Methane conversion technology and economics

The direct conversion of methane to petrochemical feedstocks and to transportation fuels, by-passing the synthesis gas step, is a continuing challenge in catalytic process development. There are high economic incentives to commercialize direct methane conversion to formaldehyde and methanol, and even higher economic incentives for conversion to ethylene and aromatic hydrocarbons. Current process developments in the direct conversion of methane to methanol, formaldehyde, ethylene and aromatics are reviewed. The processes are discussed in terms of process conditions, catalysts used, methane conversion, and product selectivities. The economics of direct methane conversion are discussed. An economic evaluation of ethylene production by the oxidative coupling of methane has been carried out. Results show that laboratory methane conversions and product selectivities are now sufficiently high to make this process economically attractive compared with conventional ethylene production.