Microwave Catalysis for Process Intensified Modular Production of Value-Added Chemicals from Natural Gas

Executive Summary

The rise in US natural gas supplied, tied to challenges/costs associated with natural gas logistics, point to the value of converting natural gas to liquid products. Indirect routes are generally energy inefficient and capital intensive. In contrast, direct non-oxidative natural gas conversion eliminates the syngas production step and required oxygen generation. However, these technologies have not been commercialized because of technical challenges such as low selectivity, coking, heat management, catalyst deactivation and catalyst regeneration. The goal of this project is to develop and demonstrate an innovative modular system intensified with microwave (MW) catalysis, which allows simultaneous production of high-value chemicals (e.g. aromatics) and hydrogen generation via direct non-oxidative natural gas conversion. Specifically, the technical merits consist of synergistically integrating microwave reaction chemistry with novel zeolite catalysts that selectively activate natural gas. The microwave catalysis will enable direct, non-oxidative natural gas conversion under mild conditions with high product yield.

Technical Challenge

  • Selectivity of catalyst and its deactivation and regeneration
  • Catalyst-reactor integration in microwave catalysis process

Potential Impact

The conventional indirect conversion process via syngas is capital intensive and energy inefficient. Direct non-oxidative methane conversion to aromatics eliminates costly syngas production, resulting in capital savings and improvement in energy efficiency. 63% improvements in energy efficiency, 51% capital cost reduction due to the reduction in the number of unit operation, and 4X improvements in energy productivity can be achieved due to elimination of syngas production.

Resources

The West Virginia University has extensive R&D experience in natural gas conversion to chemicals and natural gas upgrading. The WVU is equipped with an 180W variable frequency microwave catalytic reactor, 950W and  3kW fixed frequency reactors, National Energy Technology Laboratory (NETL) is equipped with a 500W VFM microwave catalytic reactor system and a 2kW fixed frequency microwave reactor. Shell’s R&D and Engineering supports process and reactor modeling work and engineering scale-up effort for the pilot plant demonstration.

Investigator
Date Approved
Project Number
-
Initial TRL Level
-
Current TRL level
5
Project Funding
4,650,000
Focus Areas
Partner Organizations