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

Patent metadata

Field	Value
Publication number	US-11365120-B2
Application number	US-202016775035-A
Country	US
Kind code	B2
Filing date	Jan 28, 2020
Priority date	Jan 28, 2020
Publication date	Jun 21, 2022
Grant date	Jun 21, 2022

Abstract

Modified red mud catalyst compositions, methods for production, and methods of use in steam 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 steam reforming over a modified red mud catalyst composition, the method comprising the steps of:
providing a methane feed and a steam feed to react 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 in the red mud material and a weight ratio of aluminum oxide to titanium oxide of about 1:0.27 in the red mud material; 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 particles of the modified red mud catalyst composition have a particle size of less than about 70 μm.

7. 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.

8. 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.

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

10. The method according to claim 1 , further comprising carrying out a water-gas shift reaction on the synthesis gas produced in the synthesis gas producing step.

11. The method according to claim 10 , where the step of carrying out the water-gas shift reaction applies the modified red mud catalyst composition as a catalyst.

12. The method according to claim 1 , where a molar ratio of the steam feed to the methane feed is between about 2:1 and about 4:1.

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

14. 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.

15. The method according to claim 1 , where the modified red mud catalyst composition further 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

• 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

• C01B3/26 Primary

  using catalysts · CPC title

• B01J23/005

  Spinels · CPC title

• C01B2203/0233

  the reforming step being a steam reforming step · CPC title