Process and system for steel and hydrogen production using recycled ferrous scrap and natural gas
AssigneePalo Alto Research Center Incorporated
InventorsDivyaraj Desai, Jessica Louis Baker Rivest, Dane Andrew Boysen, Rahul Pandey, Eugene Shin Ming Beh
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Abstract
A method for producing a homogenous molten composition and a fluid product is disclosed. For example, the method includes producing a first molten metal composition in an enclosed volume, contacting a hydrocarbon reactant with the first molten metal composition, decomposing the hydrocarbon reactant into at least one fluid product and carbon, forming a metal alloy from a mixture of the carbon and the first molten metal composition, and separating a homogenous second molten composition from the metal alloy.
Claims20
A method for producing a homogeneous molten composition and a fluid product, comprising:
- producing a first molten metal composition in an enclosed volume;
- contacting a hydrocarbon reactant with the first molten metal composition;
- decomposing the hydrocarbon reactant into at least one fluid product and carbon;
- forming a metal alloy from a mixture of the carbon and the first molten metal composition;
- and
- separating a homogenous second molten composition from the metal alloy.
A reactor to produce steel and hydrogen, comprising:
- an enclosed volume;
- a first inlet to feed a metal composition into the enclosed volume;
- a second inlet to feed a hydrocarbon reactant into the enclosed volume;
- a heat source to melt the metal composition into a first molten metal composition and decompose the hydrocarbon reactant into at least one fluid product and carbon, wherein a metal alloy is formed from a mixture of the carbon and the first molten metal composition, wherein a homogenous second molten composition is separated from the metal alloy.
A method for producing a powdered carbon-containing alloy and hydrogen, comprising:
- heating iron that is comminuted and a metal inside of an enclosed volume to produce a first molten alloy comprising iron and the metal;
- feeding methane gas into the enclosed volume;
- heating the enclosed volume to approximately 1000 to 1500 degrees Celsius to decompose the methane gas into a carbon saturated ternary alloy and hydrogen gas, wherein the carbon saturated ternary alloy comprises the iron, carbon, and at most 1 atomic percent of the metal;
- and
- phase-separating the carbon saturated ternary alloy into a carbon-containing alloy and the metal.
Dependencies are inferred from the claim text.