Black powder catalyst for hydrogen production via bi-reforming

Patent metadata

Field	Value
Publication number	US-2022212925-A1
Application number	US-202117140229-A
Country	US
Kind code	A1
Filing date	Jan 4, 2021
Priority date	Jan 4, 2021
Publication date	Jul 7, 2022
Grant date	—

Abstract

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

First claim

What is claimed is:

1 . A method of bi-reforming hydrocarbon, comprising reacting the hydrocarbon with steam and carbon dioxide via reforming catalyst to generate synthesis gas comprising hydrogen and carbon monoxide, wherein the reforming catalyst comprises treated black powder comprising hematite.

2 . The method of claim 1 , wherein the hydrocarbon comprises methane, and wherein the hematite is at least 50 weight percent of the treated black powder.

3 . The method of claim 1 , wherein the treated black powder comprises black powder subjected to heat, the black powder from a natural gas pipeline.

4 . The method of claim 1 , wherein the treated black powder comprises black powder collected from a natural-gas pipeline system and that is subjected to heat in presence of air to give the treated black powder.

5 . The method of claim 1 , wherein the treated black powder comprises black powder subjected to heat treatment at a temperature of at least 500° C. for at least 3 hours.

6 . The method of claim 1 , wherein the treated black powder comprises calcined black powder.

7 . The method of claim 1 , wherein the treated black powder comprises black powder subjected to heat treatment at a temperature of at least 775° C. in presence of air for at least 4 hours, and wherein the heat treatment comprises air calcination of the black powder.

8 . The method of claim 1 , wherein the treated black powder comprises black powder subjected to heat treatment at a temperature of at least 500° C. to remove carbon from the black powder and then subjected to air calcination at a temperature of at least 775° C. to give calcined black powder as the treated black powder.

9 . A method of bi-reforming hydrocarbon, comprising:
providing hydrocarbon, carbon dioxide, and steam to a bi-reformer vessel, wherein reforming catalyst comprising treated black powder is disposed in the bi-reformer vessel; bi-reforming the hydrocarbon in the bi-reformer vessel via the reforming catalyst to generate hydrogen and carbon monoxide; and discharging the hydrogen and carbon monoxide from the bi-reformer vessel.

10 . The method of claim 9 , wherein the bi-reforming comprises reacting the hydrocarbon with the carbon dioxide and steam, and wherein the hydrocarbon comprises methane.

11 . The method of claim 9 , comprising providing heat to the bi-reformer vessel for the bi-reforming comprising reacting of the hydrocarbon with the steam and the carbon dioxide, wherein the reacting of the hydrocarbon with the steam and the carbon dioxide is endothermic.

12 . A method of preparing a reforming catalyst for bi-reforming methane, comprising:
receiving black powder; applying heat to the black powder to give heat-treated black powder; and applying heat to the heat-treated black powder in presence of air to give a calcined black powder for bi-reforming of methane, wherein a majority of the calcined black powder is hematite.

13 . The method of claim 12 , wherein the reforming catalyst comprises the calcined black powder.

14 . The method of claim 12 , wherein applying heat to the black powder comprises applying the heat at a temperature of at least 500° C. to give the heat-treated black powder.

15 . The method of claim 12 , wherein applying heat to the heat-treated black powder comprises applying the heat to the heat-treated black powder at a temperature of at least 775° C. in the presence of air to give the calcined black powder.

16 . A reforming catalyst comprising:
calcined black powder for bi-reforming methane with steam and carbon dioxide, wherein the calcined black powder is black powder heat treated at a temperature of at least 500° C. for at least 3 hours and calcined at a temperature of at least 775° C. in presence of air for at least 4 hours, the black powder from a natural gas pipeline; and wherein a majority of the calcined black powder is hematite.

17 . The reforming catalyst of claim 16 , wherein the hematite is both a support and active portion of the reforming catalyst.

18 . The reforming catalyst of claim 16 , wherein the hematite being amphoteric advances cracking of the methane, dissociation of the steam, and dissociation of the carbon dioxide.

19 . The reforming catalyst of claim 16 , wherein the reforming catalyst is the calcined black powder.

20 . A bi-reformer comprising:
a bi-reformer vessel comprising:
at least one inlet to receive methane, carbon dioxide, and steam;
a reforming catalyst comprising calcined black powder to convert the methane, the carbon dioxide, and the steam into syngas; and
an outlet to discharge the syngas, wherein the syngas comprises hydrogen and carbon monoxide.

21 . The bi-reformer of claim 20 , wherein the bi-reformer vessel comprises a fixed-bed reactor vessel comprising the reforming catalyst in a fixed bed.

22 . The bi-reformer of claim 21 , wherein the fixed-bed reactor vessel comprises a multi-tubular fixed-bed reactor.

23 . The bi-reformer of claim 20 , wherein the bi-reformer vessel comprises a fluidized-bed reactor vessel to operate with a fluidized bed of the reforming catalyst.

24 . The bi-reformer of claim 20 , wherein the reforming catalyst comprising the calcined black powder comprises at least 50 weight percent of hematite.

Assignees

• Saudi Arabian Oil Co

Inventors

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

Classifications

• C01B3/382

  Processes with two or more reaction steps, of which at least one is catalytic, e.g. steam reforming and partial oxidation · CPC title

• C01B3/48

  followed by reaction of water vapour with carbon monoxide · CPC title

• C01B2203/1047

  Group VIII metal catalysts · CPC title

• C01B2203/0216

  containing a non-catalytic steam reforming step · CPC title

• C01B2203/062

  Hydrocarbon production, e.g. Fischer-Tropsch process · CPC title