Aspects of the present disclosure generally relate to catalyst compositions including metal chalcogenides, processes for producing such catalyst compositions, processes for enhancing catalytic active sites in such catalyst compositions, and uses of such catalyst compositions in, e.g., processes for producing conversion products. In an aspect, a process for forming a catalyst composition is provided. The process includes introducing an electrolyte material and an amphiphile material to a metal chalcogenide to form the catalyst composition. In another aspect, a catalyst composition is provided. The catalyst composition includes a metal chalcogenide, an electrolyte material, and an amphiphile material. Devices for hydrogen evolution reaction are also provided.

Provided in this disclosure are oxidative dehydrogenation catalysts that include a mixed metal oxide having the empirical formula:

Mo.sub.1.0V.sub.0.12-0.49Te.sub.0.05-0.17Nb.sub.0.10-0.20O.sub.d

wherein d is a number to satisfy the valence of the oxide. The oxidative dehydrogenation catalyst is characterized by having XRD diffraction peaks (2θ degrees) at 22±0.2, 27±0.2, 28.0±0.2, and 28.3±0.1. The disclosure also provides methods of making the catalysts that include wet ball milling.

Processes and associated reaction systems for the oxidative dehydrogenation of an alkane containing 2 to 6 carbon atoms, preferably ethane or propane, more preferably ethane, are provided. In particular, a process is provided that comprises supplying a feed gas comprising the alkane and oxygen to a reactor vessel that comprises an upstream and downstream catalyst bed; contacting the feed gas with an oxidative dehydrogenation catalyst in the upstream catalyst bed, followed by contact with an oxidative dehydrogenation/oxygen removal catalyst in the downstream catalyst bed, to yield a reactor effluent comprising the alkene; and supplying an upstream coolant to an upstream shell space of the reactor vessel from an upstream coolant circuit and a downstream coolant to a downstream shell space of the reactor vessel from a downstream coolant circuit.

Provided in this disclosure are catalyst compositions. The catalyst compositions include an oxidative dehydrogenation catalyst that includes a mixed metal oxide having the empirical formula:
Mo.sub.1.0V.sub.0.12-0.49Te.sub.0.05-0.17Nb.sub.0.10-0.20Al.sub.cO.sub.d
wherein c is from 0 to 2.0 and d is a number to satisfy the valence of the oxide. The compositions are at least 40 wt. % amorphous as measured by XRD. The disclosure also provides methods of making the compositions.

Aspects of the present disclosure generally relate to catalyst compositions including metal chalcogenides, processes for producing such catalyst compositions, processes for enhancing catalytic active sites in such catalyst compositions, and uses of such catalyst compositions in, e.g., processes for producing conversion products. In an aspect, a process for forming a catalyst composition is provided. The process includes introducing an electrolyte material and an amphiphile material to a metal chalcogenide to form the catalyst composition. In another aspect, a catalyst composition is provided. The catalyst composition includes a metal chalcogenide, an electrolyte material, and an amphiphile material. Devices for hydrogen evolution reaction are also provided.

A method of preparing a pure M1 phase MoVTeNbOx catalyst with a high specific surface area, comprising the following steps: S1) mixing and dissolving a molybdenum-containing compound, a vanadium-containing compound, a tellurium-containing compound, a niobium-containing compound and a protective agent to obtain a precursor-protective agent mixed solution, in which the protective agent is a surfactant or a small molecule organic acid and a salt thereof; S2) subjecting the precursor-protective agent mixed solution to a hydrothermal reaction to separate out a solid; S3) calcining the solid in an air atmosphere, followed by calcining the same in an inert gas, and then performing a hydrogen peroxide purification treatment to obtain a pure M1 phase MoVTeNbOx catalyst. The MoVTeNbOx composite oxide catalyst synthesized by the method has high pore volume and high specific surface area, and exhibits an excellent conversion rate, selectivity, space time yield and stability in the oxidative dehydrogenation reaction of ethane for preparing ethylene.

The invention relates to a process for treatment of a mixed metal oxide catalyst containing molybdenum, vanadium, niobium and optionally tellurium, comprising contacting a gas stream comprising methane, an inert gas or oxygen or any combination of two or more of these with the catalyst, wherein said gas stream comprises 0 to 25 vol. % of an alkane containing 2 to 6 carbon atoms and/or alkene containing 2 to 6 carbon atoms.

Incorporating into a fixed bed reactor for an exothermal reaction having a catalyst supported on a support having a thermal conductivity typically less than 30 W/mk within the reaction temperature control limits heat dissipative particles having a thermal conductivity of at least 50 W/mk less than 30 W/mk within the reaction temperature control limits helps control the temperature of the reactor bed.

Oxidative dehydrogenation catalysts comprising MoVNbTeO having improved consistency of composition and a 25% conversion of ethylene at less than 420° C. and a selectivity to ethylene above 95% are prepared by treating the catalyst precursor with H.sub.2O.sub.2 in an amount equivalent to 0.30-2.8 mL H.sub.2O.sub.2 of a 30% solution per gram of catalyst precursor prior to calcining.

Mixed metal oxide catalysts having an amorphous content of not less than 40 wt. % are prepared by calcining the catalyst precursor fully or partially enclosed by a porous material having a melting temperature greater than 600° C. in an inert container including heating the catalyst precursor at a rate from 0.5 to 10° C. per minute from room temperature to a temperature from 370° C. to 540° C. under a stream of pre heated gas chosen from steam and inert gas and mixtures thereof at a pressure of greater than or equal to 1 psig having a temperature from 300° C. to 540° C. and holding the catalyst precursor at that temperature for at least 2 hours and cooling the catalyst precursor to room temperature.