Direct Non-Oxidative Methane Conversion and Hydrogen Co-Production in a Proton Conducting Membrane Reactor

Abstract

Direct Non-oxidation Methane Conversion (DMNC) has been recognized a promising technology for the upgrading of cheap and abundant methane to higher hydrocarbons (C2+) and H2, but this technology has not been commercialized yet because of the low methane equilibrium conversion and severe carbon deposition.1-3 Here, we present our effort to develop a proton conducting membrane reactor (SrCe0.7Zr0.2Eu0.1O3- ⴃ) combined with the catalysts (Fe©SiO2) to circumvent the equilibrium limitations of the DMNC reaction and solve the coking (i.e., solid carbon deposition) problem. By coupling the Fe©SiO2 catalysts with H2 permeable membrane reactor, part of produced H2 during the catalytic conversion can be extracted from the effluent gas, which not only provides a one-step hydrogen production without additional separation process, but also shifts the equilibrium of the reaction to the product side and achieves an improved methane conversion and higher C2+ yield when compared to the traditional fixed-bed reactor. In addition, an air sweep outside the reactor results in O-permeation into catalyst to oxidize any deposited carbon to CO thus preventing coking.The membranes were fabricated using tape casting of the support layer followed by dip coating process to form the dense membrane layer. Using this method, we obtained 25 µm for the thickness of the dense layer and around 700 µm for the thickness of the support layer (see Fig. 1a and 1b). The catalyst was synthesized by a simple sol-gel method followed by fusing process, and then was crushed into 40-80 mesh and loaded inside of membrane reactor to test.The performance metrics include methane conversion, selectivity, and product yield. Our membrane reactor achieved single-pass methane conversion of 17.5%, and a C2+ yield of 15% (see Fig. 1c) at 1323K.Finally, our membrane reactors were stable for over 350 hours, which, along with the aforementioned performance metrics, constitutes a major advance in the development of commercial DMNC technology. References Guo, X.; Fang, G.; Li, G.; Ma, H.; Fan, H.; Yu, L.; Ma, C.; Wu, X.; Deng, D.; Wei, M.; Tan, D.; Si, R.; Zhang, S.; Li, J.; Sun, L.; Tang, Z.; Pan, X.; Bao, X., Direct Nonoxidative Conversion of Methane to Ethylene, Aromatics, and Hydrogen. Science 2014, 344 (6184), 616-619.Thyssen, V. V.; Vilela, V. B.; de Florio, D. Z.; Ferlauto, A. S.; Fonseca, F. C., Direct Conversion of Methane to C2 Hydrocarbons in Solid-State Membrane Reactors at High Temperatures. Chemical Reviews 2022, 122 (3), 3966-3995.Sakbodin, M.; Schulman, E.; Cheng, S.; Huang, Y.-L.; Pan, Y.; Albertus, P.; Wachsman, E. D.; Liu, D., Direct Nonoxidative Methane Conversion in an Autothermal Hydrogen-Permeable Membrane Reactor. Advanced Energy Materials 2021, 11 (46), 2102782. Figure 1