Oxidative coupling of methane—A complex surface/gas phase mechanism with strong impact on the reaction engineering

Optimizing hierarchical membrane/catalyst systems for oxidative coupling of methane using additive manufacturing

The advantage of a membrane/catalyst system in the oxidative coupling of methane compared with conventional reactive systems is that by introducing oxygen into the catalytic sites through a membrane, the parasitic gas-phase reactions of O2(g)-responsible for lowering product selectivity-can be avoided. The design and fabrication of membrane/catalyst systems has, however, been hampered by low volumetric chemical conversion rates, high capital cost and difficulties in co-designing membrane and catalyst properties to optimize the performance. Here we solve these issues by developing a dual-layer additive manufacturing process, based on phase inversion, to design, fabricate and optimize a hollow-fibre membrane/catalyst system for the oxidative coupling of methane. We demonstrate the approach through a case study using BaCe0.8Gd0.2O3-δ as the basis of both catalyst and separation layers. We show that by using the manufacturing approach, we can co-design the membrane thickness and catalyst surface area so that the flux of oxygen transport through the membrane and methane activation rates in the catalyst layer match each other. We demonstrate that this 'rate matching' is critical for maximizing the performance, with the membrane/catalyst system substantially overperforming conventional reactor designs under identical conditions.

Oxidative Coupling of Methane: Examining the Inactivity of the MnOx -Na2 WO4 /SiO2 Catalyst at Low Temperature

Oxidative coupling of methane (OCM) catalyzed by MnO_x -Na₂ WO₄ /SiO₂ has great industrial promise to convert methane directly to C_2-3 products, but its high light-off temperature is the most challenging obstacle to commercialization and its working mechanism is still a mystery. We report the discovery of a low-temperature active and selective MnO_x -Na₂ WO₄ /SiO₂ catalyst enriched with Q² units in the SiO₂ carrier, being capable of converting 23 % CH₄ with 72 % C_2-3 selectivity at 660 °C. From experiments and theoretical calculations, a large number of Q² units in the MnO_x -Na₂ WO₄ /SiO₂ catalyst is a trigger for markedly lowering the light-off temperature of the Mn³⁺ ↔Mn²⁺ redox cycle involved in the OCM reaction because of the easy formation of MnSiO₃ . Notably, the MnSiO₃ formation proceeds merely through the SiO₂ -involved reaction in the presence of Na₂ WO₄ : Mn₇ SiO₁₂ +6 SiO₂ ↔7 MnSiO₃ +1.5 O₂ . The Na₂ WO₄ not only drives the light-off of this cycle but also gets it working with substantial selectivity toward C_2-3 products. Our findings shine a light on the rational design of more advanced MnO_x -Na₂ WO₄ based OCM catalysts through establishing new Mn³⁺ ↔Mn²⁺ redox cycles with lowered light-off temperature.

Oxidative coupling of methane-comparisons of MnTiO3-Na2WO4 and MnOx-TiO2-Na2WO4 catalysts on different silica supports

The oxidative coupling of methane (OCM) converts CH₄ to value-added chemicals (C₂₊), such as olefins and paraffin. For a series of MnTiO₃-Na₂WO₄ (MnTiO₃-NW) and MnO_x-TiO₂-Na₂WO₄ (Mn-Ti-NW), the effect of loading of MnTiO₃ or MnO_x-TiO₂, respectively, on two different supports (sol-gel SiO₂ (SG) and commercial fumed SiO₂ (CS)) was examined. The catalyst with the highest C₂₊ yield (21.6% with 60.8% C₂₊ selectivity and 35.6% CH₄ conversion) was 10 wt% MnTiO₃-NW/SG with an olefins/paraffin ratio of 2.2. The catalyst surfaces with low oxygen-binding energies were associated with high CH₄ conversion. Stability tests conducted for over 24 h revealed that SG-supported catalysts were more durable than those on CS because the active phase (especially Na₂WO₄) was more stable in SG than in CS. With the use of SG, the activity of MnTiO₃-NW was not substantially different from that of Mn-Ti-NW, especially at high metal loading.

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

Ethylene production via oxidative coupling of methane (OCM) represents an interesting route for natural gas upscaling, being the focus of intensive research worldwide. Here, OCM developments are analysed in terms of kinetic mechanisms and respective applications in chemical reactor models, discussing current challenges and directions for further developments. Furthermore, some thermodynamic aspects of the OCM reactions are also revised, providing achievable olefins yields in a wide range of operational reaction conditions. Finally, OCM catalysts are reviewed in terms of respective catalytic performances and thermal stability, providing an executive summary for future studies on OCM economic feasibility.

New Mechanistic and Reaction Pathway Insights for Oxidative Coupling of Methane (OCM) over Supported Na2 WO4 /SiO2 Catalysts

The complex structure of the catalytic active phase, and surface-gas reaction networks have hindered understanding of the oxidative coupling of methane (OCM) reaction mechanism by supported Na₂ WO₄ /SiO₂ catalysts. The present study demonstrates, with the aid of in situ Raman spectroscopy and chemical probe (H₂ -TPR, TAP and steady-state kinetics) experiments, that the long speculated crystalline Na₂ WO₄ active phase is unstable and melts under OCM reaction conditions, partially transforming to thermally stable surface Na-WO_x sites. Kinetic analysis via temporal analysis of products (TAP) and steady-state OCM reaction studies demonstrate that (i) surface Na-WO_x sites are responsible for selectively activating CH₄ to C₂ H_x and over-oxidizing CH_y to CO and (ii) molten Na₂ WO₄ phase is mainly responsible for over-oxidation of CH₄ to CO₂ and also assists in oxidative dehydrogenation of C₂ H₆ to C₂ H₄ . These new insights reveal the nature of catalytic active sites and resolve the OCM reaction mechanism over supported Na₂ WO₄ /SiO₂ catalysts.

"Soft" oxidative coupling of methane to ethylene: Mechanistic insights from combined experiment and theory

The oxidative coupling of methane to ethylene using gaseous disulfur (2CH₄ + S₂ → C₂H₄ + 2H₂S) as an oxidant (SOCM) proceeds with promising selectivity. Here, we report detailed experimental and theoretical studies that examine the mechanism for the conversion of CH₄ to C₂H₄ over an Fe₃O₄-derived FeS₂ catalyst achieving a promising ethylene selectivity of 33%. We compare and contrast these results with those for the highly exothermic oxidative coupling of methane (OCM) using O₂ (2CH₄ + O₂ → C₂H₄ + 2H₂O). SOCM kinetic/mechanistic analysis, along with density functional theory results, indicate that ethylene is produced as a primary product of methane activation, proceeding predominantly via CH₂ coupling over dimeric S-S moieties that bridge Fe surface sites, and to a lesser degree, on heavily sulfided mononuclear sites. In contrast to and unlike OCM, the overoxidized CS₂ by-product forms predominantly via CH₄ oxidation, rather than from C₂ products, through a series of C-H activation and S-addition steps at adsorbed sulfur sites on the FeS₂ surface. The experimental rates for methane conversion are first order in both CH₄ and S₂, consistent with the involvement of two S sites in the rate-determining methane C-H activation step, with a CD₄/CH₄ kinetic isotope effect of 1.78. The experimental apparent activation energy for methane conversion is 66 ± 8 kJ/mol, significantly lower than for CH₄ oxidative coupling with O₂ The computed methane activation barrier, rate orders, and kinetic isotope values are consistent with experiment. All evidence indicates that SOCM proceeds via a very different pathway than that of OCM.

Realization of Ethylene Production from Its Quaternary Mixture through Metal-Organic Framework Materials

Ethylene production from oxidative coupling of methane is a sustainable and economically attractive alternative to that through traditional hydrocarbon cracking technology. However, efficient ethylene separation from the complex reaction mixture is a daunting challenge that hinders the practical adoption of this technology. Herein, we report the efficient adsorptive separation of the CH₄/CO₂/C₂H₄/C₂H₆ mixture using three representative metal-organic frameworks (MOFs) (UTSA-74, MOF-74, and HKUST-1) with diverse open metal sites. The efficient separation relies on tuning the selectivity through the convergence of characteristics including Lewis acidity of open metal sites, pore space, and cooperative binding behavior. The separation performance of these materials has been evaluated through single-component gas adsorption and dynamic breakthrough experiments. HKUST-1 provides the highest separation potential (4.1 mmol/g) thanks to its simultaneously high ideal adsorbed solution theory (IAST) selectivity and ethylene adsorption capacity, representing a benchmark material for such a challenging quaternary separation.

Alternative Oxidants for the Catalytic Oxidative Coupling of Methane

The catalytic oxidative coupling of methane (OCM) to C₂ hydrocarbons with oxygen (O₂ -OCM) has garnered renewed worldwide interest in the past decade due to the emergence of enormous new shale gas resources. However, the C₂ selectivity of typical OCM processes is significantly challenged by overoxidation to CO_x products. Other gaseous reagents such as N₂ O, CO₂ , and S₂ have been investigated to a far lesser extent as alternative, milder oxidants to replace O₂ . Although several authoritative review articles have summarized OCM research progress in depth, recent oxidative coupling developments using alternative oxidants (X-OCM) have not been overviewed in detail. In this perspective, we review and analyze OCM research results reporting the implementation of N₂ O, CO₂ , S₂ , and other non-O₂ oxidants, highlighting the unique chemistries of these systems and their advantages/challenges compared to O₂ -OCM. Current outlook and potential areas for future study are also discussed.

Effect of thermal treatment on the stability of Na-Mn-W/SiO2 catalyst for the oxidative coupling of methane

In this study, we investigate the effect of thermal treatment/calcination on the stability and activity of a Na-Mn-W/SiO₂ catalyst for the oxidative coupling of methane. The catalyst performance and characterisation measurements suggest that the W species are directly involved in the catalyst active site responsible for CH₄ conversion. Under operating conditions, the active components, present in the form of a Na-W-O-Mn molten state, are highly mobile and volatile. By varying the parameters of the calcination protocol, it was shown that these molten components can be partially stabilised, resulting in a catalyst with lower activity (due to loss of surface area) but higher stability even for long duration OCM reaction experiments.

Oxidative coupling of methane over sodium zirconate catalyst

Previously only known for CO₂ absorption and CO oxidation, Na₂ZrO₃ is shown to be a selective catalyst for the oxidative coupling of methane (OCM) by detailed kinetic measurements and kinetic analysis.

Exploiting oxidative coupling of methane performed over La2(Ce1−xMgx)2O7−δ catalysts with disordered defective cubic fluorite structure

The oxidative coupling of methane reaction to produce C₂ compounds was studied using La₂(Ce_1−xMg_x)₂O_7−δ catalysts with disordered defective cubic fluorite structures, varying the Mg content (0.0 ≤ x ≤ 1.0), CH₄/O₂ ratio, temperature, and WHSV.

Reactor engineering calculations with a detailed reaction mechanism for the oxidative coupling of methane

The oxidative coupling of methane (OCM) is a potential option for conversion of excess natural gas to higher value products or useful feedstocks. The preferred or ideal OCM stoichiometry is: 2CH4 + O2 → C2H4 + 2H2O, but real OCM produces a variety of species. Using a detailed mechanism from the literature for OCM over a La2O3/CeO2 catalyst that combines coupled elementary gas phase and surface reactions, a reactor engineering study has been done. Adiabatic packed bed reactor (PBR, modeled as plug flow) and continuous stirred tank reactor (CSTR, perfect mixing) simulations using this mechanism are presented. Each reactor simulation used the same total number of catalyst sites. Process variables included CH4/O2 feed ratio (7, 11), feed temperature (843–1243 K), and feed rate. All runs were conducted at 1.01E5 Pa pressure. The results show the CSTR produces high conversions at much lower feed temperatures than those required by the PBR. Once full PBR “light off” occurs, however, its CH4 conversions exceed CSTR. The simulations reveal OCM over this catalyst at these conditions gives a mixture of synthesis gas (CO, H2) and C2Hx (primarily C2H4 plus small quantities of C2H6 and C2H2). The CSTR favors the production of synthesis gas, while the PBR favors C2Hx. Within the suite of CSTR cases, C2Hx is favored at the lowest feed temperature and highest CH4/O2 feed ratio.

Oxidative Dehydrogenation of Methane When Using TiO2- or WO3-Doped Sm2O3 in the Presence of Active Oxygen Excited with UV-LED

There are active oxygen species that contribute to oxidative coupling or the partial oxidation during the oxidative dehydrogenation of methane when using solid oxide catalysts, and those species have not been definitively identified. In the present study, we clarify which of the active oxygen species affect the oxidative dehydrogenation of methane by employing photo-catalysts such as TiO2 or WO3, which generate active oxygen from UV-LED irradiation conditions under an oxygen flow. These photo-catalysts were studied in combination with Sm2O3, which is a methane oxidation coupling catalyst. For this purpose, we constructed a reaction system that could directly irradiate UV-LED to a solid catalyst via a normal fixed-bed continuous-flow reactor operated at atmospheric pressure. Binary catalysts prepared from TiO2 or WO3 were either supported on or kneaded with Sm2O3 in the present study. UV-LED irradiation clearly improved the partial oxidation from methane to CO and/or slightly improved the oxidative coupling route from methane to ethylene when binary catalysts consisting of Sm2O3 and TiO2 are used, while negligible UV-LED effects were detected when using Sm2O3 and WO3. These results indicate that with UV-LED irradiation the active oxygen of O2− from TiO2 certainly contributes to the activation of methane during the oxidative dehydrogenation of methane when using Sm2O3, while the active oxygen of H2O2 from WO3 under the same conditions afforded only negligible effects on the activation of methane.

Lower olefins from methane: recent advances

Modern methods for methane conversion to lower olefins having from 2 to 4 carbon atoms per molecule are generalized. Multistage processing of methane into ethylene and propylene via syngas or methyl chloride and methods for direct conversion of CH4 to ethylene are described. Direct conversion of syngas to olefins as well as indirect routes of the process via methanol or dimethyl ether are considered. Particular attention is paid to innovative methods of olefin synthesis. Recent achievements in the design of catalysts and development of new techniques for efficient implementation of oxidative coupling of methane and methanol conversion to olefins are analyzed and systematized. Advances in commercializing these processes are pointed out. Novel catalysts for Fischer – Tropsch synthesis of lower olefins from syngas and for innovative technique using oxide – zeolite hybrid catalytic systems are described. The promise of a new route to lower olefins by methane conversion via dimethyl ether is shown. Prospects for the synthesis of lower olefins via methyl chloride and using non-oxidative coupling of methane are discussed. The most efficient processes used for processing of methane to lower olefins are compared on the basis of degree of conversion of carbonaceous feed, possibility to integrate with available full-scale production, number of reaction stages and thermal load distribution.

The bibliography includes 346 references.