Effects of operating parameters on oxidative coupling of methane over Na-W-Mn/SiO2 catalyst at elevated pressures

Lithium carbonate-promoted mixed rare earth oxides as a generalized strategy for oxidative coupling of methane with exceptional yields

The oxidative coupling of methane to higher hydrocarbons offers a promising autothermal approach for direct methane conversion, but its progress has been hindered by yield limitations, high temperature requirements, and performance penalties at practical methane partial pressures (~1 atm). In this study, we report a class of Li2CO3-coated mixed rare earth oxides as highly effective redox catalysts for oxidative coupling of methane under a chemical looping scheme. This catalyst achieves a single-pass C2+ yield up to 30.6%, demonstrating stable performance at 700 °C and methane partial pressures up to 1.4 atm. In-situ characterizations and quantum chemistry calculations provide insights into the distinct roles of the mixed oxide core and Li2CO3 shell, as well as the interplay between the Pr oxidation state and active peroxide formation upon Li2CO3 coating. Furthermore, we establish a generalized correlation between Pr4+ content in the mixed lanthanide oxide and hydrocarbons yield, offering a valuable optimization strategy for this class of oxidative coupling of methane redox catalysts.

Techno-Economic Analysis of a Process to Convert Methane to Olefins, Featuring a Combined Reformer via the Methanol Intermediate Product

The substantial growth in shale-derived natural gas production in the US has caused significant changes in the chemical and petrochemical markets. Ethylene production of ethane and naphtha via steam cracking is one of the most energy- and emission-intensive activities in chemical manufacturing. High operating temperatures, high reaction endothermicity, and complex separation create high energy demands as well as considerable CO2 emissions. In this study, a demonstration of a transformational methane-to-ethylene process that offers lower emissions using energy optimization and a CO2 minimum-emission approach is presented. The comparisons of different reforming processes suggest that the dry reforming of methane has a negative carbon footprint at low syngas ratios of 1 and below, and that additional carbon emissions can be reduced using integrated heating and cooling utilities, resulting in a 99.24 percent decrease in CO2. A process design implemented to convert methane into value-added chemicals with minimum CO2 emissions is developed.

Synthesis of Value-Added Chemicals via Oxidative Coupling of Methanes over Na2WO4-TiO2-MnO x /SiO2 Catalysts with Alkali or Alkali Earth Oxide Additives

Na₂WO₄-TiO₂-MnO _x /SiO₂ (SM) catalysts with alkali (Li, K, Rb, Cs) or alkali earth (Mg, Ca, Sr, Ba) oxide additives, which were prepared using incipient wetness impregnation, were investigated for oxidative coupling of methane (OCM) to value-added hydrocarbons (C₂₊). A screening test that was performed on the catalysts revealed that SM with Sr (SM-Sr) had the highest yield of C₂₊. X-ray photoelectron spectroscopy analyses indicated that the catalysts with a relatively low binding energy of W 4f_7/2 facilitated a high CH₄ conversion. A combination of crystalline MnTiO₃, Mn₂O₃, α-cristobalite, Na₂WO₄, and TiO₂ phases was identified as an essential component for a remarkable improvement in the activity of the catalysts in the OCM reaction. In attempts to optimize the C₂₊ yield, 0.25 wt % Sr onto SM-Sr achieved the highest C₂₊ yield at 22.9% with a 62.5% C₂₊ selectivity and a 36.6% CH₄ conversion. A stability test of the optimal catalyst showed that after 24 h of testing, its activity decreased by 18.7%.

Intensified Ethylene Production via Chemical Looping through an Exergetically Efficient Redox Scheme

Ethylene production via steam cracking of ethane and naphtha is one of the most energy and emission-intensive processes in the chemical industry. High operating temperatures, significant reaction endothermicity, and complex separations create hefty energy demands and result in substantial CO₂ and NO_x emissions. Meanwhile, decades of optimization have led to a thermally efficient, near-"perfect" process with ∼95% first law energy efficiency, leaving little room for further reduction in energy consumption and CO₂ emissions. In this study, we demonstrate a transformational chemical looping-oxidative dehydrogenation (CL-ODH) process that offers 60%-87% emission reduction through exergy optimization. Through detailed exergy analyses, we show that CL-ODH leads to exergy savings of up to 58% in the upstream reactors and 26% in downstream separations. The feasibility of CL-ODH is supported by a robust redox catalyst that demonstrates stable activity and selectivity for over 1,400 redox cycles in a laboratory-scale fluidized bed reactor.