A method for preparing a mixed-metal oxide catalyst comprising molybdenum, vanadium, at least one of niobium or tantalum, and at least one of tellurium or antimony and useful for the oxidative dehydrogenation of ethane to ethylene, the method comprising preparing a catalyst precursor, pressing the precursor into a dense pellet using a pressure of greater than about 5,000 psi, and annealing the pellet to form the mixed-metal oxide catalyst.

An active material useful in an oxidative dehydrogenation reactor system has an active phase, and a mixed metal oxide support phase. The active phase includes a transition metal oxide such as manganese oxide, which is reversibly oxidizable and/or reducible between oxidized and reduced states. The support phase includes a mixed metal oxide of a two or more IUPAC Group 2-14 elements. The active phase can also include a promoter such as Na-WO4 and/or a selectivity modifier such as Al or ceria. Also, a reactor including the active material in a reactor, a method of making the active material, and a method of using the active material in a regenerative reaction process.

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.

A system and method for coproduction in the production of ethylene, including contacting ethane with an oxidative dehydrogenation (ODH) catalyst in presence of oxygen in a first reactor to dehydrogenate ethane to ethylene, and contacting a first-reactor effluent with an ODH catalyst in a second reactor to form ethanol and acetaldehyde.

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.

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.

A system and method for coproduction in the production of ethylene, including contacting ethane with an oxidative dehydrogenation (ODH) catalyst in presence of oxygen in a first reactor to dehydrogenate ethane to ethylene, and contacting a first-reactor effluent with an ODH catalyst in a second reactor to form ethanol and acetaldehyde.

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.

An active material useful in an oxidative dehydrogenation reactor system has an active phase, and a mixed metal oxide support phase. The active phase includes a transition metal oxide such as manganese oxide, which is reversibly oxidizable and/or reducible between oxidized and reduced states. The support phase includes a mixed metal oxide of a two or more IUPAC Group 2-14 elements. The active phase can also include a promoter such as Na-WO4 and/or a selectivity modifier such as Al or ceria. Also, a reactor including the active material in a reactor, a method of making the active material, and a method of using the active material in a regenerative reaction process.

A process for preparing an oxidative dehydrogenation catalyst or oxidative dehydrogenation catalyst precursor that includes mixing solutions of molybdenum and tellurium at a pH from about 3.3 to 7.5; adjusting the pH of the resulting solution back to about 5 and adding VOSO.sub.4 and adding a solution of Nb.sub.2O.sub.5 and oxalic acid and treating the resulting precursor slurry in a controlled pressure hydrothermal process to obtain the catalyst.