Conversion of CH/sub 4/ into C/sub 2/H/sub 4/ by the chlorine-catalyzed oxidative-pyrolysis (CCOP) process. I. Oxidative pyrolysis of CH/sub 3/Cl

Methane is available in large quantities in natural gas, thus constitutes an important raw material for the synthesis of higher molecular weight hydrocarbons. Processes exist to convert methane into acetylene, ethylene, and hydrogen using high temperature pyrolysis. However, at the high temperatures needed for the thermal decomposition of methane, the yields of more valuable liquid and gaseous products are too low due to the formation of excessive amounts of carbonaceous solids. In an earlier patent Gorin proposed a chlorine-catalyzed process in which methane conversion was achieved via CH/sub 4/ chlorination, followed by the pyrolysis of chlorinated methanes (CM) and formation of C/sub 2+/ products and HCl. The HCl produced can either be converted into chlorine via the well-known Deacon reaction, or can be used to convert CH/sub 4/ into CH/sub 3/Cl via oxychlorination process, thus completing the catalytic cycle for chlorine. Recently, Benson patented a process similar to that of Gorin, in which the flame reactions of Cl/sub 2/ and CH/sub 4/ were involved. Later, Weissman and Benson studied the kinetics of CH/sub 3/Cl pyrolysis. The mechanism of the oxidative pyrolysis of CH/sub 3/Cl is the topic of this study. The Chlorine-Catalyzed Oxidative-Pyrolysis (CCOP) process developed ameliorates the problem ofmore » formation of solid products, while maintaining high yields for acetylene and ethylene. The CCOP process exploits the high-temperature, non-flame reactions of methane, chlorine, and oxygen, and forms an important bridge between combustion chemistry, halogen inhibition processes and chemical reaction engineering. Although some carbon monoxide forms in the CCOP process, CO is a gaseous product thus can be handled easily. In addition, CO can itself be used to synthesize higher molecular hydrocarbons as well.« less