# US 2014/0154169 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 2014/0154169 A1 - Document ID: US20140154169A1 - Status: Published application - Kind: A1 - Application number: 13/691,543 - 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/US20140154169A1 ## CPC - C01B 3/24: of hydrocarbons - 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 2203/1241: Natural gas or methane - C01B 2203/1247: Higher hydrocarbons - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} ## 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 first volume of non-oxidizing, inert carrier gas with a first heat exchanger; delivering a first volume of hydrocarbon feedstock into a reaction chamber; delivering the first volume of non-oxidizing, inert carrier gas into the reaction chamber such that the first volume of non-oxidizing, inert carrier gas and the first volume of hydrocarbon feedstock mix within the reaction chamber and the first volume of non-oxidizing, inert 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; collecting a first gaseous product stream, wherein the first gaseous product stream comprises hydrogen gas and non-oxidizing, inert carrier gas; and thermally coupling heat from at least a portion of the first gaseous product stream into a second volume of non-oxidizing, inert carrier gas before delivering the second volume of non-oxidizing, inert carrier gas into the reaction chamber. ### Claim at position 2 -7. (canceled) ### Claim 8 (depends on 1) The method of claim 1, wherein after thermally coupling heat from the portion of the first gaseous product stream into the second volume of carrier gas through use of a second heat exchanger, the portion of the first gaseous product stream is converted into a second portion of the first gaseous product stream by at least partial removal of hydrogen gas from the portion of the first gaseous product stream. ### Claim 9 (depends on 8) The method of claim 8, further comprising: heating the second portion of the first gaseous product stream with a third heat exchanger. ### Claim 10 (depends on 9) The method of claim 9, wherein the first heat exchanger and the third heat exchanger share one or more components. ### Claim 11 (depends on 9) The method of claim 9, further comprising: transferring thermal energy from a heat source to the third heat exchanger prior to heating the second portion of the first gaseous product stream with the third heat exchanger. ### Claim 12 (canceled) ### Claim 13 (depends on 9) The method of claim 9, further comprising: delivering a second volume of hydrocarbon feedstock into the reaction chamber; delivering the heated second portion of the first gaseous product stream into the reaction chamber such that the heated second portion of the first gaseous product stream and the second volume of hydrocarbon feedstock mix within the reaction chamber and the heated second 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 and carbon substances; and collecting a second gaseous product stream, wherein the second gaseous product stream comprises hydrogen gas and carrier gas. ### Claim 14 (canceled) ### Claim 15 (depends on 8) The method of claim 8, further comprising: adding at least part of the second portion of the first gaseous product stream to the second volume of carrier gas before delivering the second volume of carrier gas into the reaction chamber. ### Claim at position 11 -20. (canceled) ### Claim 21 (depends on 1) The method of claim 1, wherein before thermally coupling heat from the portion of the first gaseous product stream into the second volume of carrier gas, at least a portion of hydrogen gas is removed from the portion of the first gaseous product stream. ### Claim 22 (depends on 21) The method of claim 21, further comprising: after thermally coupling heat from the portion of the first gaseous product stream into the second volume of carrier gas, adding at least part of the portion of the first gaseous product to the second volume of carrier gas before delivering the second volume of carrier gas into the reaction chamber. ### Claim at position 14 -43. (canceled) ### Claim 44 (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 16 -47. (canceled) ### Claim 48 (depends on 44) The method of claim 44, wherein the hydrocarbon feedstock comprises one or more of the following: CH4, C2H2, C2H4, C2H6, C3H8, and C4H10. ### Claim 49 (canceled) ### Claim 50 (depends on 1) The method of claim 1, wherein the hydrocarbon feedstock comprises natural gas. ### Claim at position 20 -94. (canceled) ### Claim 95 (depends on 1) The method of claim 1, wherein thermally coupling heat from at least a portion of the first gaseous product stream comprises: delivering at least a portion of the first gaseous product stream to a second heat exchanger; delivering at least a portion of the second volume of carrier gas to the second heat exchanger; and thermally coupling heat from the portion of the first gaseous product stream to the portion of the second volume of carrier gas within the second heat exchanger. ### Claim at position 22 -99. (canceled) ### Claim 100 (depends on 95) The method of claim 95, wherein the second heat exchanger and the first heat exchanger are configured such that they share common components. ### Claim at position 24 -363. (canceled) ### Claim 364 (depends on 1) The method of claim 1, wherein the non-oxidizing, inert carrier gas comprises a gas that does not readily undergo chemical reactions when being subjected to heat. ### Claim 365 (depends on 1) The method of claim 1, wherein the non-oxidizing, inert carrier gas comprises a noble gas. ### Claim 366 (depends on 1) The method of claim 1, wherein the non-oxidizing, inert carrier gas comprises argon. ### Claim 367 (depends on 1) The method of claim 1, wherein the non-oxidizing, inert carrier gas comprises helium. ### Claim 368 (depends on 1) The method of claim 1, wherein the non-oxidizing, inert carrier gas comprises hydrogen. ### Claim 369 (depends on 1) The method of claim 1, wherein the non-oxidizing, inert carrier gas comprises nitrogen.