Catalytic forms and formulations

Patent metadata

Field	Value
Publication number	US-11370724-B2
Application number	US-201916366149-A
Country	US
Kind code	B2
Filing date	Mar 27, 2019
Priority date	May 24, 2012
Publication date	Jun 28, 2022
Grant date	Jun 28, 2022

Abstract

Catalytic forms and formulations are provided. The catalytic forms and formulations are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane. Related methods for use and manufacture of the same are also disclosed.

First claim

The invention claimed is:

1. A catalytic material comprising a first and second catalyst, wherein the first and second catalysts are independently selected from a mixed oxide of lanthanide elements, a mixed oxide of magnesium and manganese, a mixed oxide of manganese and tungsten, a mixed oxide of a lanthanide element and tungsten and a mixed oxide of a rare earth element and a group 13 element and are segregated into discrete layers, wherein the second catalyst has a temperature of activation in an oxidative coupling of methane (OCM) reaction at least 25 degrees higher than the first catalyst, and wherein the catalytic material comprises a C2 selectivity of greater than 50% and a methane conversion of greater than 20% when the catalytic material is employed as a heterogeneous catalyst in the oxidative coupling of methane at a temperature of 750° C. or less.

2. The catalytic material of claim 1 , wherein the first catalyst is a nanowire catalyst.

3. The catalytic material of claim 1 , wherein the second catalyst is a bulk catalyst.

4. The catalytic material of claim 1 , wherein each of the first and second catalysts are nanowire catalysts.

5. The catalytic material of claim 1 , wherein each of the first and second catalyst are bulk catalysts.

6. The catalytic material of claim 1 , wherein the catalytic activity of the second catalyst increases with increasing temperature.

7. The catalytic material of claim 1 , wherein the catalytic material comprises a void fraction volume of about 35% to about 70%.

8. The catalytic material of claim 7 , wherein the catalytic material comprises a void fraction volume of about 45% to about 65%.

9. The catalytic material of claim 1 , wherein the catalytic material comprises catalyst particles having a cross sectional dimension in at least one dimension between about 1 mm and about 20 mm.

10. The catalytic material of claim 9 , wherein the cross sectional dimension is between about 2 mm and about 10 mm.

11. The catalytic material of claim 1 , wherein the catalytic material comprises catalyst particles having a surface area to volume ratio between about 0.1 mm −1 and about 10 mm −1 .

12. The catalytic material of claim 11 , wherein the catalytic material comprises catalyst particles having a surface area to volume ratio between about 0.1 mm −1 and about 5 mm −1 .

13. The catalytic material of claim 1 , wherein the catalytic material comprises a crush strength greater than 1 N/mm 2 .

14. The catalytic material of claim 13 , wherein the catalytic material comprises a crush strength greater than 10 N/mm 2 .

15. The catalytic material of claim 1 , wherein the catalytic material comprises a porosity of between about 10% and about 80%.

16. The catalytic material of claim 15 , wherein the porosity is between about 40% and about 60%.

17. The catalytic material of claim 1 , wherein the ratio of the surface area of the catalytic form envelope to the volume of the catalytic form envelope ranges from about 0.5 mm −1 to about 4 mm −1 .

18. The catalytic material of claim 1 , wherein the catalytic material comprises a homogenously dispersed active catalyst.

19. The catalytic material of claim 1 , wherein the catalytic material comprises a surface area ranging from about 1 m 2 /g to about 50 m 2 /g.

20. The catalytic material of claim 1 , wherein at least one of the first and second catalysts is an inorganic catalytic polycrystalline nanowire, the nanowire having a ratio of effective length to actual length of less than one and an aspect ratio of greater than ten as measured by TEM in bright field mode at 5 keV, wherein the nanowire comprises one or more elements from any of Groups 1 through 7, lanthanides, actinides or combinations thereof.

21. The catalytic material of claim 1 in combination with a diluent.

22. The catalytic material of claim 21 , wherein the diluent comprises an alkaline earth metal compound, silicon carbide, cordierite, B 2 O 3 , In 2 O 3 , SrAl 2 O 4 , B 4 SrO 7 or combinations thereof.

23. The catalytic material of claim 1 , wherein the second catalyst has a higher temperature of activation in the OCM reaction than the first catalyst.

24. The catalytic material of claim 23 , wherein the second catalyst has a temperature of activation in the OCM reaction of at least 50° C. higher than the first catalyst.

25. The catalytic material of claim 23 , wherein the second catalyst has a temperature of activation in the OCM reaction of at least 100° C. higher than the first catalyst.

26. The catalytic material of claim 23 , wherein the second catalyst has a temperature of activation in the OCM reaction of at least 200° C. higher than the first catalyst.

27. The catalytic material of claim 1 , wherein the second catalyst has a C2 selectivity of greater than 50% at a temperature above 700° C., and the first catalyst has a C2 selectivity of greater than 50% at a temperature below 700° C.

28. The catalytic material of claim 1 , wherein the second catalyst comprises LiMgMnB or Na/MnWO4.

29. A method for the oxidative coupling of methane, the method comprising contacting the catalytic material of claim 1 with a mixture comprising methane and oxygen.

30. A method for the preparation of ethane or ethylene, the method comprising contacting the catalytic material of claim 1 with a mixture comprising methane and oxygen.

31. A method for the preparation of a downstream product of ethylene, the method comprising oligomerizing ethylene, wherein the ethylene has been prepared by a method comprising contacting the catalytic material of claim 1 with a mixture comprising methane and oxygen.

Assignees

• Lummus Technology Inc

Inventors

• Cizeron Joel M
• Zurcher Fabio R
• Mccormick Jarod
• Gamoras Joel
• Vogel Roger
• Vincent Joel David
• Nyce Greg
• Schammel Wayne P
• Scher Erik C
• Rosenberg Daniel
• Ras Erik-Jan
• Freer Erik

Classifications

• B01J35/37

  Crush or impact strength · CPC title

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/50

  characterised by their shape or configuration · CPC title

• C07C2523/02

  of the alkali- or alkaline earth metals or beryllium · CPC title