A Process for Methane to Methanol Conversion at Low Temperature

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This invention describes a new process for directly converting methane into methanol at low temperatures (below 280°C), using molecular oxygen and a catalyst composed of single or multiple transition metals loaded onto porous materials like zeolites. The process can be performed isothermally, avoids high temperature steps typical in current methods, and achieves high selectivity and yield for methanol production. Importantly, methane and oxygen are introduced separately, minimizing the risk of dangerous explosive mixtures.

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• On-site conversion of natural gas (methane) to liquid methanol for easier storage and transport, especially in remote gas fields where flaring is currently practiced.
• Industrial methanol production with lower energy consumption compared to traditional high-temperature and multi-step processes.
• Small- to medium-scale methanol plants located near methane sources, reducing transportation and infrastructure costs.
• Integration into chemical plants needing methanol as a feedstock with more flexible and energy-efficient operations.
• Decentralized or modular installations for converting biomethane or landfill gas to methanol.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables direct methane to methanol conversion at low temperatures, improving energy efficiency and reducing operational costs.
• High selectivity for methanol reduces undesired byproducts and increases process yield.
• Isothermal process simplifies reactor design and operation; avoids repeated heating and cooling cycles.
• Improved safety by avoiding the co-feeding of methane and oxygen, thus reducing explosion risks.
• Flexible process can operate at a wide range of pressures, allowing adaptation to different industrial requirements.
• Suitable for various catalyst materials (single or multi-metallic, various zeolites), providing tunability and potential cost optimization.
• Facilitates on-site or decentralized methanol production, potentially reducing methane flaring and greenhouse gas emissions.

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Patent Abstract

It is the objective of the present invention to provide a process for the conversion of methane into methanol that has a high selectivity, while providing advantageous and energy-saving conditions for this process. This objective is achieved according to the present invention by a process for low temperature and isothermal methane to methanol conversion at temperatures below 280°C using oxygen; comprising the steps of: a) activating a catalyst material with an oxygen-containing gas, preferably molecular oxygen, or an inert gas such as helium, nitrogen and argon; b) feeding methane to the activated catalyst material thereby reacting the methane to a methanol precursor; c) reacting and/or desorbing the methanol precursor from the catalyst material by treating with a gas or a liquid such as water, protic molecules, and/or CO; wherein the steps mentioned above are executed in successive order, thereby applying a temperature in the range of 20 to 280°C, providing methane and the oxygen-containing gas at ambient pressure or at a pressure up to 250 bar, and using as catalyst material a transition or multi-metal loaded porous material. This process allows the safe and selective conversion of methane to methanol at high methanol yields and advantageous energy consumption. Major improvement in the present process is the use of low temperature, possibly in isothermal conditions and in all cases, significantly below the temperatures so far disclosed in the prior art.