Production method and production device of nanocarbon

Patent metadata

Field	Value
Publication number	US-9511338-B2
Application number	US-201214115202-A
Country	US
Kind code	B2
Filing date	May 10, 2012
Priority date	May 10, 2011
Publication date	Dec 6, 2016
Grant date	Dec 6, 2016

Abstract

Using a device for producing nanocarbon, a fluidized bed is formed by supplying a low hydrocarbon and oxygen to a fluid catalyst, and nanocarbon and hydrogen are produced by a decomposition reaction of the low hydrocarbon accompanied by a self-combustion of the low hydrocarbon and the oxygen. The device includes: a fluidized bed reactor for containing the fluid catalyst and for causing the self-combustion thereof while being supplied with the low hydrocarbon and the oxygen; a gas supplying unit connected to the fluidized bed reactor for supplying the low hydrocarbon and the oxygen to the fluidized bed reactor; an exhaust gas path connected to the fluidized bed reactor for exhausting an exhaust gas in the fluidized bed reactor to outside; and a supplying unit connected to the fluidized bed reactor for supplying the fluid catalyst to the fluidized bed reactor.

First claim

The invention claimed is:

1. A method for producing nanocarbon, comprising:
pre-heating a low hydrocarbon and oxygen to a temperature of 400 to 500° C., wherein the low hydrocarbon comprises methane;
heating, by an ignition device, a mixed gas of the low hydrocarbon and the oxygen to a decomposition temperature of methane of 600° C. or higher;
supplying the mixed gas that has been heated by the ignition device to a fluidized bed reactor comprising a fluid catalyst or a fluid catalyst used in combination with a fluid medium, and make the mixed gas contact with the fluid catalyst or the fluid catalyst used in combination with the fluid medium so as to initiate a self-combustion of the low hydrocarbon and the oxygen at the fluidized bed; and
producing nanocarbon and hydrogen by a decomposition reaction of the low hydrocarbon accompanied by the self-combustion of the low hydrocarbon and the oxygen while supplying the mixed gas, wherein the oxygen in the mixed gas is supplied in a ratio of 5 to 25% by volume,
wherein an amount of carbon dioxide included in an exhaust gas from the decomposition reaction is 1 to 10% by volume, and an amount of water included in the exhaust gas from the decomposition reaction is 1 to 20% by volume,
wherein the ignition device is the only external heat source that causes the heating of the mixed gas to the decomposition temperature of methane prior to catalyst contact and to maintain the decomposition reaction.

2. The method for producing nanocarbon according to claim 1 ,
wherein the fluid catalyst comprises:
a fluid catalyst including a silica carrier of 1 μm to 200 μm and a nickel fine particle in an amount of 50% by mass or less relative to the carrier; or
a fluid catalyst including an alumina carrier of 1 μm to 200 μm and an iron fine particle in an amount of 50% by mass or less relative to the carrier.

3. The method for producing nanocarbon according to claim 1 ,
wherein a fluid medium comprising one or two or more selected from a sand particle, a silica particle and an alumina particle of 200 μm or less is added to the fluid catalyst, and the fluidized bed is formed with the fluid catalyst.

4. The method for producing nanocarbon according to claim 1 ,
wherein temperature of the decomposition reaction is 500° C. to 1000° C.

5. The method for producing nanocarbon according to claim 1 ,
wherein a pressure of the decomposition reaction is 10 atmospheres or less.

6. The method for producing nanocarbon according to claim 1 ,
wherein the low hydrocarbon is supplied to the fluid catalyst or the fluid catalyst used in combination with the fluid medium under a condition that the SV value is 80,000 NL/kg-catal./h or less in the methane conversion.

7. The method for producing nanocarbon according to claim 1 ,
wherein an unreacted low hydrocarbon included in the exhaust gas from the decomposition reaction is refluxed and supplied to the decomposition reaction.

8. The method for producing nanocarbon according to claim 1 ,
wherein the decomposition reaction is set as a first stage,
wherein the exhaust gas from the decomposition reaction and oxygen having a concentration lower than the oxygen supplied in the first stage are supplied to a fluid catalyst or a fluid catalyst used in combination with a fluid medium of a second stage so as to form another fluidized bed, and
wherein the unreacted low hydrocarbon included in the exhaust gas is decomposed accompanied by the self-combustion of the exhaust gas and the oxygen so as to further produce the nanocarbon and the hydrogen.

9. The method for producing nanocarbon according to claim 1 ,
wherein the nanocarbon produced by the decomposition reaction has a diameter of 1 μm to 500 nm and a length of 100 μm or less.

10. A method for producing nanocarbon using a fluidized bed reactor including a fluidized bed part and a free board part which is a space above the fluidized bed part, and a dispersing plate disposed at a lower part of the fluidized bed reactor and an ignition device disposed under the dispersing plate, comprising:
pre-heating a low hydrocarbon and oxygen to a temperature of 400 to 500° C., wherein the low hydrocarbon comprises methane;
forming a fluidized bed by supplying the low hydrocarbon and oxygen into the lower part of the fluidized bed reactor to a fluid catalyst or a fluid catalyst used in combination with a fluid medium;
mixing the low hydrocarbon and oxygen into a mixed gas and heating the mixed gas using the ignition device until a temperature of the fluidized bed reactor has reached a decomposition temperature of methane of 600° C. or higher;
producing nanocarbon and hydrogen by a decomposition reaction of the low hydrocarbon accompanied by a self-combustion of the low hydrocarbon and the oxygen due to the heating by the ignition device; and
exhausting the nanocarbon that has reached the free board part through a nanocarbon exhaust path directly connected to a wall of the fluidized bed reactor, and exhausting an exhaust gas through an exhaust path connected to an upper part of the fluidized bed reactor,
wherein the ignition device is the only external heat source that causes the heating of the mixed gas to the decomposition temperature of methane prior to catalyst contact and to maintain the decomposition reaction.

11. The method for producing nanocarbon according to claim 10 ,
wherein in the producing the nanocarbon and the hydrogen, the oxygen in the mixed gas is supplied in a ratio of 5 to 25% by volume.

Assignees

• Nakamura Satoru
• Tada Akio
• Japan Steel Works Ltd
• Nat Univ Corp Kitami Inst Of Tech

Inventors

• Nakamura Satoru
• Tada Akio

Classifications

• C01B3/42 Primary

  using moving solid particles, e.g. fluidised bed technique · CPC title

• C01B3/44

  Chemistry & Metallurgy · mapped topic

• B01J8/0045

  by means of a rotary device in the flow channel · CPC title

• C01B2203/1241

  Natural gas or methane · CPC title

• C01B2203/1058

  Nickel catalysts · CPC title