High Performance Carbon Materials and Fuels from Cold Plasma Catalysis of Natural Gas

Despite the dramatic growth of natural gas resources, methane (the major component in natural gas) is underutilized as a feedstock for the production of chemicals and liquid fuels. Currently, methane conversion relies on an indirect two-step gas-to-liquid (GTL) technology. This process is energy intensive and has high operating costs. We propose to develop a new approach to directly convert methane to chemical fuels and high performance carbon materials. The method is expected to have high efficiency so as to be commercially viable. General statement of how this problem is being addressed The proposed Phase I STTR program aims to develop a novel cold plasma catalysis hybrid technology to selectively convert methane into C2-C3 hydrocarbons that are precursors for diverse useful commercial products. Cold plasma catalysis at lower temperatures opens up a pool of less active (but more selective) catalysts that are not sufficiently active or stable for use in high-temperature thermal methane reforming. In collaboration with our STTR partner at Princeton University, we will synthesize and test the performance of the catalyst in a non-equilibrium plasma. The collaborative effort will advance the state-of-the-art by carrying out the process with high energy efficiency. What is to be done in Phase I? The Phase I program entails first, synthesizing the catalysts and characterizing the structure. Subsequently, the catalyst performance will be evaluated in the cold plasma-catalysis hybrid reactor. Catalyst synthesis and materials characterization will be done at NEI while performance testing will be carried out by our collaborator. Commercial Applications and Other Benefits Natural gas is used as both a raw material and as a source of heat in manufacturing processes. In the chemical sector, it is used to manufacture a wide range of chemicals such as ammonia, methanol, butane, ethane, propane and acetic acid. With the depletion of petroleum reserves, methane is expected to become the most important hydrocarbon feedstock for the synthesis of fuels and chemicals. The proposed cold plasma-catalysis hybrid approach for chemical conversion provides an economical alternative for conversion of natural gas to chemical fuels and high performance carbon materials. The success of the disruptive technology will open up new markets for natural gas. Chemical manufacturers are seeking economical methods for direct conversion of natural gas into higher value products. We propose an alternative to directly convert methane to chemical fuels with high energy efficiency. By the end of Phase II or Phase III, we will have developed a value proposition and positioned ourselves to license the cold plasma catalysis technology to chemical manufacturers. Key Words Natural gas, methane, cold plasma, non-equilibrium plasma, catalyst, selectivity, energy efficiency