Process for the Oxidative Conversion of Alkanes and Reactor Arrangement for Carrying Out This Process

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This patent describes a novel process and reactor system for the oxidative conversion of alkanes (such as methane) into more valuable chemicals like ethylene and ethane. The core invention is the use of an advanced fixed bed membrane reactor (PPBMR) where both the alkane and oxygen are supplied together into a catalytic bed, while additional alkane is introduced into the surrounding shell. This design improves control over reactant concentrations and enhances the yield and selectivity towards desired products, while limiting unwanted byproducts like carbon dioxide. The patent also covers optimized membrane designs and the integration of different reactor types into a process network for further efficiency gains.

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• Conversion of natural gas (methane) into higher-value olefins such as ethylene or ethane for the petrochemical industry.
• Direct production of basic chemical feedstocks from natural gas in remote or resource-rich locations where traditional processes are less economical.
• Flexible chemical plants capable of efficiently adjusting to different feedstocks and output targets.
• Integration of efficient oxidative coupling technologies for reducing energy and resource consumption in large-scale chemical manufacturing.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly increased efficiency and selectivity in the conversion of alkanes to higher-value chemicals, reducing waste and undesired byproducts.
• Enhanced control over the reaction process, leading to higher yields.
• Ability to recycle unreacted materials and optimize resource use within the reactor network, reducing raw material consumption and emissions.
• Improved reactor membrane stability and longevity at high temperatures, ensuring reliability and cost-effectiveness in industrial applications.
• Enables the economical use of natural gas reserves for the direct production of olefins, potentially lowering dependence on more expensive or less accessible raw materials.

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Patent Abstract

The invention relates to a method for oxidatively converting at least one alkane, preferably a C1-C4 alkane, in particular preferably methane, in at least one first fixed bed membrane reactor (PPBMR, 18), which comprises a tubular membrane, which has an interior as a reaction chamber, the interior being filled with at least one catalytic solid (18a) as a fixed bed, an outer reactor jacket that surrounds the membrane, and a jacket chamber (18b) formed between the reactor jacket and the membrane. The method is characterized in that at least one gas flow (2, 11, 12) containing a mixture of at least one alkane and oxygen or an oxygen-containing gas is introduced into the catalytic solid (18a) in the interior of the tubular membrane and additionally at least one gas flow (2a) containing at least one alkane can be introduced into the jacket chamber (18b). The invention further relates to a reactor assembly for carrying out said method and to a membrane that can be used in a fixed bed membrane reactor.