Synthesis of methyl formate via two-step methane partial oxidation

Using a two reactor system the direct catalytic conversion of methane to methyl formate is achieved. The two-step reaction sequence consists of the partial oxidation of methane to HCHO at 600-700 degrees C on a SiO2-based catalyst and the dimerisation of HCHO to methyl formate at 130-170 degrees C on amphoteric oxides such as TiO2, ZrO2 and Al2O3. By adopting a continuous flow recycle reactor mode methyl formate yield up to 12% has been attained. A preliminary analysis of the factors controlling activity and reaction pattern of oxide catalysts in the dimerisation of formaldehyde is given. (C) 1998 Elsevier Science B.V. All rights reserved.