Support material variation for the MnxOy-Na2WO4/SiO2 catalyst

Metal Ions (Li, Mg, Zn, Ce) Doped into La2O3 Nanorod for Boosting Catalytic Oxidative Coupling of Methane

A series of La2O3 nanorod catalysts with doping of active metal ions (Li, Mg, Zn and Ce) were synthesized successfully by the hydrothermal method. The La2O3 nanorods show a uniform size with the length of 50–200 nm and the width of 5–20 nm, and the {110} crystal facet is a preferentially exposed surface. The active metal ions (Li, Mg, Zn and Ce) doped into the lattice of La2O3 nanorods enhance the selectivity of the desired products during oxidative coupling of methane (OCM) and decrease the reaction temperature. Among these catalysts, the Mg-La2O3 catalyst exhibits the best catalytic performance during the OCM reaction, i.e., its selectivity and yield of C2 products at 780 °C is 73% and 21%, respectively. The effect of doped metal ions on catalytic activity for OCM was systematically investigated. Insight into the fabrication strategy and promoting factors of the OCM reaction indicates the potential to further design a high-efficient catalyst in the future.

Oxidative Coupling of Methane: Examining the Inactivity of the MnOx -Na2 WO4 /SiO2 Catalyst at Low Temperature

Oxidative coupling of methane (OCM) catalyzed by MnO_x -Na₂ WO₄ /SiO₂ has great industrial promise to convert methane directly to C_2-3 products, but its high light-off temperature is the most challenging obstacle to commercialization and its working mechanism is still a mystery. We report the discovery of a low-temperature active and selective MnO_x -Na₂ WO₄ /SiO₂ catalyst enriched with Q² units in the SiO₂ carrier, being capable of converting 23 % CH₄ with 72 % C_2-3 selectivity at 660 °C. From experiments and theoretical calculations, a large number of Q² units in the MnO_x -Na₂ WO₄ /SiO₂ catalyst is a trigger for markedly lowering the light-off temperature of the Mn³⁺ ↔Mn²⁺ redox cycle involved in the OCM reaction because of the easy formation of MnSiO₃ . Notably, the MnSiO₃ formation proceeds merely through the SiO₂ -involved reaction in the presence of Na₂ WO₄ : Mn₇ SiO₁₂ +6 SiO₂ ↔7 MnSiO₃ +1.5 O₂ . The Na₂ WO₄ not only drives the light-off of this cycle but also gets it working with substantial selectivity toward C_2-3 products. Our findings shine a light on the rational design of more advanced MnO_x -Na₂ WO₄ based OCM catalysts through establishing new Mn³⁺ ↔Mn²⁺ redox cycles with lowered light-off temperature.

Oxidative coupling of methane-comparisons of MnTiO3-Na2WO4 and MnOx-TiO2-Na2WO4 catalysts on different silica supports

The oxidative coupling of methane (OCM) converts CH₄ to value-added chemicals (C₂₊), such as olefins and paraffin. For a series of MnTiO₃-Na₂WO₄ (MnTiO₃-NW) and MnO_x-TiO₂-Na₂WO₄ (Mn-Ti-NW), the effect of loading of MnTiO₃ or MnO_x-TiO₂, respectively, on two different supports (sol-gel SiO₂ (SG) and commercial fumed SiO₂ (CS)) was examined. The catalyst with the highest C₂₊ yield (21.6% with 60.8% C₂₊ selectivity and 35.6% CH₄ conversion) was 10 wt% MnTiO₃-NW/SG with an olefins/paraffin ratio of 2.2. The catalyst surfaces with low oxygen-binding energies were associated with high CH₄ conversion. Stability tests conducted for over 24 h revealed that SG-supported catalysts were more durable than those on CS because the active phase (especially Na₂WO₄) was more stable in SG than in CS. With the use of SG, the activity of MnTiO₃-NW was not substantially different from that of Mn-Ti-NW, especially at high metal loading.

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

Ethylene production via oxidative coupling of methane (OCM) represents an interesting route for natural gas upscaling, being the focus of intensive research worldwide. Here, OCM developments are analysed in terms of kinetic mechanisms and respective applications in chemical reactor models, discussing current challenges and directions for further developments. Furthermore, some thermodynamic aspects of the OCM reactions are also revised, providing achievable olefins yields in a wide range of operational reaction conditions. Finally, OCM catalysts are reviewed in terms of respective catalytic performances and thermal stability, providing an executive summary for future studies on OCM economic feasibility.

Porous Silicon Carbide (SiC): A Chance for Improving Catalysts or Just Another Active-Phase Carrier?

There is an obvious gap between efforts dedicated to the control of chemicophysical and morphological properties of catalyst active phases and the attention paid to the search of new materials to be employed as functional carriers in the upgrading of heterogeneous catalysts. Economic constraints and common habits in preparing heterogeneous catalysts have narrowed the selection of active-phase carriers to a handful of materials: oxide-based ceramics (e.g. Al₂O₃, SiO₂, TiO₂, and aluminosilicates-zeolites) and carbon. However, these carriers occasionally face chemicophysical constraints that limit their application in catalysis. For instance, oxides are easily corroded by acids or bases, and carbon is not resistant to oxidation. Therefore, these carriers cannot be recycled. Moreover, the poor thermal conductivity of metal oxide carriers often translates into permanent alterations of the catalyst active sites (i.e. metal active-phase sintering) that compromise the catalyst performance and its lifetime on run. Therefore, the development of new carriers for the design and synthesis of advanced functional catalytic materials and processes is an urgent priority for the heterogeneous catalysis of the future. Silicon carbide (SiC) is a non-oxide semiconductor with unique chemicophysical properties that make it highly attractive in several branches of catalysis. Accordingly, the past decade has witnessed a large increase of reports dedicated to the design of SiC-based catalysts, also in light of a steadily growing portfolio of porous SiC materials covering a wide range of well-controlled pore structure and surface properties. This review article provides a comprehensive overview on the synthesis and use of macro/mesoporous SiC materials in catalysis, stressing their unique features for the design of efficient, cost-effective, and easy to scale-up heterogeneous catalysts, outlining their success where other and more classical oxide-based supports failed. All applications of SiC in catalysis will be reviewed from the perspective of a given chemical reaction, highlighting all improvements rising from the use of SiC in terms of activity, selectivity, and process sustainability. We feel that the experienced viewpoint of SiC-based catalyst producers and end users (these authors) and their critical presentation of a comprehensive overview on the applications of SiC in catalysis will help the readership to create its own opinion on the central role of SiC for the future of heterogeneous catalysis.

"Soft" oxidative coupling of methane to ethylene: Mechanistic insights from combined experiment and theory

The oxidative coupling of methane to ethylene using gaseous disulfur (2CH₄ + S₂ → C₂H₄ + 2H₂S) as an oxidant (SOCM) proceeds with promising selectivity. Here, we report detailed experimental and theoretical studies that examine the mechanism for the conversion of CH₄ to C₂H₄ over an Fe₃O₄-derived FeS₂ catalyst achieving a promising ethylene selectivity of 33%. We compare and contrast these results with those for the highly exothermic oxidative coupling of methane (OCM) using O₂ (2CH₄ + O₂ → C₂H₄ + 2H₂O). SOCM kinetic/mechanistic analysis, along with density functional theory results, indicate that ethylene is produced as a primary product of methane activation, proceeding predominantly via CH₂ coupling over dimeric S-S moieties that bridge Fe surface sites, and to a lesser degree, on heavily sulfided mononuclear sites. In contrast to and unlike OCM, the overoxidized CS₂ by-product forms predominantly via CH₄ oxidation, rather than from C₂ products, through a series of C-H activation and S-addition steps at adsorbed sulfur sites on the FeS₂ surface. The experimental rates for methane conversion are first order in both CH₄ and S₂, consistent with the involvement of two S sites in the rate-determining methane C-H activation step, with a CD₄/CH₄ kinetic isotope effect of 1.78. The experimental apparent activation energy for methane conversion is 66 ± 8 kJ/mol, significantly lower than for CH₄ oxidative coupling with O₂ The computed methane activation barrier, rate orders, and kinetic isotope values are consistent with experiment. All evidence indicates that SOCM proceeds via a very different pathway than that of OCM.

Effect of thermal treatment on the stability of Na-Mn-W/SiO2 catalyst for the oxidative coupling of methane

In this study, we investigate the effect of thermal treatment/calcination on the stability and activity of a Na-Mn-W/SiO₂ catalyst for the oxidative coupling of methane. The catalyst performance and characterisation measurements suggest that the W species are directly involved in the catalyst active site responsible for CH₄ conversion. Under operating conditions, the active components, present in the form of a Na-W-O-Mn molten state, are highly mobile and volatile. By varying the parameters of the calcination protocol, it was shown that these molten components can be partially stabilised, resulting in a catalyst with lower activity (due to loss of surface area) but higher stability even for long duration OCM reaction experiments.

Oxidative Coupling of Methane over Mn2O3-Na2WO4/SiC Catalysts

The oxidative coupling of methane (OCM) is operated at high temperatures and is a highly exothermic reaction; thus, hotspots form on the catalyst surface during reaction unless the produced heat is removed. It is crucial to control the heat formed because surface hotspots can degrade catalytic performance. Herein, we report the preparation of Mn2O3-Na2WO4/SiC catalysts using SiC, which has high thermal conductivity and good stability at high temperatures, and the catalyst was applied to the OCM. Two Mn2O3-Na2WO4/SiC catalysts were prepared by wet-impregnation on SiC supports having different particle sizes. For comparison, the Mn2O3-Na2WO4/SiO2 catalyst was also prepared by the same method. The catalysts were analyzed by nitrogen adsorption–desorption, X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. The transformation of SiC into α-cristobalite was observed for the Mn2O3-Na2WO4/SiC catalysts. Because SiC was completely converted into α-cristobalite for the nano-sized SiC-supported Mn2O3-Na2WO4 catalyst, the catalytic performance for the OCM reaction of Mn2O3-Na2WO4/n-SiC was similar to that of Mn2O3-Na2WO4/SiO2. However, only the surface layer of SiC was transformed into α-cristobalite for the micro-sized SiC (m-SiC) in Mn2O3-Na2WO4/m-SiC, resulting in a SiC@α-cristobalite core–shell structure. The Mn2O3-Na2WO4/m-SiC showed higher methane conversion and C2+ yield at 800 and 850 °C than Mn2O3-Na2WO4/SiO2.

Critical Surface Parameters for the Oxidative Coupling of Methane over the Mn-Na-W/SiO2 Catalyst

The work here presents a thorough evaluation of the effect of Mn-Na-W/SiO₂ catalyst surface parameters on its performance in the oxidative coupling of methane (OCM). To do so, we used microporous dealuminated β-zeolite (Zeo), or mesoporous SBA-15 (SBA), or macroporous fumed silica (Fum) as precursors for catalyst preparation, together with Mn nitrate, Mn acetate and Na₂WO₄. Characterizing the catalysts by inductively coupled plasma-optical emission spectroscopy, N₂ physisorption, X-ray diffraction, high-resolution scanning electron microscopy-energy-dispersive spectroscopy, X-ray photoelectron spectroscopy, and catalytic testing enabled us to identify critical surface parameters that govern the activity and C₂ selectivity of the Mn-Na-W/SiO₂ catalyst. Although the current paradigm views the phase transition of silica to α-cristobalite as the critical step in obtaining dispersed and stable metal sites, we show that the choice of precursors is equally or even more important with respect to tailoring the right surface properties. Specifically, the SBA-based catalyst, characterized by relatively closed surface porosity, demonstrated low activity and low C₂ selectivity. By contrast, for the same composition, the Zeo-based catalyst showed an open surface pore structure, which translated up to fourfold higher activity and enhanced selectivity. By varying the overall composition of the Zeo catalysts, we show that reducing the overall W concentration reduces the size of the Na₂WO₄ species and increases the catalytic activity linearly as much as fivefold higher than the SBA catalyst. This linear dependence correlates well to the number of interfaces between the Na₂WO₄ and Mn₂O₃ species. Our results combined with prior studies lead us to single out the interface between Na₂WO₄ and Mn₂O₃ as the most probable active site for OCM using this catalyst. Synergistic interactions between the various precursors used and the phase transition are discussed in detail, and the conclusions are correlated to surface properties and catalysis.

Feasibility study of the Mn–Na2WO4/SiO2 catalytic system for the oxidative coupling of methane in a fluidized-bed reactor

The catalytic system Mn–Na₂WO₄/SiO₂, was studied in a miniplant fluidized-bed reactor for oxidative coupling of methane.

Enhanced catalytic performance of MnxOy–Na2WO4/SiO2 for the oxidative coupling of methane using an ordered mesoporous silica support

The oxidative coupling of methane is a highly promising reaction for its direct conversion.