Catalyst carrier for autothermal reforming processes

Patent metadata

Field	Value
Publication number	US-11242246-B2
Application number	US-202016775102-A
Country	US
Kind code	B2
Filing date	Jan 28, 2020
Priority date	Jan 28, 2020
Publication date	Feb 8, 2022
Grant date	Feb 8, 2022

Abstract

Methods for autothermal reforming with a red mud catalyst support composition, one method including providing a methane feed with oxygen and carbon dioxide 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 autothermal reforming with a red mud catalyst support composition, the method comprising the steps of:
providing a methane feed with oxygen and carbon dioxide to react in an autothermal 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:
red mud waste material produced from an alumina extraction process from bauxite ore with a weight ratio of aluminum oxide to iron oxide of about 1:0.74 and a weight ratio of aluminum oxide to titanium oxide of about 1:0.27, where produced H 2 is at least about 10 mol. % of produced products from autothermal reforming 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 originally being present at greater than about 1 wt. % in the 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 about 750° C.

6. The method according to claim 1 , where the increased pressure is between about 10 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 gas hourly space velocity of the methane feed with oxygen and carbon dioxide is between about 1000 h −1 to 10000 h −1 .

9. 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 .

10. 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.

11. The method according to claim 1 , where a molar ratio is about 2:1:1 for CH 4 :CO 2 :O 2 .

12. The method according to claim 1 , where the red mud catalyst support composition includes between about 5 wt. % and about 10 wt. % CaO, between about 5 wt. % and about 15 wt. % Na 2 O and between about 15 wt. % and about 25 wt. % SiO 2 .

Assignees

• Saudi Arabian Oil Co

Inventors

• Bamagain Rami
• Fadhel Bandar A
• Alsolami Bandar H
• Albuali Mohammed A

Classifications

• B01J35/40

  characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77) · CPC title

• C01B2203/1241

  Natural gas or methane · CPC title

• C01B2203/1082

  Composition of support materials · CPC title

• B01J23/02

  of the alkali- or alkaline earth metals or beryllium · CPC title

• C01B2203/0244

  the reforming step being an autothermal reforming step, e.g. secondary reforming processes · CPC title