# US 12,113,254 B1 · Combined hydrogen supply and fuel cell processes for increased efficiency of electricity generation > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,113,254 B1 - Document ID: US12113254B1 - Status: Granted - Kind: B1 - Application number: 18/197,493 - Filed: 2023-05-15 - Granted: 2024-10-08 - Earliest claimed: 2023-05-15 - Assignees: Halliburton Energy Services, Inc. - Applicants: Halliburton Energy Services, Inc. - Inventors: Philip D. Nguyen; Stanley Vernon Stephenson; Ronald Glen Dusterhoft - Web page: https://patentgrep.com/patent/US12113254B1 ## CPC - H01M 8/0612: from carbon-containing material - C01B 3/26: using catalysts - E21B 43/2607: {Surface equipment specially adapted for fracturing operations} - H01M 8/04007: related to heat exchange - H01M 8/04201: {Reactant storage and supply, e.g. means for feeding, pipes} - C01B 2203/0277: containing a catalytic decomposition step - C01B 2203/066: with fuel cells - C01B 2203/1241: Natural gas or methane - F04B 17/03: driven by electric motors - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - F04B: POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS (machines for liquids, or pumps, of rotary-piston or oscillating-piston type F04C; non-positive-displacement pumps F04D; pumping of fluid by direct contact of another fluid or by using inertia of fluid to be pumped F04F) ## Abstract Provided are methods and systems for combining hydrogen supply and fuel cell processes for increased efficiency of electricity generation. The method may include decomposing methane to produce at least hydrogen, introducing at least a portion of the hydrogen to a fuel cell to generate at least electricity and heat, and capturing at least a portion of the heat from the fuel cell to reduce an electricity requirement for the methane decomposition. The system may include a methane preheater, a reaction system, a hydrogen storage system, a hydrogen fuel cell, and a heat recovery unit. The reaction system may comprise one or more reaction chambers containing a liquid base fluid, carrier droplets and a catalyst, wherein the reaction system is configured to decompose methane. The heat recovery unit may be configured to supply waste heat from the hydrogen fuel cell to the methane preheater. ## Claims ### Claim 1 A method comprising: decomposing methane to produce at least hydrogen, wherein the decomposition of methane comprises: reacting the methane with a catalyst, wherein the methane is introduced into a reaction chamber containing a liquid base fluid, carrier droplets, and the catalyst; introducing at least a portion of the hydrogen to a fuel cell to generate at least electricity and heat; and capturing at least a portion of the heat from the fuel cell to reduce an electricity requirement for the decomposing. ### Claim 2 (depends on 1) The method of claim 1, wherein the catalyst comprises a plurality of solid particles selected from the group consisting of a metal, a metal alloy, a salt, and combinations thereof. ### Claim 3 (depends on 1) The method of claim 1, wherein the carrier droplets have a mean particle size of about 0.1 micrometers to about 50 micrometers, and wherein solid particles of the catalyst have a mean particle size of about 10 nanometers to about 100 nanometers, and where the particles of the catalyst are carried in the carrier droplets. ### Claim 4 (depends on 1) The method of claim 1, wherein the carrier droplets comprise a pure metal or a metal alloy comprising a post-transition metal selected from the group consisting of aluminum, gallium, indium, thallium, tin, bismuth, and combinations thereof. ### Claim 5 (depends on 1) The method of claim 1, wherein the catalyst is carried by the carrier droplets, wherein the carrier droplets comprise a post-transition metal alloyed with an alkali metal, alkaline earth metal, actinide metal, lanthanide metal, transition metal, or combinations thereof. ### Claim 6 (depends on 1) The method of claim 1, wherein the carrier droplets comprise a metal that has a melting point of about 150° C. or less, and wherein the liquid base fluid has a temperature greater than the melting point. ### Claim 7 (depends on 1) The method of claim 1, further comprising powering well equipment with at least a portion of the electricity from the hydrogen fuel cell. ### Claim 8 (depends on 7) The method of claim 7, further comprising recovering at least a portion of additional waste heat from the well equipment to further reduce the electricity requirement for the decomposing. ### Claim 9 (depends on 1) The method of claim 1, further comprising powering one or more pumps to deliver a fracturing fluid to a wellhead. ### Claim 10 (depends on 1) The method of claim 1, wherein the capturing at least a portion of the heat from the fuel cell comprises heating a heat transfer medium. ### Claim 11 (depends on 1) The method of claim 1, further comprising preheating at least a portion of the methane with at least a portion of the captured heat. ### Claim 12 A method comprising: reacting methane with a catalyst in one or more reaction chambers to produce at least hydrogen and solid carbon, wherein the one or more reaction chambers each contain a liquid base fluid, carrier droplets, and the catalyst; introducing at least a portion of the hydrogen to a fuel cell to generate at least electricity and heat; pumping a fracturing fluid into a wellbore with one or more pumps powered by at least a portion of the electricity from the fuel cell; and capturing a portion of the heat from the fuel cell and a portion of a waste heat generated from the one or more pumps to preheat at least a portion of the methane prior to the reacting. ### Claim 13 (depends on 12) The method of claim 12, wherein the carrier droplets have a mean particle size of about 0.1 micrometers to about 50 micrometers, and wherein solid particles of the catalyst have a mean particle size of about 10 nanometers to about 100 nanometers, and where the particles of the catalyst are carried in the carrier droplets. ### Claim 14 (depends on 13) The method of claim 13, wherein the catalyst is carried by the carrier droplets, wherein the carrier droplets comprise a post-transition metal alloyed with an alkali metal, alkaline earth metal, actinide metal, lanthanide metal, transition metal, or combinations thereof. ### Claim 15 (depends on 13) The method of claim 13, wherein the carrier droplets comprise a metal that has a melting point of about 150° C. or less, and wherein the liquid base fluid has a temperature greater than the melting point. ### Claim 16 (depends on 13) The method of claim 13, further comprising heating at least one of the one or more reaction chambers with at least a portion of the captured heat. ### Claim 17 A system comprising: a methane preheater; a reaction system in fluid communication with the methane preheater, wherein the reaction system comprises one or more reaction chambers containing a liquid base fluid, carrier droplets and a catalyst, wherein the reaction system is configured to decompose methane; a hydrogen storage system in fluid communication with the reaction system; a hydrogen fuel cell in fluid communication with the hydrogen storage system, wherein the hydrogen fuel cell is configured to generate electricity from hydrogen; and a heat recovery unit configured to supply waste heat from the hydrogen fuel cell to the methane preheater. ### Claim 18 (depends on 17) The system of claim 17, further comprising one or more pumps fluidly coupled to a wellhead, wherein the one or more pumps use at least a portion of the electricity from the hydrogen fuel cell.