Supported Chromium Catalysis for Mild Methane-to-Methanol Conversion
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Solution Overview
Problem
Existing methods for converting methane to methanol often require harsh reaction conditions or halogens, making them undesirable.
Innovation Solution
A process involving a supported chromium catalyst in a hexavalent oxidation state, combined with UV-visible light irradiation and an oxidizing atmosphere, is used to convert methane to methanol, with optional regeneration steps to reuse the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional synthesis techniques are used to convert methane to methanol, then methanol can be produced, but harsh reaction conditions and halogens are required
Solution Approach 1:
The patent changes the oxidation state parameter of the chromium catalyst to hexavalent (Cr(VI)) and uses UV-visible light irradiation to activate the catalyst under mild conditions, eliminating the need for harsh reaction conditions and halogens while maintaining effective methane-to-methanol conversion
Solution Approach 2:
The patent replaces conventional thermal or chemical activation methods with photochemical activation using UV-visible light irradiation, substituting a harsher mechanical/thermal system with a lighter, more selective optical system that activates the chromium catalyst under milder conditions
2Productivity
If a supported chromium catalyst in hexavalent oxidation state is used with UV-visible light irradiation, then high yields of methanol are achieved, but catalyst regeneration is required
Solution Approach 1:
The patent implements a catalyst regeneration process where the reduced chromium catalyst is recovered and re-oxidized to its hexavalent state, allowing the catalyst to be reused multiple times while maintaining high methanol yields, thus balancing productivity with operational complexity
Solution Approach 2:
The patent enables continuous operation by implementing an in-situ regeneration process where the chromium catalyst is re-oxidized during the reaction cycle, maintaining continuous catalytic activity and methanol production without requiring complete catalyst replacement or prolonged shutdowns
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves high yields of methanol without harsh conditions, allowing for efficient and continuous production of methanol from methane.
Implementation Method 1
contacting methane, water, and a supported chromium catalyst comprising chromium in a hexavalent oxidation state with a light beam at a wavelength in the UV-visible spectrum in an oxidizing atmosphere
Implementation Method 2
contacting methane and a supported chromium catalyst comprising chromium in a hexavalent oxidation state with a light beam at a wavelength in the UV-visible spectrum to form a reduced chromium catalyst, contacting the reduced chromium catalyst with water to form a reaction product comprising methanol
Data Source
AI summary
Processes for converting methane into methanol are disclosed in which methane, water, and a supported chromium (VI) catalyst are contacted with a light beam at a wavelength in the UV-visible spectrum in an oxidizing atmosphere in a single reactor to form a reaction product comprising methanol, followed by discharging a reactor effluent containing the reaction product from the single reactor, and then separating methanol from the reaction product. Processes to produce methanol using additional reactors also are described, as well as related methanol production systems.