Fischer methane oxidation

Due to the known limitations of the world oil reserves, methane oxidation under fuel rich conditions will become increasingly important for the production of synthesis gas. which through methanol synthesis and Fischer-Tropsch reactions is the basis of many important petrochemical synthesis routes. Therefore, catalytic oxidation of methane has again become the focus of much basic and applied catalysis research in recent years. In this context, Schmidt and coworkers were able to show recently, that catalytic direct oxidation of methane over noble metal coated monoliths can yield CO and H2 with very high conversions and selectivities at the desired 1 2 CO H2 ratio (Hickman and Schmidt. 1992 and 1993a Torniainen and Schmidt. 1994 Bharadwaj and Schmidt. 1995). 

Methane oxidation to syngas has recently been presented as the most interesting method for methane valorization. In fact, the catalytic partial oxidation (CPO) of methane to syngas has widely been studied as a potential alternative to methane steam reforming since it is mildly exothermic and a H2/CO ratio of 2 is obtained in the ideal reaction CH4 -I- 1/2O2 CO - - 2H2 (AH gg = -36kJ/mol ), which is comparable to Fischer-Tropsch synthesis.This has been reviewed recently. ... 

The syn gas process is usually run for specific purposes. Examples include feedstock for ammonia production, feedstock for methanol production, feedstock for the Fischer-Tropsch synthesis, or for the energy output. Depending on the reason for running the reaction, a different ratio of H2 CO is needed. This ratio is influenced strongly by the material undergoing partial oxidation. Coal gives a 1 1 ratio of H2 CO petroleum about a 2 1 ratio and natural gas somewhat higher than a 2 1 ratio as will be evident from the discussion on methane oxidation. 

A topic of current interest is that of methane activation to give ethane or selected oxidation products such as methanol or formaldehyde. Oxide catalysts are used, and there may be mechanistic connections with the Fischer-Tropsch system (see Ref. 285). 

The catalytic partial oxidation of methane for the production of synthesis gas is an interesting alternative to steam reforming which is currently practiced in industry [1]. Significant research efforts have been exerted worldwide in recent years to develop a viable process based on the partial oxidation route [2-9]. This process would offer many advantages over steam reforming, namely (a) the formation of a suitable H2/CO ratio for use in the Fischer-Tropsch synthesis network, (b) the requirement of less energy input due to its exothermic nature, (c) high activity and selectivity for synthesis gas formation. 

A search for alternative energy supplies has triggered efforts to develop efficient homogeneous catalysts for Fischer-Tropsch-type syntheses via hydrogenation of carbon monoxide, a likely future key material available, for example, through oxidation of coal (33, 327, 328, 417, 418). Metal cluster systems have been used in attempts to emulate the presently used heterogeneous catalysts. The important reactions are methanation,... 

If the gasifier product stream is intended for downstream use as the feedstock for further upgrading such as methanation, methanol or Fischer Tropsch synthesis, very thorough desulphuri-sation is essential since the catalysts in these upgrading processes are highly sensitive to sulphur poisoning. The methanation catalysts normally cannot tolerate more than 0.05 ppm of sulphur in the feedstock. In addition to H2S sulphur values in the gasifier product it may contain COS, CS2, mercaptans and thiophenes. These are normally removed by activated carbon or zinc oxide filters ahead of the sensitive synthesis catalyst beds. 

Reasons for interest in the catalyzed reactions of NO, CO, and COz are many and varied. Nitric oxide, for example, is an odd electron, hetero-nuclear diatomic which is the parent member of the environmentally hazardous oxides of nitrogen. Its decomposition and reduction reactions, which occur only in the presence of catalysts, provide a stimulus to research in nitrosyl chemistry. From a different perspective, the catalyzed reactions of CO and COz have attracted attention because of the need to develop hydrocarbon sources that are alternatives to petroleum. Carbon dioxide is one of the most abundant sources of carbon available, but its utilization will require a cheap and plentiful source of hydrogen for reduction, and the development of catalysts that will permit reduction to take place under mild conditions. The use of carbon monoxide in the development of alternative hydrocarbon sources is better defined at this time, being directly linked to coal utilization. The conversion of coal to substitute natural gas (SNG), hydrocarbons, and organic chemicals is based on the hydrogen reduction of CO via methanation and the Fischer-Tropsch synthesis. Notable successes using heterogeneous catalysts have been achieved in this area, but most mechanistic proposals remain unproven, and overall efficiencies can still be improved. 

These activities were based on activities per unit metallic area rather than on activities per gram, as in the results of Fischer and Tropsch. Rostrup-Nielsen suggests that the low activity of the cobalt may be due to the fact that the reaction was carried out under conditions when the cobalt can be oxidized by the steam of the reaction mixture. For the methanation reaction, Fischer, Tropsch, and Dilthey49 give the following order of activities for the Group VIII metals ... 

The role of iron clusters in Fischer-Tropsch catalysis has been the focus of considerable studies. Cagnoli et al. have recently studied the role of Fe clusters on silica and alumina supports for methanation.22 Chemisorption, catalysis and Mossbauer spectroscopy experiments were used to study the effect of dispersion and the role of various supports. Although several oxidation states of iron were observed, the focus of this research was on Fe clusters which were found to be on the order of 12 A crystal size. The authors proposed that metal support interactions were greater for silica than alumina supports and that selectivity differences between these catalysts were due to differences in surface properties of silica vs. alumina. Differences in selectivity for Fe/SiC>2 catalysts at different H2/CO ratios were attributed to differences in coadsorption of H2 and CO. Selectivity differences are difficult to explain in such systems even when only one metal is present. 

Ruthenium supported on oxides is a catalyst of various reactions. It is active in methanation reactions [e.g. 1, 2, 3], in Fischer-Tropsch synthesis [e.g. 4, 5, 6], in CO oxidation [7, 8], in the synthesis of methyl alcohol [9], 1" the redu ction of NO to nitrogen CIO] and in hydrogenolysis of ethane [11] and of butane [12]. Ru supported on carbon is supposed to replace the iron in ammonia synthesis [13]. Lately ruthenium supported on oxides is intensively investigated as a potential... 

Although metals or even promoted metals have very low sulfur tolerances in synthesis reactions, other materials, such as metal oxides, nitrides, borides, and sulfides, may have greater tolerance to sulfur poisoning because of their potential ability to resist sulfidation (18). The extremely low steady-state activities of Co, Ni, and Ru metals in a sulfur-contaminated stream actually correspond to the activities of the sulfided metal surfaces. However, if more active sulfides could be found, their activity/selectivity properties would be presumably quite stable in a reducing, H2S-containing environment. This is, in fact, the basis for the recent development of sulfur active synthesis catalysts (211-215), which are reported to maintain stable activity/ selectivity properties in methanation and Fischer-Tropsch synthesis at H2S levels of 1% or greater. Happel and Hnatow (214), for example, reported in a recent patent that rare-earth and actinide-metal-promoted molybdenum oxide catalysts are reasonably active for methanation in the presence of 1-3% H2S. None of these patents, however, have reported intrinsic activities... 

Hydrocarbon Research Inc., elected partial oxidation for the Carthage Hydrocol plant at Brownsville. After initial experiments that Hydrocarbon Research conducted at Olean, New York, The Texas Company assumed responsibility for further development of partial oxidation at its Montebello, California, laboratory, under duBois ( Dubie ) Eastman. For conversion of natural gas to gasoline by Fischer-Tropsch synthesis, partial oxidation s advantage over steam-methane reforming lay in its ability to operate at a pressure approximating that of the synthesis, thereby essentially eliminating need for compression of synthesis gas. 

The adsorption of CO is probably the most extensively investigated surface process. CO is a reactant in many catalytic processes (methanol synthesis and methanation, Fischer-Tropsch synthesis, water gas shift, CO oxidation for pollution control, etc. (1,3-5,249,250)), and CO has long been used as a probe molecule to titrate the number of exposed metal atoms and determine the types of adsorption sites in catalysts (27,251). However, even for the simplest elementary step of these reactions, CO adsorption, the relevance of surface science results for heterogeneous catalysis has been questioned (43,44). Are CO adsorbate structures produced under typical UHV conditions (i.e., by exposure of a few Langmuirs (1 L = 10 Torrs) at 100—200 K) at all representative of CO structures present under reaction conditions How good are extrapolations over 10 or more orders of magnitude in pressure Such questions are justified, because there are several scenarios that may account for differences between UHV and high-pressure conditions. Apart from pressure, attention must also be paid to the temperature. 

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