Microchannel reactors for catalytic oxidative dehydrogenation

Apparatus for oxidatively dehydrogenating a hydrocarbon, comprising:

• a microchannel reaction chamber;
• and
• an oxidative dehydrogenation catalyst comprising an oxide or phosphate of a metal selected from the group consisting of Li, Mo, V, Nb, Sb, Sn, Zr, Cr, Mg, Mn, Ni, Co, Ce, rare-earth metals, and mixtures thereof;
• and wherein the oxidative dehydrogenation catalyst is disposed in the microchannel reaction chamber and comprises one of the following forms:
• a) a particulate catalyst;
• or
• b) a porous insert;
• or
• c) a catalyst wall coating comprising a first layer formed between a reaction chamber wall and a second layer;
• wherein the reaction chamber wall, first layer and second layer have different compositions, wherein the first layer has a thickness of at least 0.1 micrometers.

A catalytic system for oxidatively dehydrogenating a hydrocarbon, comprising:

• a reaction chamber;
• and
• an oxidative dehydrogenation catalyst disposed in the reaction chamber;
• wherein the system is characterizable by a catalytic activity such that when propane and O2, with no diluents, in a 1:1 ratio are fed into the reaction chamber at an LHSV of 32 and a catalyst temperature of 580° C., there is a propane conversion of at least 30% and an olefin yield of at least 20%.

Apparatus for oxidatively dehydrogenating a hydrocarbon, comprising:

• a process channel comprising a u-turn;
• wherein the u-turn is disposed between a forward section of the process channel and a return section of the process channel;
• a microchannel reaction chamber disposed in the process channel;
• an oxidative dehydrogenation catalyst disposed in the microchannel reaction chamber;
• wherein the return channel comprises at least one alkene and/or aralkene;
• and
• an oxygen channel adjacent to said process channel and separated by an oxygen channel wall, wherein apertures through said oxygen channel wall form passageways between the oxygen channel and the process channel.