Batch conversion of methane to methanol using copper load-ed mordenite: influence of the main variables of the process

Due to the demands of oxygenated derivatives of hydrocarbons for the industry, the methane (CH4) to methanol (MeOH) conversion through solid-state catalysis is a current topic, with definite questions and specific challenges. This work shows a statistical model that predicts the quantity of methanol produced through a batch conversion process employing copper-exchanged mordenite in accordance with a full factorial experimental design. Synthesis was performed through solid-state ion exchange from Cu(acac)2 and NH4-Mordenite, obtaining weight percentages (%Cu) of 1%, 3%, and 5%, which was followed by activation through calcination at a range of temperatures (Tcal) between 300-500 °C, as well as a reaction with methane under 2-10 bar pressure (P) in static conditions employing a batch reactor. The quantities of MeOH produced, and their yields were determined through a gas chromatography and mass spectrometry analysis of the reaction samples. Finally, the role and contribution of each of the variables considered in the conversion process were analyzed. By using a nonlinear model, a quadratic dependence with %Cu and P in the studied range of the variables was found, as well as a linear dependence with Tcal. Finally, for this experiment, the highest yields (µmol/g) were obtained with the following conditions: %Cu=3 %, P=6 bar, and Tcal=400 °C.