inlet via the pre-heating component, each reactor body having a plurality of channels extending there through, wherein the channels are configured to receive a catalyst.2. The reactor system of :{'sup': th', 'th, 'wherein the channels have a diameter, and wherein the catalyst has a particle size of from about ¼to about 1/20the size of the diameter of a channel, and'}wherein the reactor system further comprises one or more walls disposed adjacent one or more of the first surface and the second surface, wherein the walls are configured to maintain the catalyst within the channels.3. The reactor system of claim 1 , wherein the pre-heating component comprises a silicon carbide claim 1 , quartz claim 1 , a metal coated with inert materials claim 1 , or a combination thereof.4. The reactor system of claim 1 , wherein the plurality of channels extend in parallel and are conterminous.5. The reactor system of claim 1 , wherein the reactor bodies have a cylindrical shape and have a diameter of about 20 mm or greater.6. The reactor system of claim 1 , wherein at least one channel of the plurality of channels has a length no greater than 300 mm.7. The reactor system of claim 1 , at least one channel of the plurality of channels has a diameter of less than about 10 mm.8. The reactor system of claim 1 , at least one channel of the plurality of channels has a diameter of about 5 mm.9. The reactor system of claim 1 , wherein the reactor body comprises an inert material having a thermal conductivity of at least about 2 Watts per meter Kelvin.10. The ...

METHODS OF PRODUCING ETHYLENE AND SYNTHESIS GAS BY COMBINING THE OXIDATIVE COUPLING OF METHANE AND DRY REFORMING OF METHANE REACTIONS

Disclosed is a method for production of synthesis gas and ethylene by a combined oxidative coupling and dry reforming of methane process. Heat generated from the oxidative coupling of methane can be used to drive the endothermic dry reforming of methane reaction. 1. A method of producing ethylene and synthesis gas from a reactant mixture comprising methane (CH) , oxygen (O) and carbon dioxide (CO) , the method comprising:{'sub': 4', '2', '4, 'contacting the reactant mixture with a catalytic material to produce a product stream comprising ethylene and synthesis gas, wherein the ethylene is obtained from oxidative coupling of CHand the synthesis gas is obtained from COreforming of CH,'}{'sub': 4', '2', '4, 'wherein heat produced by the oxidative coupling of CHis used in the COreforming of CH.'}2. The method of claim 1 , wherein the catalytic material comprises a catalyst claim 1 , or a mixture of catalysts claim 1 , that catalyze the oxidative coupling of CHand the COreforming of CH.3. The method of claim 2 , wherein the mixture of catalysts includes a first catalyst that catalyzes the oxidative coupling of CHand a second catalyst that catalyzes the COreforming of CH.4. The method of claim 3 , wherein the mixture of catalysts includes NaO claim 3 , MnO claim 3 , WO claim 3 , and LaO claim 3 , NaO claim 3 , MnO claim 3 , WOand SiOor both.5. The method of claim 1 , wherein the ratio of CH:O:COin the reactant mixture is 1:0.5:1.6. The method of claim 5 , wherein the reaction temperature is 750° C. to 900° C.7. The method of claim 4 , wherein 20% to 60% methane was converted claim 4 , and the selectivity to ethylene is 30% to 35% and the selectivity to carbon monoxide is 15% to 70% claim 4 , or 65% to 70%.8. The method of claim 1 , wherein the method occurs in a continuous flow reactor.9. The method of claim 8 , wherein the continuous flow reactor is a fixed-bed reactor or a fluidized reactor.10. The method of claim 1 , wherein heat produced by the oxidative coupling of ...

Catalyst composition for the oxidative coupling of methane

A catalyst composition, suitable for producing ethylene and other C2+ hydrocarbons from methane. The composition includes a blended product of two distinct catalyst components, blended at such synergistic proportions, that results in a catalyst having high C2+ hydrocarbon selectivity while maintaining an overall sufficient catalyst activity and low ethyne selectivity. Methods for preparing such a catalyst composition and a process for producing C2+ hydrocarbons using such a catalyst composition are provided.

OXIDATIVE COUPLING OF METHANE AT NEAR AMBIENT FEED TEMPERATURE

Methods of performing a startup of an oxidative coupling of methane reaction to produce C2+ hydrocarbons are described. The methods can include incrementally varying startup parameters of the oxidative methane reactor and using the feed gas as a coolant such that high C2+ hydrocarbon selectivity is achieved.

CONVERSION OF METHANE TO ETHYLENE COMPRISING INTEGRATION WITH THE IN-SITU ETHANE CRACKING AND DIRECT CONVERSION OF CO2 BYPRODUCT TO METHANOL

Methods and catalysts for producing ethylene and methanol from natural gas are presented. Methods include integration of oxidative conversion of methane to ethane, ethane in situ thermal cracking using the thermal heat generated thereby and direct hydrogenation of byproducts to methanol or oxidative COautothermal reforming of methane to syngas. 1. A process for preparing ethylene from natural gas , the process comprising the steps of:(a) combining methane and oxygen gas in a reactor zone to undergo oxidative conversion to form produced ethylene, carbon dioxide, water, and heat;(b) providing ethane to a post-reactor zone;(c) cracking the ethane using the heat produced by the oxidative conversion to form ethylene; and(d) contacting the produced carbon dioxide with a first catalyst to generate methanol.2. The process of claim 1 , wherein the combining further includes contacting methane and oxygen gas with a second catalyst in the reactor zone.3. The process of claim 2 , wherein the second catalyst comprises 10% Na-15% Mn—O/SiO.4. The process of claim 1 , wherein the first catalyst comprises CuO—ZnO—CrO—AlO.5. The process of claim 4 , wherein the first catalyst comprises 69.3% CuO-27.4% ZnO-4.24% CrO-3.97% Al2O3.6. The process of claim 1 , wherein the first catalyst comprises CuO—ZnO—AlO.7. The process of claim 6 , wherein the first catalyst comprises 44.26% CuO-36.44% ZnO-11.68% AlO.8. The process of claim 1 , wherein the first catalyst comprises 55.2% CuO-24.9% ZnO-19.83% ZrO.9. The process of claim 1 , wherein the contacting proceeds at a pressure of from about 250 psi to about 900 psi.10. The process of claim 9 , wherein the pressure is from about 750 psi to about 800 psi.11. The process of claim 1 , wherein the combining proceeds at a temperature from about 750° C. to about 850° C.12. The process of claim 11 , wherein the temperature is about 830° C. claim 11 , about 740° C. claim 11 , or about 720° C.13. The process of claim 1 , wherein the contacting proceeds at ...

STABLE CATALYSTS FOR OXIDATIVE COUPLING OF METHANE

A method of selecting a stable mixed metal oxide catalyst for an oxidative coupling of methane (OCM) reaction is disclosed. The method may include, obtaining a mixed metal oxide material having catalytically active metal oxides for the OCM reaction and identifying the Tammann temperature (TTam) of at least one of the catalytically active metals oxides of the mixed metal oxide material. The method further includes selecting the mixed metal oxide material for use as a catalyst in the OCM reaction if the at least one catalytically active metal oxides present in the mixed metal oxide material has a TTam greater than a predetermined temperature.

Methane oxidative coupling with La—Ce catalysts

A metal oxide catalyst capable of catalyzing an oxidative coupling of methane reaction is described. The metal oxide catalyst includes a lanthanum (La) cerium (Ce) metal oxide and further including a lanthanum hydroxide (La(OH)3) crystalline phase. The catalyst is capable of catalyzing the production of C2+ hydrocarbons from methane and oxygen. Methods and systems of using the metal oxide catalyst to produce C2+ hydrocarbons from a reactant gas are also described.

Ignition of oxidative coupling of methane while reducing ratio of methane to oxygen

Methods of performing a startup of an oxidative coupling of methane reaction to produce C2+ hydrocarbons are described. The methods can include incrementally varying startup parameters of the oxidative methane reactor and using the feed gas as a coolant such that high C2+ hydrocarbon selectivity is achieved.

Oxidative coupling of methane at near ambient feed temperature

Methods of performing a startup of an oxidative coupling of methane reaction to produce C2+ hydrocarbons are described. The methods can include incrementally varying startup parameters of the oxidative methane reactor and using the feed gas as a coolant such that high C2+ hydrocarbon selectivity is achieved.

CATALYSTS MADE WITH MANGANESE TUNGSTEN OXIDE FOR THE OXIDATIVE COUPLING OF METHANE

Disclosed is a supported catalyst and methods to prepare and use the supported catalyst in an oxidative coupling of methane (OCM) reaction. The supported catalyst can contain MnWOor MnWOnanostructures that are in contact with the surface of a sodium containing silicon dioxide support material. The supported MnWOcatalyst can have an active MnWOcrystal phase. 1. A supported MnWOcatalyst comprising:{'sub': '2', 'a silicon dioxide (SiO) support material comprising sodium (Na); and'}{'sub': 4', '2, 'manganese tungsten tetroxide (MnWO) in contact with the SiOsupport material.'}2. The supported catalyst of claim 1 , wherein the molar ratio of Mn to W is 1:1.3. The catalyst of claim 1 , wherein the supported catalyst comprises a MnWOcrystal phase.4. The supported catalyst of claim 1 , wherein the Mn and W are chemically bound together or are in close proximity with one another.5. The supported catalyst of claim 1 , wherein the MnWOis MnWOnanostructures claim 1 , and wherein the nanostructures have at least one dimension of 1 nm to 1000 nm claim 1 , 25 nm to 500 nm claim 1 , or 30 nm to 200 nm.6. The supported catalyst of claim 5 , wherein the MnWOnanostructures are nanowires claim 5 , nanoparticles claim 5 , nanorods claim 5 , nanotubes claim 5 , or nanocubes claim 5 , or a combination thereof7. The supported catalyst of claim 6 , wherein the MnWOnanostructures are nanorods having a diameter of 10 nm to 50 nm and/or a length of 150 nm to 250 nm.8. The supported catalyst of claim 1 , wherein the supported catalyst is devoid of a NaWOcrystal phase and devoid of a MnMnSiOcrystal phase.9. The supported catalyst of claim 1 , wherein the catalyst is capable of catalyzing an oxidative coupling of methane reaction.10. The supported catalyst of claim 1 , wherein the MnWOnanostructures are grafted to the surface of the support material.11. A method for preparing the supported MnWOcatalyst of claim 1 , the method comprising:{'sub': 4', '4, '(a) obtaining an aqueous mixture comprising ...

CATALYST COMPOSITION FOR THE OXIDATIVE COUPLING OF METHANE

A catalyst composition, suitable for producing ethylene and other C hydrocarbons from methane. The composition includes a blended product of two distinct catalyst components, blended at such synergistic proportions, that results in a catalyst having high C hydrocarbon selectivity while maintaining an overall sufficient catalyst activity and low ethyne selectivity. Methods for preparing such a catalyst composition and a process for producing C hydrocarbons using such a catalyst composition are provided. 1. A composition , comprising a blended product of: (i) a first catalyst component , represented by a general formula (I): (AERE1RE2ATO) , wherein , (a) ‘AE’ represents an alkaline earth metal; (b) ‘RE1’ represents a first rare earth element; (c) ‘RE2’ represents a second rare earth element; and (d) ‘AT’ represents a third rare earth element ‘RE3’ or a redox agent selected from antimony , tin , nickel , chromium , molybdenum , tungsten; wherein , ‘a’ , ‘b’ , ‘c’ and ‘d’ represents relative molar ratio; wherein ‘a’ is 1; ‘b’ ranges from 0.1 to 10; ‘c’ ranges from about 0.01 to about 10; ‘d’ ranges from 0 to about 10; ‘x’ balances the oxidation state; wherein , the first rare earth element , the second rare earth element and the third rare earth element , are different; and (ii)a second catalyst component , represented by a general formula (II): ((AM)WO)/SiO; wherein , (AM)WOrepresents an alkali metal tungstate , wherein , ‘AM’ represents an alkali metal; wherein , ‘e’ represents relative weight ratio and ranges from about 0.02 to about 0.8; and wherein , the composition has a catalyst activity for the reaction of oxygen and methane of at least 100 times greater than that of the catalyst activity of the second catalyst component.2. The composition of claim 1 , wherein the relative molar ratio ‘b’ ranges from 0.5 to 8.3. The composition of claim 1 , wherein the alkali metal tungstate is selected from the group consisting of lithium tungstate claim 1 , sodium tungstate ...

Mixed oxide catalyst for the oxidative coupling of methane

A mixed oxide catalyst for the oxidative coupling of methane can include a catalyst with the formula AaBbCcDdOx, wherein: element A is selected from alkaline earth metals; elements B and C are selected from rare earth metals, and wherein elements B and C are different rare earth metals; the oxide of at least one of A, B, C, and D has basic properties; the oxide of at least one of A, B, C, and D has redox properties; and elements A, B, C, and D are selected to create a synergistic effect whereby the catalytic material provides a methane conversion of greater than or equal to 15% and a C2+ selectivity of greater than or equal to 70%. Systems and methods can include contacting the catalyst with methane and oxygen and purifying or collecting C2+ products.

Low inlet temperature for oxidative coupling of methane

Disclosed is a process for producing C2+ hydrocarbons, and systems for implementing the process, that includes providing a reactant feed that includes methane and an oxygen containing gas to a first reaction zone, wherein the temperature of the reactant feed is less than 700° C. contacting the reactant feed with a first catalyst capable of catalyzing an oxidative coupling of methane reaction (OCM) to produce a first product stream that includes C2+ hydrocarbons and heat, and contacting the first product stream with a second catalyst capable of catalyzing an OCM reaction to produce a second product stream that includes C2+ hydrocarbons, wherein the produced heat is at least partially used to heat the first product stream prior to or during contact with the second catalyst, wherein the amount of C2+ hydrocarbons in the second product stream is greater than the amount of C2+ hydrocarbons in the first product stream.

ENHANCED SELECTIVITY TO C2+HYDROCARBONS BY ADDITION OF HYDROGEN IN FEED TO OXIDATIVE COUPLING OF METHANE

A method of producing C2+ and higher hydrocarbons includes: (a) introducing a reactant mixture to a reactor having an oxidative coupling catalyst disposed therein, the reactant mixture including methane, oxygen, and hydrogen; (b) operating the reactor under such conditions that at least some of the methane of the reactant mixture undergoes an oxidative coupling reaction that gives rise to a product mixture that includes unreacted methane and primary products, the primary products including C2+ hydrocarbons; and (c) recovering at least a portion of the product mixture. 1. A method of producing C2+ and higher hydrocarbons , comprising:(a) introducing a reactant mixture to a reactor having an oxidative coupling catalyst disposed therein,the reactant mixture comprising methane, oxygen, and hydrogen;(b) operating the reactor under such conditions that at least some of the methane of the reactant mixture undergoes an oxidative coupling reaction that gives rise to a product mixture that comprises unreacted methane and primary products,the primary products comprising C2+ hydrocarbons; and(c) recovering at least a portion of the product mixture.2. The method of claim 1 , wherein the reactor is maintained at a temperature in a range of from about 750° C. to about 1000° C.3. The method of claim 1 , wherein at least a portion of the unreacted methane of the product mixture is recycled to the reactor.4. The method of claim 1 , wherein a molar ratio of methane to oxygen introduced to the reactor is from about 20:1 to about 2:1.5. The method of claim 1 , wherein the operating is substantially free of combustion.6. The method of claim 1 , wherein a molar ratio of hydrogen to oxygen introduced to the reactor is less than about 1:1.7. The method of claim 1 , wherein the hydrogen introduced to the reactor is present at less than about 8 mol % in relation to total feed to the reactor.8. The method of claim 1 , wherein the reactor is operated such that at least about 10% of the methane ...

METHANE OXIDATIVE COUPLING WITH LA-CE CATALYSTS

A metal oxide catalyst capable of catalyzing an oxidative coupling of methane reaction is described. The metal oxide catalyst includes a lanthanum (La) cerium (Ce) metal oxide and further including a lanthanum hydroxide (La(OH) 3 ) crystalline phase. The catalyst is capable of catalyzing the production of C 2 + hydrocarbons from methane and oxygen. Methods and systems of using the metal oxide catalyst to produce C 2 + hydrocarbons from a reactant gas are also described.

Silver Promoted Catalysts for Oxidative Coupling of Methane

An oxidative coupling of methane (OCM) catalyst composition comprising one or more oxides doped with Ag; wherein one or more oxides comprises a single metal oxide, mixtures of single metal oxides, a mixed metal oxide, mixtures of mixed metal oxides, or combinations thereof; and wherein one or more oxides is not LaOalone. A method of making an OCM catalyst composition comprising calcining one or more oxides and/or oxide precursors to form one or more calcined oxides, wherein the one or more oxides comprises a single metal oxide, mixtures of single metal oxides, a mixed metal oxide, mixtures of mixed metal oxides, or combinations thereof, wherein the one or more oxides is not LaOalone, and wherein the oxide precursors comprise oxides, nitrates, carbonates, hydroxides, or combinations thereof; doping the one or more calcined oxides with Ag to form the OCM catalyst composition; and thermally treating the OCM catalyst composition. 1. An oxidative coupling of methane (OCM) catalyst composition doped with silver (Ag).2. The OCM catalyst composition of claim 1 , wherein the OCM catalyst composition comprises one or more oxides doped with silver (Ag); wherein the one or more oxides comprises a single metal oxide claim 1 , mixtures of single metal oxides claim 1 , a mixed metal oxide claim 1 , mixtures of mixed metal oxides claim 1 , or combinations thereof; and wherein the one or more oxides is not LaOalone.3. The OCM catalyst composition of claim 2 , wherein the single metal oxide comprises one metal cation selected from the group consisting of alkali metal cations claim 2 , alkaline earth metal cations claim 2 , rare earth element cations claim 2 , and cations of elements that can form oxides with redox properties.4. The OCM catalyst composition of claim 2 , wherein the mixed metal oxide comprises two or more different metal cations claim 2 , wherein each metal cation can be independently selected from the group consisting of alkali metal cations claim 2 , alkaline earth ...

Method for Producing Hydrocarbons by Oxidative Coupling of Methane with a Heavy Diluent

A method for producing C 2 hydrocarbons comprising (a) introducing a reactant mixture to a reactor comprising a catalyst, wherein the reactant mixture comprises CH 4 , O 2 and a heavy diluent, and wherein the reactant mixture is characterized by a bulk CH 4 /O 2 molar ratio; (b) allowing the reactant mixture to contact a surface of the catalyst and react via an oxidative coupling of CH 4 (OCM) reaction to form a product mixture, wherein the reactant mixture is characterized by a local CH 4 /O 2 molar ratio on the catalyst surface, wherein the local CH 4 /O 2 molar ratio is greater than the bulk CH 4 /O 2 molar ratio, wherein the product mixture comprises C 2 hydrocarbons, and wherein a selectivity to C 2 hydrocarbons is increased by at least about 1% when compared to a selectivity of an otherwise similar OCM reaction conducted in the absence of the heavy diluent; and (c) recovering the product mixture from the reactor.

Method and Reactor for Oxidative Coupling of Methane

A method of autothermal oxidative coupling of methane (OCM) utilizes introducing a methane-containing feedstock and an oxygen-gas-containing feedstock into a reactor () as a flowing mixture () with a space time of 500 ms or less. The reactor () contains a catalyst bed () of an OCM catalyst that contacts the flowing mixture and wherein the catalyst bed () has a heat Peclet number (Pe) of from 5 or less, a mass Peclet number (Pe) of from 5 or more, and a transverse Peclet number (P) of from 1 or less while contacting the flowing mixture. The methane and oxygen of the feedstocks are allowed to react within the reactor () to form methane oxidative coupling reaction products. A reactor () for carrying out the OCM reaction is also disclosed. 1. A method of carrying out autothermal oxidative coupling of methane (OCM) comprising:{'sub': h', 'm, 'introducing a methane-containing feedstock and an oxygen-gas-containing feedstock into a reactor as a flowing mixture with a space time of 500 ms or less, the reactor containing a catalyst bed of an OCM catalyst that contacts the flowing mixture and wherein the catalyst bed has a heat Peclet number (Pe) of from 5 or less, a mass Peclet number (Pe) of from 5 or more, and a transverse Peclet number (P) of from 1 or less while contacting the flowing mixture; and'}allowing the methane and oxygen of the feedstocks to react within the reactor to form methane oxidative coupling reaction products.2. The method of claim 1 , wherein: a layer of OCM catalyst formed as catalyst particles having a particle size of from 0.1 mm to 3 mm;', 'at least one monolithic body of one of a ceramic or metal material having pores or channels with a pore or channel size from 0.1 to 5 mm, the monolithic body having an OCM catalyst material present on at least all or a portion of the surface of the monolithic body;', 'at least one monolithic body of one of a ceramic or metal material having pores or channels with a pore or channel size from 0.1 to 5 mm, and ...

Mixed Oxides Catalysts for Oxidative Coupling of Methane

An OCM catalyst composition characterized by general formula ALaEDO; wherein A is an alkaline earth metal; wherein E is a first rare earth element; wherein D is a redox agent or a second rare earth element; wherein the first rare earth element and second rare earth element are different; wherein a is 1.0; wherein b is 0.01-10.0; wherein c is 0-10.0; wherein d is 0-10.0; and wherein x balances the oxidation states. The alkaline earth metal is selected from the group consisting of Mg, Ca, Sr, Ba, and combinations thereof. The first rare earth element and the second rare earth element can each independently be selected from the group consisting of Sc, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Y, Tb, Dy, Ho, Er, Tm, Yb, Lu, and combinations thereof. The redox agent is selected from the group consisting of Mn, W, Bi, Sb, Sn, Ce, Pr, and combinations thereof. 1. An oxidative coupling of methane (OCM) catalyst composition characterized by the general formula ALaEDO; wherein A is an alkaline earth metal; wherein E is a first rare earth element; wherein D is a redox agent or a second rare earth element; wherein the first rare earth element and the second rare earth element are different; wherein a is 1.0; wherein b is from about 0.01 to about 10.0; wherein c is from about 0 to about 10 ,0; wherein d is from about 0 to about 10.0; and wherein x balances the oxidation states.2. The OCM catalyst composition of claim 1 , wherein the alkaline earth metal is selected from the group consisting of magnesium (Mg) claim 1 , calcium (Ca) claim 1 , strontium (Sr) claim 1 , barium (Ba) claim 1 , and combinations thereof.3. The OCM catalyst composition of claim 1 , wherein the first rare earth element and the second rare earth element can each independently be selected from the group consisting of scandium (Sc) claim 1 , cerium (Ce) claim 1 , praseodymium (Pr) claim 1 , neodymium (Nd) claim 1 , promethium (Pm) claim 1 , samarium (Sm) claim 1 , europium (Eu) claim 1 , gadolinium (Gd) claim 1 , yttrium ( ...

Mixed Oxides Catalysts for Oxidative Coupling of Methane

An OCM nanoplate catalyst comprising >25 wt. % nanoplates; wherein a nanoplate is a three-dimensional object defined in accordance with ISO/TS 80004-2:2015; wherein a nanoplate is characterized by a first external dimension (thickness (t)>100 nm), a second external dimension (length (l)≥t), and a third external dimension (width (w)≥t); wherein l and w can be the same or different; and wherein l≥5 t, w≥5 t, or l≥5 t and w≥5 t; and wherein the OCM nanoplate catalyst has general formula A a Z b E c D d O x ; wherein A=alkaline earth metal; Z=first rare earth element; E=second rare earth element; D=redox agent/third rare earth element; wherein the first, second, and third rare earth element are not the same; wherein a=1.0; wherein b=1.0 to 3.0; wherein c=0 to 1.5; wherein d=0 to 1.5; wherein (b>(c+d)); and wherein x balances the oxidation states.

Carbon Efficient Process for Converting Methane to Olefins and Methanol by Oxidative Coupling of Methane

A method for producing olefins and methanol comprising introducing a first reactant mixture comprising CHand Oto a first reaction zone; allowing the first reactant mixture to react via an OCM reaction to form a first product mixture characterized by a first H/CO molar ratio; introducing a second reactant mixture comprising the first product mixture and an ethane stream to a second reaction zone, wherein ethane of the second reactant mixture undergoes a cracking reaction to produce ethylene; recovering a second product mixture from the second reaction zone, wherein the second product mixture is characterized by a second H/CO molar ratio, and wherein the second H/CO molar ratio is greater than the first H/CO molar ratio; recovering from the second product mixture a methanol production feed stream comprising methane, Hand CO; and introducing the methanol production feed stream to a third reaction zone to produce methanol. 1. A method for producing olefins and methanol comprising:{'sub': 4', '2, '(a) introducing a first reactant mixture to a first reaction zone, wherein the first reactant mixture comprises methane (CH) and oxygen (O), and wherein the first reaction zone is characterized by a first reaction zone temperature of from about 700° C. to about 1,100° C.;'}{'sub': 4', '2+', '2', '2', '2', '2', '2+', '2', '3+', '2', '2', '6', '2', '4, '(b) allowing at least a portion of the first reactant mixture to react via an oxidative coupling of CH(OCM) reaction to form a first product mixture, wherein the first product mixture comprises C hydrocarbons, hydrogen (H), carbon monoxide (CO), water, CO, and unreacted methane, wherein the first product mixture is characterized by a first hydrogen (H) to carbon monoxide (CO) (H/CO) molar ratio, wherein the C hydrocarbons comprise Chydrocarbons and C hydrocarbons, and wherein the Chydrocarbons comprise ethane (CH) and ethylene (CH);'}(c) introducing a second reactant mixture comprising at least a portion of the first product ...

Process for Converting a Natural Gas Feedstock with Inert Content to Chemical Intermediates

A methane conversion process for producing C 2+ hydrocarbons comprising (a) introducing a reactant mixture comprising methane (>20 mol %) and an inert compound to a reaction unit to produce a reactor effluent stream comprising C 2+ hydrocarbons, methane, the inert compound, and water and/or carbon dioxide; (b) removing at least a portion of the water and/or at least a portion of the carbon dioxide from the reactor effluent stream to produce a demethanizer feed stream; (c) feeding at least a portion of the demethanizer feed stream to a demethanizer unit to produce two or more vapor streams (methane rich stream and inert rich stream), and at least one liquid stream (C 2+ hydrocarbons); (d) withdrawing at least a portion of the inert rich stream as a purge stream; (e) recycling any remaining portion of the inert rich stream to the reaction unit; and (f) recycling the methane rich stream to the reaction unit.

LOW INLET TEMPERATURE FOR OXIDATIVE COUPLING OF METHANE

Disclosed is a process for producing C+ hydrocarbons, and systems for implementing the process, that includes providing a reactant feed that includes methane and an oxygen containing gas to a first reaction zone, wherein the temperature of the reactant feed is less than 700° C. contacting the reactant feed with a first catalyst capable of catalyzing an oxidative coupling of methane reaction (OCM) to produce a first product stream that includes C2+ hydrocarbons and heat, and contacting the first product stream with a second catalyst capable of catalyzing an OCM reaction to produce a second product stream that includes C+ hydrocarbons, wherein the produced heat is at least partially used to heat the first product stream prior to or during contact with the second catalyst, wherein the amount of C+ hydrocarbons in the second product stream is greater than the amount of C+ hydrocarbons in the first product stream. 1. A method of producing C+ hydrocarbons from an oxidative coupling of methane reaction , the method comprising:(a) providing a reactant feed that includes methane and an oxygen containing gas to a first reaction zone, wherein the temperature of the reactant feed is 275° C. to less than 700° C.;{'sub': '2', '(b) contacting the reactant feed with a first catalyst capable of catalyzing an oxidative coupling of methane reaction to produce a first product stream comprising C+ hydrocarbons and heat; and'}{'sub': '2', '(c) contacting the first product stream with a second catalyst capable of catalyzing an oxidative coupling of methane reaction to produce a second product stream comprising C+ hydrocarbons, wherein heat produced in step (b) is at least partially used to heat the first product stream prior to or during contact with the second catalyst, and'}{'sub': 2', '2, 'wherein the amount of C+ hydrocarbons in the second product stream is greater than the amount of C+ hydrocarbons in the first product stream.'}2. The method of claim 1 , wherein:the oxidative ...

Oxidative Coupling of Methane Process with Enhanced Selectivity to C2+ Hydrocarbons by Addition of H2O in the Feed

A process for producing olefins comprising introducing to a reactor a reactant mixture comprising methane, oxygen, and water, wherein the reactor comprises a catalyst, and wherein water is present in the reactant mixture from 0.5 mol % to 20 mol %; allowing the reactant mixture to contact the catalyst and react via an OCM reaction to form a product mixture comprising C hydrocarbons, unreacted methane, and byproducts; wherein C hydrocarbons comprise olefins and paraffins; and wherein the process is characterized by a productivity, a C selectivity, or both that is increased when compared to a productivity, a C selectivity, or both, respectively, of an otherwise similar process conducted (i) with a reactant mixture comprising methane and oxygen and (ii) without water present in the reactant mixture from 0.5 mol % to 20 mol %; recovering the product mixture from the reactor; recovering C hydrocarbons from the product mixture; and recovering olefins from C hydrocarbons. 1. A process for producing olefins comprising:(a) introducing a reactant mixture to a reactor, wherein the reactant mixture comprises methane, oxygen, and water, wherein the reactor comprises a catalyst, and wherein the water is present in the reactant mixture in an amount of from about 0.5 mot % to about 20 mol %;{'sub': 2+', '2+', '2+', '2+, '(b) allowing at least a portion of the reactant mixture to contact the catalyst and react via an oxidative coupling of methane (OCM) reaction to form a product mixture; wherein the product mixture comprises C hydrocarbons, unreacted methane, and byproducts; Wherein the C hydrocarbons comprise olefins and paraffins; and wherein the process is characterized by a productivity, a Cselectivity, or both that is increased when compared to a productivity, a C selectivity, or both, respectively, of an otherwise similar process conducted (i) with a reactant mixture comprising methane and oxygen and (ii) without the water present in the reactant mixture in an amount of from ...

Ethylbenzene Production with Ethylene from Oxidative Coupling of Methane

A method for producing ethylbenzene (EB) comprising introducing to an oxidative coupling of methane (OCM) reactor an OCM reactant mixture comprising CHand O; allowing the OCM reactant mixture to react via OCM reaction to form an OCM product mixture comprising CH, CH, water, CO, COand unreacted methane; separating the water and optionally CO and/or COfrom the OCM product mixture to yield an EB reactant mixture comprising CH, CH, unreacted methane, and optionally CO and/or CO; (d) introducing benzene and an EB reactant mixture to an EB reactor; allowing benzene to react in a liquid phase with the ethylene of the EB reactant mixture to form EB; recovering from the EB reactor an EB product mixture comprising EB and unreacted benzene, and an unreacted alkanes mixture comprising CHand unreacted methane, and optionally CO and/or CO; and optionally recycling the unreacted alkanes mixture to the OCM reactor. 1. A method for producing ethylbenzene (EB) comprising:(a) introducing a first oxidative coupling of methane (OCM) reactant mixture to a first OCM reactor, wherein the first OCM reactant mixture comprises methane (CH4) and oxygen (O2);(b) allowing at least a portion of the first OCM reactant mixture to react via an OCM reaction to form a first OCM product mixture, wherein the first OCM product mixture comprises ethylene (C2H4), ethane (C2H6), water, carbon monoxide (CO), carbon dioxide (CO2) and unreacted methane;(c) separating components of the first OCM product mixture, wherein separating components comprises removing at least a portion of the water and optionally at least a portion of the CO and/or CO2 from the first OCM product mixture to yield a first EB reactant mixture, and wherein the first EB reactant mixture comprises C2H4, C2H6, unreacted methane, and optionally CO and/or CO2;(d) introducing benzene and at least a portion of the first EB reactant mixture to a first EB reactor;(e) allowing a portion of the benzene to react with at least a portion of the ...

Sr-Ce-Yb-O Catalysts for Oxidative Coupling of Methane

An oxidative coupling of methane (OCM) catalyst composition characterized by the overall general formula Sr 1.0 Ce a Yb b O c , wherein a is from about 0.01 to about 2.0, wherein b is from about 0.01 to about 2.0, wherein the sum (a+b) is not 1.0, and wherein c balances the oxidation states. A method of making an oxidative coupling of methane (OCM) catalyst composition comprising (a) forming an oxide precursor mixture, wherein the oxide precursor mixture comprises one or more compounds comprising a Sr cation, one or more compounds comprising a Ce cation, and one or more compounds comprising a Yb cation, and wherein the oxide precursor mixture is characterized by a molar ratio of Sr:(Ce+Yb) that is not about 1:1, and (b) calcining at least a portion of the oxide precursor mixture to form the OCM catalyst composition, wherein the OCM catalyst composition comprises Sr—Ce—Yb—O perovskite in an amount of less than about 75.0 wt. %.

Supported Mixed Oxides Catalysts for Oxidative Coupling of Methane

A supported oxidative coupling of methane (OCM) catalyst comprising a support and an OCM catalytic composition characterized by the general formula A a Z b E c D d O x ; wherein A is an alkaline earth metal; wherein Z is a first rare earth element; wherein E is a second rare earth element; wherein D is a redox agent or a third rare earth element; wherein the first rare earth element, the second rare earth element, and the third rare earth element, when present, are not the same; wherein a is 1.0; wherein b is from about 0.1 to about 10.0; wherein c is from about 0.1 to about 10.0; wherein d is from about 0 to about 10.0; and wherein x balances the oxidation states.

Catalysts Prepared from Nanostructures of MnO2 and WO3 for Oxidative Coupling of Methane

Disclosed is a process to prepare a [MnNaW]O/SiOcatalyst using manganese oxide (MnO) and tungsten oxide (WO) nanostructures. Also disclosed are methods and systems using the aforementioned catalyst having higher methane conversion and Cto Cselectivity compared to similar catalysts not prepared with MnOand WOnanostructures. 1. A method for preparing a [MnNaW]O/SiOcatalyst , the method comprising:{'sub': 2', '2', '3', '3', '2', '3, '(a) contacting manganese oxide (MnO) nanostructures (nano MnO), tungsten oxide (WO) nanostructures (nano WO), silica sol, and a sodium source to form a mixture, wherein the MnOnanostructures and WOnanostructures are dispersed throughout the mixture, and wherein a nanostructure has at least one dimension of from 1 nm to 1000 nm;'}(b) drying the mixture at a temperature of 110° C. to 125° C. for 1 hour to 15 hours to obtain a crystalline material; and{'sub': n', '2, '(c) calcining the crystalline material to obtain a [MnNaW]O/SiOcatalyst, wherein n balances the combined valence states of Mn, Na, and W.'}2. The method of claim 1 , wherein the MnOnanostructures and WOnanostructures are each individually nanowires claim 1 , nanoparticles claim 1 , nanorods claim 1 , nanotubes claim 1 , nanocubes claim 1 , or a combination thereof.3. The method of claim 1 , wherein the sodium source is NaNO claim 1 , NaCO claim 1 , NaCl claim 1 , or NaO claim 1 , or a mixture thereof.4. The method of claim 1 , wherein the mixture in step (a) is obtained by:{'sub': 2', '2, '(i) contacting the nano MnOand the silica sol to form an aqueous MnOnanostructures/silica sol mixture;'}{'sub': 3', '2', '2', '3, '(ii) adding an aqueous nano WOmixture to the aqueous MnOnanostructures/silica sol mixture to form an aqueous MnOnanostructures/WOnanostructures/silica sol mixture; and'}{'sub': 2', '3, '(iii) agitating and heating the aqueous MnOnanostructures/WOnanostructures/silica sol mixture.'}5. The method of claim 4 , wherein agitating comprises sonicating or ultrasonicating ...

Sr-Ce-Yb-O Catalysts for Oxidative Coupling of Methane

An oxidative coupling of methane (OCM) catalyst composition comprising (i) Sr—Ce—Yb—O perovskite; and (ii) one or more oxides of a metal selected from the group consisting of strontium (Sr), cerium (Ce), and ytterbium (Yb), wherein the one or more oxides comprises a single metal oxide, mixtures of single metal oxides, a mixed metal oxide, mixtures of mixed metal oxides, mixtures of single metal oxides and mixed metal oxides, or combinations thereof.

Method for Producing Hydrocarbons by Oxidative Coupling of Methane without Catalyst

A method for producing olefins and synthesis gas comprising (a) introducing a reactant mixture to a reactor, wherein the reactant mixture comprises methane (CH 4 ) and oxygen (O 2 ), wherein the reactor is characterized by a reaction temperature of from about 700° C. to about 1,100° C.; (b) allowing at least a portion of the reactant mixture to react via an oxidative coupling of CH 4 reaction to form a product mixture, wherein the product mixture comprises primary products and unreacted methane, wherein the primary products comprise C 2+ hydrocarbons and synthesis gas, wherein the C 2+ hydrocarbons comprise olefins, and wherein a selectivity to primary products is from about 70% to about 99%; and (c) recovering at least a portion of the product mixture from the reactor.

Method of Producing Higher Value Hydrocarbons by Isothermal Oxidative Coupling of Methane

A method for producing olefins comprising (a) introducing to an isothermal reactor a reactant mixture comprising CHand O, wherein the reactor comprises a catalyst bed comprising a catalyst, wherein a catalyst bed temperature is 750-1,000° C., and wherein the reactor has a residence time of 1-100 ms; (b) wherein isothermal conditions minimize hot spots in the bed, thereby decreasing deep oxidation reactions; (c) allowing the reactant mixture to contact the catalyst and react via oxidative coupling of CHreaction to form a product mixture comprising Chydrocarbons (olefins and paraffins; Chydrocarbons and Chydrocarbons) and synthesis gas (Hand CO), wherein the product mixture has an olefin/paraffin molar ratio of from 0.5:1 to 20:1, and wherein the product mixture has a H/CO molar ratio of from 0.2:1 to 2.5:1; (d) recovering the product mixture from the reactor; and (e) recovering Chydrocarbons and/or synthesis gas from the product mixture. 1. A method for producing olefins comprising:(a) introducing a reactant mixture to an isothermal reactor, wherein the reactant mixture comprises methane (CH4) and oxygen (O2), wherein the isothermal reactor comprises a catalyst bed comprising a catalyst, wherein an isothermal reaction temperature in the catalyst bed is from about 750° C. to about 1,000° C., and wherein the reactor is characterized by a residence time of from about 1 millisecond to about 100 milliseconds in the catalyst bed;(b) wherein isothermal reactor conditions minimize hot spots formation in the catalyst bed, thereby decreasing an incidence of deep oxidation reactions, when compared to an incidence of deep oxidation reactions in an otherwise similar oxidative coupling of CH4 reaction conducted under non-isothermal conditions;(c) allowing at least a portion of the reactant mixture to contact the catalyst and react via an oxidative coupling of CH4 reaction to form a product mixture under isothermal conditions, wherein the product mixture comprises C2+ hydrocarbons ...

CATALYST COMPOSITION FOR THE OXIDATIVE COUPLING OF METHANE USING A SILVER PROMOTER

The invention relates to a catalyst composition, suitable for producing ethylene and other commercially high value C hydrocarbons from methane. The composition contains a silver promoted mixed metal catalyst composition comprising at least two rare earth elements and an alkaline rare earth metal element. The catalyst composition has high catalyst activity and enables oxidative coupling of methane reactions to be conducted at a low reactor temperature while retaining sufficient catalyst selectivity. The invention further provides a method for preparing such a catalyst composition and a process for producing C hydrocarbons, using such a catalyst composition. 1. A composition , comprising a catalyst represented by a general formula (I):{'br': None, 'sub': z', 'a', 'b', 'c', 'd', 'X, '(AgAERE1RE2ATO)'}wherein,(i) ‘Ag’ represents silver;(ii) ‘AE’ represents an alkaline earth metal;(iii) ‘RE1’ represents a first rare earth element;(iv) ‘RE2’ represents a second rare earth element; and(v) ‘AT’ represents a third rare earth element ‘RE3’, or a redox agent selected from antimony, tin, nickel, chromium, molybdenum, tungsten; wherein, ‘a’, ‘b’, ‘c’, ‘d’ and ‘z’ represents relative molar ratio; wherein ‘a’ is 1; ‘b’ ranges from about 0.1 to about 10; ‘c’ ranges from about 0.01 to about 10; ‘d’ ranges from 0 to about 10; ‘z’ ranges from about 0.01 to about 1; ‘x’ balances the oxidation state; wherein, the first rare earth element, the second rare earth element and the third rare earth element, are different.2. The composition of claim 1 , wherein the relative molar ratio ‘z’ ranges from about 0.04 to about 0.18.3. The composition of claim 1 , wherein the relative molar ratio ‘a’ is 1 claim 1 , the relative molar ratio ‘b’ is 0.9 claim 1 , the relative molar ratio ‘c’ is 0.7 claim 1 , the relative molar ratio ‘d’ is 0.1 claim 1 , and the relative molar ratio ‘z’ ranges from about 0.043 to about 0.093.4. The composition of claim 1 , wherein the alkaline earth metal ‘AE’ is ...

A Process for Oxidative Conversion of Methane to Ethylene

A process for producing ethylene and syngas comprising reacting, via OCM, first reactant mixture (CH&O) in first reaction zone comprising OCM catalyst to produce first product mixture comprising ethylene, ethane, hydrogen, CO, CO, and unreacted methane; introducing second reactant mixture comprising first product mixture to second reaction zone excluding catalyst to produce second product mixture comprising ethylene, ethane, hydrogen, CO, CO, and unreacted methane, wherein a common reactor comprises both the first and second reaction zones, wherein ethane of second reactant mixture undergoes cracking to ethylene, wherein COof second reactant mixture undergoes hydrogenation to CO, and wherein an amount of ethylene in the second product mixture is greater than in the first product mixture; recovering methane stream, ethane stream, COstream, ethylene stream, and syngas stream (CO&H) from the second product mixture; and recycling the ethane stream and the carbon dioxide stream to second reaction zone. 1. A process for producing ethylene and syngas comprising:(a) reacting, via an oxidative coupling of methane (OCM) reaction, a first reactant mixture in a first reaction zone to produce a first product mixture, wherein the first reaction zone comprises an OCM catalyst, wherein the first reactant mixture comprises methane and oxygen, and wherein the first product mixture comprises ethylene, ethane, hydrogen, carbon monoxide, carbon dioxide, and unreacted methane;(b) introducing a second reactant mixture comprising at least a portion of the first product mixture to a second reaction zone to produce a second product mixture, wherein the second reaction zone excludes a catalyst, wherein a common reactor comprises both the first reaction zone and the second reaction zone, wherein at least a portion of ethane of the second reactant mixture undergoes a cracking reaction to produce ethylene, wherein at least a portion of the carbon dioxide of the second reactant mixture undergoes ...

A process for converting a natural gas feedstock with inert content to chemical intermediates

A methane conversion process for producing C2+ hydrocarbons comprising (a) introducing a reactant mixture comprising methane (>20 mol%) and an inert compound to a reaction unit to produce a reactor effluent stream comprising C2+ hydrocarbons, methane, the inert compound, and water and/or carbon dioxide; (b) removing at least a portion of the water and/or at least a portion of the carbon dioxide from the reactor effluent stream to produce a demethanizer feed stream; (c) feeding at least a portion of the demethanizer feed stream to a demethanizer unit to produce two or more vapor streams (methane rich stream and inert rich stream), and at least one liquid stream (C2+ hydrocarbons); (d) withdrawing at least a portion of the inert rich stream as a purge stream; (e) recycling any remaining portion of the inert rich stream to the reaction unit; and (f) recycling the methane rich stream to the reaction unit.

Integrated process combining methane oxidative coupling and dry methane reforming

The disclosure concerns processes for conversion of methane to C2 hydrocarbons comprising: (i) contacting methane with oxygen in the presence of a first catalyst in a first reactor to produce a first reaction product comprising C2 hydrocarbons and CO 2 ; (ii) separating the first reaction product to produce a first stream comprising C2 hydrocarbons and a second stream comprising methane, CO and CO 2 ; and (iii) contacting the second stream with oxygen and additional CO 2 in the presence of a second catalyst in a second reactor to produce a second reaction product comprising H 2 and CO.

Mixed oxides catalysts for oxidative coupling of methane

An OCM catalyst composition characterized by general formula AaLabEcDdOx; wherein A is an alkaline earth metal; wherein E is a first rare earth element; wherein D is a redox agent or a second rare earth element; wherein the first rare earth element and second rare earth element are different; wherein a is 1.0; wherein b is 0.01-10.0; wherein c is 0-10.0; wherein d is 0-10.0; and wherein x balances the oxidation states. The alkaline earth metal is selected from the group consisting of Mg, Ca, Sr, Ba, and combinations thereof. The first rare earth element and the second rare earth element can each independently be selected from the group consisting of Sc, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Y, Tb, Dy, Ho, Er, Tm, Yb, Lu, and combinations thereof. The redox agent is selected from the group consisting of Mn, W, Bi, Sb, Sn, Ce, Pr, and combinations thereof.

Conversion of methane to ethylene comprising integration with the in-situ ethane cracking and direct conversion of co2 byproduct to methanol

Methods and catalysts for producing ethylene and methanol from natural gas are presented. Methods include integration of oxidative conversion of methane to ethane, ethane in situ thermal cracking using the thermal heat generated thereby and direct hydrogenation of byproducts to methanol or oxidative CO2 autothermal reforming of methane to syngas.

Method for converting methane to ethylene and in situ transfer of exothermic heat

Disclosed is a method for production of ethylene by an oxidative coupling of methane process in the presence of a catalytic material. Heat generated from the oxidative coupling of methane can be transferred to an inert material in an amount sufficient to reduce thermal deactivation of the catalytic material.

A process for converting a natural gas feedstock with inert content to chemical intermediates

A methane conversion process for producing C2+ hydrocarbons comprising (a) introducing a reactant mixture comprising methane (>20 mol%) and an inert compound to a reaction unit to produce a reactor effluent stream comprising C2+ hydrocarbons, methane, the inert compound, and water and/or carbon dioxide; (b) removing at least a portion of the water and/or at least a portion of the carbon dioxide from the reactor effluent stream to produce a demethanizer feed stream; (c) feeding at least a portion of the demethanizer feed stream to a demethanizer unit to produce two or more vapor streams (methane rich stream and inert rich stream), and at least one liquid stream (C2+ hydrocarbons); (d) withdrawing at least a portion of the inert rich stream as a purge stream; (e) recycling any remaining portion of the inert rich stream to the reaction unit; and (f) recycling the methane rich stream to the reaction unit.

Silver promoted catalysts for oxidative coupling of methane

An oxidative coupling of methane (OCM) catalyst composition comprising one or more oxides doped with Ag; wherein one or more oxides comprises a single metal oxide, mixtures of single metal oxides, a mixed metal oxide, mixtures of mixed metal oxides, or combinations thereof; and wherein one or more oxides is not La2O3 alone. A method of making an OCM catalyst composition comprising calcining one or more oxides and/or oxide precursors to form one or more calcined oxides, wherein the one or more oxides comprises a single metal oxide, mixtures of single metal oxides, a mixed metal oxide, mixtures of mixed metal oxides, or combinations thereof, wherein the one or more oxides is not La2O3 alone, and wherein the oxide precursors comprise oxides, nitrates, carbonates, hydroxides, or combinations thereof; doping the one or more calcined oxides with Ag to form the OCM catalyst composition; and thermally treating the OCM catalyst composition.

Process for oxidative conversion of methane to ethylene

A process for producing ethylene and syngas comprising reacting, via OCM, first reactant mixture (CH4&O2) in first reaction zone comprising OCM catalyst to produce first product mixture comprising ethylene, ethane, hydrogen, CO2, CO, and unreacted methane; introducing second reactant mixture comprising first product mixture to second reaction zone excluding catalyst to produce second product mixture comprising ethylene, ethane, hydrogen, CO, CO2, and unreacted methane, wherein a common reactor comprises both the first and second reaction zones, wherein ethane of second reactant mixture undergoes cracking to ethylene, wherein CO2 of second reactant mixture undergoes hydrogenation to CO, and wherein an amount of ethylene in the second product mixture is greater than in the first product mixture; recovering methane stream, ethane stream, CO2 stream, ethylene stream, and syngas stream (CO&H2) from the second product mixture; and recycling the ethane stream and the carbon dioxide stream to second reaction zone.

Highly selective mixed oxide catalyst for oxidative coupling of methane

A supported oxidative coupling of methane (OCM) catalyst composition characterized by the general formula Mn-Na2WO4/SiO2; wherein equal to or greater than about 50% of any 100 mm2 regions of an external surface of the OCM catalyst composition having Na and/or W are characterized by a surface molar ratio of Na to W (Na:W) of from about 1.0:1 to about 4:1.

Method and reactor for oxidative coupling of methane

Sr-Ce-Yb-O-CATALYSTS FOR THE OXIDATIVE COUPLING OF METHANE

Eine Katalysatorzusammensetzung für die oxidative Kopplung von Methan (OCM), umfassend: (i) Sr-Ce-Yb-O-Perowskit; und (ii) ein oder mehrere Oxide eines Metalls aus der Gruppe bestehend aus Strontium (Sr), Cer (Ce) und Ytterbium (Yb), wobei das eine Oxid bzw. die mehreren Oxide ein Einzelmetalloxid, Mischungen von Einzelmetalloxiden, ein Mischmetalloxid, Mischungen von Mischmetalloxiden, Mischungen von Einzelmetalloxiden und Mischmetalloxiden oder Kombinationen davon umfasst bzw. umfassen. A catalyst composition for the oxidative coupling of methane (OCM) comprising: (i) Sr-Ce-Yb-O-perovskite; and (ii) one or more oxides of a metal selected from the group consisting of strontium (Sr), cerium (Ce) and ytterbium (Yb), said one or more oxides being a single metal oxide, mixtures of single metal oxides, a mixed metal oxide, mixtures of mixed metal oxides, mixtures of single metal oxides and mixed metal oxides, or combinations thereof.

Mixed oxides catalysts for oxidative coupling of methane

An oxidative coupling of methane (OCM) catalyst composition characterized by the general formula (EaDbOx)-Mn/Na2WO4; wherein E is a first rare earth element; wherein D is a second rare earth element; wherein the first rare earth element and the second rare earth element are different; wherein a is 1.0; wherein b is from about 0 to about 10.0; wherein when b is 0, the first rare earth element is not lanthanum (La) alone or cerium (Ce) alone; and wherein x balances the oxidation states.

A carbon efficient process for converting methane to olefins and methanol by oxidative coupling of methane

A method for producing olefins and methanol comprising introducing a first reactant mixture comprising CH 4 and O 2 to a first reaction zone; allowing the first reactant mixture to react via an OCM reaction to form a first product mixture characterized by a first H 2 /CO molar ratio; introducing a second reactant mixture comprising the first product mixture and an ethane stream to a second reaction zone, wherein ethane of the second reactant mixture undergoes a cracking reaction to produce ethylene; recovering a second product mixture from the second reaction zone, wherein the second product mixture is characterized by a second H 2 /CO molar ratio, and wherein the second H 2 /CO molar ratio is greater than the first H 2 /CO molar ratio; recovering from the second product mixture a methanol production feed stream comprising methane, H 2 and CO; and introducing the methanol production feed stream to a third reaction zone to produce methanol.

Process for Producing Ethylene Oxide from Ethane by Oxidative Dehydrogenation and Epoxidation with Split Recycle

An ethylene oxide (EO) production process comprising (a) introducing a first reactant mixture (C2H6, O2) to a first reactor to produce a first effluent stream (C2H4, C2H6, O2); (b) introducing a second reactant mixture to a second reactor to produce a second effluent stream (EO, C2H4, C2H6, O2); wherein the second reactant mixture comprises at least a portion of first effluent stream; (c) separating the second effluent stream into an EO product stream (EO) and recycle stream (C2H4, C2H6, O2); wherein ethylene is not separated from recycle stream and/or first effluent stream; and (d) recycling a first portion of recycle stream to the first reactor, and a second portion of recycle stream to the second reactor; wherein recycle split ratio <0.6; and wherein recycle split ratio is defined as ratio of volumetric flowrate of first portion of recycle stream divided by the sum of volumetric flowrates of first portion and second portion of recycle stream.

Process for producing ethylene oxide from ethane by oxidative dehydrogenation and epoxidation with split recycle

Process for producing ethylene oxide from ethane by oxidative dehydrogenation and epoxidation using a recycle reactor design

Stable catalysts for oxidative coupling of methane

A method of selecting a stable mixed metal oxide catalyst for an oxidative coupling of methane (OCM) reaction is disclosed. The method may include, obtaining a mixed metal oxide material having catalytically active metal oxides for the OCM reaction and identifying the Tammann temperature (TTam) of at least one of the catalytically active metals oxides of the mixed metal oxide material. The method further includes selecting the mixed metal oxide material for use as a catalyst in the OCM reaction if the at least one catalytically active metal oxides present in the mixed metal oxide material has a TTam greater than a predetermined temperature.

Catalyst composition for the production c2 hydrocarbons from methane

A catalyst composition, suitable for producing ethylene and other C 2+ hydrocarbons, from methane. The composition comprises a blended product of two distinct catalyst components, blended at such synergistic proportions that results in a catalyst having high ethylene selectivity while maintaining low ethyne selectivity and sufficient catalytic activity rate. The invention further provides a method for preparing such a catalyst composition and a process for producing ethylene and other C 2+ hydrocarbons, using such a catalyst composition.

Catalyst composition for the production C2 hydrocarbons from methane

A catalyst composition, suitable for producing ethylene and other C2+ hydrocarbons, from methane. The composition comprises a blended product of two distinct catalyst components, blended at such synergistic proportions that results in a catalyst having high ethylene selectivity while maintaining low ethyne selectivity and sufficient catalytic activity rate. The invention further provides a method for preparing such a catalyst composition and a process for producing ethylene and other C2+ hydrocarbons, using such a catalyst composition.

Process for producing ethylene oxide from ethane by oxidative dehydrogenation and epoxidation with low ethane concentration in oxidative dehydrogenation effluent