MIT engineers develop catalyst that converts methane into ‘useful’ polymers

CHEMICAL engineers from MIT have designed a catalyst that can convert methane into polymers, in a process they predict will turn methane “into something useful”. 

Converting methane, which is typically generated from agriculture and burning natural gas, into other compounds has proven difficult for engineers as it requires high temperatures and pressures to react with other molecules.

Backed by the US Department of Energy (DOE), MIT have developed a hybrid catalyst that works at room temperature and atmospheric pressure. 

The researchers say this could make it easier and more economical to deploy at sites that produce methane, including power plants and cattle barns. 

Two main components

The hybrid catalyst includes two components: a zeolite mineral and a naturally occurring enzyme. Zeolites have varied applications in carbon capture, usage, and storage (CCUS) and are typically used as adsorbents and catalysts for the conversion of methane to CO2. 

For this catalyst, a zeolite called iron-modified aluminium silicate reacts with the enzyme alcohol oxidase in a two-step process. The zeolite converts the methane to methanol, and the enzyme converts the methanol to formaldehyde. 

The catalyst also produces a hydrogen peroxide byproduct that is subsequently fed back into the zeolite as an oxygen source for the methane to methanol conversion. 

The researchers found that methane-to-formaldehyde selectivity could exceed 90% at room temperature. The reaction also does not require high pressures as the catalyst particles are suspended in water, which can absorb methane from the surrounding air. 

Manufacturing polymers

Once the formaldehyde has been produced, the researchers convert it into a synthetic resin polymer by adding urea, a molecule that contains nitrogen and is found in urine. 

The “urea-formaldehyde” can be used in many applications, including as a glue for plywood and particleboard, and as a component in kitchen utensils, buttons, and toys. 

Future applications

The MIT team are currently exploring the applications for the catalyst, including the possibility of its use as a crack sealant for pipes used to transport natural gas. 

These pipes are often susceptible to methane leakages. The polymer could also be applied in the manufacturing industry as a film to coat surfaces exposed to methane gas.