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Catalysts and methods for natural gas processes

a natural gas and catalyst technology, applied in the direction of physical/chemical process catalysts, bulk chemical production, metal/metal-oxide/metal-hydroxide catalysts, etc., can solve the problem of not being able to commercialize the ocm reaction, the rate limitation step of reactant adsorption is often the limit step, and the lack of effective catalysts and catalytic effects

Inactive Publication Date: 2017-09-21
SILURIA TECH INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patent relates to new catalysts and methods for preparing them that can be used for converting natural gas to higher fuel. The technical effects of the invention include improved conversion rates and selectivity, as well as reduced catalyst deactivation. The catalysts and methods described in the patent have applications in various chemical reactions, such as petrochemical catalysis and the oxidative coupling of methane. The method involves flowing methane gas through a catalyst bed containing an OCM active catalyst, which has a specific surface area and volume loss when heated. The formed catalytic material comprises a nanostructured catalyst and a catalyst with lower surface area, and has high stability at high temperatures. The technical effects of the invention aid in the efficient and effective production of higher fuel from natural gas.

Problems solved by technology

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.
However, over oxidation of ethylene can reduce the ethylene selectivity, and better catalysts and processes are needed before the full potential of this reaction can be realized.

Method used

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  • Catalysts and methods for natural gas processes
  • Catalysts and methods for natural gas processes
  • Catalysts and methods for natural gas processes

Examples

Experimental program
Comparison scheme
Effect test

example 1

Oxidative Coupling of Methane with a Surface Area Gradient

[0538]Three different catalyst beds having a length L are prepared as follows:

[0539]1) the first catalyst bed comprises about 70% of the total OCM active catalyst surface area in a portion of the catalyst bed ranging from the front end to a distance equal to about 80% of L;

[0540]2) the second catalyst bed comprises about 95% of the total OCM active catalyst surface area in a portion of the catalyst bed ranging from the front end to a distance equal to about 50% of L; and

[0541]3) the third catalyst bed comprises a total OCM active catalyst surface area evenly distributed throughout the entire length L of the catalyst bed.

[0542]The oxidative coupling of methane is performed in the above catalyst beds under flow conditions of 17,000, 21,000 and 26,000 GHSV / h. It is found that C2+ selectivity of the OCM reaction in catalyst beds 1 and 2 is higher under all flow conditions relative to the COM reaction in catalyst bed 3.

example 2

Catalytic Materials with Low Shrinkage

[0543]A catalytic material was prepared by sintering a nanostructured catalyst having a BET surface area of greater than 5 m2 / g at a temperature of approximately 1,100° C. to obtain a catalyst having a BET surface area of less than 2 m2 / g. The thus obtained low surface area catalyst was admixed with the nanostructured catalyst at various ratios and the resulting admixture was sintered at temperatures ranging from approximately 800° C. to 900° C. The catalyst was then briefly heated in CO2 / N2 atmosphere at about 650° C.

[0544]The catalytic material is optionally doped before or after the foregoing sintering steps and is tableted or extruded into the desired form. It was found that the prepared catalytic material has reduced shrinkage relative to a catalytic material comprising only the nanostructured catalyst or the low surface area catalyst as the only OCM active catalyst.

[0545]Table 1 provides data for a catalytic material prepared according to ...

example 3

Catalysts of Formula (I) and (IA)

[0546]Catalysts of Formula (I) and (IA) were prepared by admixing the appropriate elements in their nitrate or oxide form and calcining the resulting mixture. FIGS. 8 and 9 provide C2 yield, C2+ selectivity and methane conversion data for a catalyst of Formula (I) and a catalyst of Formula (II), respectively.

[0547]The catalyst of Formula (I) (FIG. 8) comprised approximately equal amounts of barium and cerium and from about 5-10% each of yttrium and zirconium dopants. This catalyst had a C2+ selectivity of greater than 65% at temperatures above 700° C.

[0548]The catalyst of Formula (IA) (FIG. 9) comprised approximately a 2:1 ratio of barium to cerium and about 15-25% of each of a group 13 element and a lanthanide. This catalyst had a C2+ selectivity of greater than 55% at temperatures above 700° C.

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Abstract

Catalysts and catalytic methods are provided. The catalysts and methods are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane.

Description

BACKGROUND[0001]Technical Field[0002]This invention is generally related to catalysts and methods for natural gas processes, such as the oxidative coupling of methane.[0003]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 lower the rate-limiting free energy change to the transition state, and thus increase the speed of a chemical reaction at a given temperature. Negative catalysts have the opposite effect. Catalysts are generally characterized as either heterogeneous or homogeneous. Heterogeneous catalysts exist in a different phase than the reactants (e.g., a solid metal catalyst and gas phase reactants), and the catalytic reaction generally occurs on the surface of the heterogeneous catalyst. Thus, for the catalytic reaction to occur, the reactants must diffuse to and / or adsorb onto the catalyst surface. This transport and adsorption of reactants is ofte...

Claims

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Application Information

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IPC IPC(8): C07C2/84B01J37/04B01J35/10B01J37/08B01J23/10B01J35/06
CPCB01J35/06B01J35/1009B01J37/08B01J23/10C07C2523/10C07C2/84B01J37/04B82Y30/00C07C2521/02C07C2521/06C07C2523/02C07C2523/08B01J23/002Y02P20/52B01J35/31B01J35/19B01J35/30B01J35/00B01J35/58B01J35/612B01J35/61C07C11/04B01D2255/2063B01J2523/37B01J2523/25B01J2531/25
Inventor TANUR, ADRIENNEUSEN, NDIFREKE INISCHAMMEL, WAYNE P.HAROUN, YACINEFREER, ERIK M.CIZERON, JOEL M.
Owner SILURIA TECH INC
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