Catalyst carrier for bi-reforming processes

Patent metadata

Field	Value
Publication number	US-11247898-B2
Application number	US-202016775119-A
Country	US
Kind code	B2
Filing date	Jan 28, 2020
Priority date	Jan 28, 2020
Publication date	Feb 15, 2022
Grant date	Feb 15, 2022

Abstract

Methods for bi-reforming with a red mud catalyst support composition, one method including providing a methane feed in the presence of carbon dioxide and steam 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 bi-reforming with a red mud catalyst support composition, the method comprising the steps of:
providing a methane feed in the presence of carbon dioxide and steam to react in a bi-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 1 mol. % of produced products from the bi-reforming reaction for at least about 5 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 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 in the presence of carbon dioxide and steam 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 of methane:carbon dioxide:steam is about 3:1:2.

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, between about 15 wt. % and about 25 wt. % SiO 2 .

Assignees

• Saudi Arabian Oil Co

Inventors

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

Classifications

• B01J35/40

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

• C01B2203/1041

  Composition of the catalyst · CPC title

• C01B2203/0233

  the reforming step being a steam reforming step · CPC title

• B01J37/009

  Preparation by separation, e.g. by filtration, decantation, screening · CPC title

• C01B2203/1082

  Composition of support materials · CPC title