Formaldehyde (FA) is an important chemical intermediate with an annual production of 52 Mte. Currently, FA is synthesised 𝑣𝑖𝑎 oxidative dehydrogenation (ODH) of methanol, whereby methanol and air are passed either over Ag-based catalysts at 600‑720°C or over Fe‑Mo‑based catalysts at 250‑400°C. Both catalytic processes yield 80‑90% FA, however, challenges include: (1) the processes are prone to thermal deactivation, either because of Ag sintering or MoO₃ volatilisation; and (2) both methods pose significant explosive risks because flammable mixtures of methanol and oxygen are used. Here, we demonstrate the first-ever production of FA using a chemical looping (CL) ODH setup. Instead of gaseous oxygen, the CL‑ODH approach provides oxygen to the ODH reaction from a mixed metal oxide (SrFeO₃), termed an oxygen carrier. Supporting Ag on SrFeO₃ eliminates the need to co-feed methanol and oxygen, improving process safety. The CL-ODH of methanol over Ag/SrFeO₃ was evaluated in a packed bed at 200‑300°C, with 4vol% CH₃OH/N₂ fed at gas hourly space velocities (GHSVs) of 9,600‑40,000 h⁻¹; higher GHSVs were employed to limit the overoxidation of FA and its thermal decomposition to CO and H₂. Preliminary experiments demonstrated promising results and produced FA at 15% selectivity and with 25% conversion of methanol, giving a yield of 4%. Throughout 40 CL-ODH cycles, Ag/SrFeO₃ showed no signs of deactivation. The CL-ODH strategy demonstrates potential for the low-temperature production of FA, with enhanced process safety and catalytic stability. Future research will focus on improving FA yield through process optimisation and modifications to the oxygen carrier.
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