New catalyst turns methane into fuel

July 04, 2026

Scientists in the United States have developed a low-cost, sulfur-resistant catalyst that can transform wasted methane into valuable liquid chemicals and fuels, offering a promising solution for reducing emissions while making better use of natural gas resources.

The breakthrough comes from researchers at the U.S. Department of Energy’s Brookhaven National Laboratory (BNL), who focused on molybdenum disulfide (MoS₂)—an abundant and inexpensive industrial material. Their study demonstrates that, with only minor modifications, the catalyst can efficiently convert methane into methyl peroxide and other liquid oxygenates at temperatures below 100°C (212°F).

Methyl peroxide is an important intermediate used in the production of methanol, a versatile liquid fuel and essential feedstock for numerous industrial applications.

Low-cost catalyst offers high methane conversion efficiency

According to Dr. Sanjaya Senanayake, the study’s corresponding author, the catalyst delivers exceptional methane conversion performance while maintaining remarkable selectivity toward valuable products.

The research showed that the material produces high yields of methanol precursors, opening new possibilities for cleaner chemical manufacturing and more efficient utilization of natural gas.

Turning wasted methane into transportable liquid chemicals

Large quantities of methane produced at remote oil and gas fields are often flared or vented because transporting the gas requires expensive pipeline infrastructure. This practice wastes a valuable energy source while releasing significant greenhouse gas emissions into the atmosphere.

The Brookhaven team believes its new catalyst could help solve this long-standing problem by converting stranded methane directly into liquid chemicals that are far easier and cheaper to transport.

Researcher Dr. Steve Farrell explained that the technology effectively transforms an otherwise wasted resource into products with real commercial value.

Sulfur-tolerant design eliminates a major industry challenge

One of the catalyst's biggest advantages is its natural resistance to sulfur contamination.

Conventional methane-conversion catalysts often lose efficiency because sulfur compounds commonly found in raw natural gas poison their active surfaces. Since molybdenum disulfide already contains sulfur within its crystal structure, it remains highly stable under these challenging conditions.

Co-author Dr. Juan Jiménez noted that natural gas composition varies significantly from one location to another. The research team is therefore developing multiple catalyst materials capable of processing different methane sources across the United States and worldwide.

Advanced x-ray analysis reveals how the catalyst works

To better understand the catalyst's behavior, scientists used advanced X-ray spectroscopy at Brookhaven's National Synchrotron Light Source II, allowing them to observe atomic-level structural changes while the chemical reaction occurred in real time.

During testing, methane reacted with diluted hydrogen peroxide in water at approximately 75°C (167°F). The catalyst converted methane into liquid oxygenates with complete selectivity, producing only the desired family of chemical products.

Performance equaled—and in some cases surpassed—that of significantly more expensive catalysts based on precious metals such as palladium and rhodium, despite requiring only minimal treatment before use.

Durable catalyst could lower methane processing costs

Further experiments revealed that the catalyst became more metallic while operating, enabling electrons to move more freely and improving reaction efficiency. At the same time, its crystal structure remained stable, indicating strong durability and the potential for repeated industrial use.

Researchers also discovered that hydroxyl radicals generated from hydrogen peroxide play a crucial role in breaking methane's exceptionally strong carbon-hydrogen bonds. Rather than allowing these reactive molecules to trigger unwanted side reactions, the catalyst directs them toward forming a single, highly desirable product stream.

Patent filed for promising methane conversion technology

The researchers believe their discovery could pave the way for affordable, sulfur-resistant methane conversion technologies capable of reducing emissions while creating valuable fuels and chemical feedstocks from wasted natural gas.

Recognizing the commercial potential of the innovation, Brookhaven Science Associates has already filed a provisional patent covering the catalyst and its methane conversion process.