Abstract: This invention relates to processes and systems for the conversion of methane in high yields to C4+ hydrocarbons. The principal steps of the recycle process include reacting methane and O2 in an oxidative coupling reactor over a Mn/Na2WO4/SiO2 catalyst at 800° C. to convert the methane to ethylene, and oligomerizing the ethylene product by reacting it with an H-ZSM-5 zeolite catalyst at 275° C. in a catalytic reactor for subsequent conversion of the ethylene to higher hydrocarbons. Total yields of C4+ products using the process of the invention are in the range of about 60% to about 80%, and yields of C4+ nonaromatic hydrocarbons are in the range of about 50% to about 60%.

Abstract: An improved method for preparing a catalyst which is superior for converting methane to ethane and ethylene is described. The method involves mixing a solution of a magnesium alkoxide in alcohol with a solution of a lithium compound in alcohol. Preferably, chlorine is introduced into the mixture. A solution of an aluminum alkoxide in an alcohol may also be added to the mixture. The magnesium alkoxide is hydrolyzed to produce a gel, and the gel is then calcined to produce the catalyst. Catalysts prepared by this method are superior for converting methane to ethane and ethylene, and have superior selectivities for ethylene and ethane over conventional lithium carbonate/magnesium oxide catalysts.

Abstract: A method for the oxidative conversion of methane, at a high conversion and high selectivity to ethylene and ethane, in which a methane-containing gas, such as a natural gas, and an oxygen-containing gas are contacted with a contact material comprising lithium, in an effective amount, preferably 0.1 to 50 wt. % (expressed as the metal), and magnesium oxide, as by passing a mixture of the methane-containing gas and the oxygen-containing gas through a body of the contact material.

Abstract: An improved method for preparing a catalyst which is superior for converting methane to ethane and ethylene is described. The method involves mixing a solution of a magnesium alkoxide in alcohol with a solution of a lithium compound in alcohol. Preferably, chlorine is introduced into the mixture. A solution of an aluminum alkoxide in an alcohol may also be added to the mixture. The magnesium alkoxide hydrolyzed to produce a gel, and the gel is then calcined to produce the catalyst. Catalysts prepared by this method are superior for converting methane to ethane and ethylene, and have superior selectivities for ethylene and ethane over conventional lithium carbonate/magnesium oxide catalysts.