CONVERSION OF METHANE TO PROPANAL AT AMBIENT PRESSURE

A continuous process is described using three catalysts in sequence for the synthesis of the C3 oxygenate propanal, from methane and air, at 1 atm in 13.2 % yield. The three catalytic reactions are the methane oxidative coupling to ethene, methane partial oxygenation to synthesis gas, and the hydroformylation of ethene. The combined process implies that a higher yield of propanal can be obtained than for the formation of ethene from the oxidative coupling reaction alone. We have examined the effect of reaction conditions on the yield of propanal.