# US 2014/0151601 A1 · Systems and methods for producing hydrogen gas > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0151601 A1 - Document ID: US20140151601A1 - Status: Published application - Kind: A1 - Application number: 13/691,552 - Filed: 2012-11-30 - Published: 2014-06-05 - Earliest claimed: 2012-11-30 - Assignees: Elwha LLC - Applicants: Elwha LLC - Inventors: Roderick A. Hyde; Lowell L. Wood, JR. - Web page: https://patentgrep.com/patent/US20140151601A1 ## CPC - C01B 3/24: of hydrocarbons - B01J 7/00: Apparatus for generating gases (production of inert gas mixtures B01J19/14; for generating specific gases, see the relevant subclasses, e.g. C01B, C10J {; in "air bags" on vehicles B60R21/26; for starter gas F02C7/26; blasting cartridges for producing gas under pressure F42B3/04}) - C01B 2203/0272: containing a non-catalytic decomposition step - C01B 2203/0277: containing a catalytic decomposition step - C01B 2203/0805: Methods of heating the process for making hydrogen or synthesis gas - C01B 2203/0833: Heating by indirect heat exchange with hot fluids, other than combustion gases, product gases or non-combustive exothermic reaction product gases - C01B 2203/1235: Hydrocarbons - C01B 2203/1241: Natural gas or methane - C01B 2203/1247: Higher hydrocarbons - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS ## Abstract Systems and methods for thermally decomposing hydrocarbon feedstock may comprise a hydrocarbon feedstock, a non-oxidizing carrier gas, one or more heat exchangers, and a reaction chamber. The carrier gas may be used to transfer heat to the hydrocarbon feedstock. The heat exchanger(s) may be configured to heat the carrier gas. And the reaction chamber may be configured to receive hydrocarbon feedstock and heated carrier gas. Inside the reaction chamber, the hydrocarbon feedstock and the heated carrier gas may mix with one another causing the thermal decomposition reaction. The thermal decomposition reaction occurs in a substantially oxidant-free environment thereby eliminating or greatly reducing the production of carbon oxide byproducts. Hydrogen gas may be separated from a gaseous product stream that is thereafter collected from the reaction chamber. A portion of the gaseous product stream may be thermally coupled to the carrier gas and may thereafter be recycled through the system. ## Claims ### Claim 1 A method for thermally decomposing hydrocarbon feedstock, comprising: heating a non-oxidative carrier gas; delivering a first volume of hydrocarbon feedstock into a reaction chamber; and delivering the carrier gas into the reaction chamber using a high speed injection method such that the carrier gas and the first volume of hydrocarbon feedstock mix within the reaction chamber and the carrier gas transfers heat to the first volume of hydrocarbon feedstock within the reaction chamber causing the decomposition of the first volume of hydrocarbon feedstock, and wherein the decomposition of the first volume of hydrocarbon feedstock results in a product comprising hydrogen gas and carbon substances. ### Claim 2 (depends on 1) The method of claim 1, further comprising: collecting a first gaseous product stream, wherein the first gaseous product stream comprises hydrogen gas and carrier gas. ### Claim at position 3 -11. (canceled) ### Claim 12 (depends on 2) The method of claim 2, further comprising: delivering at least a portion of the first gaseous product stream to a first heat exchanger; and heating the portion of the first gaseous product stream using the first heat exchanger. ### Claim 13 (depends on 12) The method of claim 12, wherein the first gaseous product stream is filtered to remove the hydrocarbons before completion of the heating. ### Claim 14 (depends on 12) The method of claim 12, further comprising: delivering a second volume of hydrocarbon feedstock into the reaction chamber; delivering the portion of first gaseous product stream into the reaction chamber such that the portion of the first gaseous product stream and the second volume of hydrocarbon feedstock mix within the reaction chamber and the portion of the first gaseous product stream transfers heat to the second volume of hydrocarbon feedstock within the reaction chamber causing the decomposition of the second volume of hydrocarbon feedstock, and wherein the decomposition of the second volume of hydrocarbon feedstock results in a product comprising hydrogen gas and carbon substances; and collecting a second gaseous product stream, wherein the second gaseous product stream comprises hydrogen gas and carrier gas. ### Claim at position 7 -33. (canceled) ### Claim 34 (depends on 1) The method of claim 1, wherein the hydrocarbon feedstock comprises a compound with the formula CnHm, wherein n is 1, 2, 3 or 4, and m is independently selected from 2, 4, 6, 8 or 10. ### Claim at position 9 -37. (canceled) ### Claim 38 (depends on 34) The method of claim 34, wherein the hydrocarbon feedstock comprises one or more of the following: CH4, C2H2, C2H4, C2H6, C3H8, and C4H10. ### Claim 39 (canceled) ### Claim 40 (depends on 1) The method of claim 1, wherein the hydrocarbon feedstock comprises natural gas. ### Claim at position 13 -50. (canceled) ### Claim 51 (depends on 1) The method of claim 1, wherein the high speed injection method is continuous. ### Claim 52 (depends on 1) The method of claim 1, wherein substantially all of the heated carrier gas is delivered into the reaction chamber by the high speed injection method. ### Claim 53 (canceled) ### Claim 54 (depends on 1) The method of claim 1, wherein the high speed injection method comprises passing the carrier gas through one or more discrete injectors. ### Claim 55 (canceled) ### Claim 56 (depends on 54) The method of claim 54, wherein the one or more discrete injectors are coupled to the reaction chamber at one or more injection cites. ### Claim 57 (depends on 56) The method of claim 56, wherein passing the carrier gas through the one or more discrete injectors aids in keeping the carbon substance from depositing on and blocking the one or more injection sites. ### Claim 58 (depends on 1) The method of claim 1, wherein the high speed injection method converts at least a portion of the static pressure of the carrier gas into dynamic pressure. ### Claim 59 (depends on 1) The method of claim 1, wherein heating the carrier gas comprises: transferring thermal energy to the carrier gas either directly or indirectly. ### Claim 60 (canceled) ### Claim 61 (depends on 59) The method of claim 59, wherein thermal energy is indirectly transferred to the carrier gas. ### Claim 62 (depends on 61) The method of claim 61, wherein thermal energy is indirectly transferred to the carrier gas through the use of a first heat exchanger. ### Claim 63 (depends on 59) The method of claim 59, wherein the thermal energy is generated by a heat source. ### Claim at position 27 -104. (canceled) ### Claim 105 A system for thermally decomposing hydrocarbon feedstock, comprising: a non-oxidative carrier gas; a first volume of hydrocarbon feedstock; a heat source configured to heat the carrier gas; a high speed injection system; and a reaction chamber configured to receive each of the first volume of hydrocarbon feedstock and the carrier gas such that the carrier gas mixes with the first volume of hydrocarbon feedstock within the reaction chamber, wherein the carrier gas transfers heat to the first volume of hydrocarbon feedstock within the reaction chamber thereby causing the decomposition of the first volume of hydrocarbon feedstock to a product comprising hydrogen gas and carbon substances. ### Claim 106 (depends on 105) The system of claim 105, further comprising a first gaseous product stream comprising hydrogen gas and carrier gas. ### Claim at position 30 -115. (canceled) ### Claim 116 (depends on 106) The system of claim 106, wherein at least a portion of the first gaseous product stream is delivered to a first heat exchanger and heated by the first heat exchanger. ### Claim 117 (depends on 116) The system of claim 116, wherein the first gaseous product stream is filtered to remove hydrocarbons before completion of the heating. ### Claim 118 (depends on 116) The system of claim 116, wherein a second volume of hydrocarbon feedstock is delivered to the reaction chamber such that the second volume of hydrocarbon feedstock mixes with a portion of the first gaseous product stream that also is delivered to the reaction chamber and the portion of the first gaseous product stream transfers heat to the second volume of hydrocarbon feedstock within the reaction chamber causing the decomposition of the second volume of hydrocarbon feedstock, and wherein the decomposition of the second volume of hydrocarbon feedstock results in a product comprising hydrogen gas and carbon substances. ### Claim at position 34 -139. (canceled) ### Claim 140 (depends on 105) The system of claim 105, wherein the hydrocarbon feedstock comprises a compound with the formula CnHm, wherein n is 1, 2, 3 or 4, and m is independently selected from 2, 4, 6, 8 or 10. ### Claim at position 36 -143. (canceled) ### Claim 144 (depends on 140) The system of claim 140, wherein the hydrocarbon feedstock comprises one or more of the following: CH4, C2H2, C2H4, C2H6, C3H8, and C4H10. ### Claim 145 (depends on 140) The system of claim 140, wherein the hydrocarbon feedstock comprises a mixture of two or more of the following: CH4, C2H2, C2H4, C2H6, C3H8, and C4H10. ### Claim 146 (depends on 105) The system of claim 105, wherein the hydrocarbon feedstock comprises natural gas. ### Claim at position 40 -156. (canceled) ### Claim 157 (depends on 105) The system of claim 105, wherein the high speed injection system is used to deliver the carrier gas into the reaction chamber. ### Claim 158 (depends on 157) The system of claim 157, wherein substantially all of the heated carrier gas is delivered into the reaction chamber by the high speed injection system. ### Claim 159 (canceled) ### Claim 160 (depends on 157) The system of claim 157, wherein the high speed injection system comprises one or more discrete injectors through which the carrier gas may be passed. ### Claim 161 (canceled) ### Claim 162 (depends on 160) The system of claim 160, wherein the one or more discrete injectors are coupled to the reaction chamber at one or more injection sites. ### Claim 163 (depends on 162) The system of claim 162, wherein passing the carrier gas through the one or more discrete injectors aids in keeping the carbon substance from depositing on and blocking the one or more injection sites. ### Claim 164 (depends on 105) The system of claim 105, wherein the high speed injection system converts at least a portion of the static pressure of the carrier gas into dynamic pressure. ### Claim 165 (depends on 105) The system of claim 105, wherein thermal energy is generated from the heat source to heat the carrier gas either directly or indirectly. ### Claim 166 (canceled) ### Claim 167 (depends on 165) The system of claim 165, wherein thermal energy is indirectly transferred to the carrier gas. ### Claim 168 (depends on 167) The system of claim 167, wherein thermal energy is indirectly transferred to the carrier gas through the use of a first heat exchanger. ### Claim at position 53 -209. (canceled)