Disclosed are a method and apparatus with alternate embodiments that use commercial
chemical free radical initiators to directly convert
methane to
methanol in a low energy, one step, catalytic reaction. In one embodiment an apparatus converts “packets” of
methane gas to liquid
methanol.
Methane gas and aqueous
hydrogen peroxide are injected into the packet apparatus through valved ports and mixed in a structurally robust, rotating
reaction chamber coated with
metal cation catalyst. Although operating at low
temperature and pressure, the rotating chamber is sufficiently strong enough to contain spontaneous ignition of the mixture should that occur. The
reactive oxygen species, primarily hydroxyl radicals, released in the chamber of mildly elevated temperature, oxidize the
methane molecule, replacing one
hydrogen atom on its molecule with one stable hydroxyl OH molecule, converting vapor methane CH4 to vapor
methanol CH3OH. Vapor exiting the exhaust port condenses on ambient temperature drip screens to stable liquid methanol. An alternate continuous process embodiment uses flow-through conversion screens coated with immobilized dry chemicals.
Water vapor entering the apparatus releases
molecular oxygen from screens coated with dry
urea hydrogen peroxide. A circulating endless belt screen is used to continual recoat the dry
urea hydrogen peroxide.
Reactive oxygen species are generated on successive conversion screens through which the
molecular oxygen, and
methane gas entering the apparatus, must pass.
Metal cation catalyst molecules physically entrapped within interstitial cavities of a three dimensional, fixed porous colloidal matrix
coating on the screens create powerful hydroxyl radicals from the
molecular oxygen. These reactive species in turn convert methane molecules impacting the conversion screens to methanol molecules. The method and apparata operate at modest temperature, pressure, and
energy requirement levels, and are scalable from portable units to
industrial scale methanol refineries.