# US 12,214,335 B2 · Syngas and method of making the same

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- Number: US 12,214,335 B2
- Document ID: US12214335B2
- Status: Granted
- Kind: B2
- Application number: 18/448,326
- Filed: 2023-08-11
- Published: 2023-11-30
- Granted: 2025-02-04
- Earliest claimed: 2021-07-30
- Assignees: HYCO1, Inc.
- Applicants: HYCO1, Inc.
- Inventors: Gregory Carr; David DeVilliers; Kurt A. Dieker
- Web page: https://patentgrep.com/patent/US12214335B2

## CPC

- B01J 23/755: Nickel
- B01J 23/78: with alkali- or alkaline earth metals
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 35/60: characterised by their surface properties or porosity
- B01J 35/612: {less than 10 m2/g}
- B01J 35/613: {10-100 m2/g}
- B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst}
- B01J 37/0063: {Granulating}
- B01J 37/0201: {Impregnation}
- B01J 37/0236: {Drying, e.g. preparing a suspension, adding a soluble salt and drying}
- B01J 37/03: Precipitation; Co-precipitation
- B01J 37/031: {Precipitation}
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/082: {Decomposition and pyrolysis}
- B01J 38/06: using steam
- C01B 3/40: characterised by the catalyst
- C01B 32/40: Carbon monoxide
- C07C 29/1518: {one step being the formation of initial mixture of carbon oxides and hydrogen for synthesis}
- B01J 21/10: Magnesium; Oxides or hydroxides thereof
- B01J 35/70: characterised by their crystalline properties, e.g. semi-crystalline (catalysts comprising carbon B01J21/18; molecular sieves B01J29/00)
- B01J 35/80: characterised by their amorphous structures
- B01J 2235/15: X-ray diffraction
- C01B 2203/0238: the reforming step being a carbon dioxide reforming step
- C01B 2203/1047: Group VIII metal catalysts
- C01B 2203/1052: Nickel or cobalt catalysts
- C01B 2203/1058: Nickel catalysts
- C01B 2203/1082: Composition of support materials
- C01B 2203/1241: Natural gas or methane
- Y02P 20/52: using catalysts, e.g. selective catalysts
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Various aspects disclosed a catalyst particle for catalyzing the production of syngas from carbon dioxide and methane. The catalyst particle includes a metal oxide substrate. The substrate includes a particulate nickel phase. An exposed surface of the catalyst particle includes at least some of the particulate nickel phase. Additionally, the exposed surface is substantially nonporous.

## Claims

### Claim 1

A catalyst particle for catalyzing the production of syngas from carbon dioxide and methane, the catalyst particle comprising:
a metal oxide substrate comprising a particulate nickel phase, wherein an exposed surface of the catalyst particle comprises at least some of the particulate nickel phase and the catalyst particle comprises a low porosity,
wherein at least 51 wt % of the particulate nickel phase is located proximate to a surface of the metal oxide substrate.

### Claim 2 (depends on 1)

The catalyst particle of claim 1, wherein the metal oxide substrate comprises NiO, CoO, FeO, MnO, MgO, or a mixture thereof.

### Claim 3 (depends on 1)

The catalyst particle of claim 1, wherein the metal oxide substrate comprises MgO.

### Claim 4 (depends on 1)

The catalyst particle of claim 1, wherein the particulate nickel phase is 0.2 wt % to 30 wt % of the catalyst particle.

### Claim 5 (depends on 1)

The catalyst particle of claim 1, wherein the particulate nickel phase comprises elemental nickel, nickel oxide, or a mixture thereof.

### Claim 6 (depends on 1)

The catalyst particle of claim 1, wherein the catalyst particle comprises less than about 0.5 wt % free elemental nickel, free nickel oxide, or a mixture thereof in the particulate nickel phase.

### Claim 7 (depends on 1)

The catalyst particle of claim 1, wherein the catalyst particle is a solid-solution catalyst particle.

### Claim 8 (depends on 1)

A method of using a catalyst particle, the method comprising:
contacting the catalyst particle of claim 1 with methane and carbon dioxide to produce carbon monoxide and hydrogen.

### Claim 9 (depends on 8)

The method of using the catalyst particle of claim 8, wherein the carbon monoxide and the hydrogen are produced in a molar ratio in a range of from about 1:1 to about 1:3.

### Claim 10 (depends on 8)

The method of using the catalyst particle of claim 8, wherein at least 70 percent of a total weight of the carbon dioxide and the methane that contacts the catalyst particle are converted to carbon monoxide and hydrogen per turn.

### Claim 11 (depends on 8)

The method of using the catalyst particle of claim 8, wherein at least 90 percent of a total weight of the carbon dioxide and the methane that interact with the catalyst particle are converted to carbon monoxide and hydrogen per turn.

### Claim 12 (depends on 8)

The method of using the catalyst particle of claim 8, wherein the catalyst particle is substantially free of coking during performance of the method.

### Claim 13 (depends on 8)

The method of using the catalyst particle of claim 8, further comprising forming a product from a feedstock comprising syngas.

### Claim 14 (depends on 13)

The method of using the catalyst particle of claim 13, wherein the product comprises a paraffinic base oil, a paraffinic wax, a solvent, a fuel, ammonia, methanol, ethanol, propanol, butanol, pentanol, acetic acid, dimethoxyethane, or a mixture thereof.

### Claim 15 (depends on 8)

The method of using the catalyst particle of claim 8, further comprising contacting the catalyst particle with air, steam, or a mixture thereof to clean the catalyst particle.

### Claim 16 (depends on 15)

The method of claim 15, wherein the air, steam, or the mixture thereof is intermittently contacted with the catalyst particle.