BORON-PROMOTED REDUCIBLE METAL OXIDES AND METHODS FOR THEIR USE

Abstract: Compositions comprising boron-promoted reducible metal oxides (especially reducible oxides of Mn) and optionally containing alkali and alkaline earth metal components are disclosed, as well as use thereof for hydrocarbon conversions characterized by formation of by-­ product water. Particular processes comprise the conversion of methane to higher hydrocarbons and the dehydrogenation of dehydrogenatable hydrocarbons, e.g., dehydrogenation of C₂-C₅ alkanes to form the correspond­ ing olefins.

Description: This invention relates to methane conversion processes employing reducible metal oxide compositions and to catalyst compositions suitable for use in these processes. In the present invention, the catalyst composition comprises a boron promoted reducible metal oxide optionally in combination with alkaline earth metal or both alkaline earth metal and alkali metal. Recently, it has been discovered that methane may be converted to higher hydrocarbons by a process which comprises contacting methane and an oxidative synthesizing agent at synthesizing conditions (e.g., at a temperature selected within the range from about 500° to about 1000°C.). Oxidative synthesizing agents are compositions having as a principal component at least one oxide of at least one metal which compositions produce C₂+ hydrocarbon products, co-product water, and a composition comprising a reduced metal oxide when contacted with methane at synthesizing conditions. Reducible oxides of several metals have been identified which are capable of converting methane to higher hydrocarbons. In particular, oxides of manganese, tin, indium, germanium, lead, antimony, bismuth, praseodymium, terbium, cerium, iron and ruthenium are most useful. See commonly-assigned U.S. Patent Numbers 4,443,649 (Mn); 4,444,984 (Sn); 4,443,648 (In); 4,443,645 (Ge); 4,443,647 (Pb); 4,443,646 (Bi); 4,499,323 (Pr); 4,499,324 (Ce); and 4,593,139 (Ru). Commonly-assigned U.S. Patent Number 4,554,395 discloses and claims a process which comprises contacting methane with an oxidative synthesising agent under elevated pressure (2-100 atmospheres) to produce greater amounts of C₃+ hydrocarbon products. Commonly-assigned U.S. Patent Number 4,560,821 discloses and claims a process for the conversion of methane to higher hydrocarbons which comprises contacting methane with particles comprising an oxidative synthesizing agent which particles recirculate between two physically separate zones--a methane contact zone and an oxygen contact zone. As noted, the reaction products of such processes are mainly ethylene, ethane, other light hydrocarbons, carbon oxides, coke and water. It would be beneficial to these oxidative synthesis processes to reduce selectivities to carbon oxides and coke. Methane conversion processes according to the present invention are characterized by relatively severe reaction conditions and by the formation of coproduct water. Thus, hydrothermal stability at elevated temperatures (e.g., 500 to 1000°C) is an important criterion for the catalytic compositions employed. Moreover, uses contemplated for the catalytic compositions described herein require catalysts which are rugged, attrition-resistant, and stable at high temperatures. It is also desirable that the compositions are able to operate effectively for relatively long periods while cycling between oxidized and reduced states. The present invention thus also provides rugged, stable, attrition-resistant oxidant compositions suitable for methane conversion processes, especially for processes characterised by the formation of by-product water. Of particular interest is the process for converting methane to higher hydrocarbons with the formation of by-product water. SUMMARY OF THE INVENTION It has now been found that the conversion of methane to higher hydrocarbons wherein a feed gas comprising methane is contacted at elevated temperatures with a solid comprising a reducible metal oxide is improved when the contacting is conducted in the presence of a promoting amount of at least one member of the group consisting of boron and compounds thereof. According to the present invention, there is provided a method for converting methane to higher hydrocarbon products which comprises contacting a gas comprising methane at synthesising conditions with a solid composition comprising a reducible oxide of at least one metal other than Mn which oxide when contacted with methane at synthesising conditions is reduced and produces higher hydrocarbon products and water, and a promoting amount of at least one member of the group consisting of boron and compounds thereof. One class of catalyst compositions useful in the process of this invention comprises: (1) at least one reducible metal oxide (other than Mn), (2) at least one member of the group consisting of boron and compounds thereof, and (3) at least one member of the group consisting of oxides of alkaline earth metals. A related class of catalyst compositions further comprises at least one alkali metal or compound thereof. Alkali metals are selected from the group consisting of lithium, sodium, potassium, rubidium and cesium. Lithium, sodium and potassium, and especially lithium and sodium, are preferred alkali metals. Alkaline earth metals are selected from the group consisting of magnesium, calcium, strontium and barium. Presently preferred members of this group are magnesium and calcium. Compositions derived from magnesia have been found to be particularly effective catalytic materials. According to the present invention, there is also provided a catalyst composition comprising a reducible oxide of a metal other than Mn, at least one member of the group consisting of Li and compounds thereof, at least one member of the group consisting of boron and compounds thereof, and at least one member of the group consisting of alkaline earth metals and compounds thereof. In a particular embodiment, the catalyst composition comprises a mixed oxide composition satisfying the empirical formula: MLi a B b E c O x wherein M is selected from the group consisting of Sn, In, Ge, Pb, Sb, Bi, Pr, Tb, Ce, Fe, Ru and mixtures thereof; B is boron; E is at least one alkaline earth metal; a is within the range of 0.01 to 10; b is within the range of 0.1 to 20, preferably 0.1 to 10; c is within the range of 0.1 to 100, preferably 1 to 7; and x is the number of oxygen atoms required by the valence states of the other elements. The alkaline earth metal is preferably selected from calcium and magnesium. The compositions of this invention are useful in a variety of hydrocarbon conversion processes. When the active form of the composition (i.e., the composition in an oxidized state) is contacted with methane at elevated temperatures (e.g., at temperatures within the range of about 500 to 1000°C), methane is converted to higher hydrocarbon products. The compositions are also effective contact agents (i.e., catalysts) in oxidative dehydrogenation processes. DETAILED DESCRIPTION OF THE INVENTION While the compositions employed in the present invention are referred to as "catalysts", it will be understood that , under conditions of use, they serve as selective oxidants and, therefore, take on the characteristics of a reactant during use. Thus, for example, the term "metal-containing oxides" is meant to embrace both reducible oxides of the metal and reduced oxides of the metal, it being understood reducible oxides comprise the principal active component of the compositions. Consider the requirements of the oxidant. For selective reaction to take place, the oxidant must release the proper quantity of oxygen in the reaction zone within the proper period of time. If this does not occur, either non-selective oxidation reactions result (forming CO x ), or the degree of conversion is restricted. Furthermore, the oxidant must be capable of being repeatedly regenerated. Minimal or no coke formation is desirable. The oxidant must exhibit long life; the oxidant must exhibit relatively constant performance over the time while sequentially: (1) achieving selective conversion of reactants and (2) being regenerated to its active state. Mechanisms for the acquisition and release of oxygen by the oxidant are not fully understood. Undoubtedly, both physical and chemical phenomena are involved. For example, the oxygen may be both physically adsorbed and chemically reacted to form compounds of higher oxidation states. In the following formulae describing the compositions of this invention, the relative number of oxygens is designated by "x". This x is variable because the compositions may continually gain and lose oxygen during use. Thus setting a strict range of values for x would be imprecise and possibly misleading. Generally, the value ascribed to x falls within the range of the number of oxygens required in the higher oxidation states (the "active" or "oxidized" composition) to the number of oxygens required in the lower oxidation states (the "reduced" composition). The catalysts of the present invention, in their active state, comprise at least one reducible oxide of at least one metal (other than Mn), which oxide when contacted with methane at synthesizing conditions (e.g., at a temperature within the range of about 500 to 1000°C) produces higher hydrocarbon products, coproduct water, and a reduced metal oxide. The term "reducible" is used to identify those oxides of metals which are reduced under the aforesaid conditions. The term "reducible oxides of metals" includes: (1) compounds described by the general formula M x O y wherein M is a metal and x and y designate the relative atomic proportions of metal and oxygen in the composition and/or (2) one or more oxygen-containing metal compounds (i.e., compounds containing elements in addition to the metal and 0), provided that such oxides and compounds have the capability of producing higher hydrocarbon products from methane, as described herein. Effective agents for the conversion of methane to higher hydrocarbons have previously been found to comprise reducible oxides of metals selected from the group consisting of manganese, tin, indium, germanium, antimony, lead, bismuth and mixtures thereof. See U.S. Patent Numbers 4,443,649; 4,444,984; 4,443,648; 4,443,645; 4,443,647; 4,443,644; and 4,443,646. The use of boron-promoted reducible oxides of Mn is the subject of our copending EP-A-0 253 522. Reducible oxides of cerium, praseodymium, and terbium have also been found to be effective for the conversion of methane to higher hydrocarbons, particularly associated with an alkali metal component and/or an alkaline earth metal component. Reducible oxides of iron and ruthenium are also effective, particularly when associated with an alkali or alkaline earth component. One class of preferred compositions is characterized by the substantial absence of catalytically effective Ni and the noble metals (e.g., Rh, Pd, Ag, Os, Ir, Pt and Au) and compounds thereof, to minimize the deleterious catalytic effects of such metals and compounds thereof. For example, at the conditions (e.g., temperatures) under which the present compositions are used, these metals tend to promote coke formation and oxides of these metals tend to promote formation of combustion products (CO x ) rather than the desired hydrocarbons. The term "catalytically effective" is used to identify that quantity of one or more of nickel and the noble metals and compounds thereof which, when present, substantially changes the distribution of products obtained when employing the compositions of this invention. Other additives may be incorporated into the composition of this invention. For example, addition of a phosphorus component has been found to enhance the stability of the composition. When used, phosphorus may be present up to an amount providing an atomic ratio of P to the reducible metal oxide component (expressed as the metal) of about 2/1. If phosphorus is employed, it is desirable to provide it during catalyst preparation in the form of phosphates of alkali metals (e.g., orthophosphates, metaphosphates and pyrophosphates). Pyrophosphates are preferred. Sodium pyrophosphate is particularly preferred. P can be provided in other forms though. Examples include orthophosphoric acid, ammonium phosphates and ammonium hydrogenphosphates. Further examples of other components which may be present in the compositions of this invention are halogen and chalcogen components. Such components may be added either during preparation of the catalysts or during use. Methane conversion processes employing halogen-promoted, reducible metal oxides are disclosed in U.S. Patent Number 4,544,784. Methane conversion processes employing chalcogen-promoted, reducible metal oxides are disclosed in U.S. Patent Number 4,544,785. CATALYST COMPOSITIONS One broad class of compositions useful in the processes of this invention comprises: (1) at least one reducible oxide of at least one metal (other than Mn) which oxides when contacted with methane at synthesizing conditions are reduced and produce higher hydrocarbon products and water and (2) at least one member selected from the group consisting of boron and compounds thereof. The relative amounts of the two components used to form the catalyst is not narrowly critical. However, the preferred atomic ratio of the reducible metal oxide component (expressed as the metal) to the boron component (expressed as B) is within the range of about 0.1-20:1, more preferably within the range of about 0.5-5:1, and most preferably within the range of greater than 1:1 but not greater than 5:1. One narrower class of compositions useful in the processes of this invention comprises: (1) at least one reducible metal oxide (other than Mn), (2) at least one member of the group consisting of boron and compounds hereof, and (3) at least one member of the group consisting of oxides of alkaline earth metals. Preferred compositions contain more than about 10 wt. % of the alkaline earth component, more preferably they contain more than about 20 wt. % of the alkaline earth component. Reducible metal oxides are preferably present in an amount within the range of about 1 to 40 wt. % based on the combined weight of the metal and the alkaline earth component, more preferably within the range of about 5 to 30 wt. %, and still more preferably within the range of about 5 to 20 wt. %. Preferred catalysts of this class are mixed oxide compositions satisfying the following empirical formula: MB b E c O x wherein M is the reducible metal component, B is boron, and E is the alkaline earth component and wherein b is within the range of 0.1 to 10, c is within the range of 0.1 to 100, and x is the number of oxygen atoms required by the valence states of the other elements. Preferably, b is within the range of 0.1 to 4, more preferably at least 0.2 but less than 1. Preferably, c is within the range of 0.5 to 15, more preferably 1 to 6. A further class of compositions useful in the processes of this invention comprises: (1) at least one reducible metal oxide (other than Mn), (2) at least one alkali metal or compound thereof, (3) at least one member of the group consisting of boron and compounds thereof, and (4) at least one member of the group consisting of oxides of alkaline earth metals. Preferred catalysts of this class are mixed oxide compositions satisfying the following empirical formula: MA a B b E c O x wherein M is the reducible metal component, A is at least one alkali metal, B is boron, E is at least one alkaline earth metal and wherein a is within the range of 0.01 to 10, b is within the range of 0.1 to 20, c is within the range of 0.1 to 100, and x is the number of oxygen atoms required by the valence states of the other elements. Preferably b is within the range of .1 to 10, more preferably at least 0.2 but less than 1. Preferably c is within the range of 1 to 7. One preferred catalyst of this class is where A is Li and b is in the range 0.5 to 5. CATALYST PREPARATION The boron-promoted reducible metal oxide compositions may be supported by or diluted with conventional support materials such as silica, alumina, titania, zirconia and the like, and combinations thereof. When supports are employed, alkaline earth oxides, especially magnesia, are preferred. The catalysts are conveniently prepared by any of the methods associated with similar compositions known in the art. Thus, such methods as precipitation, co-precipitation, impregnation, granulation, spray drying or dry-mixing can be used. Supported solids may be prepared by methods such as adsorption, impregnation, precipitation, co-precipitation, and dry-mixing. Thus, a compound of Sn,In,Ge,Pb,Sb,Bi,Pr,Tb,Ce,Fe and/or Ru and a compound of boron (and other components) can be combined in any suitable way. Substantially any compound of the recited components can be employed. Typically, compounds used would be oxides or organic or inorganic salts of the recited components. To illustrate, when preparing a catalyst containing: (1) a reducible metal oxide component, (2) an alkali metal component, (3) a boron component and (4) an alkaline earth component: one suitable method of preparation is to impregnate a compound of the fourth component of the composition with a solution of the metal of component (1), an alkali metal, and/or boron. Suitable compounds for impregnation include the acetates, acetyl acetonates, oxides, carbides, carbonates, hydroxides, formates, oxalates, nitrates, phosphates, sulfates, sulfides, tartrates, fluorides, chlorides, bromides, or iodides. After impregnation the preparation is dried to remove solvent and the dried solid is calcined at a temperature selected within the range of about 300 to 1200°C. Particular calcination temperatures will vary depending on the compounds employed. Preferably, the alkaline earth component is provided as the oxide. Preferably, the alkali metal component is provided as a basic composition of the alkali metal(s). Examples are sodium hydroxide, sodium acetate, lithium hydroxide, lithium acetate, etc. When P is employed as an additive, it has been found desirable to add the alkali metal and P to the composition as compounds such as the orthophosphates, metaphosphates, and pyrophosphates of alkali metals. Pyrophosphates are preferred. Sodium pyrophosphate is particularly preferred. Preferably, the boron component is provided as boric acid, boric oxide (or anhydride), alkali metal borates, boranes, borohydrides, etc., especially boric acid or oxide. Regardless of which particular catalyst is prepared or how the components are combined, the resulting composite will generally be dried and calcined at elevated temperatures prior to use. Calcination can be done under air, H₂, carbon oxides, steam, and/or inert gases such as N₂ and the noble gases. HYDROCARBON CONVERSION PROCESS The catalyst compositions of the present invention are generally useful for hydrocarbon conversion processes. Contacting a hydrocarbon feed with the active composition produces hydrocarbon product, coproduct water, and a reduced catalyst composition. The reduced catalyst composition is readily reoxidized to an active state by contact with an oxidant such as air or other oxygen-containing gases. The process may be effected in a cyclic manner wherein the catalyst is contacted alternatively with a hydrocarbon feed and then with an oxygen-containing gas. The process may also be effected in a noncyclic manner wherein the catalyst is contacted concurrently with a hydrocarbon feed and an oxygen-containing gas. Operating conditions are not critical to the use of this invention, although temperatures are generally within the range of about 500 to 1000°C. Gas/solid contacting steps may be performed according to any of the known techniques: e.g., the solids may be maintained as fixed beds, fluidized beds, moving beds, ebullating beds, etc. Solids may be maintained in one contact zone or may recirculate between multiple contact zones (e.g., between oxygen-contact and hydrocarbon-contact zones). METHANE CONVERSION PROCESS One more specific application for the compositions of this invention is the conversion of methane to higher hydrocarbon products. The process comprises contacting a gas comprising methane with a composition comprising a boron-promoted reducible metal oxide to produce higher hydrocarbon products, coproduct water, and a composition comprising a reduced metal oxide. In addition to methane, the feedstock may contain other hydrocarbon or non-hydrocarbon components, although the methane content should typically be within the range of about 40 to 100 volume percent, preferably about 80 to 100 volume percent, more preferably about 90 to 100 volume percent. Operating temperatures are generally within the range of about 500 to 1000°C. Although not narrowly critical in the context of this invention, both total pressure and methane partial pressures effect results. Preferred operating pressures are within the range of about 1 to 100 atmospheres, more preferably about 1 to 30 atmospheres. As indicated in the description of hydrocarbon conversion processes, a variety of process embodiments, including various gas/solids-contacting modes, may be employed. METHANE CONVERSION PROCESS (COFEED) In one particular embodiment of the broader methane conversion processes of this invention, methane is contacted with a boron-promoted catalyst in the presence of a gaseous oxidant. The gaseous oxidant is selected from the group consisting of molecular oxygen, oxides of nitrogen, and mixtures thereof. Preferably, the gaseous oxidant is an oxygen-containing gas. A preferred oxygen-containing gas is air. Suitable oxides of nitrogen include N₂O, NO, N₂O₃, N₂O₅ and NO₂. Nitrous oxide (N₂O) is a presently preferred oxide of nitrogen. The ratio of hydrocarbon feedstock to gaseous oxidant gas is not narrowly critical. However, the ratio will desirably be controlled to avoid the formation of gaseous mixtures within the flammable region. The volume ratio of hydrocarbon/gaseous oxidant is preferably within the range of about 0.1 - 100:1, more preferably within the range of about 1 - 50:1. Methane gaseous oxidant feed mixtures containing about 50 to 90 volume % methane have been found to comprise a desirable feed-stream. Operating temperatures for this embodiment of the invention are generally within the range of about 300 to 1200°C, more preferably within the range of about 500 to 1000°C. Best results for contact solids containing manganese have been found at operating temperatures within the range of about 800 to 900°C. If reducible oxides of metals such as In, Ge or Bi are present in the solid, the particular temperature selected may depend, in part, on the particular reducible metal oxide(s) employed. Thus, reducible oxides of certain metals may require operating temperatures below the upper part of the recited range to minimize sublimation or volatilization of the metals (or compounds thereof) during methane contact. Examples are: (1) reducible oxides of indium, (operating temperatures will preferably not exceed about 850°C); (2) reducible oxides of germanium (operating temperatures will preferably not exceed about 850°C); and (3) reducible oxides of bismuth (operating temperatures will preferably not exceed about 850°C). Operating pressures for the methane contacting step are not critical. However, both general system pressure and partial pressures of methane and oxygen have been found to effect overall results. Preferred operating pressures are within the range of about 0.1 to 30 atmospheres. The space velocity of the gaseous reaction streams are similarly not critical, but have been found to effect overall results. Preferred total gas hourly space velocities are within the range of about 10 to 100,000 hr.⁻¹ more preferably within the range of about 600 to 40,000 hr. ⁻¹. Contacting methane and a reducible metal oxide to form higher hydrocarbons from methane also produces coproduct water and reduces the metal oxide. The exact nature of the reduced metal oxides are unknown, and so are referred to as "reduced metal oxides". Regeneration of reducible metal oxides in this "cofeed" embodiment of the present invention occures "in situ"--by contact of the reduced metal oxide with the gaseous oxidant cofed with methane to the contact zone. The contact solids may be maintained in the contact zone as fixed, moving, or fluidized beds of solids. A fixed bed of solids is currently preferred for this embodiment of the invention. The effluent from the contact zone contains higher hydrocarbon products (e.g., ethylene, ethane and other light hydrocarbons), carbon oxides, water, unreacted hydrocarbon (e.g., methane) and oxygen, and other gases present in the oxygen-containing gas fed to the contact zone. Higher hydrocarbons may be recovered from the effluent and, if desired, subjected to further processing using techniques known to those skilled in the art. Unreacted methane may be recovered and recycled to the contact zone. OXIDATIVE DEHYDROGENATION PROCESS Another more specific application for the compositions of this invention is the dehydrogenation of dehydrogenatable hydrocarbons. The process comprises contacting a gas comprising a dehydrogenatable hydrocarbon with a composition comprising the boron-promoted reducible metal oxide to produce dehydrogenated hydrocarbon product, coproduct water, and a composition comprising reduced metal oxide. Dehydrogenatable hydrocarbons include a wide variety of hydrocarbons: e.g., C₂+ alkanes, cycloalkanes, olefins, alkylaromatics, etc. The dehydrogenated product depends in part on the feedstock selected. For example, alkanes may be dehydrogenated to form olefins, diolefins, alkynes, etc., and olefins may be dehydrogenated to form diolefins, alkynes, etc. One preferred class of feedstock comprises C₂-C₅ alkanes (both branched and unbranched). One preferred process embodiment comprises oxidative dehydrogenation of C₂-C₅ alkanes to form the corresponding mono-olefins. Operating temperatures are generally within the range of about 500 to 1000°C. Operating pressures are not narrowly critical. In general, the process is conducted within the parameters of the oxidative dehydrogenation art, but uses a novel catalyst. The invention is further illustrated by reference to the following Example. Experimental results reported below include conversions and selectivities calculated on a carbon mole basis. Space velocitites are reported as gas hourly space velocities (hour⁻¹) and are identified below as "GHSV". Methane and methane/air contact runs were made after the solids had been heated to reaction temperature in a stream of heated nitrogen. At the end of each methane contact run, the reactor was flushed with nitrogen and the solids were regenerated under a flow of air (usually at 800°C. for 30 minutes). The reactor was then again flushed with nitrogen and the cycle repeated. Results reported below are based on samples collected after the catalysts had "equilibrated", i.e., after any aberrrant characteristics of freshly prepared catalyst had dissipated. Example and Comparative Example A catalyst (Example) was prepared by mixing sodium acetate, boric acid, magnesia and ferrous nitrate in the following mole ratio, 1:2:4:2. The mixture was calcined in air at 940°C for 16 hours. When the catalyst was contacted with an equal volume mixture of methane/air at 850°C and a total GHSV of 2400 hr.⁻¹, the methane conversion was 22.5% with 67% selectivity to C₂+ hydrocarbon products. A catalyst (Comparative Example) was prepared as described above except the boron component was omitted. When the catalyst was contacted with an equal volume mixture of methane/air at 850°C and a total GHSV of 2400 hr.⁻¹, the methane conversion was 18.2% with 41.0% selectivity to C₂+ hydrocarbon products.

Claims: A method for converting methane to higher hydrocarbon products which comprises contacting a gas comprising methane at synthesising conditions with a solid composition comprising a reducible oxide of at least one metal other than Mn which oxide when contacted with methane at synthesising conditions is reduced and produces higher hydrocarbon products and water, and a promoting amount of at least one member of the group consisting of boron and compounds thereof. A method as claimed in claim 1 in which the atomic ratio of the reducible oxide component (expressed as the metal) to the boron component (expressed as B) is within the range of 0.1:1 to 20:1, and preferably 0.5:1 to 5:1. A method as claimed in claim 1 or claim 2 wherein the reducible metal oxide is selected from the group consisting of reducible oxides of Sn, In, Ge, Pb, Sb, Bi, Pr, Tb, Ce, Fe, Ru and mixtures thereof. A method as claimed in any one of claims 1 to 3 wherein the reducible oxide and the boron promoter are associated with a support material. A method as claimed in any one of claims 1 to 4 wherein said solid composition further includes at least one member of the group consisting of alkaline earth metals and compounds thereof. A method as claimed in claim 5 wherein the alkaline earth metal compound is an oxide. A method as claimed in claim 5 or claim 6 wherein the solid composition is a mixed oxide composition satisfying the empirical formula MB b E c O x wherein M is selected from the group consisting of Sn, In, Ge, Pb, Sb, Bi, Pr, Tb, Ce, Fe, Ru and mixtures thereof; B is boron; and E is at least one alkaline earth metal; b is within the range of 0.1 to 10, and preferably 0.1 to 0.4; c is within the range of 0.1 to 100, preferably 0.5 to 15 and more preferably 1 to 6; and x is the number of oxygen atoms required by the valence states of the other elements. A method as claimed in any one of claims 5 to 7 wherein the solid composition further includes at least one member of the group consisting of alkali metals and compounds thereof. A method as claimed in claim 8 wherein the solid is a mixed oxide composition satisfying the empirical formula: MA a B b E c O x wherein M is selected from the group consisting of Sn, In, Ge, Pb, Sb, Bi, Pr, Tb, Ce, Fe, Ru and mixtures thereof; A is at least one alkali metal; B is boron; E is at least one alkaline earth metal; a is within the range of 0.01 to 10; b is within the range of 0.1 to 20, preferably 0.1 to 0.10; c is within the range of 0.1 to 100, preferably 1 to 7; and x is the number of oxygen atoms required by the valence states of the other elements. A method as claimed in claim 8 or claim 9 wherein the alkali metal is selected from sodium and lithium. A method as claimed in any one of claims 5 to 10 wherein the alkaline earth metal is selected from calcium and magnesium. A method as claimed in any one of claims 1 to 11 which involves contacting the said solid composition alternately with (a) the methane and (b) a gaseous oxidant. A method as claimed in claim 12 in which the said composition is contacted with the methane, at a temperature selected within the range of about 500°C to about 1000°. A method as claimed in any one of claims 1 to 11 which involves contacting the said composition concurrently with (a) the methane and (b) a gaseous oxidant. A method as claimed in claim 14 wherein said concurrent contact is conducted at a temperature selected within the range of 300° to 1200°C, preferably 500 to 1000° and most preferably 800 to 900°. A catalyst composition comprising a reducible oxide of a metal other than Mn, at least one member of the group consisting of Li and compounds thereof, at least one member of the group consisting of boron and compounds thereof, and at least one member of the group consisting of alkaline earth metals and compounds thereof. A catalyst composition as claimed in claim 16 comprising a mixed oxide composition satisfying the empirical formula: MLi a B b E c O x wherein M is selected from the group consisting of Sn, In, Ge, Pb, Sb, Bi, Pr, Tb, Ce, Fe, Ru and mixtures thereof; B is boron; E is at least one alkaline earth metal; a is within the range of 0.01 to 10; b is within the range of 0.1 to 20, preferably 0.1 to 10; c is within the range of 0.1 to 100, preferably 1 to 7; and x is the number of oxygen atoms required by the valence states of the other elements. A composition as claimed in claim 16 or claim 17 wherein the alkaline earth metal is selected from Mg and Ca.

Inventors: GASTINGER, ROBERT G., JONES, ANDREW C., SOFRANKO, JOHN A.
Applicants: ATLANTIC RICHFIELD COMPANY
Application year: 1987
Main classification: C07C2
IPC codes: B01J23, C07C67, C07B61, C07C2, B01J21, C07C1, C07C5