Methane is a key component of natural, potent greenhouse gas and a challenging molecule to convert. Oxidative coupling of methane (OCM) is a promising route to transform it into high-value species, notably ethane and ethylene, crucial in the petrochemical industry for consumer and industrial applications. OCM involves a reaction between methane and oxygen, facilitated by a catalyst, yielding C2 hydrocarbons alongside undesired by-products like CO and CO2. Designing an optimal catalyst with high activity, selectivity, and stability is crucial for efficient OCM, addressing the core challenge and opportunity in sustainable chemical production and energy transition.

Mn-Na-W-based catalysts, commonly supported on SiO2, exhibit promising performance in literature. However, their challenges in managing the highly exothermic nature and elevated temperatures of OCM reactions, resulting in sintering, have stimulated interest in exploring alternative support materials, like SiC, recognized for superior thermal properties. This thesis aims to address this by integrating SiC as a co-support alongside SiO2, harnessing the thermal attributes of SiC while retaining the well-documented catalytic properties of Mn-Na-W. For the challenge, spray-drying is studied as it provides versatile control over chemical composition, particle size, and morphology.