Heterogeneous catalysts

Patent metadata

Field	Value
Publication number	US-9956544-B2
Application number	US-201514701963-A
Country	US
Kind code	B2
Filing date	May 1, 2015
Priority date	May 2, 2014
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

Heterogeneous catalysts with optional dopants are provided. The catalysts are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane to C 2+ hydrocarbons. Related methods for use and manufacture of the same are also disclosed.

First claim

The invention claimed is:

1. A catalyst comprising a mixed oxide base material for the oxidative coupling of methane, the mixed oxide base material comprising lanthanide elements and a dopant combination selected from the group consisting of Sr/Sm, Sr/Gd, Sr/Dy, Sr/Er, Sr/Lu, Sr/Ba/B, Ba/B, Ba/Sr, Er/W, Sr/K, Ba/Ce, Ba/Hf, Ga/Mg, Mg/Er, Y/Ba, Sr/Ga/Mg, Sr/Y, Sr/B/Y, Ca/B, Sr/Al, Ba/W, B/W, Sr/Ba/W, Sr/W/B, Ba/W/B and Sr/Ba/WB,
wherein the mixed oxide base material has the following formula (III):
Ln1 a Ln2 b Ln3 d Ln4 e Ln5 f O c   (III)

wherein:
Ln1, Ln2, Ln3, Ln4 and Ln5 are independently different lanthanide elements;
O is oxygen; and
a, b and c are each independently numbers greater than 0; and
d, e and f are independently 0 or a number greater than 0,
provided that one of the lanthanide elements is not lanthanum when another lanthanide element is neodymium.

2. The catalyst of claim 1 , wherein:
a, b, c and d are each independently numbers greater than 0; and
e and f are independently 0 or a number greater than 0.

3. The catalyst of claim 1 , wherein the catalyst is a nanowire catalyst.

4. The catalyst of claim 1 , further comprising an alkaline earth metal diluent.

5. 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 heterogeneous catalyst in the oxidative coupling of methane at a temperature of 750° C. or less.

6. The catalyst of claim 1 , in combination with a support material.

7. A method for conversion of methane to C 2 + hydrocarbons, the method comprising contacting the catalyst of claim 1 with methane and an oxidant source.

8. The catalyst of claim 1 , wherein Ln1 is Gd.

9. The catalyst of claim 1 , wherein Ln2 is Nd.

10. The catalyst of claim 1 , wherein at least one lanthanide element is erbium (Er).

11. The catalyst of claim 10 , wherein the mixed oxide base material comprises a physical blend of Er, or an oxidized form thereof, and a further lanthanide element, or an oxidized form thereof.

12. The catalyst of claim 1 , further comprising a support, diluent, binder, or combinations thereof.

13. The catalyst of claim 1 , in the form of a pellet or extrudate.

14. A catalyst comprising a mixed oxide base material for the oxidative coupling of methane, the mixed oxide base material comprising three different lanthanide elements and a dopant combination selected from the group consisting of Sr/Sm, Sr/Gd, Sr/Dy, Sr/Er, Sr/Lu, Sr/Ba/B, Ba/B, Ba/Sr, Er/W, Sr/K, Ba/Ce, Ba/Hf, Ga/Mg, Mg/Er, Y/Ba, Sr/Ga/Mg, Sr/Y, Sr/B/Y, Ca/B, Sr/Al, Ba/W, B/W, Sr/Ba/W, Sr/W/B, Ba/W/B and Sr/Ba/W/B, provided that one of the lanthanide elements is not lanthanum when another lanthanide element is neodymium.

15. The catalyst of claim 14 , wherein the catalyst is a nanowire catalyst.

16. The catalyst of claim 14 , further comprising an alkaline earth metal diluent.

17. The catalyst of claim 14 , 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 heterogeneous catalyst in the oxidative coupling of methane at a temperature of 750° C. or less.

18. The catalyst of claim 14 , in combination with a support material.

19. A method for conversion of methane to C 2 + hydrocarbons, the method comprising contacting the catalyst of claim 14 with methane and an oxidant source.

20. The catalyst of claim 14 , further comprising a support, diluent, binder, or combinations thereof.

21. The catalyst of claim 14 , in the form of a pellet or extrudate.

Assignees

• Siluria Technologies Inc

Inventors

• Schammel Wayne P
• Rumplecker Anja
• Zurcher Fabio R
• Scher Erik C
• Cizeron Joel M
• Gamoras Joel

Classifications

• C07C2521/02

  Boron or aluminium; Oxides or hydroxides thereof · CPC title

• B01J35/0013

  Operations & Transport · mapped topic

• C07C2529/83

  Aluminophosphates (APO compounds) · CPC title

• C07C2523/04

  Alkali metals · CPC title

• B01J35/0006

  Operations & Transport · mapped topic