Catalytic, low temperature oxidation of methane into methanol over copper-exchanged zeolites

Abstract

As production of shale gas has increased greatly in the United States, the amount of stranded shale gas that is flared as carbon dioxide has become significant enough to be considered an environmental hazard and a wasted resource. The conversion of methane, the primary component of natural gas, into methanol, an easily stored liquid, is of practical interest. However, shale wells are generally inaccessible to reforming facilities, and construction of on-site, conventional methanol synthesis plants is cost prohibitive. Capital costs could be reduced by the direct conversion of methane into methanol at low temperature. Existing strategies for the partial oxidation of methane require harsh solvents, need exotic oxidizing agents, or deactivate easily. Copper-exchanged zeolites have emerged as candidates for methanol production due to high methanol selectivity (> 99%), utilization of oxygen, and low reaction temperature (423-473 K). Despite these advantages, three significant shortcomings exist: 1) the location of surface intermediates on the zeolite is not well understood; 2) methane oxidation is stoichiometric, not catalytic; 3) there are few active sites and methanol yield is low. This work addresses all three shortcomings. First, a new reaction pathway is identified for methane oxidation in copper-exchanged mordenite zeolites using tandem methane oxidation and Koch carbonylation reactions. Methoxy species migrate away from the copper active sites and adsorb onto Bronsted acid sites, signifying spillover on the zeolite surface. Second, a process is developed as the first instance of the catalytic oxidation of methane into methanol at low temperature, in the vapor phase, and using oxygen as the oxidant. A variety of commercially available copper-exchanged zeolites are shown to exhibit stable methanol production with high methanol selectivity. Third, catalytic methanol production rates and methane conversion are further improved 100- fold through the synthetic control of copper speciation in chabazite zeolites. Isolated monocopper species, directed through the one-pot synthesis of copper-exchanged chabazite zeolites, correlates with methane oxidation activity and is likely the precursor to the catalytic site. Together, these synthetic methods provide guidelines for catalyst design and further improvements in catalytic activity.