A detailed reaction mechanism for oxidative coupling of methane over Mn/Na₂WO₄/SiO₂ catalyst for non-isothermal conditions

Direct production of ethylene from natural gas or other methane sources has proven to be challenging from catalytic, process design and economic perspectives, with no reports of a commercially viable process to date. Understanding of the underlying non-ideal homogeneous and heterogeneous reactions involved could lead to success, enabling utilization of vast natural gas resources as a replacement for petrochemicals. In this regards, an improved reaction mechanism and computational model, validated experimentally, for oxidative coupling of methane (OCM) over a Mn/Na₂WO₄/SiO₂ catalyst is developed, taking into account the non-isothermal behavior exhibited by the gas and surface reactions. The reaction mechanism involves detailed gas-phase and surface elementary steps to describe the OCM chemistry and employing a reduced model for computational efficiency. The model uses laboratory-scale packed-bed reactor experiments for kinetic mechanism development. The modeling and simulation is particularly focused on a one-dimensional packed-bed reactor. The kinetic model is validated over a wide range of experimental conditions. The model-predicted results and their comparisons with the experimental data are presented wide temperature ranges and methane-to-oxygen feed ratios under adiabatic reactor conditions. The kinetic model is first of its kind in which non-isothermal OCM kinetic behavior is captured using detailed gas-phase and heterogeneous reaction kinetics.