Solid oxide cells for methane conversion

• Grant number: 24/19207-9
• Support Opportunities: Regular Research Grants
• Start date: February 01, 2025
• End date: January 31, 2027
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Nonmetallic Materials
• Mobility Program: SPRINT - Projetos de pesquisa - Mobilidade
• Principal Investigator: Fabio Coral Fonseca
• Grantee: Fabio Coral Fonseca
• Principal researcher abroad: Marlu Cesar STEIL
• Institution abroad: Centre National de la Recherche Scientifique, France
• Host Institution: Instituto de Pesquisas Energéticas e Nucleares (IPEN). Secretaria de Desenvolvimento Econômico (São Paulo - Estado). São Paulo , SP, Brazil
• Associated research grant: 17/11937-4 - A sustainable path to methane conversion by advanced electrochemical technologies, AP.PCPE

Abstract

Converting methane (CH4) into value-added products such as ethylene, ethane, or methanol in an economical and environmentally friendly manner remains a significant challenge in chemistry. Light olefins, such as ethylene (C2), are important building blocks for a wide range of products ubiquitous in our society, such as polymers, cosmetics, and lubricants, and represent a huge challenge for more sustainable petrochemicals. As pointed out by the International Energy Agency, decarbonizing the petrochemical industry is a blind spot in the energy transition, essential for ensuring the sustainability of these materials' production. Methane (or biomethane), as a widely available raw material, can be converted into these chemicals via an indirect route through synthesis gas (a mixture of CO and H2). However, the production of synthesis gas is energy-intensive and capital-intensive. The conversion of methane to ethylene (C2H4) is considered potentially more productive than other products due to the utility of ethylene in a wide variety of industrial processes as a chemical feedstock. Currently, ethylene is produced through the cracking of naphtha at high temperatures (> 750 °C), which is an energy-intensive and carbon-intensive process. Therefore, direct conversion of methane to ethylene without the multi-step process is a significant advancement. Traditionally, in heterogeneous catalysis, the oxidative coupling of methane (OCM) is the reaction that allows direct conversion to higher hydrocarbons, especially ethylene. However, the main obstacle is that methane is quite stable, has strong C-H bonds, and its activation remains a challenge. During OCM, over-oxidation to CO2 and H2O can occur, as the partial oxidation products of methane, such as ethane and ethylene, are less stable than methane, thus creating selectivity challenges. Therefore, developing more efficient viable catalysts and processes is a critical issue. Our proposal aims to continue the work started at the CPE FAPESP-Shell CINE, discontinued by the company. We have a patent application in progress and preliminary results pointing to promising methane conversion routes overcoming some limitations of heterogeneous catalysis using SOC electrochemical cells. LEPMI has extensive experience in these electrochemical reactors and has collaborated with IPEN in this development. In fact, there is an ongoing French project at LEPMI, in collaboration with IPEN, funding a postdoctoral researcher on this topic and ensuring the French counterpart for this Sprint. In this Sprint project, the planned activities include the manufacture and testing of SOC with advanced catalysts developed to be tested in methane conversion experiments by an innovative electrochemical method coupled with catalytic reactions. The present proposal aims to test new electrode materials that simplify the manufacture of SOC. Joint activities and bilateral missions between IPEN and LEPMI are planned, which will allow for faster advancement of the planned tests. (AU)