Process for simultaneous production of carbon nanotube and a product gas from crude oil and its products

Patent metadata

Field	Value
Publication number	US-9890045-B2
Application number	US-201415105563-A
Country	US
Kind code	B2
Filing date	Dec 29, 2014
Priority date	Dec 30, 2013
Publication date	Feb 13, 2018
Grant date	Feb 13, 2018

Abstract

The present invention is directed to a process for the simultaneous production of carbon nanotubes and product gas comprising hydrogen and lighter hydrocarbons, from a liquid hydrocarbon comprising feeding a liquid hydrocarbon in a reactor; and converting the liquid hydrocarbon with a catalyst for simultaneous production of the carbon nanotubes, hydrogen and lighter hydrocarbons, wherein the liquid hydrocarbon comprises petroleum crude oil, its products, or mixtures thereof.

First claim

We claim:

1. A process for the simultaneous production of carbon nanotubes and product gas comprising hydrogen and lighter hydrocarbons, from a petroleum crude oil or its products or mixtures thereof, comprising:
feeding the petroleum crude oil or its products or mixtures thereof, in a vibrating reactor operated with vibrating function; and
converting the petroleum crude oil or its products or mixtures thereof, having heteroatomic intrinsic growth promotors with a catalyst for simultaneous production of the carbon nanotubes, hydrogen and lighter hydrocarbons; wherein,
the petroleum crude oil or its products or mixtures thereof, comprises at least one of naphtha, light cycle oil, decanted clarified oil from fluid catalytic cracking, aromatic extract, unconverted oil from hydrocracker bottom, deasphalted oil, coker furnace oil, pyrolysis furnace oil, reduced crude oil, or vacuum gas oil; and
output products comprising carbon nanotubes having purity ranges from 70 wt % to 99.5 wt %; and
product gas comprising of C 1 to C 5 lighter hydrocarbons which mainly consists of methane, ethane, ethylene, propane, propylene, butane, isobutane, 2-butene and pentane, is in the range of 10 vol. % to 90 vol. %; wherein, methane composition is in the range of 10 vol. % to 90 vol. % of the product gas.

2. The process of claim 1 , wherein the catalyst is bulk or supported active metal catalyst, with or without promoter.

3. The process of claim 2 , wherein the active metal is supported on a metal oxide support and the metal oxide is selected from the group comprising of alumina, silica, silica-alumina, zeolite, titania, magnesia, clay materials.

4. The process of claim 2 , wherein ratio of active metal to metal oxide support is in the range of 1 to 100 wt. %/wt. % and the ratio of active metal to promoter is in the range of 0 to 20 wt. %/wt. %.

5. The process of claim 2 , wherein ratio of active metal to support is in the range of 5-40 wt. %/wt. % and ratio of active metal to promoter is in the range of 1-10 wt. %/wt. %.

6. The process of claim 2 , wherein the active metal is selected from Group VIII metals and the promoter is selected from Group IB, VIB, VIIB, VIII metals.

7. The process of claim 6 , wherein the active metal is selected from the group comprising of Fe, Co, Ni and the promoter is selected from the group comprising of Fe, Ni Co, Cu, Mo, W, Cr or Mn.

8. The process of claim 1 , wherein the heteroatomic intrinsic growth promotors are sulphur and nitrogen containing molecules.

9. The process of claim 1 , wherein the temperature of the vibrating reactor is maintained in the range of 300-1200° C.

10. The process of claim 1 , wherein the temperature of the vibrating reactor is maintained in the range of 500-900° C.

11. The process of claim 1 , wherein the vibrating reactor is maintained at an operating pressure in the range of 1 mbar to 10 bar.

12. The process of claim 1 , wherein the vibrating reactor is maintained at an operating pressure in the range of 1 mbar to 5 bar.

13. The process of claim 1 , wherein catalytic conversion is carried out at an elevated temperature in the range of 500-1200° C.

14. The process of claim 1 , wherein feeding of the petroleum crude oil or its products or mixtures thereof, into the vibrating reactor is carried out with help of a carrier gas and the carrier gas comprises nitrogen, helium, argon, hydrogen, carbon dioxide, or mixture thereof.

15. The process of claim 1 , wherein the carbon nanotube yield ranges from from 1 wt. % to 80 wt. % of the petroleum crude oil or its products or mixtures thereof.

16. The process of claim 1 , wherein the carbon nanotube purity ranges from 90 wt. % to 98 wt. %.

17. The process of claim 1 , wherein the yield of product gas comprising hydrogen and lighter hydrocarbons is in the range of 10 vol. % to 90 vol. %.

18. The process of claim 1 , wherein the yield of hydrogen is in the range of 1 wt. % to 12 wt. % of the petroleum crude oil or its products or mixtures thereof.

19. The process of claim 1 , wherein the product gas stream comprising C 1 to C 5 hydrocarbons is partially or completely recycled back into the vibrating reactor or as feed to another vibrating reactor.

20. The process of claim 1 , wherein the carbon nanotubes are produced with diameter of 1 to 100 nm.

Assignees

• Indian Oil Corp Ltd

Inventors

• Raman Naduhatty Selai
• Mohanasundaram Palvannan
• Seshubabu Narayanam
• Christopher Jayaraj
• Kumar Brijesh
• Gupta Anurag Ateet
• Das Biswapriya
• Malhotra Ravinder Kumar

Classifications

• C07C2523/881

  and iron · CPC title

• C01B2203/1047

  Group VIII metal catalysts · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title

• Y10S977/842

  for carbon nanotubes or fullerenes · CPC title

• C01B2203/0277

  containing a catalytic decomposition step · CPC title