Using a membrane reactor for the oxidative coupling of methane: simulation and optimization

An oxidative coupling of methane (OCM) is a promising process to convert methane into ethylene and ethane; however, it suffers from the relatively low selectivity and yield of ethylene at high methane conversion. In this study, a membrane reactor is applied to the OCM process in order to prevent the deep oxidation of a desirable ethylene product. The mathematical model of OCM process based on mass and energy balances coupled with detailed OCM kinetic model is employed to examine the performance of OCM membrane reactor in terms of CH₄ conversion, C₂ selectivity, and C₂ yield. The influences of key operating parameters (i.e., temperature, methane-to-oxygen feed ratio, and methane flow rate) on the OCM reactor performance are further analyzed. The simulation results indicate that the OCM membrane reactor operated at higher operating temperature and lower methane-to-oxygen feed ratio can improve C₂ production. An optimization of the OCM membrane reactor using a surface response methodology is proposed in this work to determine its optimal operating conditions. The central composite design is used to study the interaction of process variables (i.e., temperature, methane-to-oxygen feed ratio, and methane flow rate) and to find the optimum process operation to maximize the C₂ products yield.