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

Comparing BaZrO3 Perovskite and La2Zr2O7 Pyrochlore for Oxidative Coupling of Methane (OCM): The Importance of Basic Sites vs Oxygen Vacancies

La2Zr2O7 pyrochlore with intrinsic oxygen vacancies and BaZrO3 perovskite without intrinsic oxygen vacancies were synthesized for the OCM reaction. It has been revealed that the OCM performance and surface selective oxygen species of BaZrO3 are higher than that of La2Zr2O7 under the reaction condition. This is because BaZrO3 possesses more basic sites than La2Zr2O7, and thus it can stabilize the OCM reactive oxygen species better at elevated temperature. In the structure, the A-O bond lattice oxygen of the two compounds mainly provides basic sites, but the B-O bond lattice oxygen mainly promotes deep oxidation of methane and the generated hydrocarbons. The types of the OCM reactive oxygen species are prone to be associated with the properties of the A-site metal oxides.

Preparation of La2Zr2O7 composite oxides with fluorite/pyrochlore phases by excluding element influences for catalyzing oxidative coupling of methane

To elucidate the effect of the A2B2O7 phase on the oxidative coupling of methane (OCM) while excluding elemental influences, La2Zr2O7 compounds with a disordered defect fluorite (La2Zr2O7-F) structure and an ordered pyrochlore phase (La2Zr2O7-P) have been synthesized. Irrespective of their element composition, the catalytic performance of La2Zr2O7-F exceeds that of La2Zr2O7-P. Furthermore, the La2Zr2O7-F surface has more oxygen vacancies/defects than the La2Zr2O7 surface because La2Zr2O7-F exhibits a higher lattice disorder degree and lower B-O bond strength, which leads to the formation of more reactive oxygen anions (O2- and O22-) and basic sites for OCM. Isotopic exchange results have testified that surface-active oxygen sites are generated due to the gaseous O2 adsorption/activation occurring on the surface vacancies via both simple and multiple hetero-exchange mechanisms. In conclusion, crystal structure is the primary factor that governs the catalytic performance of A2B2O7 compounds, with the disordered defect fluorite phase being the most optimal structure for OCM.

Fabrication of Ln2Zr2O7 Fluorite and LnAlO3 Perovskite (Ln = La, Nd, Sm) Compounds to Catalyze the OCM Reaction: On the Temperature-Induced Phase Transformation and Oxygen Vacancy

Through synthesizing Ln2Zr2O7 and LnAlO3 (Ln = La, Nd, Sm) catalysts, the origin of active sites for oxidative coupling of methane (OCM) on A2B2O7 fluorite and ABO3 perovskite compounds has been compared and elucidated. Ln2Zr2O7 catalysts show much better reaction performance than the respective LnAlO3 catalysts at low temperatures (500-600 °C), but the difference will be mitigated significantly above 600 °C. The reaction performance ranks in the order of La2Zr2O7 > Nd2Zr2O7 > Sm2Zr2O7 > LaAlO3 > NdAlO3 > SmAlO3. It is revealed that the unit cell free volume (Vf) plays an important role in affecting the catalytic activity, and the Ln2Zr2O7 catalysts with a disordered defect fluorite phase have inherent oxygen vacancies, which can directly activate gas-phase O2 molecules to generate OCM reactive O2- anions. However, the oxygen vacancies of LnAlO3 with a perovskite structure can only be generated by lattice distortion/transformation above 600 °C. Moreover, Ln2Zr2O7 fluorites have weaker B-O bonds than LnAlO3 perovskites, thus making it easier to generate surface vacancies as well as active O2- sites. The surface alkalinity is intimately relevant to the active oxygen species, which act together to decide the OCM performance on both types of catalysts. Indeed, this explains that LnAlO3 catalysts show much worse performance than Ln2Zr2O7 catalysts below 600 °C, which will be evidently improved at elevated temperatures due to phase transformation.

Optimization of the Oxidative Coupling of Methane Process for Ethylene Production

The oxidative coupling of methane (OCM) process is considered an intriguing route for the production of ethylene, one of the most demanded petrochemical products on the market. Ethylene can be produced by various methods, but the most widely used is the steam cracking process. However, due to the current instability of the crude oil market and the shale gas revolution, the production of olefins from natural gas has opened a new path for companies to mitigate the high demand for crude oil while utilizing an abundant amount of natural gas. In this work, the OCM process was compared with other existing processes, and the process was simulated using Aspen HYSYS. The flowsheet was divided into four sections, namely (i) the reaction section, (ii) the water removal section, (iii) the carbon dioxide capture section, and (iv) the ethylene purification section. Each section was thoroughly discussed, and the heat integration of the process was performed to ensure maximum energy utilization. The heat exchanger network was constructed, and the results show that the heating utility can be reduced by more than 95% (from 76567 kW to 2107.5 kW) and the cooling utility can be reduced by more than 60% (from 116398 kW to 41939.2 kW) at an optimum minimum temperature difference of 25 °C. In addition, a case study on the recovery of the high exothermic heat of reaction for power production shows that 16.68 MW can be produced through the cycle, which can cover the total cost of compression.

Progress and Recent Strategies in the Synthesis and Catalytic Applications of Perovskites Based on Lanthanum and Aluminum

Lanthanum aluminate-based perovskite (LaAlO₃) has excellent stability at high temperatures, low toxicity, and high chemical resistance and also offers wide versatility to the substitution of La³⁺ and Al³⁺, thus, allowing it to be applied as a catalyst, nano-adsorbent, sensor, and microwave dielectric resonator, amongst other equally important uses. As such, LaAlO₃ perovskites have gained importance in recent years. This review considers the extensive literature of the past 10 years on the synthesis and catalytic applications of perovskites based on lanthanum and aluminum (LaAlO₃). The aim is, first, to provide an overview of the structure, properties, and classification of perovskites. Secondly, the most recent advances in synthetic methods, such as solid-state methods, solution-mediated methods (co-precipitation, sol–gel, and Pechini synthesis), thermal treatments (combustion, microwave, and freeze drying), and hydrothermal and solvothermal methods, are also discussed. The most recent energetic catalytic applications (the dry and steam reforming of methane; steam reforming of toluene, glycerol, and ethanol; and oxidative coupling of methane, amongst others) using these functional materials are also addressed. Finally, the synthetic challenges, advantages, and limitations associated with the preparation methods and catalytic applications are discussed.

Raw Biogas as Feedstock for the OCM Process

The paper presents the research results obtained in the process of oxidative coupling of methane, in which unpurified biogas was used as the feedstock. Biogas obtained from two kinds of biomass materials, i.e., plant materials (potato and beet pulp, Corn-Cob-Mix—biogas 1) and animal waste (waste from fish filleting—biogas 2) was considered. The influence of temperature, the ratio of methane/oxygen and total flows of feedstock on the catalytic performance in oxidative coupling of methane process was investigated. Comparative tests were carried out using pure methane and a mixture of methane-carbon dioxide to simulate the composition of biogas 2. The process was carried out in the presence of an Mn-Na2WO4/SiO2 catalyst. Fresh and used catalysts were characterised by means of powder X-ray diffraction, X-ray photoelectron spectroscopy, and low-temperature nitrogen adsorption techniques. In oxidative coupling of methane, the type of raw material used as the source of methane has a small effect on methane conversion (the differences in methane conversion are below 3%), but a significant effect on the selectivity to C2. Depending on the type of raw material, the differences in selectivity to C2 reach as high as 9%. However, the Mn-Na2WO4/SiO2 catalyst operated steadily in the tested period of time at any feedstock composition. Moreover, it was found that CO2, which is the second main component of biogas in addition to methane, has an effect on catalytic performance. Comparative results of catalytic tests indicate that the CO2 effect varies with temperature. Below 1073 K, CO2 exerts a small poisoning effect on methane conversion, while above this temperature the negative effect of CO2 disappears. In the case of selectivity to C2+, the negative effect of CO2 was observed only at 1023 K. At higher temperatures, CO2 enhances selectivity to C2+. The effect of CO2 was established by correlating the catalytic results with the temperature programmed desorption of CO2 investigation. The poisoning effect of CO2 was connected with the formation of surface Na2CO3, whose concentration depends on temperature.