Catalyst carrier for dry reforming processes

Patent metadata

Field	Value
Publication number	US-11059720-B1
Application number	US-202016775081-A
Country	US
Kind code	B1
Filing date	Jan 28, 2020
Priority date	Jan 28, 2020
Publication date	Jul 13, 2021
Grant date	Jul 13, 2021

Abstract

Methods for dry reforming with a red mud catalyst support composition, one method including providing a methane feed and carbon dioxide feed to react over the red mud catalyst support composition at increased temperature and increased pressure to produce synthesis gas comprising H 2 and CO, the composition comprising red mud material produced from an alumina extraction process from bauxite ore.

First claim

What is claimed is:

1. A method for dry reforming with a red mud catalyst support composition, the method comprising the steps of:
providing a methane feed and carbon dioxide feed to react in a dry reforming reaction over the red mud catalyst support composition at a temperature between about 500° C. to about 1000° C. and a pressure between about 5 bar and about 20 bar to produce synthesis gas comprising H 2 and CO, the red mud catalyst support composition comprising:
caustic red mud waste material produced from an alumina extraction process from bauxite ore, where the methane conversion rate via dry reforming is at least about 4% for at least about 6 hours.

2. The method according to claim 1 , where the red mud catalyst support composition further comprises at least one added catalytic metal, the added catalytic metal not being present at greater than about 1 wt. % in the caustic red mud waste material produced from the alumina extraction process from bauxite ore.

3. The method according to claim 2 , where the at least one added catalytic metal is a Periodic Table Group 3-12 metal.

4. The method according to claim 1 , where the increased temperature is between about 600° C. to about 800° C.

5. The method according to claim 1 , where the increased temperature is between about 700° C. to about 750° C.

6. The method according to claim 1 , where the increased pressure is between about 7 bar and about 15 bar.

7. The method according to claim 1 , where the increased pressure is about 14 bar.

8. The method according to claim 1 , where the methane conversion rate is at least about 10% for at least about 6 hours.

9. The method according to claim 1 , where gas hourly space velocity of the methane feed and carbon dioxide feed mixed is between about 1000 h −1 to 10000 h −1 .

10. The method according to claim 1 , where the red mud catalyst support composition includes at least one component selected from the group consisting of: Fe 2 O 3 , Al 2 O 3 , SiO 2 , Na 2 O, CaO, and TiO 2 .

11. The method according to claim 1 , where a majority of particles of the red mud catalyst support composition have a particle size of less than about 70 μm.

12. The method according to claim 1 , where a molar ratio of the methane feed to the carbon dioxide feed is between about 1:1 and about 1:1.75.

13. The method according to claim 1 , where produced H 2 is at least about 5 mol. % of produced products from the dry reforming reaction.

14. The method according to claim 1 , where the red mud catalyst support composition includes between about 20 wt. % and about 30 wt. % Al 2 O 3 , between about 5 wt. % and about 10 wt. % CaO, between about 15 wt. % and about 25 wt. % Fe 2 O 3 , between about 5 wt. % and about 15 wt. % Na 2 O, between about 15 wt. % and about 25 wt. % SiO 2 , and between about 5 wt. % and about 10 wt. % TiO 2 .

Assignees

• Saudi Arabian Oil Co

Inventors

• Fadhel Bandar A
• Alsolami Bandar H
• Bamagain Rami

Classifications

• Y02P20/141

  Feedstock · CPC title

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title

• C01B2203/0238

  the reforming step being a carbon dioxide reforming step · CPC title

• C01B2203/1623

  Adjusting the temperature · CPC title

• C01B2203/1041

  Composition of the catalyst · CPC title