Deep oxidation of methane using catalysts and carriers produced by self-propagating high-temperature synthesis Original Research Article

The self-propagating high-temperature synthesis (SHS) method has been used to produce a range of oxide catalysts which have been found to be active for deep oxidation of methane. The SHS materials studied include various compositions based on the systems Al–Mn–Mg–O, Mg–Cr–O, Mg–Al–O, Mg–Cr–Al–O and Cu–Cr–O with and without the addition of Cerium oxide and an epoxide additive. Specific compositions of these systems were identified as being significantly active for this process (maximum conversion of up to 76%) and were thus investigated further. Many of the systems can be easily formed by extrusion and SHS into catalytically active, mechanically strong, honeycomb block structures in one step. Coating these active blocks with a known catalyst (known to be active in this process), was found to enhance the overall catalytic activity giving maximum conversion of up to 100% and offers an inexpensive and viable alternative to traditional catalyst systems.