Technical and Economic Feasibility of Direct Methane Conversion for Hydrocarbon Production: Process Design and Techno-economic Analysis

In this study, we have developed a modelling and evaluation framework of a direct conversion of methane (CH4) to value-added chemicals including light hydrocarbons, FT fuels, and aromatics. As novel catalysts for a direct CH4 conversion are targeted to adapt to industrial applications, it is important to access the technological and economic feasibility. Various techniques in process systems engineering play a crucial role here in the application of the current or extended methodologies to support R&D targets and planning: identification of major cost- and energy-drivers, preliminary process scheme and debottleneck strategies. In this framework, we developed a conceptual conversion process, which consists of a reaction section of directly converting CH4 into hydrocarbons, and a separation section of sequentially integrated technologies for recycles of CH4, purifying ethylene, other C2+ hydrocarbon, and aromatics production. Then, the technical and economic feasibility of the process was evaluated, included a sensitivity analysis for identifying the bottleneck factors. Outstandingly, the direct methane conversion process achieves high energy efficiency (58.9 %), consumed a large amount of utility but still overcomes the intensive-energy penalty as in other petrochemical processes that are primarily due to the contribution of hydrogen as a byproduct. The ethylene as one of main products was produced at 0.97 $/kg that can be reduced and competitive to the market in promised scenarios. Otherwise, the study provides the perspective on improving catalyst performance (e.g. higher yield of ethylene), which is critical to achieve high technical performance and economic benefits.