Electrochemical partial oxidation
of methane to methanol is a promising
approach to the transformation of stranded methane resources into
a high-value, easy-to-transport fuel or chemical. Transition metal
oxides are potential electrocatalysts for this transformation. However,
a comprehensive and systematic study of the dependence of methane
activation rates and methanol selectivity on catalyst morphology and
experimental operating parameters has not been realized. Here, we
describe an electrochemical method for the deposition of a family
of thin-film transition metal (oxy)hydroxides as catalysts for the
partial oxidation of methane. CoO
x
, NiO
x
, MnO
x
, and CuO
x
are discovered to be active for the partial
oxidation of methane to methanol. Taking CoO
x
as a prototypical methane partial oxidation electrocatalyst, we
systematically study the dependence of activity and methanol selectivity
on catalyst film thickness, overpotential, temperature, and electrochemical
cell hydrodynamics. Optimal conditions of low catalyst film thickness,
intermediate overpotentials, intermediate temperatures, and fast methanol
transport are identified to favor methanol selectivity. Through a
combination of control experiments and DFT calculations, we show that
the oxidized form of the as-deposited (oxy)hydroxide catalyst films
are active for the thermal oxidation of methane to methanol even without
the application of bias potential, demonstrating that high valence
transition metal oxides are intrinsically active for the activation
and oxidation of methane to methanol at ambient temperatures. Calculations
uncover that electrocatalytic oxidation enables reaching an optimum
potential window in which methane activation forming methanol and
methanol desorption are both thermodynamically favorable, methanol
desorption being favored by competitive adsorption with hydroxide
anion.