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US 2012/0258037 A1Published application
Metal supported silica based catalytic membrane reactor assembly
AssigneeSaudi Arabian Oil Company
InventorsThang V. Pham, Sai P. Katikaneni, Jorge N. Beltramini, Moses O. Adebajo, Joao Carlos Diniz Da Costa, G.Q. Lu
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Abstract
A catalytic membrane reactor assembly for producing a hydrogen stream from a feed stream having liquid hydrocarbons, steam, and an oxygen source through the use of an autothermal reforming reaction, a water-gas-shift reaction, and a hydrogen permeable membrane.
Claims30
A catalytic membrane reactor assembly comprising:
- a ceramic tubular support having a porous structure;
- an autothermal reforming (ATR) catalytic structure disposed throughout an inner surface layer of the porous structure of the ceramic tubular support, the ATR catalytic structure comprising mixed metal oxides;
- a water-gas-shift (WGS) catalytic structure also disposed throughout the inner surface layer of the porous structure of the ceramic tubular support, the WGS catalytic structure comprising mixed metal oxides, wherein the ATR and WGS catalytic structures are operable to react with a feed stream comprising liquid hydrocarbon, steam, and an oxygen source to form hydrogen through a combination of autothermal reforming and water-gas-shift reactions;
- a γ-alumina layer disposed on an outer surface of the ceramic tubular support, the γ-alumina layer having a porous structure;
- and
- a membrane layer disposed on an outer surface of the γ-alumina layer, the membrane layer being selectively permeable to hydrogen,
- wherein the catalytic membrane reactor assembly is operable to produce a permeate stream and a retentate stream, wherein the permeate stream consists essentially of hydrogen gas, and the retentate stream comprises carbon dioxide.
4 more elements
A method for formulating a catalytic membrane reactor assembly having an autothermal reforming (ATR) catalytic structure, the method comprising the steps of:
- introducing an α-alumina membrane tube into a boehmite sol-gel for a sufficient period of time to allow the boehmite sol-gel to adequately coat the α-alumina membrane tube;
- removing the boehmite sol-gel soaked α-alumina membrane tube from the boehmite sol-gel and allow the α-alumina membrane tube to dry;
- calcining the α-alumina membrane tube at a temperature within a range from about 450° C. to 600° C. until a bimodal distribution of α-alumina and γ-alumina phases form to yield a calcined membrane tube;
- obtaining an ATR catalytic solution comprising an ATR catalyst, said ATR catalyst comprising mixed metal oxide nanoparticles;
- coating the calcined membrane tube with a metal doping solution to form an activated catalytic support, the metal doping solution comprising the ATR catalytic solution and a WGS catalyst solution, the WGS catalyst solution comprising mixed metal oxide nanoparticles, the activated catalytic support having a layer that includes ATR nanoparticles and WGS nanoparticles disposed throughout an inner surface layer of the calcined membrane tube;
- and
- coating an outer surface of the activated catalytic support with a silica colloidal sol-gel to produce a silica containing hydrogen permeable layer on the outer surface of the activated catalytic support to produce the catalytic membrane reactor assembly, wherein the catalytic membrane reactor assembly is operable to produce a hydrogen rich permeate stream and a carbon dioxide rich retentate stream through a combination of an autothermal reformation reaction and a water-gas-shift reaction from a feed stream comprising liquid hydrocarbons, steam, and oxygen.
4 more elements
Dependencies are inferred from the claim text.