Black powder catalyst for hydrogen production via autothermal reforming

Patent metadata

Field	Value
Publication number	US-12559369-B2
Application number	US-202318484865-A
Country	US
Kind code	B2
Filing date	Oct 11, 2023
Priority date	Jan 4, 2021
Publication date	Feb 24, 2026
Grant date	Feb 24, 2026

Abstract

A autothermal 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. An autothermal reformer having the treated black powder as reforming catalyst, and a method of producing syngas with the autothermal reformer.

First claim

What is claimed is:

1 . A method of preparing a reforming catalyst for autothermal reforming methane, comprising:
receiving black powder comprising carbon magnetite and hematite; applying heat to the black powder to remove carbon from the black powder, wherein applying heat comprises applying the heat at a temperature of 500° C. for at least 3 hours to remove the carbon from the black powder; and calcining the heated black powder in presence of air to give calcined black powder as the reforming catalyst for the autothermal reforming of methane, wherein the calcined black powder comprises hematite, wherein the calcining comprises applying heat to the black powder in the presence of air at a temperature of from 700 to 800° C. for at least 4 hours to give the calcined black powder as the reforming catalyst, and wherein the hematite is at least 50 weight percent of the calcined black powder.

2 . The method of claim 1 , comprising collecting the black powder from a steel natural-gas pipeline system.

3 . The method of claim 1 , wherein applying heat to the black powder to remove carbon from the black powder gives a heat-treated black powder, and wherein calcining the black powder comprises calcining the heat-treated black powder at 775° C. in the presence of air to give the calcined black powder as the reforming catalyst.

4 . The method of claim 2 , wherein the black powder is formed on an inside surface of the steel natural-gas pipeline of the natural gas pipeline system.

5 . The method of claim 1 , wherein the black powder further comprises, oxygen, magnesium, silicon, sulfur, chlorine, calcium, iron and manganese.

6 . The method of claim 1 , wherein applying heat to the black powder comprises applying the heat under air.

Assignees

• Saudi Arabian Oil Co

Inventors

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

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

• B01J8/065

  Feeding reactive fluids · CPC title

• C01B2203/1241

  Natural gas or methane · CPC title

• C01B2203/0244

  the reforming step being an autothermal reforming step, e.g. secondary reforming processes · CPC title