Multi-staged catalyst systems and process for converting alkanes to alkenes and to their corresponding oxygenated products

A multi-staged catalyst system for converting a C3-C8 alkane to the corresponding C3-C8 alkene, the corresponding C3-C8 oxygenate, and mixtures thereof, said catalyst system comprising:

• (A) a first catalyst capable of catalyzing the full oxidation of the C3-C8 alkane to produce heat, carbon dioxide and steam, and comprising (a) at least one metal selected from the group consisting of Ag, Au, Ir, Ni, Pd, Pt, Rh, Ru, alloys thereof and combinations thereof;
• and (b) at least one modifier selected from the group of metal oxides including the metals Bi, In, Mg, P, Sb, Zr, Group 1-3 metals, lanthanide metals and combinations thereof, the first catalyst being situated in a first reaction stage comprising a temperature between 500° C. and 1000° C. and a residence time no greater than 100 milliseconds;
• (B) a second catalyst comprising an activated zeolite and capable of catalyzing the endothermic dehydrogenation of the C3-C8 alkane to produce the corresponding C3-C8 alkene, in the presence of the heat and carbon dioxide produced using the first catalyst, in a second reaction stage comprising a temperature greater than 500° C. and a residence time no greater than 100 milliseconds;
• and
• (C) a third catalyst capable of selective oxidation of the corresponding C3-C8 alkene, produced using the second catalyst, to produce C3-C8 oxygenates, in a third reaction stage comprising a temperature greater than 300° C.