Nickel-containing catalyst composition having enhanced acidity for autothermal reforming processes

Patent metadata

Field	Value
Publication number	US-11286160-B2
Application number	US-202016775050-A
Country	US
Kind code	B2
Filing date	Jan 28, 2020
Priority date	Jan 28, 2020
Publication date	Mar 29, 2022
Grant date	Mar 29, 2022

Abstract

Modified red mud catalyst compositions, methods for production, and methods of use in autothermal reforming, the composition comprising: red mud material produced from an alumina extraction process from bauxite ore; and nickel oxide, the nickel oxide present at between about 5 wt. % to about 40 wt. % of the modified red mud catalyst composition.

First claim

That claimed is:

1. A method for autothermal reforming over a modified red mud catalyst 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 modified red mud catalyst 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 modified red mud catalyst composition comprising:
red mud 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; and
nickel oxide, the nickel oxide present at between about 5 wt. % to about 40 wt. % of the modified red mud catalyst composition.

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

3. The method according to claim 1 , where the temperature is about 750° C.

4. The method according to claim 1 , where the pressure is between about 10 bar and about 15 bar.

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

6. 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 .

7. The method according to claim 1 , where the 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 .

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

9. The method according to claim 1 , where the nickel oxide is present at between about 10 wt. % to about 30 wt. % of the modified red mud catalyst composition.

10. The method according to claim 1 , where the nickel oxide is present at between about 15 wt. % to about 25 wt. % of the modified red mud catalyst composition.

11. The method according to claim 1 , where the nickel oxide is present at about 20 wt. % of the modified red mud catalyst composition.

12. The method according to claim 1 , where methane conversion is greater than at least about 40% for at least about 6 hours.

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

14. The method according to claim 1 , where produced H 2 is at least about 25 mol. % of produced products from the reaction for at least about 5 hours.

15. The method according to claim 1 , where the Brunauer-Emmett-Teller (BET) surface area of the modified red mud catalyst composition is between about 50 m 2 /g and about 90 m 2 /g.

16. The method according to claim 1 , where the composition includes between about 2 wt. % and about 10 wt. % CaO, and between about 5 wt. % and about 20 wt. % SiO 2 .

Assignees

• Saudi Arabian Oil Co

Inventors

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

Classifications

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title

• B01J35/40

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

• C01B2203/1058

  Nickel catalysts · CPC title

• C01B2203/0244

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

• C01B3/40 Primary

  characterised by the catalyst · CPC title