Catalysts for petrochemical catalysis

Patent metadata

Field	Value
Publication number	US-11795123-B2
Application number	US-202016834972-A
Country	US
Kind code	B2
Filing date	Mar 30, 2020
Priority date	May 24, 2011
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

Metal oxide catalysts comprising various dopants are provided. The catalysts are useful as heterogenous catalysts in a variety of catalytic reactions, for example, the oxidative coupling of methane to C2 hydrocarbons such as ethane and ethylene. Related methods for use and manufacture of the same are also disclosed.

First claim

The invention claimed is:

1. A catalyst comprising a lanthanide oxide doped with an alkali metal, an alkaline earth metal or combinations thereof, and in combination with a support comprising calcium aluminate, where the dopant is present in the catalyst in an amount up to 75% by weight.

2. The catalyst of claim 1 , wherein the lanthanide oxide comprises La 2 O 3 , Nd 2 O 3 , Yb 2 O 3 , Eu 2 O 3 , Sm 2 O 3 , Ln1 4-x Ln2 x O 6 , or combinations thereof, wherein Ln1 and Ln2 are each independently a lanthanide element, and wherein Ln1 and Ln2 are not the same and x is a number ranging from greater than 0 to less than 4.

3. The catalyst of claim 1 , wherein the catalyst comprises an alkali metal dopant selected from lithium (Li), sodium (Na), potassium (K), rubidium (Ru) and caesium (Cs).

4. The catalyst of claim 1 , wherein the catalyst comprises an alkaline earth metal dopant selected from beryllium (Be), magnesium (Mg), calcium (Ca), strontium (Sr) and barium (Ba).

5. The catalyst of claim 1 , wherein the lanthanide oxide is doped with Li/Sr, Sr/Na, Sr/Cs, Mg/K, Mg/Na, Mg/Sr, or Ca/Sr.

6. The catalyst of claim 1 , further comprising at least one other dopant from groups 3-16.

7. The catalyst of claim 6 , wherein the lanthanide oxide is doped with Ca/W, Ca/Ce, La/Mg, In/Sr, Sr/Sn, Sr/W, Sr/Nb, Sr/Tm, Sr/Ta, Sr/Pb, Sr/Nd, Sr/Hf, La/Sr, Eu/Sr, Ho/Sr, Rb/Sr, Sb/Sr, Yb/Sr, Au/Sr, Ta/Sr, Ce/Mg, Mg/W, La/Mg, Sn/Mg, Ba/Ta, Li/Sr/Cs, Li/Na/Sr, Sr/W/Li, La/Nd/Sr, La/Bi/Sr, Ca/Sr/W, Sr/Zn/La, Sr/Cs/Zn, La/S/Sr, Rb/Sr/La, Sr/Cs/La, Sr/Ho/Tm, Na/Sr/Lu, Sr/Eu/Dy, Na/Ca/Lu, Ca/Mg/Na, Na/K/Mg, Mg/Nd/Fe, Ba/Rh/Ta, Sr/Tm/Li/Cs, Ba/Sm/Yb/S, Ba/Tm/K/La, Ba/Tm/Zn/K, Na/Sr/Eu/Ca, K/Cs/Sr/La, Mg/La/Yb/Zn, Na/Mg/Tl/P, Sr/La/Dy/S, Sr/Ho/Tm/Na, Sr/Sm/Ho/Tm, La/Ce/Nd/Sr La/Bi/Ce/Nd/Sr, Li/Cs/Sr/Tm, Li/Sr/Zn/K, Li/K/Sr/La, or Li/Na/Sr/La.

8. The catalyst of claim 1 , wherein the catalyst exhibits a C 2 selectivity of greater than 50% and a methane conversion of greater than 20% when the catalyst is employed as a heterogenous catalyst in the oxidative coupling of methane at a temperature of 700° C. or less.

9. The catalyst of claim 1 , wherein an amount of catalyst present on the support ranges from 1 to 100 parts by weight of catalyst per 100 parts by weight of support.

10. The catalyst of claim 9 , wherein an amount of catalyst present on the support ranges from 10 to 50 parts by weight of catalyst per 100 parts by weight of support.

11. The catalyst of claim 1 , wherein an amount of catalyst present on the support ranges from 100 to 1000 parts by weight of catalyst per 100 parts by weight of support.

12. The catalyst of claim 1 , further comprising a diluent.

13. The catalyst of claim 12 , wherein the diluent comprises MgO, MgCO 3 , MgSO 4 , Mg 3 (PO 4 ) 2 , MgAl 2 O 4 , CaO, CaCO 3 , CaSO 4 , Ca 3 (PO 4 ) 2 , CaAl 2 O 4 , SrO, SrCO 3 , SrSO 4 , Sr 3 (PO 4 ) 2 , SrAl 2 O 4 , BaO, BaCO 3 , BaSO 4 , Ba 3 (PO 4 ) 2 or BaAl 2 O 4 .

14. A catalyst comprising a lanthanide oxide doped with an alkali metal, an alkaline earth metal or combinations thereof, and in combination with a support comprising calcium aluminate, wherein the catalyst further comprises a diluent selected from MgO, MgCO 3 , MgSO 4 , Mg 3 (PO 4 ) 2 , MgAl 2 O 4 , CaO, CaCO 3 , CaSO 4 , Ca 3 (PO 4 ) 2 , CaAl 2 O 4 , SrO, SrCO 3 , SrSO 4 , Sr 3 (PO 4 ) 2 , SrAl 2 O 4 , BaO, BaCO 3 , BaSO 4 , Ba 3 (PO 4 ) 2 and BaAl 2 O 4 .

Assignees

• Lummus Technology Inc

Inventors

• Cizeron Joel M
• Scher Erik C
• Zurcher Fabio R
• Schammel Wayne P
• Nyce Greg
• Rumplecker Anja
• Mccormick Jarod
• Alcid Marian
• Gamoras Joel
• Rosenberg Daniel
• Ras Erik-Jan

Classifications

• C07C2/84 Primary

  catalytic · CPC title

• B01J19/0046

  Sequential or parallel reactions, e.g. for the synthesis of polypeptides or polynucleotides; Apparatus and devices for combinatorial chemistry or for making molecular arrays (synthesis methods per se C40B50/00) · CPC title

• B01J21/066

  Zirconium or hafnium; Oxides or hydroxides thereof · CPC title

• B01J21/08

  Silica · CPC title

• B01J23/002

  Mixed oxides other than spinels, e.g. perovskite · CPC title