US 11,753,357 B2
Multilayer mixed oxide supported catalyst for oxidative coupling of methane
Wugeng Liang, Sugar Land, TX (US); Azim Ali, Sugar Land, TX (US); Hector Perez, Sugar Land, TX (US); Jae Hyung Kim, Sugar Land, TX (US); Pankaj Gautam, Sugar Land, TX (US); and David West, Sugar Land, TX (US)
Assigned to SABIC Global Technologies B.V., Bergen op Zoom (NL)
Appl. No. 17/769,884
Filed by SABIC Global Technologies B.V., Bergen op Zoom (NL); Wugeng Liang, Sugar Land, TX (US); Azim Ali, Sugar Land, TX (US); Hector Perez, Sugar Land, TX (US); Jae Hyung Kim, Sugar Land, TX (US); Pankaj Gautam, Sugar Land, TX (US); and David West, Sugar Land, TX (US)
PCT Filed Sep. 21, 2020, PCT No. PCT/US2020/051724
§ 371(c)(1), (2) Date Apr. 18, 2022,
PCT Pub. No. WO2021/080716, PCT Pub. Date Apr. 29, 2021.
Claims priority of provisional application 62/924,509, filed on Oct. 22, 2019.
Prior Publication US 2022/0380275 A1, Dec. 1, 2022
Int. Cl. C07C 2/84 (2006.01); B01J 23/00 (2006.01); B01J 23/02 (2006.01); B01J 23/10 (2006.01); B01J 35/00 (2006.01); B01J 35/10 (2006.01); B01J 37/02 (2006.01)
CPC C07C 2/84 (2013.01) [B01J 23/002 (2013.01); B01J 23/02 (2013.01); B01J 23/10 (2013.01); B01J 35/0006 (2013.01); B01J 35/108 (2013.01); B01J 35/1009 (2013.01); B01J 35/1014 (2013.01); B01J 35/1038 (2013.01); B01J 35/1042 (2013.01); B01J 37/0236 (2013.01); B01J 2523/24 (2013.01); B01J 2523/3706 (2013.01); C07C 2523/02 (2013.01); C07C 2523/10 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A multilayer supported oxidative coupling of methane (OCM) catalyst composition characterized by the general formula AaZbEcDdOx/alpha-Al2O3, wherein the multilayer supported OCM catalyst composition comprises an alpha-Al2O3 support, a first single oxide layer, one or more mixed oxide layers, and an optional second single oxide layer;
wherein A is an alkaline earth metal; wherein Z is a first rare earth element; wherein E is a second rare earth element; wherein D is a redox agent or a third rare earth element; wherein the first rare earth element, the second rare earth element, and the third rare earth element, when present, are not the same; wherein a is 1.0; wherein b is from about 0.1 to about 10.0; wherein c is from about 0.1 to about 10.0; wherein d is from about 0 to about 10.0; wherein x balances the oxidation states;
wherein the first single oxide layer contacts the alpha-Al2O3 support and the one or more mixed oxide layers, wherein the first single oxide layer is characterized by the general formula Zb1Ox1, wherein b1 is from about 0.1 to about 10.0; and wherein x1 balances the oxidation states;
wherein the one or more mixed oxide layers contacts the first single oxide layer and optionally the second single oxide layer, wherein the one or more mixed oxide layers is characterized by the general formula Aa2Zb2Ec2Dd2Ox2, wherein a2 is 1.0; wherein b2 is from about 0.1 to about 10.0; wherein c2 is from about 0.1 to about 10.0; wherein d2 is from about 0 to about 10.0; wherein x2 balances the oxidation states; wherein the general formula AaZbEcDdOx and the general formula Aa2Zb2Ec2Dd2Ox2 are different; wherein the multilayer supported OCM catalyst composition characterized by the general formula AaZbEcDdOx/alpha-Al2O3 comprises a first single oxide characterized by the general formula Zb1Ox1, one or more mixed oxides characterized by the general formula Aa2Zb2Ec2Dd2Ox2, and optionally a second single oxide characterized by the general formula AO;
wherein the second single oxide layer, when present, contacts the one or more mixed oxide layers and optionally the first single oxide layer, and wherein the second single oxide layer is characterized by the general formula AO; and
wherein the crush strength of the multilayer supported OCM catalyst composition is greater than the crush strength of the alpha-Al2O3 support.