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A one-stage process involving CH4 catalytic oxidative coupling over Li/MgO at ~730 °C to C2 hydrocarbons and thermal decomposition of the formed C2Hg to C2H4 at ~850 °C in the postcatalytic zone (PCZ) was studied in a multisectional stainless steel tubular reactor of a scaled-up laboratory unit. Alternative forms of the process with admission of C2Hg or CgHg to PCZ were also examined. Product distribution along the catalyst bed and along the PCZ in the large steel tubular reactor was determined and, on this ground, a verification of a one-stage concept provided. A one-stage process was shown to be generally acceptable. It was confirmed, however, that severe operating conditions applied in PCZ for securing effective C2He dehydrogenation increased C2H4 decomposition to H2 and a coke deposit, C02 reduction to CO (by reactions with H2, a coke, and hydrocarbons), and some other surface-sensitive transformations. Under applied operating conditions, the C2H4/C2He ratio was increased from 1.52 (standard coupling) to 4.89 (one-stage process), whereas the total C2 yield decreased from 15.4% to 13.5%, respectively.

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