Black powder catalyst for hydrogen production via autothermal reforming

Patent metadata

Field	Value
Publication number	US-2024034624-A1
Application number	US-202318484865-A
Country	US
Kind code	A1
Filing date	Oct 11, 2023
Priority date	Jan 4, 2021
Publication date	Feb 1, 2024
Grant date	—

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; applying heat to the black powder to remove carbon from the black powder; and calcining the 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.

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

3 . The method of claim 1 , wherein receiving the black powder comprises receiving the black powder collected from a natural-gas pipeline system, 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 in the presence of air to give the calcined black powder as the reforming catalyst.

4 . The method of claim 1 , wherein applying heat comprises applying the heat at a temperature of at least 500° C. for at least 3 hours to remove the carbon from the black powder.

5 . The method of claim 1 , wherein the calcining comprises applying heat to the black powder in the presence of air at a temperature of at least 775° 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.

6 . A reforming catalyst for autothermal reforming of methane with carbon dioxide and oxygen prepared according to the method of claim 1 .

7 . The reforming catalyst according to claim 6 , wherein the reforming catalyst comprises at least 70 weight percent of hematite, wherein the hematite is both a support and active portion of the reforming catalyst, and wherein the hematite being amphoteric advances both cracking of the methane and dissociation of the carbon dioxide in the autothermal reforming (ATR) of the methane.

8 . The reforming catalyst according to claim 6 , wherein the reforming catalyst comprises calcined black powder comprising the hematite.

9 . The reforming catalyst according to claim 8 , 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.

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

• C01B3/40 Primary

  characterised by the catalyst · CPC title

• B01J23/745 Primary

  Iron · CPC title

• B01J37/08

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