Black powder catalyst for hydrogen production via steam reforming

Patent metadata

Field	Value
Publication number	US-12515949-B2
Application number	US-202318482261-A
Country	US
Kind code	B2
Filing date	Oct 6, 2023
Priority date	Jan 4, 2021
Publication date	Jan 6, 2026
Grant date	Jan 6, 2026

Abstract

A steam reforming catalyst that includes treated black powder (primarily hematite), and a method of treating black powder (e.g., from a natural gas pipeline) to give the treated black powder. A steam reformer having the treated black powder as reforming catalyst, and a method of producing syngas with the steam reformer.

First claim

What is claimed is:

1 . A method of preparing a reforming catalyst for steam reforming methane, comprising:
receiving black powder comprising carbon and iron, wherein the black powder comprising a solid formed in a steel hydrocarbon gas pipeline by corrosion of the steel hydrocarbon gas pipeline; removing the carbon from the black powder by heating the black powder at a first temperature of 500° C. for at least 3 hours and heating the black powder in presence of air at a second temperature from 700° C. to 800° C. for at least 4 hours to give calcined black powder as the reforming catalyst, wherein the calcined black powder comprises hematite.

2 . The method of claim 1 , comprising collecting the black powder from the steel hydrocarbon gas pipeline.

3 . The method of claim 1 , wherein the second temperature is 775° C.

4 . The method of claim 1 , wherein the heating at the second temperature in presence of air cause a formation of at least a portion of the hematite.

5 . The method of claim 1 , wherein the hematite is at least 50 weight percent of the calcined black powder.

6 . The method of claim 1 , wherein the hematite is at least 80 weight percent of the calcined black powder.

7 . The method of claim 1 , wherein the black powder comprises iron oxides, silica, a metal carbonate, a hydroxide, and a sulfide iron carbonate.

8 . The method of claim 1 , wherein the black powder comprises oxygen (O), magnesium (Mg), silicon (Si), sulfur(S), chlorine (Cl), calcium (Ca), and manganese (Mn).

9 . The method of claim 1 , wherein the black powder comprises hematite and magnetite.

10 . The method of claim 2 , wherein the black powder is collected from the steel hydrocarbon gas pipeline between a wellhead and a natural gas processing plant.

11 . The method of claim 10 , wherein the black powder is collected from a filter in the steel hydrocarbon gas pipeline.

Assignees

• Saudi Arabian Oil Co

Inventors

• Wedhaya Ahmad A
• Fadhel Bandar A
• Albuali Mohammed A
• Bamagain Rami

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J2235/00

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

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• C01B2203/0233

  the reforming step being a steam reforming step · CPC title

• B01J8/065

  Feeding reactive fluids · CPC title