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New catalyst can convert methane into useful polymers

Although it is less abundant than carbon dioxide, methane gas contributes disproportionately to global warming because it traps more heat in the atmosphere than carbon dioxide, due to its molecular structure.

MIT chemical engineers have now designed a new catalyst that can convert methane into useful polymers, which could help reduce greenhouse gas emissions.

"What to do with methane has been a longstanding problem," says Michael Strano, the Carbon P. Dubbs, Professor of Chemical Engineering at MIT and the senior author of the study. "It's a source of carbon, and we want to keep it out of the atmosphere but also turn it into something useful."

The new catalyst works at room temperature and atmospheric pressure, which could make it easier and more economical to deploy at sites of methane production, such as power plants and cattle barns.

Daniel Lundberg Ph.D. and MIT postdoc Jimin Kim are the lead authors of the study, which appears in Nature Catalysis. Former postdoc Yu-Ming Tu and postdoc Cody Ritt are also authors of the paper.

Capturing methane

Methane is produced by bacteria known as methanogens, which are often highly concentrated in landfills, swamps, and other sites of decaying biomass. Agriculture is a major source of methane, and methane gas is also generated as a byproduct of transporting, storing, and burning natural gas. Overall, it is believed to account for about 15% of global temperature increases.

At the molecular level, methane is made of a single carbon atom bound to four hydrogen atoms. In theory, this molecule should be a good building block for making useful products such as polymers. However, converting methane to other compounds has proven difficult because getting it to react with other molecules usually requires high temperature and high pressures.

To achieve methane conversion without that input of energy, the MIT team designed a hybrid catalyst with two components: a zeolite and a naturally occurring enzyme. Zeolites are abundant, inexpensive clay-like minerals, and previous work has found that they can be used to catalyze the conversion of methane to carbon dioxide.

In this study, the researchers used a zeolite called iron-modified aluminum silicate, paired with an enzyme called alcohol oxidase. Bacteria, fungi, and plants use this enzyme to oxidize alcohols.

This hybrid catalyst performs a two-step reaction in which zeolite converts methane to methanol, and then the enzyme converts methanol to formaldehyde. That reaction also generates hydrogen peroxide, which is fed back into the zeolite to provide a source of oxygen for the conversion of methane to methanol.

This series of reactions can occur at room temperature and doesn't require high pressure. The catalyst particles are suspended in water, which can absorb methane from the surrounding air. For future applications, the researchers envision that it could be painted onto surfaces.

"Other systems operate at high temperature and high pressure, and they use hydrogen peroxide, which is an expensive chemical, to drive the methane oxidation. But our enzyme produces hydrogen peroxide from oxygen, so I think our system could be very cost-effective and scalable," Kim says.

Building polymers

Once formaldehyde is produced, the researchers showed they could use that molecule to generate polymers by adding urea, a nitrogen-containing molecule found in urine. This resin-like polymer, known as urea-formaldehyde, is now used in particle board, textiles and other products.

The researchers envision that this catalyst could be incorporated into pipes used to transport natural gas. Within those pipes, the catalyst could generate a polymer that could act as a sealant to heal cracks in the pipes, which are a common source of methane leakage.

The catalyst could also be applied as a film to coat surfaces that are exposed to methane gas, producing polymers that could be collected for use in manufacturing, the researchers say.

Strano's lab is now working on catalysts that could be used to remove carbon dioxide from the atmosphere and combine it with nitrate to produce urea. That urea could then be mixed with the formaldehyde produced by the zeolite-enzyme catalyst to produce urea-formaldehyde.