CATALYST DEVELOPMENT FOR NON-OXIDATIVE METHANE UPGRADING TOWARDS HYDROCARBONS AND HYDROGEN PRODUCTION

Abstract

Methane, the main constituent of natural gas and biogas is deemed to be an alternative source to replace crude oil in the production of chemicals and fuel. Non-oxidative methane conversion enables methane coupling or splitting to produce hydrogen and more significant hydrocarbons, but catalyst deactivation has been a challenge in past research. This dissertation addresses catalyst deactivation issues in non-oxidative methane conversion by inventing novel catalyst systems. For direct non-oxidative methane coupling, a pathway for methane upgrading into hydrogen, olefin, and aromatic products, the silica-supported catalysts were synthesized by flame fusion of a mixture of quartz silica and metal silicate precursors. Compared to the cristobalite silica-supported catalysts reported previously, vitreous silica-supported catalysts have disordered Si-O bonds and structural defects, enabling better metal dispersion and more vital metal-support interaction. The as-prepared vitreous silica-supported iron catalyst had a shorter induction period in methane activation and lower coke yield. The increase in iron concentration elongated the catalyst induction period and promoted aromatics and coke formation. Among different transition metal catalysts, the cobalt supported by vitreous silica had the best methane conversion, hydrocarbon product yield, and catalyst stability. For catalytic methane pyrolysis, a pathway producing COx-free hydrogen and valuable carbon product, a siliceous zeolite-supported cobalt catalyst was invented. In comparison to the methane pyrolysis catalysts in literature, the siliceous zeolite support in the invented catalyst has limited Brönsted acidity and increased mesoporosity, which limited the acid-catalyzed deactivation mechanism and facilitated the mass transport, and thus significantly increased the catalyst lifetime. The cobalt sites change the cluster sizes and coordination structures with the loading concentrations in the zeolite support, which leads to carbon products with different properties.