Oxidative coupling of methane systems and methods

• US 9,469,577 B2
• Filed: 05/23/2013
• Issued: 10/18/2016
• Est. Priority Date: 05/24/2012
• Status: Active Grant

• Current Assignee: Lummus Technology LLC
• Original Assignee: Siluria Technologies, Inc. (Lummus Technology LLC)
• Inventors: Karshtedt, Dmitry, Schammel, Wayne P., Wolfenbarger, Julian, Ajinkya, Milind, McCarty, Jon, Cizeron, Joel M., Weinberger, Sam, Edwards, Justin Dwight, Sheridan, Dave, Scher, Erik C., McCormick, Jarod, Zurcher, Fabio R., Tkachenko, Alex, Gamoras, Joel, Nyce, Greg
• Primary Examiner(s): Dang, Thuan D
• Application Number:
  US13/900,898
• Publication Number:
  US 20140107385A1
• Time in Patent Office: 1,244 Days
• Field of Search: 585/501, 585/648, 585/943
• US Class Current: 1/1
• CPC Class Codes: B01J 2208/00044 Temperature measurement
• CPC Class Codes: B01J 2208/00061 of the reactants
• CPC Class Codes: B01J 2208/00176 outside the reactor
• CPC Class Codes: B01J 2208/00256 in a heat exchanger for the heat exchange medium separate from the reactor
• CPC Class Codes: B01J 2208/0053 Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
• CPC Class Codes: B01J 2208/00539 Pressure
• CPC Class Codes: B01J 2208/00548 Flow
• CPC Class Codes: B01J 2208/00557 controlling the residence time inside the reactor vessel
• CPC Class Codes: B01J 2208/00628 Controlling the composition of the reactive mixture
• CPC Class Codes: B01J 2208/025 Two or more types of catalyst
• CPC Class Codes: B01J 2208/027 Beds
• CPC Class Codes: B01J 2219/00198 at the reactor inlet
• CPC Class Codes: B01J 2219/002 inside the reactor
• CPC Class Codes: B01J 2219/00202 at the reactor outlet
• CPC Class Codes: B01J 2219/00213 Fixed parameter value
• CPC Class Codes: B01J 2219/00231 at the reactor inlet
• CPC Class Codes: B01J 2219/00238 of the heat exchange system
• CPC Class Codes: B01J 8/001 Controlling catalytic processes B01J8/1809 takes precedence
• CPC Class Codes: B01J 8/0257 in a cylindrical annular shaped bed
• CPC Class Codes: B01J 8/0453 the beds being superimposed one above the other
• CPC Class Codes: B01J 8/0457 : the beds being placed in separate reactors
• CPC Class Codes: B01J 8/0496 : Heating or cooling the reactor
• CPC Class Codes: B01J 8/067 : Heating or cooling the reactor B01J8/062 takes precedence
• CPC Class Codes: C07C 11/02 : Alkenes
• CPC Class Codes: C07C 2/84 : catalytic
• CPC Class Codes: C10G 2300/1025 : Natural gas
• CPC Class Codes: C10G 2300/1092 : C2-C4 olefins
• CPC Class Codes: C10G 2400/02 : Gasoline
• CPC Class Codes: C10G 2400/20 : C2-C4 olefins
• CPC Class Codes: C10G 50/00 : Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation
• CPC Class Codes: Y02P 30/40 : Ethylene production

Abstract

Systems and methods conducive to the formation of one or more alkene hydrocarbons using a methane source and an oxidant in an oxidative coupling of methane (OCM) reaction are provided. One or more vessels each containing one or more catalyst beds containing one or more catalysts each having similar or differing chemical composition or physical form may be used. The one or more catalyst beds may be operated under a variety of conditions. At least a portion of the catalyst beds may be operated under substantially adiabatic conditions. At least a portion of the catalyst beds may be operated under substantially isothermal conditions.

Claims

1. A method of controlling the production of alkene hydrocarbons generated by the exothermic reaction of methane from a methane source and oxygen from an oxidant source over an oxidative coupling of methane (OCM) catalyst bed to provide an OCM gas comprising the alkene hydrocarbons, the method comprising:

monitoring a temperature of the OCM catalyst bed during production of the OCM gas, wherein said OCM catalyst bed comprises at least one nanostructure catalyst;

identifying a deviation in a maximum temperature of the OCM catalyst bed, which deviation is to a temperature that is above or below said maximum temperature; and

responsive to said deviation, performing at least one of the following;

(i) adjusting a quantity of the methane over the OCM catalyst bed;

(ii) adjusting a quantity of the oxygen over the OCM catalyst bed;

(iii) adjusting a proportion between a quantity of the oxygen and a quantity of the methane over the OCM catalyst bed;

(iv) adjusting a temperature of the methane source; and

(v) adjusting a temperature of the oxidant source.

2. The method of claim 1, wherein the temperature that is above or below said maximum temperature is greater than at least 800°

C.

3. The method of claim 1, further comprising conducting the production of the OCM gas with the OCM catalyst bed under substantially adiabatic conditions.

4. The method of claim 1, further comprising conducting the production of the OCM gas at a selectivity for hydrocarbons having two or more carbon atoms (C₂₊ hydrocarbons) of at least about 50%.

5. The method of claim 1, further comprising maintaining the methane source at a temperature of at least about 400°

C. using at least one heat transfer unit thermally coupled to the methane source.

6. The method of claim 1, further comprising maintaining the methane source at a temperature of at most about 600°

C. using at least one heat transfer unit thermally coupled to the methane source.

7. The method of claim 1, further comprising maintaining the oxidant source at a temperature of at least about 400°

C. using at least one heat transfer unit thermally coupled to the oxidant source.

8. The method of claim 1, further comprising conducting the production of the OCM gas at a pressure of greater than about 15 pounds per square inch gauge (psig) in the OCM catalyst bed.

9. The method of claim 1, further comprising conducting the production of the OCM gas at a pressure of less than about 150 pounds per square inch gauge (psig) in the OCM catalyst bed.

10. The method of claim 9, further comprising conducting the production of the OCM gas at a pressure of less than about 100 pounds per square inch gauge (psig) in the OCM catalyst bed.

11. The method of claim 1, further comprising adjusting a proportion between a concentration of the methane and a concentration of the oxygen to provide a ratio between the methane and the oxygen over the OCM catalyst bed such that the oxidant acts as a limiting reagent.

12. The method of claim 1, wherein the monitoring is conducted using a temperature sensor positioned within the OCM catalyst bed.

13. The method of claim 1, wherein the OCM catalyst bed comprises at least one nanostructure catalyst that is pressed or formed into at least one shape.

14. The method of claim 13, wherein the at least one nanostructure catalyst is selected from the group consisting of a metal oxide, a metal hydroxide, a perovskite, a metal oxyhydroxide, a metal oxycarbonate, a metal carbonate, a metal element from any of Groups 1 through 7, a lanthanide, and an actinide.

15. The method of claim 13, wherein the at least one nanostructure catalyst comprises at least one metal dopant.