Highly Efficient Non-Oxidative Methane Conversion with Continuous Hydrogen Removal

Abstract

A non-oxidative methane conversion catalytic system has been successfully developed. Ball-milling and annealing above 1973 K are necessary in order to synthesize the unique methane activation catalyst. Characterization and evaluation of catalysts shows that the surface area should be carefully controlled to minimize coke deposition. The influence of temperature, pressure, space velocity and hydrogen concentration on catalytic process was systematically studied. The reaction conditions were optimized to a combination of 1323 K, ambient pressure and a space velocity of 4900 ml/g·h. A process, using 0.5% Fe/SiO 2 catalyst under these conditions, yield a methane conversion of 15.62%, with product distribution of 40.05% C 2 , 26.48% BTX and 10.7% naphthalene and demonstrated stable operation of at least 50 hours. This result meets the milestone in the phase I proposal. A non-oxidative methane catalyst-integrated SOFC reactor was accomplished, using nickel-free cells of both ScSZ oxygen-ion conductor and BZY proton conductor. With in-situ hydrogen removal enabled by SOFC, hydrogen concentration in the reactor was effectively reduced, shifting reaction equilibrium and boosting methane conversion. However, due to the high temperature requirement of this reaction, most available proton-conducting SOFCs become oxygen-ion conducting, leading to side reactions and counteracting the benefits from hydrogen removal. To take advantage of the enhanced oxygen-ion conductance of SOFC at high temperatures, we have also paired the nickel-free SOFCs with high-performance oxidative coupling of methane (OCM) catalysts. The SOFC-OCM tubular membrane reactor, employing a Mn-Ce-Na 2 WO 4 /SiO 2 -based catalyst, demonstrates a remarkable performance of 60.7% methane conversion with 41.6% C 2 + selectivity, 5.8 ethylene-to-ethane ratio and 19.4% ethylene yield. The use of integrated SOFC-OCM reactor enables better hydrocarbon selectivity and higher ethylene-to-ethane ratio, eliminating the need of an expensive air separation unit and preventing the direct co-feed of explosive methane-oxygen mixture. We believe this presents a great promise towards commercialization as an advanced methane conversion technology.