IP Library › Granted Patent US 12,447,465
Granted Patent B2
US 12,447,465 · App. 18/115,611 · Granted Oct 21, 2025

Catalysts for oxidative coupling of methane

Inventors: Fabio R. Zurcher (Brisbane, CA); Daniel Rosenberg (San Francisco, CA); Richard P. James (Berkeley, CA); David Grauer (Redwood City, CA); Wayne P. Schammel (Brisbane, CA); Joel M. Cizeron (Redwood City, CA); Joel Gamoras (Vallejo, CA); Ginger DeMars (Santa Clara, CA); Adrienne Tanur (Sunnyvale, CA)
Assignee: Lummus Technology LLC
B01J23/002B01J23/30B01J23/34B01J35/37B01J35/55B01J35/59C07C2/84B01J21/04B01J2235/15B01J2235/30C07C2523/30
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Quick Facts
Patent No.
US 12,447,465
App. No.
18/115,611
Granted
Oct 21, 2025
Kind
B2
Abstract

Catalysts, catalytic materials having catalysts present on supports and catalytic methods are provided. The catalysts, catalytic material and methods are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane.

Claims (18)

1. A catalytic material for oxidative coupling of methane (OCM) comprising an OCM active catalyst in combination with a support, wherein the OCM active catalyst comprises one or more elements from the lanthanides in the form of an oxide, a hydroxide or an oxyhydroxide, and the support comprises alpha phase alumina, gamma phase alumina or a combination thereof, the support having a local maxima pore diameter greater than 1 micrometer.

2. The catalytic material of claim 1 , wherein the support comprises gamma phase alumina.

3. The catalytic material of claim 1 , wherein the support has a bimodal pore size distribution with a first local maxima pore diameter that is less than 5 micrometers, and a second local maxima pore diameter that is greater than 15 micrometers.

4. The catalytic material of claim 1 , wherein the support comprises

a pore volume greater than about 0.3 cubic centimeters per gram (cc/g),

wherein the pore volume and pore size are determined by Hg porosimetry.

5. The catalytic material of claim 1 , wherein in a weight ratio of the OCM active catalyst to the support ranges from 95:5 to 5:95.

6. The catalytic material of claim 1 , wherein the OCM active catalyst comprises an oxide of a lanthanide element or a mixed oxide of two or more lanthanide elements.

7. The catalytic material of claim 1 , wherein the OCM active catalyst comprises La 2 O 3 , Ce 2 O 3 , Pr 2 O 3 , Nd 2 O 3 , Sm 2 O 3 , Eu 2 O 3 , Gd 2 O 3 , Yb 2 O 3 , Y 2 O 3 or combinations thereof.

8. The catalytic material of claim 1 , wherein OCM catalyst further comprises one or more dopants selected from group 2 elements.

9. The catalytic material of claim 8 , wherein the one or more dopants are each independently present in the OCM active catalyst from 1% to 10% by weight of the OCM active catalyst.

10. The catalytic material of claim 1 , further comprising a diluent.

11. The catalytic material of claim 10 , wherein the diluent comprises an alkaline earth aluminate selected from MgAl 2 O 4 , CaAl 2 O 4 , Ca 3 Al 2 O 6 , SrAl 2 O 4 or BaAl 2 O 4 .

12. A formed catalytic material comprising the catalytic material of claim 1 .

13. The formed catalytic material of claim 12 , wherein the formed catalytic material is a pressed pellet, an extrudate, a cast article or a monolith.

14. The formed catalytic material of claim 12 , wherein a shape of the formed catalytic material is selected from a cylinder, rod, star, rib, trilobe, disk, donut, ring, tube, sphere, honeycomb, cup, bowl and an irregular shape.

15. The formed catalytic material of claim 11 , wherein the formed catalytic material comprises a crushing strength greater than 1 N/mm 2 .

16. A method for oxidative coupling of methane (OCM), the method comprising contacting a feed gas comprising methane and oxygen with the formed catalytic material of claim 12 to form a product gas comprising C2+ hydrocarbons.

Continuity (3)
Division 16777352 · Jan 30, 2020
Provisional Application 62798896 · Jan 30, 2019
Related Publication 20230201803A1 · Jun 29, 2023
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