Catalysts for oxidative coupling of methane

Patent metadata

Field	Value
Publication number	US-12447465-B2
Application number	US-202318115611-A
Country	US
Kind code	B2
Filing date	Feb 28, 2023
Priority date	Jan 30, 2019
Publication date	Oct 21, 2025
Grant date	Oct 21, 2025

Abstract

Catalysts, catalytic materials having catalysts present on supports and catalytic methods are provided. The catalysts, catalytic material and methods are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane.

First claim

The invention claimed is:

1. A catalytic material for oxidative coupling of methane (OCM) comprising an OCM active catalyst in combination with a support, wherein the OCM active catalyst comprises one or more elements from the lanthanides in the form of an oxide, a hydroxide or an oxyhydroxide, and the support comprises alpha phase alumina, gamma phase alumina or a combination thereof, the support having a local maxima pore diameter greater than 1 micrometer.

2. The catalytic material of claim 1 , wherein the support comprises gamma phase alumina.

3. The catalytic material of claim 1 , wherein the support has a bimodal pore size distribution with a first local maxima pore diameter that is less than 5 micrometers, and a second local maxima pore diameter that is greater than 15 micrometers.

4. The catalytic material of claim 1 , wherein the support comprises
a pore volume greater than about 0.3 cubic centimeters per gram (cc/g),
wherein the pore volume and pore size are determined by Hg porosimetry.

5. The catalytic material of claim 1 , wherein in a weight ratio of the OCM active catalyst to the support ranges from 95:5 to 5:95.

6. The catalytic material of claim 1 , wherein the OCM active catalyst comprises an oxide of a lanthanide element or a mixed oxide of two or more lanthanide elements.

7. The catalytic material of claim 1 , wherein the OCM active catalyst comprises La 2 O 3 , Ce 2 O 3 , Pr 2 O 3 , Nd 2 O 3 , Sm 2 O 3 , Eu 2 O 3 , Gd 2 O 3 , Yb 2 O 3 , Y 2 O 3 or combinations thereof.

8. The catalytic material of claim 1 , wherein OCM catalyst further comprises one or more dopants selected from group 2 elements.

9. The catalytic material of claim 8 , wherein the one or more dopants are each independently present in the OCM active catalyst from 1% to 10% by weight of the OCM active catalyst.

10. The catalytic material of claim 1 , further comprising a diluent.

11. The catalytic material of claim 10 , wherein the diluent comprises an alkaline earth aluminate selected from MgAl 2 O 4 , CaAl 2 O 4 , Ca 3 Al 2 O 6 , SrAl 2 O 4 or BaAl 2 O 4 .

12. A formed catalytic material comprising the catalytic material of claim 1 .

13. The formed catalytic material of claim 12 , wherein the formed catalytic material is a pressed pellet, an extrudate, a cast article or a monolith.

14. The formed catalytic material of claim 12 , wherein a shape of the formed catalytic material is selected from a cylinder, rod, star, rib, trilobe, disk, donut, ring, tube, sphere, honeycomb, cup, bowl and an irregular shape.

15. The formed catalytic material of claim 11 , wherein the formed catalytic material comprises a crushing strength greater than 1 N/mm 2 .

16. A method for oxidative coupling of methane (OCM), the method comprising contacting a feed gas comprising methane and oxygen with the formed catalytic material of claim 12 to form a product gas comprising C2+ hydrocarbons.

Assignees

• Lummus Technology Inc

Inventors

• Zurcher Fabio R
• Rosenberg Daniel
• James Richard P
• Grauer David
• Schammel Wayne P
• Cizeron Joel M
• Gamoras Joel
• Demars Ginger
• Tanur Adrienne

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/37

  Crush or impact strength · CPC title

• B01J35/55

  Cylinders or rings · CPC title

• B01J35/59

  Membranes · CPC title