Method of fabricating catalyst carrier for generating hydrogen through methane reformation

Patent metadata

Field	Value
Publication number	US-9630166-B1
Application number	US-201615014104-A
Country	US
Kind code	B1
Filing date	Feb 3, 2016
Priority date	Feb 3, 2016
Publication date	Apr 25, 2017
Grant date	Apr 25, 2017

Abstract

A method is provided for fabricating a catalyst carrier. At first, aluminum hydroxide is used for forming an alumina powder. The alumina powder is mixed with carbon nanotubes and a complex additive to be shaped into a cake. The cake is kneaded into a noodle-like shape to be hot-dried. Then, calcination is processed in a furnace under 1200 celsius degrees (° C.) with air passed through. The crystal structure remains without phase change. A catalyst carrier of α-alumina having nano-scaled pores is formed. The catalyst carrier is a powdery material made into different three-dimensional forms. The catalyst carrier thus fabricated is suitable for generating hydrogen through methane reformation. The catalyst carrier has a methane conversion greater than 99 percents. The catalyst carrier will not be crumbled under 800° C. for 4000 hours without carbon deposit.

First claim

What is claimed is:

1. A method of fabricating a catalyst carrier for generating hydrogen through methane reformation, comprising steps of
(a) heat treating aluminum hydroxide (Al(OH) 3 ) in a furnace and drying said Al(OH) 3 under a temperature of 95-140° C. and, then, placing said Al(OH) 3 in a high-temperature furnace to be calcined at a temperature of 320-480° C. for 4-6 hours to obtain an alumina powder;
(b) mixing said alumina powder with carbon nanotubes to be added with a complex additive;
(c) kneading said carbon nanotubes, said alumina powder and said complex additive in a kneading device to obtain a cake;
(d) extruding said kneaded cake using an extruding machine to extrude an extruded carrier; and
(e) drying said extruded carrier under a temperature of 110-150° C. and calcining said extruded carrier to obtain an α-alumina (α-Al 2 O 3 ) carrier distributed with a plurality of nano-scaled pores.

2. The method according to claim 1 ,
wherein, in step (b), said carbon nanotubes are mixed to said alumina powder at a weight ratio of 3:97; and said complex additive has an adding amount of 1%-3% to a total mass of said carbon nanotubes and said alumina powder.

3. The method according to claim 1 ,
wherein said complex additive comprises a diluted nitric acid, an extrusion aid, an adhesive and a lubricant.

4. The method according to claim 3 ,
wherein said extrusion aid is sesbania powder and/or kaolin.

5. The method according to claim 3 ,
wherein said adhesive is methyl cellulose.

6. The method according to claim 3 ,
wherein said lubricant is magnesium stearate.

7. The method according to claim 1 ,
wherein, in step (e), said calcination is processed by heating from a room temperature to a temperature of 320-480° C. at a rate of 2 celsius degrees per minute (° C./min) followed by holding said temperature for 1.5˜2.5 hours (hr); then, said temperature is raised to 520˜780° C. at a rate of 1° C./min followed by holding said temperature for 1.5-2.5 hrs; and, at last, said temperature is raised to 1080-1320° C. at a rate of 1° C./min followed by holding said temperature for 4-6 hrs.

8. The method according to claim 1 ,
wherein said α-Al 2 O 3 carrier is a powdery material made into different three-dimensional forms.

9. The method according to claim 1 ,
wherein said α-Al 2 O 3 carrier is further impregnated to coat active metals on surface of said α-Al 2 O 3 carrier and embed said active metals into said nano-scaled pores.

10. The method according to claim 9 ,
wherein said α-Al 2 O 3 carrier is a catalyst of Pt/CeO 2 /α-Al 2 O 3 .

Assignees

• Inst Nuclear Energy Res Atomic Energy Council Executive Yuan Roc

Inventors

• Huang Meng-Han
• Chou Yi-Sin
• Hsu Ning-Yih
• Lee Ruey-Yi
• Hwang Wen-Song

Classifications

• B01J37/08

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

• B01J37/0009

  Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst · CPC title

• B01J21/04 Primary

  Alumina · CPC title

• B01J37/04

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

• B01J21/185

  Carbon nanotubes (carbon nanotubes per se C01B32/15) · CPC title