Economically viable co-production of methanol and sulfuric acid via direct methane oxidation

Abstract

The direct oxidation of methane to methanol has been spotlighted research for decades, but has never been commercialized. This study introduces cost-effective process for co-producing methanol and sulfuric acid through a direct oxidation of methane. In the initial phase, methane oxidation forms methyl bisulfate (CH3OSO3H), then transformed into methyl trifluoroacetate (CF3CO2CH3) via esterification, and hydrolyzed into methanol. This approach eliminates the need for energy-intensive separation of methyl bisulfate from sulfuric acid by replacing the former with methyl trifluoroacetate. Through the superstructure optimization, our sequential process reduces the levelized cost of methanol to nearly two-fold reduction from the current market price. Importantly, this process demonstrates adaptability to smaller gas fields, assuring its economical operation across a broad range of gas fields. The broader application of this process could substantially mitigate global warming by utilizing methane, leading to a significantly more sustainable and economically beneficial methanol industry.

Liquid-Phase Selective Oxidation of Methane to Methane Oxygenates

“…Accordingly, the MBS produced should be separated from H2SO4 before it is converted to methanol [45]. Im et al [46] proposed a modified reactive distillation process in which HTFA was used as a mediator to form MeTFA and H2SO4 from MBS to facilitate the separation of methanol from a mixture of MBS and H2SO4 (Figure 8). Compared with homogeneous catalysts, heterogenized homogeneous or heterogeneous catalysts have practical advantages [43].…”

“…Reaction scheme for the direct synthesis of methanol from methane with SO 3 using HTFA as a mediator in the separation. The blue letters mean chemical species related to methane[46].…”