SBIR-STTR Award

Although there is an abundant supply of methane, the costs of transporting it are very high since it requires cryogenic conditions to liquefy the gas. Tremendous benefits could be derived if it were possible to convert the gas to a value added product and at the same time generate hydrogen during the process. Incorporating the products into more efficient systems for electricity generation would be an additional benefit. Although methane is a very stable molecule, transformation is usually achieved via a catalytic route. Therefore, this project will utilize a catalytic approach for the conversion of methane into a high-tech material, graphite nanofibers. Phase I involves (1) the catalytic conversion of methane via partial oxidation into a mixture of CO and H2, and (2) the subsequent decomposition of this mixture to produce tailored carbon nanostructures that can be used in fuel cell applications. Various catalysts will be evaluated in order to ascertain the most efficient and economical system. Commercial Applications and Other Benefits as described by awardee: Rather than burning natural gas in a wasteful manner, its conversion into graphics nanofibers should find use in the efficient and clean generation of electricity, contributing to the reduction of US dependence on foreign oil.

Although, there is an abundant supply of methane in natural gas, the costs of transporting it are very high; therefore converting the gas into a highly desirable value added product would result in enormous benefits. Because methane is a very stable molecule, this project will utilize a catalytic approach for its conversion into a high-tech material, graphite nanofibers. These solids would be suitable for use in a variety of applications, including electronic materials as well as energy storage and generation devices. Phase I demonstrated that high conversions of methane could be achieved by catalytic partial oxidation into a mixture of CO and H2 and that the decomposition of equivalent CO/H2 mixtures could generate highly crystalline nanotubular structures. A preliminary economic evaluation of the process indicated that these materials can be produced at relatively low cost. In Phase II, the two processes, partial oxidation and carbon nanostructure synthesis, will be integrated, and the effect of impurities present in both natural gas and the purification processes will be evaluated. Finally, in collaboration with industrial partners, a pilot plant for the large-scale production of carbon nanostructures from natural gas will be constructed.

Commercial Applications and Other Benefits as described by the awardee:
Carbon nanostructures should have applications ranging from anti-static shielding to advanced energy. The high production costs, which have hampered commercial implementation in the past, could be overcome by the use of natural gas as the source of solid carbon. A further advantage is that the hydrogen, which is formed in the process, could be used as an energy source for electricity generation using fuel cells.