Preparation of catalyst and use for high yield conversion of methane to ethylene
First Claim
1. A method of oxidative coupling of methane for the formation of heavier hydrocarbons, the method comprising the steps of:
- producing a perovskite catalyst, the catalyst produced by a process comprising;
forming an aqueous slurry comprising an alkaline earth metal salt, a powdered metal salt and a powdered transition metal oxide;
adding a polymeric binder to the slurry to form a paste;
drying the paste for forming a powder;
heating the powder at increasing temperatures at a predetermined profile commensurate with the polymeric binder; and
calcining the heated powder; and
contacting a feed gas stream containing methane and oxygen in an oxidative coupling reactor under oxidative coupling conditions in the presence of the perovskite catalyst.
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Abstract
A perovskite catalyst is prepared using a ceramic sol-sol methodology comprising preparing slurry in water of an alkaline earth metal salt, a powdered metal salt and a powdered transition metal oxide, adding a polymeric binder to form a paste, drying and comminuting the paste into a powder and heating the powder with a temperature profile to calcination temperatures. In one embodiment the slurry is formed of titanium oxide with barium carbonate and tin chloride in deionized water, and more specifically by a mixture according to Ba (1−0.05x)+TiO2+SnCl2(0.05x) where x is in moles. The perovskite catalyst is preferably used in a process for oxidative coupling of methane. Catalyst performance is enhanced through the addition of halides to the feed gas in the reaction.
8 Citations
21 Claims
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1. A method of oxidative coupling of methane for the formation of heavier hydrocarbons, the method comprising the steps of:
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producing a perovskite catalyst, the catalyst produced by a process comprising;
forming an aqueous slurry comprising an alkaline earth metal salt, a powdered metal salt and a powdered transition metal oxide;
adding a polymeric binder to the slurry to form a paste;
drying the paste for forming a powder;
heating the powder at increasing temperatures at a predetermined profile commensurate with the polymeric binder; and
calcining the heated powder; and
contacting a feed gas stream containing methane and oxygen in an oxidative coupling reactor under oxidative coupling conditions in the presence of the perovskite catalyst. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method of oxidative coupling of methane for the formation of heavier hydrocarbons, the method comprising the steps of:
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producing a perovskite catalyst, the catalyst produced by a process comprising;
forming an aqueous slurry comprising an alkaline earth metal salt, a powdered transition metal salt and a powdered transition metal oxide;
drying the slurry to form a powder;
heating the powder at increasing temperatures at a predetermined profile; and
calcining the heated powder to produce the perovskite catalyst, wherein the perovskite catalyst comprises a mixture including Ba+TiO2+R, wherein R is Sn; and
contacting a feed gas stream containing methane and oxygen in an oxidative coupling reactor under oxidative coupling conditions in the presence of the perovskite catalyst. - View Dependent Claims (17, 18, 19, 20, 21)
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Specification