Fecralloy Partially Oxidizes Methane Selectively

Ma, Z., Polytechnique Montreal
Patience, G. S., Polytechnique Montreal
Boffito, D. C., Polytechnique Montreal
Pelegrin, D. C., Polytechnique Montreal
Flaring natural gas contributes to the climate change and air pollution, also wastes a valuable source of energy. Micro Gas-to-Liquids technology (GtL) reduces flared natural gas and carbon emissions while producing value-added synthetic crude - condensate, gasoline, diesel and wax. A mobile micro-refinery unit (MRU), integrating high pressure syngas step (catalytic partial oxidation of methane, CPOX) with Fischer-Tropsch (FT) in a single vessel, reduces investment and operating cost compared to auto thermal reforming and steam reforming.

CPOX catalyst must operate at temperature exceeding 900 oC to achieve 90+% methane conversion and at pressure of 2 MPa to combine with FT process. FeCralloy knitted fibres are ideal supports materials because the oxidized surface alumina layer resists temperature up to 1050 oC . With oxidized FeCralloy as a support, we deposited 0.1%-1% Pt over the fibre surface via solution combustion synthesis. Free of pre-reduction treatment, the selectivity to syngas of the Pt FeCralloy catalyst is superior at both 0.1 MPa and 2 MPa. High pressure restrained the methane conversion and syngas selectivity. Coking deactivates the catalyst, but a quick and simple regeneration step recovers its original reactivity. The FeCralloy surface morphology remains intact after multiple reaction-regeneration cycles.