Process and system for steel and hydrogen production using recycled ferrous scrap and natural gas

Patent metadata

Field	Value
Publication number	US-11680299-B2
Application number	US-201916560627-A
Country	US
Kind code	B2
Filing date	Sep 4, 2019
Priority date	Sep 4, 2019
Publication date	Jun 20, 2023
Grant date	Jun 20, 2023

Abstract

A method for producing a homogenous molten composition and a fluid product is disclosed. For example, the method includes producing a first molten metal composition in an enclosed volume, contacting a hydrocarbon reactant with the first molten metal composition, decomposing the hydrocarbon reactant into at least one fluid product and carbon, forming a metal alloy from a mixture of the carbon and the first molten metal composition, and separating a homogenous second molten composition from the metal alloy.

First claim

What is claimed is:

1. A method for producing a homogeneous molten composition and a fluid product, comprising:
producing a first molten metal composition in an enclosed volume, wherein the first molten metal composition comprises iron and a metal, wherein the metal comprises at least one of: iron, nickel, manganese, cobalt, scandium, or lanthanum;
contacting a hydrocarbon reactant with the first molten metal composition;
decomposing the hydrocarbon reactant into at least one fluid product and carbon in a solid phase;
dissolving the carbon in the solid phase into the first molten metal to form a metal alloy from a mixture of the carbon and the first molten metal composition;
separating a homogenous second molten composition from the metal alloy; and
removing the at least one fluid product and the homogenous second molten composition from the enclosed volume.

2. The method of claim 1 , wherein the metal has a boiling point of less than 800 degrees Celsius (° C.) and a vapor pressure of at least 1 millimeter (mm) Hg at 1500° C.

3. The method of claim 1 , wherein the producing the first molten metal composition comprises heating and maintain the enclosed volume at a temperature between 500 degrees Celsius (° C.) to 1500° C. at 1-2 bar of pressure.

4. The method of claim 1 , wherein the hydrocarbon reactant comprises a gas, the gas comprising at least one of an alkane, alkene, alkyne, or an arene that has a boiling point of less than 500 degrees Celsius.

5. The method of claim 1 , wherein the fluid product comprises hydrogen.

6. The method of claim 1 , further comprising:
purifying the fluid product to at least 99.9 percent purity; and
compressing the fluid product to above atmospheric pressure.

7. The method of claim 1 , wherein the fluid product comprises a hydrocarbon.

8. The method of claim 1 , wherein the homogeneous second molten composition comprises an iron-carbon alloy in a condensed phase.

9. A method for producing a powdered carbon- containing alloy and hydrogen, comprising:
heating iron that is comminuted and a metal inside of an enclosed volume to produce a first molten alloy comprising iron and the metal, wherein the metal comprises at least one of: iron, nickel, manganese, cobalt, scandium, or lanthanum;
feeding methane gas into the enclosed volume;
heating the enclosed volume to approximately 1000 to 1500 degrees Celsius to decompose the methane gas into a carbon saturated ternary alloy and hydrogen gas via dissolving carbon in a solid phase formed from pyrolysis of the methane gas in a presence of the first molten alloy into the first molten alloy, wherein the carbon saturated ternary alloy comprises the iron, the carbon, and at most 1 atomic percent of the metal;
phase-separating the carbon saturated ternary alloy into a carbon-containing alloy and the metal; and
removing the hydrogen gas and the carbon saturated ternary alloy from the enclosed volume.

Assignees

• Palo Alto Res Ct Inc

Inventors

• Desai Divyaraj
• Rivest Jessica Louis Baker
• Boysen Dane Andrew
• Pandey Rahul
• Beh Eugene Shin Ming

Classifications

• C01B3/0031

  Intermetallic compounds; Metal alloys · CPC title

• C21B13/0013 Primary

  introduction of iron oxide into a bath of molten iron containing a carbon reductant · CPC title

• C21B2400/032

  Separating slag from liquid, e.g. from water, after quenching · CPC title

• C01B2203/06

  Integration with other chemical processes · CPC title

• C21B2100/28

  by separation · CPC title