Systems and methods for generating hydrogen and magnetite from rock

Patent metadata

Field	Value
Publication number	US-12545576-B2
Application number	US-202418673248-A
Country	US
Kind code	B2
Filing date	May 23, 2024
Priority date	Jul 30, 2021
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

Systems and methods for sequestering carbon, evolving hydrogen gas, producing iron oxide as magnetite, and producing magnesium carbonate as magnesite through sequential carbonation and serpentinization/hydration reactions involving processed olivine- and/or pyroxene-rich ores, as typically found in mafic and ultramafic igneous rock. Precious or scarce metals, such nickel, cobalt, chromium, rare earth elements, and others, may be concentrated in the remaining ore to facilitate their recovery from any gangue material.

First claim

What is claimed is:

1 . A system for sequestering carbon and producing hydrogen and magnetite from rock, the system comprising:
a source of ore containing olivine or pyroxene; a reactor having an inlet that receives ore particles and at least one outlet, the reactor also having at least one additional inlet through which one or more of carbon dioxide or water is introduced, the reactor operable at a first temperature for a first residence time to react carbon dioxide that enters the reactor through the at least one additional inlet with the ore particles to generate magnesium carbonate, the reactor also operable at a second temperature for a second residence time to react water that enters the reactor through the at least one additional inlet with the ore particles to generate magnetite and hydrogen gas; and a gas separator that is connected to and in fluid communication with the at least one outlet of the reactor, the gas separator configured to separate hydrogen gas from gases that exit the reactor through the at least one outlet.

2 . The system of claim 1 , further comprising a crusher that physically reduces a particle size of the ore introduced therein from the source.

3 . The system of claim 2 , further comprising:
a sieve that receives the ore from the crusher and that allows the ore particles up to a pre-selected size to pass into the reactor, wherein the inlet that receives the ore particles is configurable to only receive, from the sieve, the ore particles having a size at or below to the pre-selected size.

4 . The system of claim 3 , wherein the pre-selected size comprises a size of between about 25 microns and about 150 microns.

5 . The system of claim 1 , wherein a pressure inside the reactor during the second residence time is at or above about 1 bar of carbon dioxide.

6 . The system of claim 5 , wherein a pressure inside the reactor during the second residence time is at or above 5 bars of carbon dioxide.

7 . The system of claim 6 , wherein a pressure inside the reactor during the second residence time is at or above 10 bars of carbon dioxide.

8 . The system of claim 1 , further comprising a magnetic separator that receives material from the at least one outlet of the reactor, the magnetic separator having a magnet that attracts the magnetite and thereby separates the magnetite from the material.

9 . The system of claim 1 , further comprising a washer that applies either additional water or an acidic solution to the ore particles prior to their reaction with the carbon dioxide.

10 . The system of claim 1 , further comprising a separator that separates at least one of nickel, cobalt, chromium, or rare earth elements from any remaining ore particles removed from the reactor.

11 . The system of claim 1 , wherein the reactor includes a first reactor into which the carbon dioxide is introduced and a second reactor into which the water is introduced, the first reactor being operable at the first temperature for the first residence time to react the carbon dioxide that enters the first reactor through the at least one additional inlet with the ore particles, and the second reactor being operable at the second temperature for the second residence time to react the water that enters the second reactor with any remaining ore particles introduced into the second reactor from the first reactor.

12 . The system of claim 1 , wherein the water has a pH of between about 8.3 and about 11.1.

13 . The system of claim 1 , wherein at least one of the first temperature and the second temperature is no greater than 400° C.

14 . The system of claim 1 , wherein at least one of the first temperature and the second temperature is no greater than 300° C.

15 . The system of claim 1 , wherein a pressure inside the reactor during the first residence time is at or above about 5 bars of carbon dioxide.

16 . The system of claim 1 , wherein the carbon dioxide that is introduced into the reactor is gaseous or supercritical carbon dioxide.

17 . The system of claim 1 , further comprising a separator that separates at least one of phosphates, aluminum oxides, precious metals, and other mineral gangue from any remaining ore particles removed from the reactor.

18 . A method for generating hydrogen and magnetite from rock, the method comprising:
obtaining an ore containing olivine or pyroxene; introducing the ore into a reactor that is operable at temperatures above ambient temperature and pressures above atmospheric pressure; introducing water into the reactor at a particular temperature for a particular residence time to react with the ore to generate magnetite and hydrogen gas; removing, from the reactor, a gas mixture that includes the hydrogen gas; separating the hydrogen gas from the gas mixture; and removing any remaining ore from the reactor.

19 . The method of claim 18 , further comprising washing the ore with either additional water or an acidic solution prior to comminuting the ore into the smaller size fractions.

20 . The method of claim 18 , further comprising:
sieving the ore prior to introducing the ore into the reactor to allow ore particles up to a pre-selected size to pass into the reactor, wherein introducing the ore into the reactor comprises introducing, into the reactor, only a subset of the ore having particles up to the pre-selected size.

Assignees

• Ohio State Innovation Foundation

Inventors

• Darrah Thomas
• Rao Vikram
• Whyte Colin

Classifications

• C22B59/00

  Obtaining rare earth metals · CPC title

• C22B34/32

  Obtaining chromium · CPC title

• C22B26/12

  Obtaining lithium · CPC title

• C22B23/0415

  with acids or salt solutions except ammonium salts solutions · CPC title

• C22B23/005

  Preliminary treatment of ores, e.g. by roasting or by the Krupp-Renn process · CPC title