# US 2018/0023200 A1 · Carbon Formation Reactor and Method of Using Same

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- Number: US 2018/0023200 A1
- Document ID: US20180023200A1
- Status: Published application
- Kind: A1
- Application number: 15/654,996
- Filed: 2017-07-20
- Published: 2018-01-25
- Earliest claimed: 2016-07-20
- Assignees: Paul H. Matter
- Applicants: pH Matter, LLC
- Inventors: Paul H. Matter; Michael G. Beachy; James Gaydos
- Web page: https://patentgrep.com/patent/US20180023200A1

## CPC

- C01B 32/164: involving continuous processes
- B01D 53/46: Removing components of defined structure
- B01D 53/864: {Removing carbon monoxide or hydrocarbons}
- B01D 53/96: Regeneration, reactivation or recycling of reactants
- C01B 32/15: Nano-sized carbon materials
- C01B 32/16: Preparation
- C01B 32/162: characterised by catalysts
- F23K 5/002: {Gaseous fuel}
- B01D 53/76: Gas phase processes, e.g. by using aerosols
- B01D 53/81: Solid phase processes
- C02F 1/283: {using coal, charred products, or inorganic mixtures containing them}
- C07C 1/12: from carbon dioxide with hydrogen
- C12M 43/02: {Bioreactors or fermenters combined with devices for liquid fuel extraction; Biorefineries}
- C12M 43/06: {Photobioreactors combined with devices or plants for gas production different from a bioreactor of fermenter}
- C25B 1/04: by electrolysis of water
- Y02E 60/36: Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
- Y02P 20/582: Recycling of unreacted starting or intermediate materials
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- F23K: FEEDING FUEL TO COMBUSTION APPARATUS (fuel feeders specially adapted for fluidised bed combustion apparatus F23C10/22)
- C02F: TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE (separation in general B01D; special arrangements on waterborne vessels of installations for treating water, waste water or sewage, e.g. for producing fresh water, B63J; adding materials to water to prevent corrosion C23F; treating radioactively-contaminated liquids G21F9/04; regeneration of reactants for recirculation into processes, see the relevant places for the processes)
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C12M: APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; {APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS}
- C25B: ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR (anodic or cathodic protection C23F13/00; single-crystal growth C30B)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A novel carbon formation reactor for forming carbon from a carbon-bearing fluidic stream, and method of using the same, is described. The reactor uses a catalyst bearing surface placed within a heated zone in a carbon-bearing fluidic stream to form carbon, which can then be removed from the reactor, with the process repeatable to achieve high extraction efficiencies.

## Claims

### Claim 1

A chemical composition comprising:
a mixture suitable for use in forming solid carbon from carbon-containing fluid in a non-oxidizing atmosphere further comprising;
an organic binder; and
a solid catalyst precursor component comprising a transition metal compound.

### Claim 2 (depends on 1)

The composition of claim 1, wherein the transition metal compound is selected from the group of compounds consisting of hydroxides, oxides, carbides, alloys, hydrides and mixtures thereof;

### Claim 3 (depends on 1)

The composition of claim 1, wherein the transition metal component of the transition metal compound is selected from the group of transition metals consisting of iron, cobalt, nickel, manganese, and mixtures thereof.

### Claim 4 (depends on 1)

The composition of claim 1, wherein the binder is water soluble.

### Claim 5 (depends on 1)

The composition of claim 1, wherein the transition metal compound comprises equal to or more than 25-wt % of a solids mass of the composition.

### Claim 6 (depends on 1)

The composition of claim 1, wherein the transition metal compound comprises equal to or more than 10-wt % of a solids mass of the composition.

### Claim 7 (depends on 1)

The composition of claim 1, wherein the composition is an aqueous suspension.

### Claim 8

A chemical reactor (10) comprising:
a reactor (10) suitable for use for forming carbon from a carbon-containing fluid in a non-oxidizing atmosphere wherein the reactor (10) further comprises;
a fluid inlet port (150) in fluid communication with a reaction chamber (105) having a heated zone;
the reaction chamber (105) comprising a reusable catalyst-coated substrate within the heated zone in the reaction chamber (105) in fluid communication with an exit port (140); and
wherein carbon is extracted from the carbon-containing fluid onto the substrate and the reaction chamber (105) further comprises a means for periodically loosening carbon from the substrate.

### Claim 9 (depends on 8)

The device of claim 8 wherein the reactor (10) further comprises a valve system suitable for use in automated carbon removal from the reactor (10).

### Claim 10 (depends on 8)

The device of claim 8 wherein the reaction chamber (105) is in fluid communication with a vacuum port (170).

### Claim 11 (depends on 8)

The device of claim 8 wherein the reactor (10) further comprises a spray nozzle (430) suitable for use in delivery of a catalyst coating into the reaction chamber (105).

### Claim 12 (depends on 8)

The device of claim 8 wherein the reaction chamber (105) further comprises a filter media (210) suitable for use in retaining catalyst in the heated zone of the reaction chamber (105).

### Claim 13 (depends on 12)

The device of claim 12 wherein the reactor (10) further comprises a mechanical means for periodically loosening carbon from the filter media (210).

### Claim 14 (depends on 8)

The device of claim 8 wherein the reusable substrate further comprises a portion of a reaction chamber wall (110).

### Claim 15

A method for producing carbon comprising the steps of:
a) coating a substrate with a mixture comprising binder and a predetermined mass of catalyst precursor particles selected from the group of particles consisting of forms of iron, cobalt, nickel, manganese and mixtures thereof;
b) heating the catalyst coated precursor;
c) exposing the catalyst-coated precursor to a non-oxidizing fluid stream containing carbon, thereby;
d) forming a mass of carbon equal to or greater than ten (10) times the mass of catalyst precursor;
e) separating the carbon from the substrate; and
f) repeating steps (b) through (e).

### Claim 16 (depends on 15)

The method according to claim 15, wherein the substrate is coated by spraying with at least one catalyst precursor.

### Claim 17 (depends on 15)

The method according to claim 15, wherein the catalyst precursor particles further comprise transition metal compounds such that the transition metal compounds comprise equal to or greater than 25-wt % of a solid mass of the catalyst and binder.

### Claim 18 (depends on 15)

The method according to claim 15, wherein the catalyst precursor particles further comprise transition metal compounds such that the transition metal compounds comprise equal to or greater than 10-wt % of a solid mass of the catalyst and binder.

### Claim 19 (depends on 15)

The method according to claim 15, wherein the catalyst precursor particles comprises metal hydroxide particles.

### Claim 20 (depends on 15)

The method according to claim 15, wherein the mixture is an aqueous suspension.

### Claim 21 (depends on 15)

The method according to claim 15, wherein the step of heating the catalyst-coated precursor further comprises the step of heating the catalyst-coated precursor to between about 350° C. and 650° C.

### Claim 22 (depends on 15)

The method according to claim 15, wherein the step of forming a mass of carbon equal to or greater than ten (10) times the mass of catalyst precursor further comprises the step of forming a mass of carbon equal to or greater than one hundred (100) times the mass of the catalyst precursor.

### Claim 23 (depends on 15)

The method according to claim 15, wherein the step of separating the carbon from the substrate further comprises the step of using gas flow to separate the carbon from the substrate.