The present disclosure provides oxidative coupling of methane (OCM) systems for small scale and world scale production of olefins. An OCM system may comprise an OCM subsystem that generates a product stream comprising C.sub.2+ compounds and non-C.sub.2+ impurities from methane and an oxidizing agent. At least one separations subsystem downstream of, and fluidically coupled to, the OCM subsystem can be used to separate the non-C.sub.2+ impurities from the C.sub.2+ compounds. A methanation subsystem downstream and fluidically coupled to the OCM subsystem can be used to react H.sub.2 with CO and/or CO.sub.2 in the non-C.sub.2+ impurities to generate methane, which can be recycled to the OCM subsystem. The OCM system can be integrated in a non-OCM system, such as a natural gas liquids system or an existing ethylene cracker.

A method of converting carbon oxides to olefins is provided. The method can include directing a renewable hydrogen feed stream and a carbon oxide feed stream to a methanation reactor to generate an oxidative coupling of methane (OCM) feed stream that includes methane. The OCM feed stream and an oxidant feed stream including oxygen are directed to an OCM reactor containing an OCM catalyst to produce an OCM effluent that includes ethylene. A system for converting carbon oxides to olefins is also provided. The methods and systems produce olefins including ethylene with negative carbon emissions.

A process for preparing C.sub.2 to C.sub.3 hydrocarbons may include introducing a feed stream including hydrogen gas and a carbon-containing gas comprising carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C.sub.2 to C.sub.3 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst may include a metal oxide catalyst component and a microporous catalyst component comprising 8-MR pore openings and may be derived from a natural mineral, the product stream comprises a combined C.sub.2 and C.sub.3 selectivity greater than 40 carbon mol%.

A process for preparing C.sub.2 to C.sub.3 hydrocarbons may include introducing a feed stream including hydrogen gas and a carbon-containing gas comprising carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C.sub.2 to C.sub.3 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst may include a metal oxide catalyst component and a microporous catalyst component comprising 8-MR pore openings and may be derived from a natural mineral, the product stream comprises a combined C.sub.2 and C.sub.3 selectivity greater than 40 carbon mol%.

A catalyst containing LF-type B acid preparing ethylene using direct conversion of syngas is a composite catalyst and formed by compounding component A and component B in a mechanical mixing mode. The active ingredient of the component A is a metal oxide; the component B is a zeolite of MOR topology; and a weight ratio of the active ingredients in the component A to the component B is 0.1-20. The reaction process has an extremely high product yield and selectivity, with the selectivity for light olefin reaching 80-90%, wherein ethylene has high space time yield and can reach selectivity of 75-80%. Meanwhile, the selectivity for a methane side product is extremely low (<15%).

Integrated systems are provided for the production of higher hydrocarbon compositions, for example liquid hydrocarbon compositions, from methane using an oxidative coupling of methane system to convert methane to ethylene, followed by conversion of ethylene to selectable higher hydrocarbon products. Integrated systems and processes are provided that process methane through to these higher hydrocarbon products.

The present disclosure provides oxidative coupling of methane (OCM) systems for small scale and world scale production of olefins. An OCM system may comprise an OCM subsystem that generates a product stream comprising C.sub.2+ compounds and non-C.sub.2+ impurities from methane and an oxidizing agent. At least one separations subsystem downstream of, and fluidically coupled to, the OCM subsystem can be used to separate the non-C.sub.2+ impurities from the C.sub.2+ compounds. A methanation subsystem downstream and fluidically coupled to the OCM subsystem can be used to react H.sub.2 with CO and/or CO.sub.2 in the non-C.sub.2+ impurities to generate methane, which can be recycled to the OCM subsystem. The OCM system can be integrated in a non-OCM system, such as a natural gas liquids system or an existing ethylene cracker.

The present disclosure provides oxidative coupling of methane (OCM) systems for small scale and world scale production of olefins. An OCM system may comprise an OCM subsystem that generates a product stream comprising C.sub.2+ compounds and non-C.sub.2+ impurities from methane and an oxidizing agent. At least one separations subsystem downstream of, and fluidically coupled to, the OCM subsystem can be used to separate the non-C.sub.2+ impurities from the C.sub.2+ compounds. A methanation subsystem downstream and fluidically coupled to the OCM subsystem can be used to react H.sub.2 with CO and/or CO.sub.2 in the non-C.sub.2+ impurities to generate methane, which can be recycled to the OCM subsystem. The OCM system can be integrated in a non-OCM system, such as a natural gas liquids system or an existing ethylene cracker.

Direct conversion of syngas to light olefins is carried out in a fixed bed or a moving bed reactor with a composite catalyst A+B. The active ingredient of catalyst A is active metal oxide; and catalyst B is one or more than one of zeolite of CHA and AEI structures or metal modified CHA and/or AEI zeolite. A spacing between geometric centers of the active metal oxide of the catalyst A and the particle of the catalyst B is 5 m-40 mm. A spacing between axes of the particles is preferably 100 m-5 mm, and more preferably 200 m-4 mm. A weight ratio of the active ingredients in the catalyst A and the catalyst B is within a range of 0.1-20 times, and preferably 0.3-5.

The present disclosure provides oxidative coupling of methane (OCM) systems for small scale and world scale production of olefins. An OCM system may comprise an OCM subsystem that generates a product stream comprising C.sub.2+ compounds and non-C.sub.2+ impurities from methane and an oxidizing agent. At least one separations subsystem downstream of, and fluidically coupled to, the OCM subsystem can be used to separate the non-C.sub.2+ impurities from the C.sub.2+ compounds. A methanation subsystem downstream and fluidically coupled to the OCM subsystem can be used to react H.sub.2 with CO and/or CO.sub.2 in the non-C.sub.2+ impurities to generate methane, which can be recycled to the OCM subsystem. The OCM system can be integrated in a non-OCM system, such as a natural gas liquids system or an existing ethylene cracker.