Highly Efficient Non-Oxidative Methane Conversion with Continuous Hydrogen Removal

Currently, there is no efficient method for direct conversion of methane into useful chemicals, which prohibits vast amount of produced shale gas from the wide-spectrum usage. Oxidative methane conversion methods suffer from low carbon atom utilization, heat management and temperature control, and sometimes, the requirement for corrosive reagents, whereas traditional non-oxidative ones have the coking issues along with rather low conversion efficiency limited by the thermodynamics. We propose to use single-site matrix- confined transition metal catalysts to mitigate the coking problem in the non-oxidative methane conversion reactions. We also propose to use proton conducting solid oxide fuel cells or hydrogen pumps as means to remove the produced hydrogen to enhance the conversion of methane. In Phase I, we will establish the robust synthesis of single-site matrix- confined transition metal catalysts, evaluate the performance of catalysts using a fixed bed micro- reactor equipped with online gas chromatography (GC) detection system, and implement the in situ hydrogen removal to further boost the conversion efficiency of methane. A direct, highly selective methane-to-olefin converter can cost- effectively convert vast amount of our domestically produced shale gas, which is very undervalue due to lacks of advanced methane conversion processes. The success of our proposal not only makes natural gas an abundant, cheap, and viable alternative hydrocarbon feedstock for the production of many important industrial chemical intermediates, but also significantly reduces leaking and flaring of natural gas, which is one of the worst greenhouse gases. Commercial Applications and Other Benefits: Developing a compact-in-size, preferably skid-mounted shale gas conversion unit could significantly benefit the domestic energy producers by greatly increasing the economic values of produced natural gas, as well as benefit our environment by stopping flaring and leaking of the methane gas which is one of the worst greenhouse gases.