Core-shell structured catalysts for hydrogen production from natural gas

Patent metadata

Field	Value
Publication number	US-2025387782-A1
Application number	US-202418751701-A
Country	US
Kind code	A1
Filing date	Jun 24, 2024
Priority date	Jun 24, 2024
Publication date	Dec 25, 2025
Grant date	—

Abstract

A high entropy alloy catalyst and a method of producing hydrogen via catalytic methane pyrolysis are disclosed. The catalyst comprises a core-shell structure, where the core is an internal catalyst support, and the shell comprises a high entropy alloy encapsulating the core. The method includes introducing a high entropy alloy catalyst into a reactor. The method further includes introducing natural gas into the reaction to form a reaction mixture, operating the reactor comprising the reaction mixture, thereby forming hydrogen gas and solid carbon, and separating the hydrogen gas from the solid carbon.

First claim

What is claimed:

1 . A high entropy alloy catalyst, comprising:
a core-shell structure, wherein: the core is an internal catalyst support, and the shell comprises a high entropy alloy encapsulating the core.

2 . The high entropy alloy catalyst of claim 1 , further comprising a catalyst promoter in the core, in the shell, or both; and wherein the catalyst promoter comprises from 0.0001 at % to 20 at % of the high entropy alloy catalyst.

3 . The high entropy alloy catalyst of claim 2 , wherein the catalyst promoter comprises a metal, an alkali metal, a rare earth metal, a metal oxide, or any combination thereof.

4 . The high entropy alloy catalyst of claim 1 , wherein the core comprises a metal, a metal oxide, or any combination thereof.

5 . The high entropy alloy catalyst of claim 1 , wherein the shell comprises at least four metals, and wherein each of the at least four metals is present in the shell in an amount ranging from 0.1 at % to 50 at %.

6 . The high entropy alloy catalyst of claim 5 , wherein the at least four metals are selected from the group consisting of cobalt, chromium, iron, manganese, nickel, aluminum, magnesium, copper, zinc, zirconium, molybdenum, niobium, ruthenium, rhodium, palladium, silver, tungsten, rhenium, iridium, platinum, gold, cerium, ytterbium, tin, calcium, and beryllium.

7 . The high entropy alloy catalyst of claim 1 , wherein the core has an average size of from 1 nanometers to 10 micrometers, and wherein the shell has an average thickness of from 1 nm to 10 μm.

8 . The high entropy alloy catalyst of claim 1 , wherein the high entropy alloy catalyst is spherical, square, cubic, triangular, or an irregular shape.

9 . A method of producing hydrogen via catalytic methane pyrolysis, the method comprising:
introducing a high entropy alloy catalyst into a reactor, the high entropy catalyst comprising:
a core-shell structure, wherein:
the core is an internal catalyst support; and
the shell comprises a high entropy alloy encapsulating the core;
introducing natural gas into the reactor to form a reaction mixture; operating the reactor comprising the reaction mixture, thereby forming hydrogen gas and solid carbon, and separating the hydrogen gas from the solid carbon.

10 . The method of claim 11 , wherein the operating step further comprises pressurizing the reactor to a pressure between 1 bar and 25 bar.

11 . The method of claim 11 , wherein the operating step further comprises heating the reactor to a temperature between 300° C. and 1200° C.

12 . The method of claim 13 , wherein the operating step further comprises heating the reactor using induction heating, plasma heating, microwave plasma or microwave heating, or a solar furnace.

13 . The method of claim 11 , wherein the high entropy alloy catalyst further comprises a catalyst promoter.

14 . The method of claim 15 , wherein the catalyst promoter is in the core, in the shell, or both; and wherein the catalyst promoter comprises from 0.0001 at % to 20 at % of the high entropy alloy catalyst.

15 . The method of claim 15 , wherein the catalyst promoter comprises a metal, an alkali metal, a rare earth metal, a high melting metal oxide, or any combination thereof.

16 . The method of claim 11 , wherein the core comprises a metal, a metal oxide, or any combination thereof.

17 . The method of claim 11 , wherein the shell comprises at least four metals, and wherein each of the four or more metals has a composition in the shell from 0.1 at % to 50 at %.

18 . The method of claim 11 , wherein the at least four metals are selected from the group consisting of cobalt, chromium, iron, manganese, nickel, aluminum, magnesium, copper, zinc, zirconium, ruthenium, rhodium, molybdenum, niobium, palladium, silver, tungsten, rhenium, iridium, platinum, gold, cerium, ytterbium, tin, calcium, and beryllium.

19 . The method of claim 11 , wherein the shell is designed to increase hydrogen production and decrease carbon dioxide formation by tuning at least one of the following properties: configuration entropy, lattice distortion, diffusion, catalytic activity, adsorption energy, number of catalytically active sites, desorption of reactants, particle size, and surface area.

20 . The method of claim 11 , wherein the core has an average dimension of from 1 nanometers to 10 micrometers, and wherein the shell has an average thickness of from 1 nm to 10 μm.

Assignees

• Saudi Arabian Oil Co
• Aramco Services Co

Inventors

• Ozden Sehmus
• Gizzatov Ayrat
• Liang Feng
• Abu Raqabah Atieh H

Classifications

• C01B2203/1041

  Composition of the catalyst · CPC title

• C01B3/586

  the reaction being a methanation reaction · CPC title

• B01J13/02

  Making microcapsules or microballoons {(for medical preparations A61K9/50)} · CPC title

• B01J35/50

  characterised by their shape or configuration · CPC title

• B01J35/395

  Thickness of the active catalytic layer · CPC title