Systems and methods for electrical resistance heating of composite catalysts

Patent metadata

Field	Value
Publication number	US-2025178894-A1
Application number	US-202318528074-A
Country	US
Kind code	A1
Filing date	Dec 4, 2023
Priority date	Dec 4, 2023
Publication date	Jun 5, 2025
Grant date	—

Abstract

The disclosure relates to systems and methods in which composite catalysts are heated with electrical-resistance heating. The composite catalysts include a catalytically active phase and a porous metal oxide.

First claim

What is claimed:

1 . A system, comprising:
a composite catalyst comprising:
a porous metal oxide; and
a catalytically active phase supported by the porous metal oxide; and
a power source configured to heat the composite catalyst by electrical resistance heating.

2 . The system of claim 1 , wherein the catalytically active phase is homogeneously distributed in the porous metal oxide.

3 . The system of claim 1 , wherein the catalytically active phase comprises a member selected from the group consisting of Ni, Ru, Fe, Pt, and Pd.

4 . The system of claim 1 , wherein the porous metal oxide comprises a member selected from the group consisting of:
Y-doped BaZrO 3 ; Y-doped BaCeO 3 ; AZr a Ce b B c O 3-δ , wherein A is Ba, Sr, or Ca; B is Y, Yb, Pr, Gd, Fe, Co, Ni, Cu, or Zn; a+b+c equals 1; b is 0-0.95; c is 0.05-0.5; and 8 is a number such that formula is uncharged; and X a M1M2O x , wherein M1 and M2 are Al, Si, Zr, Ce, Ti or Mg; M2 is different from M1; X is K, Ca or B; a is 0-1; and x is nonstoichiometric and can vary under different conditions.

5 . The system of claim 1 , wherein the porous metal oxide comprises BaZr 0.7 Ce 0.2 Y 0.1 O 3-δ .

6 . The system of claim 1 , wherein the composite catalyst comprises Ni/BaZr 0.7 Ce 0.2 Y 0.1 O 3-δ .

7 . The system of claim 1 , wherein the composite catalyst has a porosity of 20% to 70%.

8 . The system of claim 1 , wherein the composite catalyst has a total surface area of 20 m 2 /g to 100 m 2 /g.

9 . The system of claim 1 , wherein the catalytically active phase has a surface area of 1 m 2 /g to 20 m 2 /g.

10 . The system of claim 1 , wherein the catalytically active phase comprises a member selected from the group consisting of nanoclusters and nanoparticles.

11 . The system of claim 1 , wherein the composite catalyst comprises 30 wt. % to 70 wt. % of the catalytically active phase.

12 . The system of claim 1 , wherein the composite catalyst comprises a tubular structure.

13 . The system of claim 12 , further comprising an inlet configured to deliver a gas to an interior space of the tubular structure.

14 . The system of claim 1 , wherein the composite catalyst comprises a honeycomb structure with a plurality of parallel channels.

15 . The system of claim 14 , wherein the honeycomb structure comprises a first face and a second face;
a first portion of the parallel channels are sealed at the first face; a second portion of the parallel channels are sealed at the second face; and the second portion of the parallel channels is different from the first portion of the parallel channels.

16 . The system of claim 1 , further comprising:
a pressure vessel; and an insulation material, wherein:
the composite catalyst is disposed inside the pressure vessel; and
the insulation material is between the pressure vessel and the composite catalyst.

17 . A reformer plant comprising the system of claim 1 .

18 . The reformer plant of claim 17 , further comprising a membrane gas separation unit in fluid communication with an output of the system of claim 1 .

19 . A method, comprising:
applying a current to a composite catalyst, thereby heating the composite catalyst; contacting the heated composite catalyst with a first gas stream; and forming a second gas stream, wherein the composite catalyst comprises:
a porous metal oxide; and
an active phase supported by the porous metal oxide.

20 . The method of claim 19 , wherein the first gas stream comprises methane and water and the second gas stream comprises hydrogen and carbon monoxide.

Assignees

• Saudi Arabian Oil Co
• Coorstek Membrane Sciences As

Inventors

• Harale Aadesh
• Jamal Aqil
• Hernandez Morejudo Selene
• Liu Xin
• Vestre Per

Classifications

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01J23/755

  Nickel · CPC title

• C01B32/40

  Carbon monoxide · CPC title

• C01B3/40

  characterised by the catalyst · CPC title

• B01J35/394

  Metal dispersion value, e.g. percentage or fraction · CPC title