Co-generation of energy and synthesis gas by partial oxidation of methane

Catalytic partial oxidation (CPO) of methane was carried out over a Rh/γ-Al2O3 foam monolith catalyst at pressures up to 1.5 MPa and normal gas flow rates of up to 35 L/min. It was shown that the reaction took place autothermally once the reaction had lit off. Maintenance of short catalyst contact time and reactor cooling was necessary to prevent coke formation at elevated pressures.The concept of obtaining both syngas and energy from the partial oxidation of methane was tested using two geometries. In the first, the hot exit gases from partial oxidation catalysts were used to drive a turbine. In the second, a partial oxidation catalyst was deposited on turbine blade materials, converting ca. 55% of feed methane to syngas. The novelty in generating energy by this method lies in the combination of CPO, the catalyst configuration and the ability to capture energy via the turbine without further processing of valuable syngas product. Based on the conditions of pressure, conversion and gas composition used in this study, it has been calculated that up to 60 MW of power could be generated from 2500 tonnes per day (TPD) methane feed when the combination of CPO for syngas generation and a turbine are used.