Process intensification in the catalytic conversion of natural gas to fuels and chemicals

This paper explores alternative technologies for the conversion of natural gas to higher-value products. Because of methane’s chemical stability, all practical processes require elevated temperature (e.g., T > 700°C) and catalysts to activate the methane. Some approaches are mature and widely practiced at the commercial scale (e.g., steam reforming and Fischer–Tropsch synthesis). Others are emerging, based on laboratory-scale experimentation (e.g., oxidative coupling of methane). In all cases, the present paper is concerned with aspects of process intensification, seeking chemical methods and reactor implementations that can improve overall performance. Performance metrics include reactor size, energy efficiency, conversion rates, and product selectivity. Process intensification approaches include integrated microchannel reactors and heat exchangers as well as a range of permselective membranes.