Micro-structured functional catalytic eramic hollow fibre membrane reactor for methane conversion

Abstract

The most significant issue associated with the oxidative methane conversion processes is the use of pure oxygen, which is extremely expensive. By using a dense oxygen permeable membrane reactor, a possible decrease in the air separation cost can be expected due to the elimination of oxygen plants. Besides, higher reaction yields can be attained due to the selective dosing of oxygen into the reaction zone. This thesis focuses on the development and potential application of functional micro-structured catalytic ceramic hollow fibre membrane reactor (CHFMR) in oxidative methane conversion to syngas (known as partial oxidation of methane (POM)) and to ethane and ethylene (known as oxidative coupling of methane (OCM)).

As the membrane reactor performance is crucially dependant on the oxygen permeation rate and good contact between oxygen and methane, two types of membrane reactor designs were proposed in this study. The first design involves the development of CHFMR that consists of two layers i.e.: an outer oxygen separation layer and an inner catalytic substrate layer, known as dual-layer catalytic hollow fibre membrane reactor (DL-CHFMR). The DL-CHFMR was fabricated via a novel single-step co-extrusion and co-sintering technique, in which the thickness and the composition of each functional layer can be controlled in order to improve reactor performance.

The second design involves the development of CHFMR with an outer dense separation layer integrated with conical-shaped microchannels open at the inner surface, created via a viscous fingering induced phase inversion technique. Besides substantially reducing resistance across the membrane, the microchannels can also act as a structured substrate where catalyst can be deposited for the catalytic reaction to take place, forming a catalytic hollow fibre membrane microreactor (CHFMMR). Although the CHFMRs discussed in this study are designed particularly for POM and OCM, there are general advantages of such membrane structures and reactor designs for improving the overall reaction performance. Therefore, these reactor designs can be transferred to other important catalytic reactions.