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US 12,753,072 B2Granted
Thermocatalytic decomposition of methane using catalyst system design and operational parameters to control product yield and properties
AssigneesBattelle Memorial Institute, West Virginia University
InventorsRobert A. Dagle, Juan A. Lopez-Ruiz, Robert S. Weber, Mengze Xu, Jianli Hu, Changle Jiang
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Abstract
Disclosed herein are aspects of a method for contacting a methane composition with a catalyst system to produce H2 and a carbon co-product. In some aspects, the catalyst system comprises (i) a Ni—Cu alloy catalyst comprising Ni and Cu, and (ii) a support. In some additional aspects, the Ni and Cu are present at a Ni:Cu mass ratio ranging from greater than zero to 4.5. Also disclosed herein are aspects of a method for making the disclosed catalyst system.
Claims20
A method, comprising:
- contacting a methane composition with a thermocatalytic catalyst system at a reaction temperature ranging from 500° C. to 700° C. to produce H2 and a carbon co-product, wherein the thermocatalytic catalyst system comprises a Ni—Cu alloy catalyst and a support
- separating the thermocatalytic catalyst system from the carbon co-product;
- contacting the carbon co-product with a solution comprising a first metal that is Ni or Cu to impregnate the carbon co-product with the first metal, thereby forming an impregnated support;
- heating the impregnated support using a ramping temperature protocol to provide a pre-catalyst system, wherein the ramping temperature protocol comprises increasing a temperature to which the impregnated support is exposed by 5° C. per minute until a final temperature of 350° C. is reached;
- contacting the pre-catalyst system with a solution comprising a second metal that is Ni or Cu to re-form the thermocatalytic catalyst system;
- reusing the thermocatalytic catalyst system to produce further amounts of H2 and the carbon co-product;
- wherein the first metal and the second metal are different.
4 more elements
A method, comprising:
- contacting a methane composition with a thermocatalytic catalyst system at a reaction temperature ranging from 600° C. to 650° C. to produce H2 and a carbon nanotube, wherein the thermocatalytic catalyst system comprises a Ni—Cu alloy catalyst and a carbonaceous support
- separating the thermocatalytic catalyst system from the carbon nanotube;
- contacting the carbon nanotube with a solution comprising a first metal that is Ni or Cu to impregnate the carbon nanotube with the first metal, thereby forming an impregnated nanotube;
- heating the impregnated nanotube using a ramping temperature protocol to provide a pre-catalyst system, wherein the ramping temperature protocol comprises increasing a temperature to which the impregnated nanotube is exposed by 5° C. per minute until a final temperature of 350° C. is reached;
- contacting the pre-catalyst system with a solution comprising a second metal that is Ni or Cu to re-form the thermocatalytic catalyst system;
- reusing the thermocatalytic catalyst system to produce additional H2 and carbon nanotubes;
- wherein the first metal and the second metal are different.
4 more elements
A method for making a catalyst system, comprising:
- i) contacting a solution comprising a first metal with a support material to impregnate the support material with the first metal, thereby forming an impregnated support;
- ii) heating the impregnated support using a ramping temperature protocol to provide a pre-catalyst system, wherein the ramping temperature protocol comprises increasing a temperature to which the impregnated support is exposed by 5° C. per minute until a final temperature of 350° C. is reached;
- iii) contacting the pre-catalyst system with a solution comprising a second metal to form a bimetallic impregnated support;
- and
- (iv) heating the bimetallic impregnated support using the ramping temperature protocol to provide the catalyst system;
- wherein the first metal and the second metal are different from each other and independently are selected from Ni and Cu.
3 more elements
A method, comprising:
- separating a carbon product from a mixture comprising the carbon product and a catalyst system to provide an amount of isolated carbon product;
- contacting a portion of the amount of isolated carbon product with a solution comprising a first metal that is Ni or Cu to impregnate the isolated carbon product with the first metal, thereby forming an impregnated support;
- heating the impregnated support using a ramping temperature protocol to provide a pre-catalyst system, wherein the ramping temperature protocol comprises increasing a temperature to which the impregnated support is exposed by 5° C. per minute until a final temperature of 350° C. is reached;
- and
- contacting the pre-catalyst system with a solution comprising a second metal that is Ni or Cu to form a regenerated catalyst system;
- wherein the first metal and the second metal are different.
3 more elements
Dependencies are inferred from the claim text.