Pt on Fecralloy catalyses methane partial oxidation to syngas at high pressure

• Integrating high pressure syngas step with Fischer–Tropsch reduces investment.
• Fecralloy is a promising catalyst support that can operate at 1050 °C.
• We successful coated the Fecralloy with both Al2O3 and Al2O3/CeO2.
• Pt loaded on the coated Fecralloy performed equally well as Pt gauzes.
• At the same WHSV, methane conversion is higher at 20 bar than at 1 bar.

μ-Gas-to-Liquids technology (μ-GTL) can potentially reduce natural gas that is flared throughout the world. Integrating syngas production (at high pressure) together with Fischer–Tropsch in the same vessel addresses both investment costs and operating costs challenges related to μ-GTL. Pt on a Fecralloy woven metal support effectively oxidizes methane in the presence of O2/Ar mixtures. Both CO and H2 selectivity are higher over the Fecralloy compared to either a commercial Pt-gauze or a Pt/Rh gauze at 900 °C and 20 bar. The catalyst activity is stable over 1 h but the 80–300 nm Pt particles agglomerate and form popcorn shape particles that are as large as 1150 nm.

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