Plasma-Enhanced Catalytic Reactor for Selective Methane-to-Methanol Conversion

INVENTORS

• Dayne Swearer*
• James Ho

* Principal Investigator

NU 2024-211

IP STATUS

PCT patent application filed

DEVELOPMENT STAGE

TRL-4 Prototype Validated in Lab: Key functions have been demonstrated in a laboratory-scale prototype.

BACKGROUND
Methane conversion to methanol is challenging due to the strong C–H bond and the tendency for overoxidation. Current methods require extreme temperatures and pressures, leading to high energy consumption and limited selectivity. These limitations underscore the need for a more efficient and selective conversion process.

ABSTRACT
A plasma–catalyst–liquid interface (PCLI) enables one-step methane oxidation under ambient conditions. The technology infuses CuO catalysts into porous frits and leverages underwater pulsed plasma discharges to activate methane and water. Systematic experiments achieved a liquid-phase methanol selectivity of approximately 97% and a production rate of about 51.8 mmol MeOH per gram of CuO per hour. The process operates with a competitive specific energy consumption of 46.7 kWh per kilogram of methanol. This approach offers a promising, energy-efficient platform for electrified methane upgrading.

APPLICATIONS

• Methanol Production: Provides a scalable method for converting methane to methanol under mild conditions.
• Small Molecule Valorization: Enables production of oxygenates such as acetic acid and propanol.
• Chemical Manufacturing: Offers a novel route for producing high-value chemical building blocks.
• Sustainable Fuel Production: Presents an efficient alternative to conventional steam methane reforming.

ADVANTAGES

• High Selectivity: Achieves near 97% liquid-phase methanol selectivity.
• Energy Efficient Operation: Operates under ambient conditions with competitive electricity consumption.
• Mild Process Conditions: Eliminates the need for extreme temperatures and pressures.
• Versatile Platform: Capable of producing a range of value-added chemicals.

PUBLICATIONS

• Dayne Swearer et al., "Direct Methane Oxidation via Plasma Catalyst Interface", Journal of the American Chemical Society, 2026

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CATEGORY/INDUSTRY PIPELINE

• Engineering & Technology
• Energy & Sustainability
• Materials and Industrial Processes

KEYWORDS
Methane oxidation, Methanol production, Plasma catalysis, Nonthermal plasma, Catalyst-liquid interface, Chemical valorization, Sustainable fuels, CuO catalyst