“Soft” oxidative coupling of methane to ethylene: Mechanistic insights from combined experiment and theory

The oxidative coupling of methane to ethylene using gaseous disulfur (2CH₄ + S₂ → C₂H₄ + 2H₂S) as an oxidant (SOCM) proceeds with promising selectivity. Here, we report detailed experimental and theoretical studies that examine the mechanism for the conversion of CH₄ to C₂H₄ over an Fe₃O₄-derived FeS₂ catalyst achieving a promising ethylene selectivity of 33%. We compare and contrast these results with those for the highly exothermic oxidative coupling of methane (OCM) using O₂ (2CH₄ + O₂ → C₂H₄ + 2H₂O). SOCM kinetic/mechanistic analysis, along with density functional theory results, indicate that ethylene is produced as a primary product of methane activation, proceeding predominantly via CH₂ coupling over dimeric S–S moieties that bridge Fe surface sites, and to a lesser degree, on heavily sulfided mononuclear sites. In contrast to and unlike OCM, the overoxidized CS₂ by-product forms predominantly via CH₄ oxidation, rather than from C₂ products, through a series of C–H activation and S-addition steps at adsorbed sulfur sites on the FeS₂ surface. The experimental rates for methane conversion are first order in both CH₄ and S₂, consistent with the involvement of two S sites in the rate-determining methane C–H activation step, with a CD₄/CH₄ kinetic isotope effect of 1.78. The experimental apparent activation energy for methane conversion is 66 ± 8 kJ/mol, significantly lower than for CH₄ oxidative coupling with O₂. The computed methane activation barrier, rate orders, and kinetic isotope values are consistent with experiment. All evidence indicates that SOCM proceeds via a very different pathway than that of OCM.

The oxidative coupling of methane (OCM) with O₂ would seem to be a concise, direct route to convert methane, one of the most Earth-abundant carbon sources (1), to ethylene (2CH₄ + O₂ → C₂H₄ + 2H₂O), a key chemical intermediate (2, 3), and this process has been extensively studied (1, 4–19) since 1982 (20). Nevertheless, the widespread use of OCM is challenged by methane overoxidation to CO₂ and other oxygenates. Furthermore, the severe reaction conditions of nonoxidative pathways (2, 21–28) typically risk carbon deposition and catalyst deactivation (2, 21–26). In preliminary studies, we reported a 2CH₄ + S₂ → C₂H₄ + 2H₂S coupling process that moderates the methane overoxidation driving force using gaseous disulfur (S₂) as a “soft” oxidant (SOCM; Fig. 1A) (29). S₂ is isoelectronic with O₂, the major sulfur vapor species at 700 to 925 °C (30–32), and is a less aggressive oxidant than O₂ (33). In this scenario, elemental sulfur is recovered from the H₂S coproduct via the known Claus process (Fig. 1B) (30), in a cycle where sulfur mediates/moderates the high nonselective O₂ reactivity. SOCM achieved promising ethylene selectivity, raising intriguing mechanistic questions and the possibility of higher selectivity. Methane + S_2(g) ethylene selectivities near ∼20% are achieved over a PdS/ZrO₂ catalyst (29), and oxide precatalysts give selectivities near 33% (34).Open in a separate windowFig. 1.Energetic comparison between the oxidative coupling of methane with O₂ (OCM) and with S₂ (SOCM) and the pathway to recover elemental sulfur from H₂S. (A) Gibbs free energy of desired and overoxidation processes in OCM and SOCM at 800 and 1,050 °C. (B) Industrialized catalytic Claus process used to recover elemental sulfur from H₂S.Nevertheless, in contrast to extensive OCM (17, 35–39) and nonoxidative CH₄ coupling studies (40), far less is known about the SOCM reaction pathway. Post-SOCM X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), and elemental analysis (29, 34) indicate that the oxide precatalysts are predominantly sulfided. Density functional theory (DFT) analyses of molybdenum sulfide catalysts suggest that methane is activated at M–S or S–S sites to form surface-bound CH₃* species which dehydrogenate to form CH₂* (methylidene) species, which then couple to produce C₂H₄. It was proposed that CH₃* species can also desorb as methyl radicals which couple to form ethane (29). The overoxidation product, CS₂, was suggested to form via sulfur addition to methylidene surface intermediates (29).Kinetic, mechanistic, and theoretical analyses are needed to better understand the CH₄ conversion pathways to C₂H₄ and other products. In principle, there are two plausible pathways following methane activation: 1) H abstraction from adsorbed methyl species forms methylidene (CH₂*) and methylidyne (CH*) species then couple to C₂ products or undergo oxidation to CS₂ or 2) coupling of surface or gas phase methyl species form ethane, which then dehydrogenates to form ethylene or oxidizes to CS₂. For further SOCM optimization it is important to determine which pathways are operative, their relative rates, and the C₂ and CS₂ formation sites.Here we investigate SOCM pathways over a sulfided Fe₃O₄ precatalyst which affords C₂H₄ selectivities near 33%, complete oxide to sulfide conversion, minimal carbon deposition (coking), and 48-h SOCM stability at 950 °C (34). We first summarize SOCM phenomenology, followed by analysis of the Fe phases during sulfurization and SOCM. Next, kinetic/mechanistic studies focus on the methane and S₂ reaction orders, activation energetics, and isotope effects and probe the pathways governing C₂ vs. CS₂ formation. Complementary DFT calculations focus on reaction mechanisms, the active sites, and their role in product formation. The results are used in a microkinetic model to simulate reaction rates, apparent activation barriers, and reaction rate orders and to compare with experiment. Finally, SOCM and OCM are compared, revealing that they follow distinctly different pathways.