Catalyst for the oxidative coupling of methane with low feed temperatures

Patent metadata

Field	Value
Publication number	US-2020101443-A1
Application number	US-201916582000-A
Country	US
Kind code	A1
Filing date	Sep 25, 2019
Priority date	Sep 27, 2018
Publication date	Apr 2, 2020
Grant date	—

Abstract

A catalytic material for oxidative coupling of methane includes: a catalyst with the formula AaBbCcOx, 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 C2+ 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.

First claim

What is claimed is:

1 . A catalytic material for oxidative coupling of methane comprising:
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.

2 . The catalytic material according to claim 1 , wherein the catalyst is thermally stable at a temperature of 797° F. (425° C.) or greater.

3 . The catalytic material according to claim 1 , wherein the catalyst is thermally stable at a temperature in the range of about 797° F. (425° C.) to about 2,372° F. (1,300° C.).

4 . The catalytic material according to claim 1 , wherein the catalyst provides the oxygen conversion and selectivity at a temperature in the range of about 797° F. (425° C.) to about 2,012° F. (1,100° C.).

5 . The catalytic material according to claim 1 , wherein: a=1.0; b and c are each in the range from about 0.01 to about 10; and x is a number selected to balance the oxidation states of A, B, and C.

6 . The catalytic material according to claim 1 , wherein A, B, and C and the ratios of A, B, and C are selected to provide an oxygen conversion of greater than or equal to 50% and a C 2 + selectivity of greater than or equal to 70% to the catalytic material.

7 . The catalytic material according to claim 1 , whereby the catalytic material provides an oxygen conversion of greater than or equal to 90% and a C 2 + selectivity of greater than or equal to 75%.

8 . The catalytic material according to claim 1 , wherein the raw materials used for the catalyst preparation of the catalytic material are nano materials.

9 . The catalytic material according to claim 1 , wherein:
A is selected from the group consisting of magnesium, calcium, strontium, and barium; and B and C are selected from the group consisting of lanthanum, scandium, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, yttrium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium.

10 . The catalytic material according to claim 1 , wherein at least one of B and C has redox properties.

11 . The catalytic material according to claim 1 , wherein the catalytic material is used in an adiabatic rector.

12 . The catalytic material according to claim 1 , further comprising D d wherein d is in the range from about 0 to about 10.

13 . The catalytic material according to claim 12 , wherein D is selected from the group consisting of manganese, tungsten, bismuth, antimony, niobium, tantalum, iron, copper, or a rare earth metal, wherein if D is selected from a rare earth metal, then D is a different rare earth metal from B and C

14 . A system for oxidative coupling of methane comprising:
a source of methane; a source of oxygen; a catalytic material, wherein the catalytic material comprises a catalyst with the formula A a B b C c O x , and 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, and
wherein the catalytic material produces ethane, ethylene, or combinations thereof; and a device for collecting the ethane, ethylene, or combinations thereof.

15 . The system according to claim 14 , wherein the ratio of methane to oxygen is selected to provide a percent yield of the ethane, ethylene, or combinations thereof that is greater than or equal to 10%.

16 . The system according to claim 14 , wherein the ratio of methane to oxygen is selected to provide a percent yield of the ethane, ethylene, or combinations thereof that is greater than or equal to 15%.

17 . A method for the oxidative coupling of methane comprising:
providing a source of methane; providing a source of oxygen; contacting the source of methane and the source of oxygen with a catalytic material, wherein the catalytic material comprises a catalyst with the formula A a B b C c O x , and 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, and
wherein the catalytic material produces ethane, ethylene, or combinations thereof after contact with the source of methane and the source of oxygen; and collecting the ethane, ethylene, or combinations thereof.

18 . The method according to claim 17 , wherein the ratio of methane to oxygen is selected to provide a percent yield of the ethane, ethylene, or combinations thereof that is greater than or equal to 10%.

19 . The method according to claim 17 , wherein the ratio of methane to oxygen is selected to provide a percent yield of the ethane, ethylene, or combinations thereof that is greater than or equal to 15%.

Assignees

• Sabic Global Technologies Bv

Inventors

• Liang Wugeng
• Sarsani Sagar
• Perez Hector
• West David
• Li Luanyi

Classifications

• B01J23/002 Primary

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

• C07C2523/10

  of rare earths · CPC title

• B01J2523/3712

  Cerium · CPC title

• C07C2/84 Primary

  catalytic · CPC title

• B01J2523/24

  Strontium · CPC title