Oxidative Coupling of Methane over a Sr-Promoted La2O3 Catalyst Supported on a Low Surface Area Porous Catalyst Carrier

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.

Importance of Process Variables and Their Optimization for Oxidative Coupling of Methane (OCM)

Oxidative coupling of methane (OCM) is a promising process for converting natural gas into high-value chemicals such as ethane and ethylene. The process, however, requires important improvements for commercialization. The foremost is increasing the process selectivity to C₂ (C₂H₄ + C₂H₆) at moderate to high levels of methane conversion. These developments are often addressed at the catalyst level. However, optimization of process conditions can lead to very important improvements. In this study, a high-throughput screening (HTS) instrument was utilized for La₂O₃/CeO₂ (3.3 mol % Ce) to generate a parametric data set within the temperature range of 600-800 °C, CH₄/O₂ ratio between 3 and 13, pressure between 1 and 10 bar, and catalyst loading between 5 and 20 mg leading to space-time between 40 and 172 s. Statistical design of experiments (DoE) was applied to gain insights into the effect of operating parameters and to determine the optimal operating conditions for maximum production of ethane and ethylene. Rate-of-production analysis was used to shed light on the elementary reactions involved in different operating conditions. The data obtained from HTS experiments established quadratic equations relating the studied process variables and output responses. The quadratic equations can be used to predict and optimize the OCM process. The results demonstrated that the CH₄/O₂ ratio and operating temperatures are key for controlling the process performance. Operating at higher temperatures with high CH₄/O₂ ratios increased the selectivity to C₂ and minimized CO_x (CO + CO₂) at moderate conversion levels. In addition to process optimization, DoE results also allowed the flexibility of manipulating the performance of OCM reaction products. A C₂ selectivity of 61% and a methane conversion of 18% were found to be optimum at 800 °C, a CH₄/O₂ ratio of 7, and a pressure of 1 bar.

Catalytic ceramic oxygen ionic conducting membrane reactors for ethylene production

Catalytic ceramic oxygen ionic conducting membrane reactors have great potential in the production of high value-added chemicals as they can couple chemical reactions with separation within a single unit, allowing process intensification.

Advances in Methods for Recovery of Ferrous, Alumina, and Silica Nanoparticles from Fly Ash Waste

Fly ash or coal fly ash causes major global pollution in the form of solid waste and is classified as a “hazardous waste”, which is a by-product of thermal power plants produced during electricity production. Si, Al, Fe Ca, and Mg alone form more than 85% of the chemical compounds and glasses of most fly ashes. Fly ash has a chemical composition of 70–90%, as well as glasses of ferrous, alumina, silica, and CaO. Therefore, fly ash could act as a reliable and alternative source for ferrous, alumina, and silica. The ferrous fractions can be recovered by a simple magnetic separation method, while alumina and silica can be extracted by chemical or biological approaches. Alumina extraction is possible using both alkali- and acid-based methods, while silica is extracted by strong alkali, such as NaOH. Chemical extraction has a higher yield than the biological approaches, but the bio-based approaches are more environmentally friendly. Fly ash can also be used for the synthesis of zeolites by NaOH treatment of variable types, as fly ash is rich in alumino-silicates. The present review work deals with the recent advances in the field of the recovery and synthesis of ferrous, alumina, and silica micro and nanoparticles from fly ash.