Research Projects

The proposed research aims to develop catalytic structured reactors for the oxidative coupling of methane (OCM), a process that can transform methane into valuable C₂ hydrocarbons like ethylene. Ethylene, a critical building block of the chemical industry, is traditionally produced through energy-intensive petrochemical cracking processes. OCM presents a more sustainable alternative production method by utilizing a potent greenhouse gas to produce ethylene with lower environmental impact and economic costs. Despite its promise, several challenges hinder the industrial viability of OCM. These include the need for high operating temperatures (700–900°C), low ethylene selectivity, and significant by-product formation (e.g., CO, CO₂), all of which necessitate advanced catalysts and reactor designs to meet industrial benchmarks of 35% ethylene yield per pass (without recycling). Most of the earlier research efforts are focused on optimizing catalysts, such as Mn-Na₂WO₄/SiO₂ and Li/MgO, etc., and exploring innovative reactor designs, including microchannel reactors and membrane reactors etc. Although catalysts like Mn-Na₂WO₄/SiO₂ exhibit relatively high yields, they still fall short of industrial requirements. Metallic microchannel reactors offer advantages such as superior heat and mass transfer properties, uniform temperature distribution, and low-pressure operation, which have the potential to enhance OCM performance significantly. However, several challenges are associated with metal microchannel reactors, such as catalyst washcoating on metal substrates and selecting suitable reactor materials etc. This project seeks to address these gaps by integrating advancements in catalyst design and reactor engineering. The proposed research is focused on improving the surface basicity and oxygen storage capacity of Li/MgO and Mn-Na₂WO₄/SiO₂ catalysts to enhance selectivity and thermal stability. Simultaneously, FeCralloy microchannel reactors will be developed to mitigate issues like hotspot formation and ensure efficient heat and mass transfer. In this project, a suitable catalyst will be developed for the OCM process, along with process parameter optimization and thermodynamic equilibrium studies. The application of microchannel reactors will also be explored to further enhance the process efficiency and ethylene yield. By addressing fundamental and applied challenges, this holistic approach aims to create a scalable and commercially viable OCM process for ethylene production, which will significantly contribute to global efforts in greenhouse gas utilization and process intensification.