New approach to the preparation of catalysts for the oxidative coupling of methane

A new approach to the preparation of systems that exhibit catalytic activity in the oxidative coupling of methane (OCM) is considered. With the use of ferrospheres separated from power-generation ashes from different sources as an example, it was demonstrated that OCM catalysts can be prepared by the crystallization/solidification of oxide melts with the formation of microspherical particles. The dependence of activity and selectivity for the oxidative reforming of methane on the ferrospheres containing from 36.2 to 92.5 wt % Fe₂O₃ into the products of deep oxidation and OCM was studied. It was found that deep oxidation reactions on ferrospheres with Fe₂O₃ contents higher than 85% were suppressed, and the main reaction path of CH₄ conversion was its oxidative coupling with the formation of C₂ products (with selectivity to 60% at 750°C); moreover, the selectivity for C₂ formation in this region was proportional to the concentration of Fe₂O₃. Phases responsible for the catalytic conversion of methane into CO _x and OCM products were considered, and it was shown that the catalytic activity and selectivity of the oxidative transformation of CH₄ on ferrospheres is determined by the position of the point that corresponds to their composition on a phase diagram of CaO-Fe₂O₃-SiO₂.