High throughput methane pyrolysis reactor for low-cost hydrogen production

Patent metadata

Field	Value
Publication number	US-11981563-B2
Application number	US-202217951308-A
Country	US
Kind code	B2
Filing date	Sep 23, 2022
Priority date	Jun 29, 2018
Publication date	May 14, 2024
Grant date	May 14, 2024

Abstract

A method to decompose a hydrocarbon reactant into a gaseous product and a solid product includes generating a mist of a liquid material within a reactor volume, heating the reactor volume, introducing a hydrocarbon reactant into the reactor volume to produce a solid product and a gaseous product, separating the solid product from the liquid material, removing the solid product and gaseous product from the reactor volume, and recirculating the liquid material be re-introduced to the reactor volume.

First claim

What is claimed is:

1. A method to decompose a hydrocarbon reactant into a gaseous product and a solid product comprising:
generating a mist of a molten metal catalyst within a reactor volume using a plurality of misting nozzles to spray the molten metal into the reactor volume, the misting nozzles having patterned grooves within the misting nozzles;
heating the reactor volume;
injecting a hydrocarbon reactant into the reactor volume to the mist of molten metal catalyst to interact with the hydrocarbon reactant to produce a solid product and a gaseous product;
separating the solid product from the molten metal;
removing the solid product and gaseous product from the reactor volume; and
recirculating the liquid material to be re-introduced to the reactor volume.

2. The method as claimed in claim 1 , wherein separating the molten metal from the solid product includes using at least one of augers, rotary separators, or gravimetric separators.

3. The method as claimed in claim 1 , wherein using at least one of augers, rotary separators, or gravimetric separators comprises using one of a rotary scraper, an auger, ladle, or a screw separator.

4. The method as claimed in claim 1 , wherein removing the solid product and gaseous product from the reactor volume comprises using a multiphase separation unit.

5. The method as claimed in claim 4 , wherein using a multiphase separation unit comprises using a particulate filter.

6. The method as claimed in claim 4 , wherein using a multiphase separation unit comprises using an electrostatic precipitator.

7. The method as claimed in claim 1 , wherein removing the solid product and gaseous product from the reactor volume comprises using a knock-out pot attached to an outlet of the reactor volume.

8. The method as claimed in claim 1 , wherein the gaseous product contains at least one of hydrogen, ethane, ethylene, acetylene, propylene, benzene, or any combination thereof.

9. The method as claimed in claim 1 , wherein the reactor volume operates at temperatures of less than 1400° C. and pressures up to 20 bar.

10. The method as claimed in claim 1 , wherein the hydrocarbon reactant comprises at least one selected from group consisting of: natural gas; liquefied petroleum gas; gasoline; diesel; kerosene; naphtha; JP-8; methane; ethane; propane; butane; pentane; hexane; benzene; xylene; toluene; and any combination thereof; alkynes, alkenes, alkanes, arenes, cyclic compounds, and any combination thereof having a boiling point less than 600° C.

11. The method as claimed in claim 1 , wherein heating the reactor volume to a temperature comprises heating the reactor volume to a temperature between 1100° C. and 1400° C.

Assignees

• Palo Alto Res Ct Inc
• Xerox Corp

Inventors

• Desai Divyaraj
• Karin Todd
• Rivest Jessica Louis Baker

Classifications

• C01B3/26 Primary

  using catalysts · CPC title

• B01J8/125

  with multiple sections one above the other separated by distribution aids, e.g. reaction and regeneration sections · CPC title

• B01J21/18

  Carbon · CPC title

• B01J35/27

  in a liquid or molten state · CPC title

• B01J38/48

  Liquid treating or treating in liquid phase, e.g. dissolved or suspended · CPC title