The
oxidative coupling of methane (OCM) is an attractive technology
for the production of ethane (C2H6) and ethylene
(C2H4); and significant performance and efficiency
gains as well as reduced carbon dioxide (CO2) emissions
are expected when OCM takes place within mixed ionic and electronic
conducting (MIEC) ceramic membrane reactors (CMRs). So far, research
on OCM in CMRs has been limited to unstable and incompatible materials
investigated under short-term measurements that hinder upscaling and
commercial application. To this end, this work demonstrates long-term
stable OCM performance enabled by a BaFe0.9Zr0.1O3−δ (BFZ91) perovskite utilized as the oxygen-ion
MIEC membrane and lanthanum oxide (La2O3) used
as the OCM catalyst. Experimental measurements conducted in the temperature
(T) range of 750–900 °C and at inlet
methane (CH4) mole fractions (
) of 0–30% revealed a highly
stable
performance during 23 days of continuous operation, which was further
confirmed by material characterization. Under the aforementioned operating
conditions, BFZ91 offers a high oxygen (O2) permeation
flux (J
O2
) between 0.5−1.5
(μmol/cm2/s); CH4 conversion (CCH4) reached ∼35% while the selectivities to C2H6 (SC2H6
) and C2H4 (SC2H4
) were as high
as ∼50% and ∼40%, respectively, showing a strong dependency
on the operating conditions. Yields of C2H6 (YC2H6
) and C2H4 (YC2H4
) in the range of 1–5% and
1–7%, respectively, were measured, with more C2H4 being produced at higher T. In the absence
of La2O3, CCH4
and C2 (C2H6 and C2H4) yields are lower confirming that BFZ91 does not promote CH4 oxidation, reforming, or coupling on its surface at high
rates. The OCM performance of BFZ91 with La2O3 was also found to be stable under partial O2 consumption
and pure CH4 conditions. Furthermore, a detailed analysis
of the mixture composition allowed the identification of the primary
reactions in the OCM chemistry. Our results reveal that within our
reactor, CH4 full oxidation to CO2 and steam
(H2O) happens simultaneously with CH4 oxidation
to C2H6 and H2O (both on the La2O3 catalyst), but the production of the valuable
C2H4 is primarily taking place through the C2H6 non-oxidative dehydrogenation in the gas phase;
this reaction was not found to proceed on the La2O3 catalyst. Besides the promise of the investigated materials
toward commercialization, the methods to study the OCM chemistry and
the membrane catalyst coupling presented here are expected to promote
further advances in the field of OCM.