Alkali Metal Zirconate Catalyst for Selective Methane OCM

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Solution Overview

Problem

In the oxidative coupling of methane (OCM) reaction, side reactions produce carbon dioxide, reducing the selectivity of olefins such as ethylene, and existing catalysts like sodium tungstate do not effectively address this issue.

Innovation Solution

A partial oxidative coupling catalyst with an alkali metal zirconate (M2ZrO3) supported on a high-specific-surface-area support, such as nanowire or micro-honeycomb ceramic, is used to enhance olefin selectivity by minimizing side reactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional catalysts like sodium tungstate are used for OCM reaction, then the reaction can proceed, but olefin selectivity decreases due to side reactions producing carbon dioxide

Engineering Contradiction:

Improveolefin selectivityVSAvoidcarbon dioxide formation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention changes the chemical composition parameters of the catalyst by using alkali metal zirconate (M2ZrO3) instead of conventional sodium tungstate, and supports it on high-surface-area materials like nanowire or micro-honeycomb ceramic to achieve both high olefin selectivity and suppressed CO2 formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite catalyst structure combining alkali metal zirconate active component with high-surface-area support material (nanowire or micro-honeycomb ceramic), where the composite structure provides both the catalytic activity for olefin production and the physical properties needed to suppress side reactions

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The catalyst improves olefin selectivity by suppressing side reactions, maintaining high ethylene production while reducing carbon dioxide formation.

Implementation Method 1

a partial oxidative coupling catalyst with sodium tungstate (Na2WO4) as an active component is used

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS12565544B2Partial oxidative coupling catalyst and olefin production device and olefin production method using catalyst

Publication Date: 2026.03.03 MITSUBISHI HEAVY IND LTD

AI summary

A partial oxidative coupling catalyst has a structure in which a component represented by M2ZrO3 is supported on a support, where M represents an alkali metal.