Nanowire catalysts and methods for their use and preparation
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C07C-002/84
B01J-023/30
B01J-023/02
B01J-023/04
B01J-037/03
B01J-037/08
B01J-037/10
B01J-021/06
B01J-021/10
B01J-023/10
B01J-023/22
B01J-023/34
B01J-035/00
B01J-035/06
B01J-037/00
C01F-005/02
C01F-005/08
C01F-005/14
C01F-017/00
C01G-025/02
C01G-031/02
C01G-045/02
C01G-045/12
B82Y-030/00
출원번호
US-0557225
(2014-12-01)
등록번호
US-9751818
(2017-09-05)
발명자
/ 주소
Zurcher, Fabio R.
Scher, Erik C.
Cizeron, Joel M.
Schammel, Wayne P.
Tkachenko, Alex
Gamoras, Joel
Karshtedt, Dmitry
Nyce, Greg
Rumplecker, Anja
McCormick, Jarod
Merzlyak, Anna
Alcid, Marian
Rosenberg, Daniel
Ras, Erik-Jan
출원인 / 주소
Siluria Technologies, Inc.
대리인 / 주소
Seed IP Law Group LLP
인용정보
피인용 횟수 :
3인용 특허 :
174
초록
Nanowires useful as heterogeneous catalysts are provided. The nanowire catalysts are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane to C2 hydrocarbons. Related methods for use and manufacture of the same are also disclosed.
대표청구항▼
1. A method for the preparation of ethane, ethylene or combinations thereof, the method comprising contacting a catalytic material with a gas comprising methane, wherein the catalytic material is in the form of a pressed pellet, extrudate or monolith and comprises: a) a plurality of catalytic nanowi
1. A method for the preparation of ethane, ethylene or combinations thereof, the method comprising contacting a catalytic material with a gas comprising methane, wherein the catalytic material is in the form of a pressed pellet, extrudate or monolith and comprises: a) a plurality of catalytic nanowires, the catalytic nanowires comprising one or more doping elements; andb) a diluent or support selected from one or more alkaline earth metal compounds,and wherein the catalytic material has a C2+ yield above 5% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 2. The method of claim 1, wherein the catalytic materials is in the form of a pressure treated, pressed pellet and comprises no binder material. 3. The method of claim 1, wherein the catalytic material is in the form of a pressed pellet or extrudate and comprises pores greater than 20 nm in diameter. 4. The method of claim 1, wherein the alkaline earth metal compound is an alkaline earth metal oxide, alkaline earth metal carbonate, alkaline earth metal sulfate or alkaline earth metal phosphate. 5. The method of claim 1, wherein the alkaline earth metal compound is an alkaline earth metal carbonate, alkaline earth metal sulfate or alkaline earth metal phosphate. 6. The method of claim 1, wherein the alkaline earth metal compound is MgO, MgCO3, MgSO4, Mg3(PO4)2, MgAl2O4, CaO, CaCO3, CaSO4, Ca3(PO4)2, CaAl2O4, SrO, SrCO3, SrSO4, Sr3(PO4)2, SrAl2O4, BaO, BaCO3, BaSO4, Ba3(PO4)2, BaAl2O4 or combinations thereof. 7. The method of claim 1, wherein the alkaline earth metal compound is MgCO3, MgSO4, Mg3(PO4)2, CaO, CaCO3, CaSO4, Ca3(PO4)2, CaAl2O4, SrO, SrCO3, SrSO4, Sr3(PO4)2, SrAl2O4, BaO, BaCO3, BaSO4, Ba3(PO4)2, BaAl2O4 or combinations thereof. 8. The method of claim 1, wherein the alkaline earth metal compound is CaO, SrO, MgCO3, CaCO3, SrCO3 or combinations thereof. 9. The method of claim 1, wherein the plurality of catalytic nanowires have a ratio of average effective length to average actual length of less than one and an average aspect ratio of greater than ten as measured by TEM in bright field mode at 5 keV, wherein the plurality of catalytic nanowires comprises one or more elements from any of Groups 1 through 7, lanthanides, actinides or combinations thereof. 10. The method of claim 1, wherein the plurality of catalytic nanowires comprises straight nanowires. 11. The method of claim 10, wherein the straight nanowires have a ratio of effective length to actual length equal to one. 12. The method of claim 1, wherein the plurality of catalytic nanowires comprises at least one nanowire selected from any one of Tables 1-12. 13. The method of claim 1, wherein the catalytic material has a C2 selectivity above 50% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 14. The method of claim 1, wherein the catalytic material has a CH4 conversion above 20% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 15. The method of claim 1, wherein the catalytic material further comprises SiC or cordierite or combinations thereof. 16. The method of claim 1, wherein the catalytic material is contacted with the gas at a temperature less than 800° C. 17. The method of claim 1, wherein the catalytic material is contacted with the gas at a temperature less than 700° C. 18. The method of claim 1, having a conversion of methane to ethylene of greater than 10%. 19. The method of claim 1, having a yield of ethylene of greater than 10%. 20. The method of claim 1, having a conversion of methane of greater than 10%. 21. The method of claim 1, having a C2 yield of greater than 10%. 22. The method of claim 2, wherein the plurality of catalytic nanowires have a ratio of average effective length to average actual length of less than one and an average aspect ratio of greater than ten as measured by TEM in bright field mode at 5 keV, wherein the plurality of catalytic nanowires comprises one or more elements from any of Groups 1 through 7, lanthanides, actinides or combinations thereof. 23. The method of claim 2, wherein the plurality of catalytic nanowires comprises straight nanowires. 24. The method of claim 23, wherein the straight nanowires have a ratio of effective length to actual length equal to one. 25. The method of claim 2, wherein the plurality of catalytic nanowires comprises at least one nanowire selected from any one of Tables 1-12. 26. The method of claim 2, wherein the alkaline earth metal compound is an alkaline earth metal oxide, alkaline earth metal carbonate, alkaline earth metal sulfate or alkaline earth metal phosphate. 27. The method of claim 2, wherein the alkaline earth metal compound is MgO, MgCO3, MgSO4, Mg3(PO4)2, MgAl2O4, CaO, CaCO3, CaSO4, Ca3(PO4)2, CaAl2O4, SrO, SrCO3, SrSO4, Sr3(PO4)2, SrAl2O4, BaO, BaCO3, BaSO4, Ba3(PO4)2, BaAl2O4 or combinations thereof. 28. The method of claim 2, wherein the alkaline earth metal compound is MgO, CaO, SrO, MgCO3, CaCO3, SrCO3 or combinations thereof. 29. The method of claim 2, wherein the catalytic material has a C2 selectivity above 50% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 30. The method of claim 2, wherein the catalytic material has a CH4 conversion above 20% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 31. The method of claim 2, wherein the catalytic material further comprises SiC or cordierite or combinations thereof. 32. The method of claim 3, wherein the plurality of catalytic nanowires have a ratio of average effective length to average actual length of less than one and an average aspect ratio of greater than ten as measured by TEM in bright field mode at 5 keV, wherein the plurality of catalytic nanowires comprises one or more elements from any of Groups 1 through 7, lanthanides, actinides or combinations thereof. 33. The method of claim 3, wherein the plurality of catalytic nanowires comprises straight nanowires. 34. The method of claim 33, wherein the straight nanowires have a ratio of effective length to actual length equal to one. 35. The method of claim 3, wherein the plurality of catalytic nanowires comprises at least one nanowire selected from any one of Tables 1-12. 36. The method of claim 3, wherein the catalytic material has a C2 selectivity above 50% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 37. The method of claim 3, wherein the catalytic material has a CH4 conversion above 20% when employed as catalytic material in the oxidative coupling of methane at an inlet temperature of 550° C. and an inlet pressure of about 2 atm in a fixed bed reactor with a gas-hour space velocity (GHSV) of at least about 20,000/hr. 38. The method of claim 3, wherein the alkaline earth metal compound is an alkaline earth metal oxide, alkaline earth metal carbonate, alkaline earth metal sulfate or alkaline earth metal phosphate. 39. The method of claim 3, wherein the alkaline earth metal compound is MgO, MgCO3, MgSO4, Mg3(PO4)2, MgAl2O4, CaO, CaCO3, CaSO4, Ca3(PO4)2, CaAl2O4, SrO, SrCO3, SrSO4, Sr3(PO4)2, SrAl2O4, BaO, BaCO3, BaSO4, Ba3(PO4)2, BaAl2O4 or combinations thereof. 40. The method of claim 3, wherein the alkaline earth metal compound is MgO, CaO, SrO, MgCO3, CaCO3, SrCO3 or combinations thereof. 41. The method of claim 3, wherein the catalytic material further comprises SiC or cordierite or combinations thereof.
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