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US 2025/0353741 A1Published application
Hydrogen production by steam reforming of dodecane using nickel-red mud catalyst
AssigneeKing Fahd University of Petroleum and Minerals
InventorsAasif HELAL, Lolwah Tawfiq ALFUHAID, Galal Atef Ahmed NASSER, Zain H. YAMANI
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Abstract
A method for producing hydrogen (H2) from a dodecane-containing fluid uses a red mud-supported nickel (Ni-SRM) catalyst, where the Ni is present at a concentration of 0.01 to 30 wt. % based on the total weight of the Ni-SRM catalyst to convert dodecane in the dodecane-containing fluid to H2. The method has a hydrocarbon conversion of at least 85% based on the initial weight of the hydrocarbon present in the dodecane-containing fluid. The H2 yield using the Ni-SRM catalyst is about 50 to 80% based on the hydrocarbon conversion.
Claims18
1:
- A method for producing hydrogen (H2) from dodecane, comprising:
- preparing an Ni-SRM catalyst by:
- mixing and heating a red mud material and an acid in water to form a first mixture;
- mixing ammonia with the first mixture until a pH of the first mixture is about 8, then heating and drying to form a red mud material precursor;
- calcining the red mud material precursor at a temperature of about 800° C. to form a treated red mud material;
- mixing a nickel salt and the treated red mud material in water to form a second mixture containing a Ni-SRM catalyst precursor;
- separating the Ni-SRM catalyst precursor from the second mixture;
- and
- calcining at a temperature of 800 to 1200° C. to form the Ni-SRM catalyst comprising Ni-SRM catalyst particles;
- wherein the Ni is present in the Ni-SRM catalyst at a concentration of 10 to 20 wt. % based on a total weight of the Ni-SRM catalyst;
- then
- introducing a H2-containing feed gas stream into a reactor containing the Ni-SRM catalyst;
- passing the H2-containing feed gas stream through the reactor to contact the H2-containing feed gas stream with the Ni-SRM catalyst particles at a temperature of 500 to 900° C. to form a reduced Ni-SRM catalyst;
- terminating the introducing the H2-containing feed gas stream;
- simultaneously introducing a dodecane-containing fluid and a water vapor stream into the reactor containing the reduced Ni-SRM catalyst;
- passing the dodecane-containing fluid and the water vapor stream through the reactor to contact the dodecane-containing fluid and the water vapor stream with the reduced Ni-SRM catalyst thereby converting at least a portion of the dodecane to H2, and producing a residue gas stream leaving the reactor;
- and
- separating the H2 from the residue gas stream to generate a H2-containing product gas stream.
15 more elements
2:
- The method of claim 1, wherein the reactor is at least one selected from a group consisting of a fixed-bed reactor, a trickle-bed reactor, a moving bed reactor, a rotating bed reactor, a fluidized bed reactor, and a slurry reactor.
3:
- The method of claim 1, wherein the reactor is a fixed-bed reactor in the form of a cylindrical reactor comprising:
- a top portion;
- a cylindrical body portion;
- a bottom portion;
- a housing having an open top and open bottom supportably maintained with the cylindrical body portion;
- wherein the Ni-SRM catalyst is supportably retained within the housing permitting fluid flow therethrough;
- at least one propeller agitator is disposed in the bottom portion of the reactor;
- wherein the bottom portion is cone shaped or pyramidal;
- and
- wherein a plurality of recirculation tubes fluidly connects the bottom portion of the cylindrical reactor with the cylindrical body portion of the cylindrical reactor.
7 more elements
4:
- The method of claim 1, wherein the H2 is present in the H2-containing feed gas stream at a concentration of 90 to 99.99 vol. % based on a total volume of the H2-containing feed gas stream.
5:
- The method of claim 1, wherein the dodecane is present in the dodecane-containing fluid at a concentration of 50 to 95 vol. % based on a total volume of the dodecane-containing fluid.
6:
- The method of claim 1, wherein the dodecane-containing fluid further comprises an inert gas selected from a group consisting of nitrogen, argon, and helium.
7:
- The method of claim 1, wherein a flow rate of the dodecane-containing fluid to the water vapor stream introduced into the reactor is about 8:1 to 1:2.
8:
- The method of claim 1, wherein the passing of the dodecane-containing fluid and the water vapor stream through the reactor is performed at a temperature of about 700° C.
9:
- The method of claim 1, wherein the dodecane-containing fluid comprises one or more C8 to C25 aliphatic hydrocarbons.
10:
- The method of claim 9, wherein the dodecane-containing fluid consists of dodecane.
11:
- The method of claim 1, wherein the dodecane-containing fluid consists of dodecane, and wherein the residue gas stream comprises H2, methane (CH4), carbon monoxide (CO), carbon dioxide (CO2), or mixtures thereof.
12:
- The method of claim 1, wherein the Ni-SRM catalyst is in the form of aggregated Ni particles disposed on porous surfaces of red mud particles.
13:
- The method of claim 1, wherein the Ni-SRM catalyst has a Brunauer-Emmett-Teller (BET) surface of 5 to 15 cubic meters per gram (m3/g).
14:
- The method of claim 1, wherein the Ni-SRM catalyst comprises hematite (Fe2O3), nickel ferrite (NiFe2O4), quartzite (SiO2), calcium silicon oxide (Ca2SiO4), calcium aluminum oxide (Ca3Al2O6), aluminum oxide (Al2O3), magnetite (Fe2O4), hercynite (FeAl2O4), nickel (Ni), nickel oxide (NiO), nickel aluminate (NiAl2O4) as determined by X-ray diffraction (XRD) analysis.
15:
- The method of claim 1, wherein the method has a hydrocarbon conversion of at least to 85% based on an initial weight of the dodecane present in the dodecane-containing fluid, and wherein the method has a H2 yield of 50 to 80% based on the hydrocarbon conversion.
16:
- The method of claim 1, wherein the acid is at least one selected from a group consisting of hydrochloric acid, nitric acid, sulfuric acid, sulfonic acid, phosphoric acid, or mixtures thereof.
17:
- The method of claim 16, wherein the nickel salt comprises nickel sulfate, nickel acetate, nickel citrate, nickel iodide, nickel chloride, nickel perchlorate, nickel nitrate, nickel phosphate, nickel triflate, nickel bis(trifluoromethanesulfonyl)imide, nickel tetrafluoroborate, nickel bromide, and/or its hydrate.
18:
- The method of claim 1, wherein the Ni-SRM catalyst precursor after the separating is calcined at a temperature of about 950° C.