Continuous Synthesis of Methanol from Methane and Steam over Copper-Mordenite

Highly Selective Synthesis of Acetic Acid from Hydroxyl-Mediated Oxidation of Methane at Low Temperatures

Direct methane conversion and, in particular, the aerobic oxidation to acetic acid, remain an eminent challenge. Here, we reported a zeolite-supported Au-Fe catalyst (Au-Fe/ZSM-5) that converted methane to acetic acid with molecular oxygen as an oxidant in the presence of CO. Specifically, Au nanoparticles catalyzed the formation of hydroxyl species from the reaction of CO, O2, and H2O, meanwhile ZSM-5-supported atomically dispersed Fe species were responsible for the hydroxyl-mediated coupling of CH4 and CO to generate acetic acid. The reaction over 50 mg of Au-Fe/ZSM-5 under 62 bar (CH4 : CO : O2=14 : 14 : 3) at 120 °C for 3.0 h yielded 5.7 millimoles of acetic acid per gram of the catalyst (mmol gcat -1) with the selectivity of 92 %, outperformed most of reported catalysts. Significantly, the catalyst remained active even at 60 °C. We anticipate that this hydroxyl-mediated route may guide the design of optimized catalysts for the direct methane functionalization at low temperatures.

Continuous selective conversion of methane to methanol over a Cu-KFI zeolite catalyst using a water-O2 mixture as the oxygen source

The continuous catalytic oxidation of methane to methanol on a Cu-KFI zeolite using water-O2 mixture as the oxidant is reported. A high methanol space-time yield of 880.3 mmol molCu-1 h-1 with 83% selectivity is achieved at 450 °C. Isotopic labelling experiments show that both H2O and O2 provide the oxygen source in this catalytic methane-to-methanol conversion reaction.

Confined Cu-OH single sites in SSZ-13 zeolite for the direct oxidation of methane to methanol

The direct oxidation of methane to methanol (MTM) remains a significant challenge in heterogeneous catalysis due to the high dissociation energy of the C-H bond in methane and the high desorption energy of methanol. In this work, we demonstrate a breakthrough in selective MTM by achieving a high methanol space-time yield of 2678 mmol molCu-1 h-1 with 93% selectivity in a continuous methane-steam reaction at 400 °C. The superior performance is attributed to the confinement effect of 6-membered ring (6MR) voids in SSZ-13 zeolite, which host isolated Cu-OH single sites. Our results provide a deeper understanding of the role of Cu-zeolites in continuous methane-steam to methanol conversion and pave the way for further improvement.

Recent Advances in the Catalytic Conversion of Methane to Methanol: From the Challenges of Traditional Catalysts to the Use of Nanomaterials and Metal-Organic Frameworks

Methane and carbon dioxide are the main contributors to global warming, with the methane effect being 25 times more powerful than carbon dioxide. Although the sources of methane are diverse, it is a very volatile and explosive gas. One way to store the energy content of methane is through its conversion to methanol. Methanol is a liquid under ambient conditions, easy to transport, and, apart from its use as an energy source, it is a chemical platform that can serve as a starting material for the production of various higher-value products. Accordingly, the transformation of methane to methanol has been extensively studied in the literature, using traditional catalysts as different types of zeolites. However, in the last few years, a new generation of catalysts has emerged to carry out this transformation with higher conversion and selectivity, and more importantly, under mild temperature and pressure conditions. These new catalysts typically involve the use of a highly porous supporting material such as zeolite, or more recently, metal-organic frameworks (MOFs) and graphene, and metallic nanoparticles or a combination of different types of nanoparticles that are the core of the catalytic process. In this review, recent advances in the porous supports for nanoparticles used for methane oxidation to methanol under mild conditions are discussed.

Mechanistic insight into the effect of active site motif structures on direct oxidation of methane to methanol over Cu-ZSM-5

Direct oxidation of methane to methanol (DMTM), a highly challenging reaction in C1 chemistry, has attracted lots of attention. Herein, we investigate the continuous H2O-mediated N2O-DMTM over a series of Cu-ZSM-5-n zeolites prepared by a solid-state ion-exchange method. Excellent CH3OH productivity (194.8 μmol gcat-1 h-1) and selectivity (67.1%) can be achieved over Cu-ZSM-5-0.3%, which surpasses most recently reported zeolite catalysts. The effect of the active site motif structure on the reaction was systematically investigated by the combined experimental and theoretical studies. It has been revealed that both the monomeric [Cu]+ and binuclear [Cu]+-[Cu]+ sites function to produce CH3OH, following the radical rebound mechanism, wherein the latter one plays a dominant role due to the synergistic effect of neighboring [Cu]+ that can efficiently reduce the N2O dissociation barrier to generate active oxygen for CH4 oxidation. Microkinetic modeling results further show that the dicopper site possesses a much higher net reaction rate (1.23 × 105 s-1) than the monomeric Cu site (0.962 s-1); moreover, H2O can shift the rate determining step from the CH3OH desorption step to the N2O dissociation step over the dicopper site, thereby efficiently favoring CH3OH production and resisting carbon deposition. Generally, the study in the present work would substantially favor other highly efficient catalyst designs.

Cu and Zn Bimetallic Co-Modified H-MOR Catalyst for Direct Oxidation of Low-Concentration Methane to Methanol

The direct oxidation of low-concentration methane to value-added chemicals can not only reduce carbon emission but also provide an alternative production route for fossil fuels. Herein, we proposed a novel catalyst for the direct oxidation of low-concentration methane to methanol via the impregnation method, which selected copper and zinc as co-modifiers to modify the MOR catalyst. The highest methanol yield of 71.35 μmol·gcat-1·h-1 was obtained over a bimetallic Cu0.5Zn0.35-MOR catalyst. The catalyst retained good activity after three cycles of testing experiments, indicating good recyclability. Based on the results of performance tests and characterization studies, it was confirmed that Cu species bound to the zeolite framework were the main active sites for methane oxidation. The introduction of Zn decreased the generation of the octahedrally coordinated extra-framework aluminum, which promoted the dispersion of Cu within the zeolite framework. In other words, more tetrahedrally coordinated FAl-stabilized Cu species were presented in our CuZn-MOR catalyst system in comparison to the monometallic Cu-MOR catalyst. Benefiting from the aforementioned modification, the agglomerative sintering of the metal during the reaction was effectively prevented. This work may provide a feasible guide for the future optimization of Cu-based catalysts designed for the selective oxidation of methane.

CuxOy nanoparticles and Cu-OH motif decorated ZSM-5 for selective methane oxidation to methyl oxygenates

Copper decorated zeolites are promising candidates for the partial oxidation of methane to generate methanol with elevated energy density, nevertheless, the modulation and possible synergism between multiple Cu active sites still need to be delved in depth. Here, ZSM-5 catalysts with modulated Cu motifs were proposed using copper oxysalts as precursors through a calcination process. By modifying the contents of copper oxysalts precursors, the Cu active sites varied, and a unique M shaped trend of CH₃OH productivity emerged. Attributed to the synergetic effects of Cu_xO_y nanoparticles (adsorbing CH₄ and generating *OCH₃ species) and Cu-OH motif (binding CH₄ and forming Si···CH₃), a maximum CH₃OH yield of 15975.73 μmol/g_cat/h (with CH₃OOH yield of 2155.59 μmol/g_cat/h) and methyl oxygenates selectivity up to 72.79 % could be achieved. This work paved an efficient, low cost, and succinct way for the manufacture of catalysts with tunable active sites and high performance over methane to methanol conversion.

Direct Catalytic Oxidation of Low-Concentration Methane to Methanol in One Step on Ni-Promoted BiOCl Catalysts

The direct oxidation of low-concentration methane (CH₄) to methanol (CH₃OH) is often regarded as the "holy grail". However, it still is very difficult and challenging to oxidize methane to methanol in one step. In this work, we present a new approach to directly oxidize CH₄ to generate CH₃OH in one step by doping non-noble metal Ni sites on bismuth oxychloride (BiOCl) equipped with high oxygen vacancies. Thereinto, the conversion rate of CH₃OH can reach 39.07 μmol/(g_cat·h) under 420 °C and flow conditions on the basis of O₂ and H₂O. The crystal morphology structure, physicochemical properties, metal dispersion, and surface adsorption capacity of Ni-BiOCl were explored, and the positive effect on the oxygen vacancy of the catalyst was proved, thus improving the catalytic performance. Furthermore, in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) was also performed to study the surface adsorption and reaction process of methane to methanol in one step. Results demonstrate that the key to keep good activity lies in the oxygen vacancies of unsaturated Bi atoms, which can adsorb and active CH₄ and to produce methyl groups and adsorbing hydroxyl groups in methane oxidation process. This study broadens the application of oxygen-deficient catalysts in the catalytic conversion of CH₄ to CH₃OH in one step, which provides a new perspective on the role of oxygen vacancies in improving the catalytic performance of methane oxidation.

Selective Methane Oxidation by Heterogenized Iridium Catalysts

Oxidative methane (CH₄) carbonylation promises a direct route to the synthesis of value-added oxygenates such as acetic acid (CH₃COOH). Here, we report a strategy to realize oxidative CH₄ carbonylation through immobilized Ir complexes on an oxide support. Our immobilization approach not only enables direct CH₄ activation but also allows for easy separation and reutilization of the catalyst. Furthermore, we show that a key step, methyl migration, that forms a C-C bond, is sensitive to the electrophilicity of carbonyl, which can be tuned by a gentle reduction to the Ir centers. While the as-prepared catalyst that mainly featured Ir(IV) preferred CH₃COOH production, a reduced catalyst featuring predominantly Ir(III) led to a significant increase of CH₃OH production at the expense of the reduced yield of CH₃COOH.

Gas-Phase Selective Oxidation of Methane into Methane Oxygenates

Methane is an abundant resource and its direct conversion into value-added chemicals has been an attractive subject for its efficient utilization. This method can be more efficient than the present energy-intensive indirect conversion of methane via syngas, a mixture of CO and H2. Among the various approaches for direct methane conversion, the selective oxidation of methane into methane oxygenates (e.g., methanol and formaldehyde) is particularly promising because it can proceed at low temperatures. Nevertheless, due to low product yields this method is challenging. Compared with the liquid-phase partial oxidation of methane, which frequently demands for strong oxidizing agents in protic solvents, gas-phase selective methane oxidation has some merits, such as the possibility of using oxygen as an oxidant and the ease of scale-up owing to the use of heterogeneous catalysts. Herein, we summarize recent advances in the gas-phase partial oxidation of methane into methane oxygenates, focusing mainly on its conversion into formaldehyde and methanol.

Synergistic Effect of Neighboring Fe and Cu Cation Sites Boosts FenCum-BEA Activity for the Continuous Direct Oxidation of Methane to Methanol

Direct oxidation of methane to methanol (DMTM), constituting a major challenge for C1 chemistry, has aroused significant interest. The present work reports the synergistic effect of neighboring [Fe]--[Cu] cations, which can significantly boost the CH3OH productivity (100.9 and 41.9 → 259.1 μmol∙g−1cat∙h−1) and selectivity (0.28 and 17.6% → 71.7%) of the best performing Fe0.6%Cu0.68%-BEA (relative to monomeric Fe1.28%- and Cu1.28%-BEA) during the continuous H2O-mediated N2O DMTM. The combined experimental (in situ FTIR, D2O isotopic tracer technique) and theoretical (DFT, ab initio molecular dynamics (AIMD)) studies reveal deeper mechanistic insights that the synergistic effect of [Fe]--[Cu] can not only significantly favor active O production (ΔG = 0.18 eV), but also efficiently motivate the reaction following a H2O proton-transfer route (ΔG = 0.07 eV), eventually strikingly promoting CH3OH productivity/selectivity. Generally, the proposed strategy by employing the synergistic effect of bimetallic cations to modify DMTM activity would substantially favor other highly efficient catalyst designs.

Methane to Methanol through Heterogeneous Catalysis and Plasma Catalysis

Direct oxidation of methane to methanol (DOMTM) is attractive for the increasing industrial demand of feedstock. In this review, the latest advances in heterogeneous catalysis and plasma catalysis for DOMTM are summarized, with the aim to pinpoint the differences between both, and to provide some insights into their reaction mechanisms, as well as the implications for future development of highly selective catalysts for DOMTM.

Copper-exchanged large-port and small-port mordenite (MOR) for methane-to-methanol conversion

Zeolite mordenite (MOR) is one of the most studied zeolites for the stepwise direct conversion of methane to methanol, but it also can exist in two forms: large port and small port. Here we report that the synthesis and selection of the parent mordenite is critical for optimizing productivity, and that large-port mordenite outperforms small-port mordenite for the stepwise conversion of methane to methanol.

The synthesis and selection of large-port mordenite is critical for optimizing productivity for the direct conversion of methane to methanol.