Sabic Global Technologies B.v.

Other

Wugeng Liang

David H West

Hector Antonio Perez

Sagar Sarsani

Luanyi Li

Vidya Sagar Reddy Sarsani

Aghaddin Mamedov

Pankaj Singh Gautam

Istvan Lengyel

Vemuri Balakotaiah

Jonathan Banke

James Lowrey

Jae Hyung Kim

James W Kauffman

Dick Alan Nagaki

Tian Gu

Robert C Schucker

Azim Ali

Hector Perez

Yu-Lun Fang

A catalyst composition, suitable for producing ethylene and other Chydrocarbons, 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 Chydrocarbons, using such a catalyst composition.

Catalyst composition for the production Chydrocarbons from methane

The invention relates to a composition containing a catalyst having high catalytic stability for conducting oxidative coupling of methane (OCM) at high carbon efficiency, while improving both methane and oxygen conversion. Particularly, the inventive catalyst is a metal oxide supported catalyst, which contains an alkali metal promoter and a mixed metal oxide component having at least one alkali earth metal and at least one rare earth metal. The metal oxide support is selected in a manner, such that at least a portion of the metal oxide support is capable of reacting with at least a part or whole of the alkali metal promoter under conditions of calcination during catalyst preparation. The invention further provides a method for preparing such a metal oxide supported catalyst composition, using a calcination process. Additionally, the invention further describes a process for producing Chydrocarbons, using such a catalyst composition.

OCM catalyst composition having improved stability and carbon efficiency

A multilayer supported oxidative coupling of methane (OCM) catalyst composition (alpha-AlOsupport, first single oxide layer, one or more mixed oxide layers, optional second single oxide layer) characterized by formula AZEDO/alpha-AlO; A is alkaline earth metal; Z is first rare earth element; E is second rare earth element; D is redox agent/third rare earth element; the first, second, third rare earth element are not the same; a=1.0; b=0.1-10.0; c=0.1-10.0; d=0-10.0; x balances oxidation states; first single oxide layer (ZO, b1=0.1-10.0; x1 balances oxidation states) contacts alpha-AlOsupport and one or more mixed oxide layers; one or more mixed oxide layers (AZEDO, a2=1.0; b2=0.1-10.0; c2=0.1-10.0; d2=0-10.0; x2 balances oxidation states; AZEDOand AZEDOare different) contacts first single oxide layer and optionally second single oxide layer, and second single oxide layer (AO), when present, contacts one or more mixed oxide layers and optionally first single oxide layer.

Multilayer mixed oxide supported catalyst for oxidative coupling of methane

Disclosed herein are systems and processes for the conversion of a methane feedstock to Chydrocarbons.

Small channel short fixed bed adiabatic reactor for oxidative coupling of methane

A multilayer supported oxidative coupling of methane (OCM) catalyst composition (support, first single oxide layer, one or more mixed oxide layers, optional second single oxide layer) characterized by formula AZEDO/support; A is alkaline earth metal; Z is first rare earth element; E is second rare earth element; D is redox agent/third rare earth element; the first, second, third rare earth element are not the same; a=1.0; b=0.1-10.0; c=0.1-10.0; d=0-10.0; x balances oxidation states; first single oxide layer (ZO, b1=0.1-10.0; x1 balances oxidation states) contacts support and one or more mixed oxide layers; one or more mixed oxide layers (AZEDO, a2=1.0; b2=0.1-10.0; c2=0.1-10.0; d2=0-10.0; x2 balances oxidation states; AZEDOand AZEDOare different) contacts first single oxide layer and optionally second single oxide layer, and second single oxide layer (AO), when present, contacts one or more mixed oxide layers and optionally first single oxide layer.

The invention relates to a composition containing a catalyst suitable for producing ethylene and other Chydrocarbons at high selectivity while improving both methane conversion and product yield. Particularly, the catalyst contains mixed metal oxides having at least one alkali earth metal and at least one rare earth metal along with an alkali metal promoter in the form of an alkali metal or in the form of an alkali metal tungstate. The invention further provides a method for preparing such a composition, using a calcination process to calcine the alkali metal promoters together with mixed metal oxides. Additionally, the invention further describes a process for producing Chydrocarbons, using such a composition.

OCM catalyst composition having improved C2+ hydrocarbon selectivity

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.

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 AZEDO; 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.

Supported mixed oxides catalysts for oxidative coupling of methane

An OCM nanoplate catalyst comprising &#x2265;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)&#x2264;100 nm), a second external dimension (length (l)&#x3e;t), and a third external dimension (width (w)&#x3e;t); wherein l and w can be the same or different; and wherein l&#x2265;5 t, w&#x2265;5 t, or l&#x2265;5 t and w&#x2265;5 t; and wherein the OCM nanoplate catalyst has general formula AZEDO; 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&#x3e;(c+d)); and wherein x balances the oxidation states.

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.

Process for oxidative conversion of methane to ethylene

A catalyst composition, suitable for producing ethylene and other Chydrocarbons 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 Chydrocarbon selectivity while maintaining an overall sufficient catalyst activity and low ethyne selectivity. Methods for preparing such a catalyst composition and a process for producing Chydrocarbons using such a catalyst composition are provided.

Catalyst composition 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 Cselectivity of greater than or equal to 70%. Systems and methods can include contacting the catalyst with methane and oxygen and purifying or collecting Cproducts.

Mixed oxide catalyst for the oxidative coupling of methane

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.

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

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)) crystalline phase. The catalyst is capable of catalyzing the production of C+ hydrocarbons from methane and oxygen. Methods and systems of using the metal oxide catalyst to produce C+ hydrocarbons from a reactant gas are also described.

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Sugar Land, TX, United States of America

Wugeng Liang