Catalytic forms and formulations

Abstract

Catalytic forms and formulations are provided. The catalytic forms and formulations are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane. Related methods for use and manufacture of the same are also disclosed.

Description

BACKGROUND[0001]1. Technical Field[0002]This invention is generally related to catalytic forms and formulations and, more specifically, to catalytic forms and formulations useful in a variety of catalytic reactions, such as the oxidative coupling of methane.[0003]2. Description of the Related Art[0004]Catalysis is the process in which the rate of a chemical reaction is either increased or decreased by means of a catalyst. Positive catalysts increase the speed of a chemical reaction, while negative catalysts slow it down. Substances that increase the activity of a catalyst are referred to as promoters or activators, and substances that deactivate a catalyst are referred to as catalytic poisons or deactivators. Unlike other reagents, a catalyst is not consumed by the chemical reaction, but instead participates in multiple chemical transformations. In the case of positive catalysts, the catalytic reaction generally has a lower rate-limiting free energy change to the transition state th...

AI Technical Summary

Benefits of technology

The patent text describes a catalytic material that can be used in various catalytic reactions, such as petrochemical catalysis. The material consists of a plurality of catalytic nanowires in combination with a diluent or support. The catalytic nanowires can be in the form of a formed aggregate, such as a cylinder, rod, star, or hollow structure. The material can also have a high surface area and pore volume fraction. The catalytic material can be used without a binder or with a minimal amount of binder and diluent. The active catalyst can be a bulk catalyst or a catalytic nanowire. The formed aggregate can have a porosity greater than 20 nm in diameter. The patent text also describes the use of a catalytic material in the form of a formed aggregate with a specific shape, such as a cylinder, rod, star, or honeycomb structure. Overall, the patent text provides a catalytic material with improved catalytic activity and selectivity for various catalytic reactions.

Problems solved by technology

Thus, at a given temperature, a positive catalyst tends to increase the yield of desired product while decreasing the yield of undesired side products.

Although catalysts are not consumed by the reaction itself, they may be inhibited, deactivated or destroyed by secondary processes, resulting in loss of catalytic activity.

This transport and adsorption of reactants is often the rate limiting step in a heterogeneous catalysis reaction.

To date, the OCM reaction has not been commercialized, due in large part to the lack of effective catalysts and catalytic forms.

The use of heterogeneous catalysts, for example in the OCM reaction, presents a number of challenges, especially on a commercial scale.

However, when a fixed bed of heterogeneous catalyst is used, the pressure drop across the catalytic bed prevents operation under the high gas space velocities demanded of a commercial operation.

In addition, many commercially important catalytic reactions, such as OCM, are exothermic and controlling the exotherm (i.e., hotspots) within the catalytic bed can be difficult.

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