# US 2014/0154170 A1 · Systems and methods for producing hydrogen gas

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- Number: US 2014/0154170 A1
- Document ID: US20140154170A1
- Status: Published application
- Kind: A1
- Application number: 13/691,585
- 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/US20140154170A1

## 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: 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 gaseous hydrocarbon feedstock, comprising:
delivering a volume of gaseous hydrocarbon feedstock into a reaction chamber;
heating the volume of gaseous hydrocarbon feedstock in a non-oxidative manner within the reaction chamber, wherein heating the gaseous hydrocarbon feedstock comprises transferring thermal energy from a non-oxidizing carrier gas to the gaseous hydrocarbon feedstock, wherein heating the volume of gaseous hydrocarbon feedstock causes the decomposition of the volume of gaseous hydrocarbon feedstock, and wherein the decomposition of the volume of gaseous hydrocarbon feedstock results in a product comprising hydrogen gas and carbon substances; and
applying ultrasonic agitation to the reaction chamber to disrupt a buildup of carbon substances on one or more selected surfaces.

### Claim at position 2

2-41. (canceled)

### Claim 42 (depends on 1)

The method of claim 1, wherein the reaction chamber comprises an inner surface and an outer surface, and wherein the inner surface is on the inside of the reaction chamber.

### Claim 43 (depends on 42)

The method of claim 42, wherein at least one selected surface is the inner surface of the reaction chamber.

### Claim 44 (depends on 1)

The method of claim 1, wherein the reaction chamber comprises one or more walls.

### Claim 45 (depends on 44)

The method of claim 44, wherein at least one selected surface is the wall of the reaction chamber.

### Claim at position 7

46-71. (canceled)

### Claim 72 (depends on 1)

The method of claim 1, wherein a parameter of the ultrasonic agitation is variable.

### Claim 73 (depends on 72)

The method of claim 72, wherein the parameter is a frequency of the ultrasonic agitation.

### Claim 74 (depends on 72)

The method of claim 72, wherein the parameter is an amplitude of the ultrasonic agitation.

### Claim 75 (depends on 72)

The method of claim 72, wherein the parameter is a duration of the ultrasonic agitation.

### Claim 76 (depends on 72)

The method of claim 72, wherein the parameter is a site of the ultrasonic agitation

### Claim 77 (depends on 72)

The method of claim 72, wherein the parameter of the ultrasonic agitation is varied based on the amount of carbon substances deposited on a selected surface.

### Claim 78 (depends on 72)

The method of claim 72, wherein the parameter of the ultrasonic agitation is varied based on the temperature of the thermal decomposition reaction.

### Claim 79 (depends on 72)

The method of claim 72, wherein the parameter of the ultrasonic agitation is varied based on the rate of the decomposition reaction.

### Claim 80 (depends on 72)

The method of claim 72, wherein the parameter of the ultrasonic agitation is varied based on the amount of time the ultrasonic agitation is being applied.

### Claim 81 (depends on 72)

The method of claim 72, wherein the parameter of the ultrasonic agitation is varied based on the deposition rate of the carbon substances on a selected surface.

### Claim 82 (depends on 72)

The method of claim 72, wherein the parameter of the ultrasonic agitation is varied based on the type of the carbon substances deposited on a selected surface.

### Claim 83

A method for thermally decomposing gaseous hydrocarbon feedstock, comprising:
heating a volume of non-oxidizing carrier gas with a first heat exchanger;
delivering a volume of gaseous hydrocarbon feedstock into a reaction chamber;
delivering the volume of non-oxidizing carrier gas into the reaction chamber such that the volume of non-oxidizing carrier gas and the volume of gaseous hydrocarbon feedstock mix within the reaction chamber and the volume of non-oxidizing carrier gas transfers heat to the volume of gaseous hydrocarbon feedstock within the reaction chamber causing the decomposition of the volume of gaseous hydrocarbon feedstock, wherein the decomposition reaction occurs in a substantially oxidant-free environment, and wherein the decomposition of the volume of gaseous 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 carrier gas; and
applying ultrasonic agitation to the reaction chamber to disrupt a buildup of carbon substances on one or more selected surfaces.

### Claim at position 20

84-146. (canceled)

### Claim 147

A system for thermally decomposing hydrocarbon feedstock, comprising:
a volume of hydrocarbon feedstock;
a reaction chamber configured to receive the volume of hydrocarbon feedstock, wherein the volume of hydrocarbon feedstock is heated in a non-oxidative manner within the reaction chamber such that the heating of the volume of hydrocarbon feedstock causes the decomposition of the volume of hydrocarbon feedstock, and wherein the decomposition of the volume of hydrocarbon feedstock results in a product comprising hydrogen gas and carbon substances; and
a source of ultrasonic agitation configured to apply ultrasonic agitation to the reaction chamber to disrupt a buildup of carbon substances on one or more selected surfaces.

### Claim at position 22

148-169. (canceled)

### Claim 170 (depends on 147)

The system of claim 147, wherein the hydrocarbon feedstock is heated by transferring thermal energy to the hydrocarbon feedstock.

### Claim 171 (depends on 170)

The system of claim 170, wherein a non-oxidizing carrier gas is used to transfer thermal energy to the hydrocarbon feedstock.

### Claim 172 (depends on 170)

The system of claim 170, wherein transferring thermal energy to the hydrocarbon feedstock comprises contacting the volume of hydrocarbon feedstock with a hot surface.

### Claim at position 26

173-187. (canceled)

### Claim 188 (depends on 147)

The system of claim 147, wherein the reaction chamber comprises an inner surface and an outer surface, wherein the inner surface is on the inside of the reaction chamber.

### Claim 189 (depends on 188)

The system of claim 188, wherein at least one selected surface is the inner surface of the reaction chamber.

### Claim 190 (depends on 147)

The system of claim 147, wherein the reaction chamber comprises one or more walls.

### Claim 191 (depends on 190)

The system of claim 190, wherein at least one selected surface is the wall of the reaction chamber.

### Claim at position 31

192-217. (canceled)

### Claim 218 (depends on 147)

The system of claim 147, wherein a parameter of the ultrasonic agitation is variable.

### Claim 219 (depends on 218)

The method of claim 218, wherein the parameter is a frequency of the ultrasonic agitation.

### Claim 220 (depends on 218)

The method of claim 218, wherein the parameter is an amplitude of the ultrasonic agitation.

### Claim 221 (depends on 218)

The method of claim 218, wherein the parameter is a duration of the ultrasonic agitation.

### Claim 222 (depends on 218)

The method of claim 218, wherein the parameter is a site of the ultrasonic agitation

### Claim 223 (depends on 218)

The system of claim 218, wherein the parameter of the ultrasonic agitation is varied based on the amount of carbon substances deposited on a selected surface.

### Claim 224 (depends on 218)

The system of claim 218, wherein the parameter of the ultrasonic agitation is varied based on the temperature of the thermal decomposition reaction.

### Claim 225 (depends on 218)

The system of claim 218, wherein the parameter of the ultrasonic agitation is varied based on the rate of the decomposition reaction.

### Claim 226 (depends on 218)

The system of claim 218, wherein the parameter of the ultrasonic agitation is varied based on the amount of time the ultrasonic agitation is being applied.

### Claim 227 (depends on 218)

The system of claim 218, wherein the parameter of the ultrasonic agitation is varied based on the deposition rate of the carbon substances on a selected surface.

### Claim 228 (depends on 218)

The system of claim 218, wherein the parameter of the ultrasonic agitation is varied based on the type of carbon substances deposited on a selected surface.

### Claim 229 (depends on 1)

The system of claim 1, wherein the gaseous hydrocarbon feedstock comprises natural gas.

### Claim 230 (depends on 1)

The system of claim 1, wherein the non-oxidizing carrier gas comprises an inert gas.

### Claim 231 (depends on 1)

The system of claim 1, wherein the decomposition reaction occurs in a substantially oxidant-free environment.