Oxidative Coupling of Methane to Higher Hydrocarbons

Surface basicity controls C-C coupling rates during carbon dioxide-assisted methane coupling over bifunctional Ca/ZnO catalysts

Carbon dioxide-assisted coupling of methane offers an approach to chemically upgrade two greenhouse gases and components of natural gas to produce ethylene and syngas. Prior research on this reaction has concentrated efforts on catalyst discovery, which has indicated that composites comprised of both reducible and basic oxides are especially promising. There is a need for detailed characterization of these bifunctional oxide systems to provide a more fundamental understanding of the active sites and their roles in the reaction. We studied the dependence of physical and electronic properties of Ca-modified ZnO materials on Ca content via X-ray photoelectron and absorption spectroscopies, electron microscopy, and infrared spectroscopic temperature-programmed desorption (IR-TPD). It was found that introduction of only 0.6 mol% Ca onto a ZnO surface is necessary to induce significant improvement in the catalytic production of C₂ species: C₂ selectivity increases from 5% on un-modified ZnO to 58%, at similar conversions. Evidence presented shows that this selectivity increase results from the formation of an interface between the basic CaO and reducible ZnO phases. The basicity of these interface sites correlates directly with catalytic activity over a wide composition range, and this relationship indicates that moderate CO₂ adsorption strength is optimal for CH₄ coupling. These results demonstrate, for the first time to our knowledge, a volcano-type relationship between CO₂-assisted CH₄ coupling activity and catalyst surface basicity, which can inform further catalyst development.

Recognizing the best catalyst for a reaction

Heterogeneous catalysis is immensely important, providing access to materials essential for the well-being of society, and improved catalysts are continuously required. New catalysts are frequently tested under different conditions making it difficult to determine the best catalyst. Here we describe a general approach to identify the best catalyst using a data set based on all reactions under kinetic control to calculate a set of key performance indicators (KPIs). These KPIs are normalized to take into account the variation in reaction conditions. Plots of the normalized KPIs are then used to demonstrate the best catalyst using two case studies: (i) acetylene hydrochlorination, a reaction of current interest for vinyl chloride manufacture, and (ii) the selective oxidation of methane to methanol using O₂ in water, a reaction that has attracted very recent attention in the academic literature.

Light olefin synthesis from a diversity of renewable and fossil feedstocks: state-of the-art and outlook

Light olefins are important feedstocks and platform molecules for the chemical industry. Their synthesis has been a research priority in both academia and industry. There are many different approaches to the synthesis of these compounds, which differ by the choice of raw materials, catalysts and reaction conditions. The goals of this review are to highlight the most recent trends in light olefin synthesis and to perform a comparative analysis of different synthetic routes using several quantitative characteristics: selectivity, productivity, severity of operating conditions, stability, technological maturity and sustainability. Traditionally, on an industrial scale, the cracking of oil fractions has been used to produce light olefins. Methanol-to-olefins, alkane direct or oxidative dehydrogenation technologies have great potential in the short term and have already reached scientific and technological maturities. Major progress should be made in the field of methanol-mediated CO and CO₂ direct hydrogenation to light olefins. The electrocatalytic reduction of CO₂ to light olefins is a very attractive process in the long run due to the low reaction temperature and possible use of sustainable electricity. The application of modern concepts such as electricity-driven process intensification, looping, CO₂ management and nanoscale catalyst design should lead in the near future to more environmentally friendly, energy efficient and selective large-scale technologies for light olefin synthesis.

Transition-Metal-Doping of CaO as Catalyst for the OCM Reaction, a Reality Check

In this study, first-row transition metal-doped calcium oxide materials (Mn, Ni, Cr, Co., and Zn) were synthesized, characterized, and tested for the OCM reaction. Doped carbonate precursors were prepared by a co-precipitation method. The synthesis parameters were optimized to yield materials with a pure calcite phase, which was verified by XRD. EPR measurements on the doped CaO materials indicate a successful substitution of Ca2+ with transition metal ions in the CaO lattice. The materials were tested for their performance in the OCM reaction, where a beneficial effect towards selectivity and activity effect could be observed for Mn, Ni, and Zn-doped samples, where the selectivity of Co- and Cr-doped CaO was strongly reduced. The optimum doping concentration could be identified in the range of 0.04-0.10 atom%, showing the strongest decrease in the apparent activation energy, as well as the maximum increase in selectivity.

Direct Conversion of Methane to C2 Hydrocarbons in Solid-State Membrane Reactors at High Temperatures

Direct conversion of methane to C₂ compounds by oxidative and nonoxidative coupling reactions has been intensively studied in the past four decades; however, because these reactions have intrinsic severe thermodynamic constraints, they have not become viable industrially. Recently, with the increasing availability of inexpensive "green electrons" coming from renewable sources, electrochemical technologies are gaining momentum for reactions that have been challenging for more conventional catalysis. Using solid-state membranes to control the reacting species and separate products in a single step is a crucial advantage. Devices using ionic or mixed ionic-electronic conductors can be explored for methane coupling reactions with great potential to increase selectivity. Although these technologies are still in the early scaling stages, they offer a sustainable path for the utilization of methane and benefit from the advances in both solid oxide fuel cells and electrolyzers. This review identifies promising developments for solid-state methane conversion reactors by assessing multifunctional layers with microstructural control; combining solid electrolytes (proton and oxygen ion conductors) with active and selective electrodes/catalysts; applying more efficient reactor designs; understanding the reaction/degradation mechanisms; defining standards for performance evaluation; and carrying techno-economic analysis.

Oxidative Coupling of Methane: Perspective for High-Value C2 Chemicals

The oxidative coupling of methane (OCM) to C2 hydrocarbons (C2H4 and C2H6) has aroused worldwide interest over the past decade due to the rise of vast new shale gas resources. However, obtaining higher C2 selectivity can be very challenging in a typical OCM process in the presence of easily oxidized products such as C2H4 and C2H6. Regarding this, different types of catalysts have been studied to achieve desirable C2 yields. In this review, we briefly presented three typical types of catalysts such as alkali/alkaline earth metal doped/supported on metal oxide catalysts (mainly for Li doped/supported catalysts), modified transition metal oxide catalysts, and pyrochlore catalysts for OCM and highlighted the features that play key roles in the OCM reactions such as active oxygen species, the mobility of the lattice oxygen and surface alkalinity of the catalysts. In particular, we focused on the pyrochlore (A2B2O7) materials because of their promising properties such as high melting points, thermal stability, surface alkalinity and tunable M-O bonding for OCM reaction.

"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.

Nanosheet-Like Ho2O3 and Sr-Ho2O3 Catalysts for Oxidative Coupling of Methane

In this work, Ho2O3 nanosheets were synthesized by a hydrothermal method. A series of Sr-modified Ho2O3 nanosheets (Sr-Ho2O3-NS) with a Sr/Ho molar ratio between 0.02 and 0.06 were prepared via an impregnation method. These catalysts were characterized by several techniques such as XRD, N2 adsorption, SEM, TEM, XPS, O2-TPD (temperature-programmed desorption), and CO2-TPD, and they were studied with respect to their performances in the oxidative coupling of methane (OCM). In contrast to Ho2O3 nanoparticles, Ho2O3 nanosheets display greater CH4 conversion and C2-C3 selectivity, which could be related to the preferentially exposed (222) facet on the surface of the latter catalyst. The incorporation of small amounts of Sr into Ho2O3 nanosheets leads to a higher ratio of (O− + O2−)/O2− as well as an enhanced amount of chemisorbed oxygen species and moderate basic sites, which in turn improves the OCM performance. The optimal catalytic behavior is achievable on the 0.04Sr-Ho2O3-NS catalyst with a Sr/Ho molar ratio of 0.04, which gives a 24.0% conversion of CH4 with 56.7% selectivity to C2-C3 at 650 °C. The C2-C3 yield is well correlated with the amount of moderate basic sites present on the catalysts.

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.

Elucidating the effects of individual components in KxMnOy/SiO2 and water on selectivity enhancement in the oxidative coupling of methane

To date, a great number of various materials have been tested for the oxidative coupling of methane (OCM).

Data-Driven Identification of the Reaction Network in Oxidative Coupling of the Methane Reaction via Experimental Data

Identifying details of chemical reactions is a challenging matter for both experiments and computations. Here, the reaction pathway in oxidative coupling of methane (OCM) is investigated using a series of experimental data and data science techniques in which data are analyzed using a variety of visualization techniques. Data visualization, pairwise correlation, and machine learning unveil the relationships between experimental conditions and the selectivities of CO, CO₂, C₂H₄, C₂H₆, and H₂ in the OCM reaction. More importantly, the reaction network for the OCM reaction is constructed on the basis of the scores provided by machine learning and experimental data. In particular, the proposed reaction map not only contains the chemical compound but also contains experimental conditions. Thus, data-driven identification of chemical reactions can be achieved in principle via a series of experimental data, leading to more efficient experimental design and catalyst development.

Cyclic redox scheme towards shale gas reforming: a review and perspectives

Alkanes are potential precursors to many value-added chemicals such as olefins and other petrochemicals.

Mechanism of selective and complete oxidation in La2O3-catalyzed oxidative coupling of methane

The catalytic mechanism and reaction network of oxidative coupling of methane over La₂O₃ are thoroughly investigated by density functional theory calculations.

Electric Field and Mobile Oxygen Promote Low-Temperature Oxidative Coupling of Methane over La1-x Ca x AlO3-δ Perovskite Catalysts

Oxidative coupling of methane (OCM) over La_1-x M _x AlO_3-δ (M = Ca, Sr, Ba; x = 0, 0.1, 0.2, 0.3) in an electric field at low temperature (423 K) was investigated. Among the tested catalysts, the La_0.7Ca_0.3AlO_3-δ catalyst showed the highest performance in terms of C₂H₆ + C₂H₄ yield (11.1%). Surface mobile oxygen species (O₂ ^2- or O^-), which were considered as active oxygen species for the OCM reaction, increased with increasing Ca doping amount, and thereby the La_0.7Ca_0.3AlO_3-δ catalyst showed the best catalytic activity.

Ambient-temperature oxidative coupling of methane in an electric field by a cerium phosphate nanorod catalyst

The application of an electric field to a CePO₄ nanorod catalyst enabled ambient-temperature oxidative coupling of methane to C₂ hydrocarbons.

Fast Optimization of LiMgMnOx/La2O3 Catalysts for the Oxidative Coupling of Methane

The development of efficient catalyst for oxidative coupling of methane (OCM) reaction represents a grand challenge in direct conversion of methane into other useful products. Here, we reported that a newly developed combinatorial approach can be used for ultrafast optimization of La₂O₃-based multicomponent metal oxide catalysts in OCM reaction. This new approach integrated inkjet printing assisted synthesis (IJP-A) with multidimensional group testing strategy (m-GT) tactfully takes the place of conventionally high-throughput synthesis-and-screen experiment. Just within a week, 2048 formulated LiMgMnO_x-La₂O₃ catalysts in a 64·8·8·8·8 = 262 144 compositional space were fabricated by IJP-A in a four-round synthesis-and-screen process, and an optimized formulation has been successfully identified through only 4·8 = 32 times of tests via m-GT screening strategy. The screening process identifies the most promising ternary composition region is Li_0-0.48Mg_0-6.54Mn_0-0.62-La₁₀₀O_x with an external C₂ yield of 10.87% at 700 °C. The yield of C₂ is two times as high as the pure nano-La₂O₃. The good performance of the optimized catalyst formulation has been validated by the manual preparation, which further prove the effectiveness of the new combinatorial methodology in fast discovery of heterogeneous catalyst.

Hydrogen-Permeable Tubular Membrane Reactor: Promoting Conversion and Product Selectivity for Non-Oxidative Activation of Methane over an Fe©SiO2 Catalyst

Non-oxidative methane conversion over Fe©SiO₂ catalyst was studied for the first time in a hydrogen (H₂ ) permeable tubular membrane reactor. The membrane reactor is composed of a mixed ionic-electronic SrCe_0.7 Zr_0.2 Eu_0.1 O_3-δ thin film (≈20 μm) supported on the outer surface of a one-end capped porous SrCe_0.8 Zr_0.2 O_3-δ tube. Significant improvement in CH₄ conversion was achieved upon H₂ removal from the membrane reactor compared to that in a fixed-bed reactor. The Fe©SiO₂ catalyst in the H₂ permeable membrane reactor demonstrated a stable ≈30 % C₂₊ single-pass yield, with up to 30 % CH₄ conversion and 99 % selectivity to C₂ (ethylene and acetylene) and aromatic (benzene and naphthalene) products, at the tested conditions. The selectivity towards C₂ or aromatics was manipulated purposely by adding H₂ into or removing H₂ from the membrane reactor feed and permeate gas streams.

Low-temperature and low-pressure non-oxidative activation of methane for upgrading heavy oil

This study creates a novel catalytic route for low-temperature and low-pressure non-oxidative utilization of methane and opens a door for upgrading heavy oil with natural gas under fairly mild operation conditions instead of expensive hydrogen under rather stringent ones.

Insights into the synergistic role of metal–lattice oxygen site pairs in four-centered C–H bond activation of methane: the case of CuO

Of the three mechanisms for activation of methane on copper and copper oxide surfaces, the under-coordinated Cu–O site pair mediated mechanism on CuO surfaces has the lowest activation energy barriers.

La2O3 catalysts with diverse spatial dimensionality for oxidative coupling of methane to produce ethylene and ethane

The La₂O₃ catalyst with a two-dimensional (2D) structure is more effective than 0D, 1D and 3D La₂O₃ for oxidative coupling of methane.

Developing catalytic materials for the oxidative coupling of methane through statistical analysis of literature data

Accuracy of models based on literature data for predicting experimental yield of C₂ hydrocarbons over La₂O₃- and MgO-based catalysts in the oxidative coupling of methane.