METHANE-TO-PETROCHEMICAL PLATFORM

Ethane & Ethylene Solution

Converting methane-rich feedstocks into hydrogen and C2 hydrocarbon value through a photochemical methane conversion platform.

Technology Architecture

Methane Feed
Biomethane / CBG / Methane-rich gas
→
Gas Conditioning
Purification and process conditioning
→
UV-Hg Photochemical Reactor
Photochemical methane activation
→
Product Formation
H2 + C2 hydrocarbons
→
Product Separation
Hydrogen, ethane and other hydrocarbons

Ethane → Ethylene → Polymer Value

The platform is designed around methane activation followed by the formation and recovery of C2 hydrocarbons. Ethane (C2H6) can serve as an intermediate product for downstream conversion to ethylene (C2H4).

Hydrogen (H2)

Recovery of hydrogen generated during methane conversion.

Ethane (C2H6)

Recovery of ethane as an intermediate C2 hydrocarbon product for downstream value addition.

Ethylene (C2H4)

Potential downstream conversion of ethane into ethylene for petrochemical and polymer applications.

Photochemical Reaction Concept

The proposed reaction pathway involves mercury photosensitisation, methane activation and subsequent radical reactions leading to hydrogen and ethane formation. Ethane can then undergo downstream dehydrogenation to produce ethylene.

1. Mercury Excitation
Hg + hν → Hg*
2. Methane Activation
Hg* + CH4 → CH3• + H• + Hg
3. Hydrogen Formation
H• + H• → H2
4. Ethane Formation
CH3• + CH3• → C2H6
5. Ethane Dehydrogenation
C2H6 → C2H4 + H2

The process uses UV-induced mercury excitation to facilitate gas-phase methane activation and radical formation, followed by hydrogen and C2-hydrocarbon formation.

UV-Hg Photochemical Reactor Concept

The reactor concept combines controlled methane-rich gas flow with ultraviolet irradiation and mercury photosensitisation to initiate photochemical methane activation.

Feed
Methane-rich gas
UV Activation
Mercury photosensitisation
Reaction
Gas-phase methane activation
Products
H2 + C2 hydrocarbons

Patent-Backed Technology Platform

Indian Patent No. 382351

Title: Method for Producing High Amount of Energy

Application No.: 1968/DEL/2013
Granted: 23 November 2021

Indian Patent No. 585517

Patent of Addition

Application No.: 202411005986
Filed: 30 January 2024

Potential Alternative to Naphtha-Derived Carbon

Conventional ethylene production is strongly associated with hydrocarbon feedstocks such as naphtha and ethane. The proposed platform explores a methane-to-C2 pathway in which methane-rich resources can be converted into ethane and potentially further processed toward ethylene.

This approach could diversify potential ethylene feedstock pathways while creating value from methane-rich resources.

Platform Advantages

Net-Zero-Aligned Potential

The technology has potential to support lower-carbon methane valorisation when combined with suitable feedstocks, renewable energy integration, methane-leakage control and efficient product recovery.

Actual emissions performance will depend on energy sourcing, methane leakage, process efficiency and lifecycle assessment.

Future Scope

Ethane (C2H6) → Ethylene (C2H4) → Polymer / Chemical Value
Ethane (C2H6) → Potential Ethanol (C2H5OH) Pathway
Potential downstream value-addition pathways requiring additional chemical processing and validation.
Polyethylene
Ethylene as a feedstock for polymer value chains.
Petrochemical Intermediates
Potential downstream chemical applications of C2 hydrocarbons.
Future Ethanol Pathway
Potential downstream conversion of ethane into value-added oxygenated products, including ethanol, through suitable chemical processing routes.
Biomethane & CBG
Utilisation of methane-rich renewable feedstocks.
Distributed Systems
Potential modular deployment close to methane sources.

Development & Scale-Up Pathway

Laboratory
Proof of Concept
→
Prototype
Process Development
→
Pilot
Scale-Up & Validation
→
Commercial
Industrial Deployment

From Methane to Molecules

Enabling a lower-carbon route to hydrogen and petrochemical value.