Towards an efficient process for small-scale, decentralized conversion of methane to synthesis gas: combined reactor engineering and catalyst synthesis

Anthropogenic methane emissions not only pose an increasing global problem but can also be seen as an untapped renewable resource for hydrogen or liquid fuel production. Utilization of this resource requires the development of efficient processes for small-scale, decentralized methane conversion. We see catalytic partial oxidation of methane to synthesis gas as an ideal candidate for such a process. In the present study, we investigate the effect of heat-integration, flow rate and catalyst stability on syngas yields over alumina-supported Pt and Rh catalysts in a reverse-flow reactor configuration. We furthermore demonstrate that novel high-temperature stable nanocomposite catalysts can dramatically lower the noble metal requirement for this reaction, improve catalyst stability and further increase synthesis gas yields. Finally, we demonstrate that the combination of the reverse-flow reactor with these nanocomposite catalysts exploits the efficiency of this reaction route very effectively while maintaining a simple and compact reactor design.