SELECTIVE OXIDATION OF METHANE WITH AIR OVER SILICA CATALYSTS

Partial oxidation of methane by oxygen to form formaldehyde, carbon oxides, and C2 products (ethane and ethene) has been studied over silica catalyst supports (fumed Cabosil and Grace 636 silica gel) in the 630-780-degrees-C temperature range under ambient pressure. The silica catalysts exhibit high space time yields (at low conversions) for methane partial oxidation to formaldehyde, and the C2 hydrocarbons were found to be parallel products with formaldehyde. Short residence times enhanced both the C2 hydrocarbons and formaldehyde selectivities over the carbon oxides even within the differential reactor regime at 780-degrees-C. This suggests that the formaldehyde did not originate from methyl radicals, but rather from methoxy complexes formed upon the direct chemisorption of methane at the silica surface at high temperature. Very high formaldehyde space time yields (e.g., 812 g/kg cat h at the gas hourly space velocity = 560 000 l(NTP)/kg cat h) could be obtained over the silica gel catalyst at 780-degrees-C with a methane/air mixture of 1.5/1. These yields greatly surpass those reported for silicas earlier, as well as those over many other catalysts. Low CO2 yields were observed under these reaction conditions, and the selectivities to formaldehyde and C2 hydrocarbons were 28.0 and 38.8%, respectively, at a methane conversion of 0.7%. A reaction mechanism was proposed for the methane activation over the silica surface based on the present studies, which can explain the product distribution patterns (specifically the parallel formation of formaldehyde and C2 hydrocarbons).