Single-Step Conversion of Methane to Liquid Hydrocarbon Fuels with a Layered Composite Catalyst

Combination of steam reforming and Fischer-Tropsch Synthesis (FTS) is a potential process to convert methane directly to liquid hydrocarbon fuels. In this study, the combination of zeolite membrane coated composite steam reforming catalyst and FTS catalyst was used for a single-step conversion of methane to hydrocarbons. The layered reforming catalyst (zeolite membrane coated NiMg/Ce_0.6Zr_0.4O₂) consisted of an outer layer of H-β zeolite encapsulating an inner reforming catalyst core. The layered reforming catalyst was synthesized using a double physical coating method. The layered reforming catalyst has been utilized for methane steam reforming and the methane conversion could reach ~ 30%. The methane conversion decreased with the increase of the zeolite shell thickness, which is proportional to the zeolite amount added [1]. The layered composite catalyst and Fe/SBA-15 catalyst were loaded in a micro fixed-bed glass U-tube. Methane and steam were used as reactants. The primary results show a high methane conversion (> 20%) and hydrocarbons were produced. The operation conditions including methane-to-steam molar ratio, temperature, and gas hourly space velocity (GHSV) will be optimized to produce more hydrocarbons.

[1] Cimenler, Ummuhan, Babu Joseph, and John N. Kuhn. "Effect of Zeolite Membrane Shell Thickness on Reactant Selectivity for Hydrocarbon Steam Reforming Using Layered Catalysts." Energy & Fuels 30, no. 7 (2016): 5300-5308.