Method for Oxidatively Converting Gaseous Alkanes in a Fluidized Bed Membrane Reactor and a Reactor for Performing Said Method

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This patent describes a method and reactor design for the oxidative conversion of gaseous alkanes (such as methane) using a fluidized bed membrane reactor. The core innovation involves introducing the alkane gas and an oxygen-containing gas separately into a reactor containing a fluidized bed of catalyst particles. Oxygen is distributed finely and controllably into the catalyst bed via a gas-permeable membrane, which enhances the efficiency and selectivity of valuable chemical production (e.g., ethylene and ethane) from lower alkanes.

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• Production of ethylene and ethane from methane (natural gas) via oxidative coupling of methane (OCM) for petrochemical applications.
• Direct conversion of natural gas resources into higher-value chemicals and fuels at large industrial scale.
• Modular reactor solutions for on-site chemical production at remote gas fields or integrated plants.
• Application in other exothermic or endothermic gas-phase catalytic reactions that benefit from controlled reactant distribution via membranes.

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• Significantly improves selectivity and yield of desired products (such as ethylene and ethane) compared to traditional reactor designs.
• Allows precise control of oxygen distribution, reducing unwanted by-products and optimizing reaction efficiency.
• Enhances safety by preventing the risk of explosive oxygen build-up and minimizing post-reaction oxidation.
• Supports isothermal operation, avoiding local hot spots and promoting catalyst longevity.
• Scalable to industrial production levels and compatible with integration into complex chemical processes.
• Adaptable to various reaction conditions and catalyst materials for different hydrocarbon conversions.

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Patent Abstract

The present invention relates to a method for oxidatively converting at least one gaseous alkane, preferably a C1-C4 alkane, especially preferably methane, in at least one fluidized bed membrane reactor, which comprises at least one first inlet line (1), at least one second inlet line (3), which is present at least in some sections within the reactor in the form of a membrane (5) having at least one active membrane surface, and at least one catalyst bed (4). According to the invention, the method comprises the steps of introducing at least one first flow (1a) containing the at least one gaseous alkane into the at least one catalyst bed in the reactor by means of the at least one first inlet line (1), and introducing at least one second flow (2) containing oxygen or a gas containing oxygen into the reactor by means of the at least one second inlet line (3), wherein the second flow is introduced into the at least one catalyst bed (4) of the reactor by means of the at least one active membrane surface. The application further relates to a reactor for performing said method.