Hydrogen production through methane gas pyrolysis using xenon gas as a catalyst

Abstract

The present invention relates to a process and system for production of clean hydrogen gas from gaseous biomass sources, such as methane gas, using pyrolysis and a catalyst gas such as xenon in a plasma-driven thermal decomposition system with an integrated carbon removal step. More particularly, the pyrolysis step occurs in a plasma-decomposition system resulting in the release of hydrogen and the catalyst gas that are captured by a cooling-pressure control system processing system using the transition boiling point (liquification) of xenon while the carbon by-product is removed. As a benefit of the above process and system, the catalyst gas xenon is filtered in cooling and can be recycled as the primary catalyst for continuous reuse.

Description

PATENT 1 BURLA.01953.P3PCT HYDROGEN PRODUCTION THROUGH METHANE GAS PYROLYSIS USING XENON GAS AS A CATALYST CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application relates to and claims priority from, US Provisional Ser. No. 63 / 453,292 filed March 20, 2024, the entire contents of which are incorporated herein fully by reference. FIGURE SELECTED FOR PUBLICATION

[0002] Fig. 1 BACKGROUND OF THE INVENTION Field of the Invention

[0003] The present invention relates to a method for production of clean hydrogen gas from liquified or gaseous biomass sources. More particularly, the present invention relates to a method and system for production of clean hydrogen gas using plasma-driven pyrolysis and xenon gas as a catalyst. Description of the Related Art

[0004] This section of this document introduces information about and / or from the art that may provide context for or be related to the subject matter described herein and / or claimed below. It provides background information to facilitate a better understanding of the various aspects of the present invention. This is a discussion of "related" art. That such art is related in no way implies that it is also "prior" art. The related art may or may not be prior art. The discussion in this section of this document is to be read in this light, and not as admissions of prior art.PATENT 2 BURLA.01953.P3PCT

[0005] Fossil fuels (liquid, solid, and are common in both the industrial and transportation fields and have the unfortunate effect of releasing carbon forms into the atmosphere during processing. At the same time, fossil fuels and petroleum are plentiful, reasonably inexpensive, and continue to be necessary precursors to many fields of endeavor and industry, and they will be for the foreseeable future. Currently, the increased use of electrically-driven transport vehicles (electric cars, buses, scooters, trams, and even aircraft etc.) is being emphasized to mitigate the negative influences of the gaseous release of carbon, and carbon containing gases into the atmosphere. Unfortunately, challenges remain, and these include the inherent dangers and high costs of dealing with high-pressure / low-temperature hydrogen and oxygen gas sources. The use of fuel cell technology, involving the reaction of hydrogen-gas and oxygen-gas in vehicles, is in an infancy stage with only the aeronautical, aerospace, and high value transport being able to utilize such fuel cells. A further challenge in the fuel cell field is the strongly detrimental impact of impure gases on fuel cell components.

[0006] One method of separating hydrogen gas from fossil fuels is the Kraener process that produces carbon black (carbon) and hydrogen gas (and other biogases) in a pyrolysis process using an endothermic reaction and a plasma burner resulting in carbon particles and hydrogen (and other biogases) in an aerosol, where the carbon forms nano-cones deposits, and tars, on surfaces and no greenhouse gases are released. This process is inherently inefficient and results in substantial losses and non-conversion.

[0007] Other forms of carbon chemical nucleation or deposition systems are known from so-called chemical vapor deposition (CVD) or plasma chemical vapor deposition (PECVD) technology wherein polycrystalline diamond films or carbon-compositions (including graphene) were grown from hydrocarbon feedstocks in a reactor. These processes are inherently inefficient and commonlyPATENT 3 BURLA.01953.P3PCT also requires the use of gas resulting in vapor errors, improper deposition and related quality losses in the process.

[0008] Noble gasses were thought to be chemically inert for many years. Xenon, a noble gas, has the most extensive chemistry in periodic Group 18, with many oxidation states but unfortunately, as might be predicted, xenon compounds are poor oxidizing agents for many compounds and are difficult to work with. Accordingly, currently known xenon chemistry often involves fluorides and oxofluorides for strong reactions with other detriments in achieving results requiring ion-donors. Xenon has also been used in anesthetic closed re-breathing circuits but unfortunately requires complex CO2 / Xe or N2 / Xe molecular sieve membranes.

[0009] Accordingly, there is a proposed need for an improved process that addresses one or more of the challenges noted above. ASPECTS AND SUMMARY OF THE INVENTION

[0010] The present disclosure provides, optionally, a process and system for production of clean hydrogen gas from gaseous or liquified-to-gas biomass sources, such as methane gas, using pyrolysis and xenon as a catalyst in a plasma- driven thermal decomposition system with an integrated carbon removal step. More particularly, the pyrolysis step occurs in a plasma-decomposition system resulting in the release of hydrogen and the catalyst gas that are captured by a cooling-pressure control processing system using the liquid point of xenon while the carbon by-product and hydrogen are removed. As a benefit of the above process and system, the catalyst gas xenon is filtered in cooling and can be recycled as the primary catalyst for continuous reuse.

[0011] In another alternative and adaptive embodiment of the present invention,PATENT 4 BURLA.01953.P3PCT there is provided a process, method system, which reduces the costs involved in hydrogen separation from alkane gases.

[0012] In another alternative and adaptive embodiment of the present invention, there is provided a process for using a plasma-driven thermal decomposition system for producing hydrogen from an alkane gas using a noble gas as a catalyst.

[0013] According to another alternative and adaptive embodiment there is provided, a process where gaseous biomass sources are used to produce purified hydrogen, carbon and xenon for use in downstream fuel cell technology utilizing pure hydrogen and oxygen to produce electricity with pure water as a by-product.

[0014] According to another alternative and adaptive embodiment there is provided, a process where gaseous biomass sources (or liquid-to-gas sources such as liquified methane or other alkane gas) are used to produce purified hydrogen, for use in transport, including vehicle transport and alternatively personal vehicle transport. With the carbon and xenon being reusable.

[0015] According to another alternative and adaptive embodiment the present invention provides a means of producing hydrogen gas on demand using xenon gas as a catalyst with the pyrolysis of light carbon alkanes such as methane, ethane, propane and butane. The pyrolysis process is produced by plasma-driven gas-phase thermal decomposition of the alkane gas. The invention further alternatively and adaptively includes the removal of solid-phase carbon by- product through the use of solid-phase plasma induced carbon crystal growth and screening / filtering processes. It will be further understood that additional filtering or purification may be conducted in any step through the use of molecular sieve membranes or other techniques known in the purification arts.

[0016] According to another alternative and adaptive embodiment of the presentPATENT 5 BURLA.01953.P3PCT invention, there is provided a system (and a means for) recycling and reusing the xenon gas for further use by a simple cooling / liquification process utilizing the liquid point of xenon (-108.1 degrees Celsius (-108.1°C) / -162.6 degrees Fahrenheit (-162.6°F) (or as is otherwise known in the field).

[0017] According to another alternative and adaptive embodiment of the present invention, there is provided a process, method, and system that provides pure hydrogen for use in a fuel cell which in turn produces electricity and pure water as another by-product.

[0018] According to another alternative and adaptive embodiment of the present invention, there is provided a method for producing a hydrogen gas using a catalyst gas, the method comprising the steps of: providing an alkane supply tank for storing an alkane gas and for releasing the alkane gas to a gas mixing system, providing a catalyst supply tank for storing a catalyst gas and for releasing the catalyst gas to the gas mixing system, operating the gas mixing system to receive the alkane gas and the catalyst gas as a gas mixture, maintaining an operational mixing temperature and mixing pressure of the gas mixture in the gas mixing system, providing the gas mixture from the gas mixing system to a pump system, receiving the gas mixture at the pump system and maintaining an operational pump pressure, operating a plasma torch system with the gas mixture as a carrier gas from the pump system and producing a plasma from the plasma torch system, providing a pyrolysis reactor that receives the plasma from the plasma torch system and operates at a pyrolysis reactor temperature and pressure, the plasma torch system and the pyrolysis reactor cracking the alkane gas with the catalyst gas and forming a carbon-catalyst gas and a hydrogen-catalyst gas, cooling the carbon-catalyst gas and the hydrogen-catalyst gas in the pyrolysis reactor and separating the catalyst gas from the carbon and separating the hydrogen from the catalyst gas, the pyrolysis reactor including a carbon sequester system that sequesters the carbon during the cooling, providing a gas separator module forPATENT 6 BURLA.01953.P3PCT separating the catalyst gas from hydrogen gas, providing a catalyst gas receiver system that receives the catalyst gas from the gas separator module and in situ returns the catalyst gas to the catalyst supply tank, and providing a hydrogen gas receiver that receives the hydrogen gas from the gas separator module and stores the hydrogen gas.

[0019] According to another alternative and adaptive embodiment of the present invention, there is provided a method, wherein, the catalyst gas is a noble gas.

[0020] According to another alternative and adaptive embodiment of the present invention, there is provided a method, wherein, the alkane gas is one of methane, ethane, propane and butane.

[0021] According to another alternative and adaptive embodiment of the present invention, there is provided a method, wherein, the step of cooling the carbon- catalyst gas and the hydrogen-catalyst gas in the pyrolysis reactor, further comprises the step of: providing a heat exchange system controlling a temperature and a pressure in the pyrolysis reactor and having a pressure and temperature control module and at least one cooling element.

[0022] According to another alternative and adaptive embodiment of the present invention, there is provided a method, wherein, the catalyst gas is xenon, and the alkane gas is methane.

[0023] According to another alternative and adaptive embodiment of the present invention, there is provided a method, wherein, the step of operating the plasma torch system further comprises the step of: providing a power control system and a cooling and safety system in operative control of the plasma torch system.

[0024] According to another alternative and adaptive embodiment of the presentPATENT 7 BURLA.01953.P3PCT invention, there is provided a method, comprising the step of: providing a gas condensing system for the catalyst gas receiver system, whereby the step of in situ returning to the catalyst supply tank returns a condensed catalyst gas to the catalyst supply tank.

[0025] According to another alternative and adaptive embodiment of the present invention, there is provided a method, wherein, the catalyst gas is xenon, the alkane gas is methane, and further comprising the step of: providing a gas condensing system for the catalyst gas receiver system, whereby the step of in situ returning to the catalyst supply tank returns a condensed catalyst gas to the catalyst supply tank, and the step of cooling the carbon-catalyst gas and the hydrogen-catalyst gas in the pyrolysis reactor, further comprises the step of: providing a heat exchange system controlling a temperature and a pressure in the pyrolysis reactor and having a pressure and temperature control module and at least one cooling element.

[0026] According to another alternative and adaptive embodiment of the present invention, there is provided a system for producing hydrogen gas using a catalyst gas, the system comprising: an alkane supply tank that stores an alkane gas and releases the alkane gas to a gas mixing system, a catalyst supply tank that stores a catalyst gas and releases the catalyst gas to the gas mixing system, the gas mixing system receiving the alkane gas and the catalyst gas as a gas mixture and maintaining an operational mixing temperature and mixing pressure of the gas mixture in the gas mixing system, a pump system for receiving the gas mixture from the gas mixing system and maintaining an operational pressure, a plasma torch system that receives the gas mixture as a carrier gas from the pump system and produces a plasma from the plasma torch system, a pyrolysis reactor that receives the plasma from the plasma torch system and operates at a pyrolysis reactor temperature and pressure, the plasma torch system and the pyrolysis reactor cracking the alkane gas with the catalyst gas and forming a carbon-catalystPATENT 8 BURLA.01953.P3PCT gas and a hydrogen-catalyst gas, heat exchange system that controls a temperature and a pressure in the pyrolysis reactor according to a pressure and temperature control module, the pyrolysis reactor separates the catalyst gas from the carbon and separates the hydrogen from the catalyst gas, a carbon sequester system in the pyrolysis reactor that sequesters the carbon during the cooling, a gas separator module separates the catalyst gas from the hydrogen gas, a catalyst gas receiver system receives the catalyst gas from the gas separator module and in situ returns the catalyst gas to the catalyst supply tank, and a hydrogen gas receiver that receives the hydrogen gas from the gas separator module and stores the hydrogen gas.

[0027] According to another alternative and adaptive embodiment of the present invention, there is provided a system, wherein: the catalyst gas is a noble gas, the alkane gas is one of methane, ethane, propane and butane, and further comprising: a gas condensing system in the catalyst gas receiver system, whereby the in situ returns to the catalyst supply tank returns a condensed the noble gas to the catalyst supply tank, and a heat exchange system that controls a temperature and a pressure in the pyrolysis reactor and has a pressure and temperature control module and at least one cooling element.

[0028] According to another alternative and adaptive embodiment of the present invention, there is provided a system wherein: the noble gas is xenon, and the alkane gas is methane.

[0029] According to another alternative and adaptive embodiment of the present invention, there is provided an apparatus for producing a hydrogen gas using a catalyst gas, the apparatus comprising: an alkane supply tank that stores an alkane gas and releases the alkane gas to a gas mixing system, a catalyst supply tank that stores a catalyst gas and releases the catalyst gas to the gas mixing system, the gas mixing system receiving the alkane gas and the catalyst gas as a gas mixture andPATENT 9 BURLA.01953.P3PCT maintaining an operational mixing and mixing pressure of the gas mixture in the gas mixing system, a pump system for receiving the gas mixture from the gas mixing system and maintaining an operational pressure, a plasma torch system that receives the gas mixture as a carrier gas from the pump system and produces a plasma from the plasma torch system, a pyrolysis reactor that receives the plasma from the plasma torch system and operates at a pyrolysis reactor temperature and pressure, the plasma torch system and the pyrolysis reactor cracking the alkane gas with the catalyst gas and forming a carbon-catalyst gas and a hydrogen-catalyst gas, a heat exchange system that controls a temperature and a pressure in the pyrolysis reactor according to a pressure and temperature control module, the pyrolysis reactor separates the catalyst gas from the carbon and separates the hydrogen from the catalyst gas, a carbon sequester system in the pyrolysis reactor that sequesters the carbon during the cooling, a gas separator module separates the catalyst gas from the hydrogen gas, a catalyst gas receiver system receives the catalyst gas from the gas separator module and in situ returns the catalyst gas to the catalyst supply tank, and a hydrogen gas receiver that receives the hydrogen gas from the gas separator module and stores the hydrogen gas.

[0030] According to another alternative and adaptive embodiment of the present invention, there is provided an apparatus, wherein: the catalyst gas is a noble gas, the alkane gas is one of methane, ethane, propane and butane, and further comprising: a gas condensing system in the catalyst gas receiver system, whereby the in situ return to the catalyst supply tank returns a condensed the noble gas to the catalyst supply tank, and a heat exchange system that controls a temperature and a pressure in the pyrolysis reactor and has a pressure and temperature control module and at least one cooling element.

[0031] According to another alternative and adaptive embodiment of the present invention, there is provided an apparatus wherein: the noble gas is xenon, and thePATENT 10 BURLA.01953.P3PCT alkane gas is methane.

[0032] According to another alternative and adaptive embodiment of the present invention, there is provided a hydrogen production method through methane gas pyrolysis using xenon gas as a catalyst including the following steps, or selections of steps: (1) providing a mixing chamber that brings together a prescribed percentage of alkane and xenon gases at a suitable pressure and temperature, (2) passing the mixed gases through a DC plasma torch at a suitable heat to cause pyrolysis and separation of the alkane gas (e.g., plasma temperatures vary by gas composition and are not limiting here, for example temperatures up to 10,000- 15,000 or more degrees °F / or roughly 5,000-10,000 or more degrees °C are known to occur in plasma (such temperatures are not limiting herein)), (3) pyrolyzing the alkane apart using xenon and forming short-lived precursor products of XeH & XeC, (4) cooling the gases and releasing the hydrogen (H2) and xenon (Xe) from XeH, and (5) cooling and releasing the xenon gas (Xe) and carbon (C) from XeC and accumulating the carbon (C) as a solid carbon by- product; optionally (5a) filtering and separating the hydrogen gas molecules for later use in processing (including in a fuel cell) or (5b) filtering and separating by cooling the xenon gas and condensing the xenon to a liquid and recycling to the primary xenon supply for the mixing chamber.

[0033] The above and other aspects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.

[0034] The above presents a simplified summary of the invention as claimed below in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of thePATENT 11 BURLA.01953.P3PCT invention. Its sole purpose is to some concepts in a simplified form as a prelude to the more detailed description that is discussed later. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Fig. 1 is a pictographic flow diagram of the system according to the present invention.

[0036] Fig. 2 is a detailed process flow diagram of one alternative embodiment of the present invention.

[0037] While the disclosed subject matter is susceptible to various modifications and alternative forms, the drawings illustrate specific implementations described in detail by way of example. It should be understood, however, that the description herein of specific examples is not intended to limit that which is claimed to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the appended claims. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] Reference will now be made in detail to embodiments of the invention. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. The word ‘couple’ and similar terms do not necessarily denote direct and immediate connections, but also include connections through intermediate elements or devices. For purposes of convenience and clarity only, directional (up / down, etc.) or motional (forward / back, etc.) terms may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope in any manner.PATENT 12 BURLA.01953.P3PCT It will also be understood that embodiments may be utilized without departing from the scope of the present invention, and that the detailed description is not to be taken in a limiting sense, and that elements may be differently positioned, or otherwise noted as in the appended claims without requirements of the written description being required thereto.

[0039] Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent.

[0040] Referring now to FIG. 1 a schematic flow process 500 of the present system is provided for production of hydrogen through alkane gas pyrolysis using a catalyst gas (xenon gas) with the recovery of carbon, hydrogen gas and the catalyst gas (xenon gas). More specifically, the process provides a system for producing hydrogen gas on demand, and continuously, using xenon gas as a catalyst and pyrolysis of light carbon alkanes such as methane, ethane, propane and butane produced by a plasma-driven gas-phase thermal decomposition of the alkanes. Unlike other methods, the process involves the removal of solid-phase carbon by-product through the use of solid-phase plasma induced carbon crystal growth deposition and a screening / filtering recovery process. Also unlike other processes, the catalyst gas (xenon gas) is purified and recycled in a continuous (in situ) process loop and may be reused. As will be noted below a xenon receiver system 14, 14A, 14B or a catalyst gas receiver system 14, 14A, 14B (noted alternatively and collectively as 14 in Fig. 2) optionally may include a liquid nitrogen cooling system (liquid N2) so as to additionally cool and liquify the xenon below the transition temperature to return via in situ process feed / process flow P6, as will be discussed herein, and below.

[0041] Flow process 500 provides an alkane supply 100 that provides for thePATENT 13 BURLA.01953.P3PCT supply of alkane gases at a suitable and form to a mixing system 102 and a catalyst supply (here a xenon supply 101) similarly provides a supply of catalyst gas (here xenon gas) at a suitable pressure and in a suitable form to mixing system 102, as will be described further below. It will be understood that the preferred alkanes are light carbon alkanes such as methane, ethane, propane and butane as well as other, preferably with single-bond-carb on / hydrogen chains, but are not limited thereto and may include branched alkanes, cycloalkanes, three-group- chain-alkanes and other carbon-hydrogen gases (or liquids that may be converted to gas) without limit other than reduction of the efficiency of the system due to the relative carbon:hydrogen ratio (e.g., methane as CH4is the highest such ratio ratio). Mixing system 102 safely provides a suitably mixed alkane / catalyst gas (xenon gas), at a suitable pressure, to a plasma system 103 (e.g., a DC Plasma Jet System). Plasma system 103 is sealed (no unintended outside gases) and is suitably cooled to allow continuous function at suitable plasma temperatures to the alkane-and-xenon system (which may be in excess of 5,000-15,000 degrees Celsius (°C) or more depending upon the gas compositions involved). As noted herein, there is no limitation on the particular temperature as the plasma system 103 (with a DC plasma jet) will operate at a suitable temperature based upon the input carrier gas (the gas provided to the plasma jet 103) (alkane gas-including- methane and xenon) without departing from the scope of the present invention. The plasma jet (not shown but within plasma system 103) receives the mixed gases under pressure in an energized manner and provides a plasma jet with the mixed gases pyrolyzing and breaking apart the alkane gas (methane for example) using the catalyst gas (preferably xenon as a catalyst) forming XeH and XeC as the resultant product (from CH4(or other alkane) and Xe) received within the pyrolysis reactor 104 which is temperature and pressure controlled.

[0042] As additionally noted in Fig. 1, the product gases (XeH and XeC) existing in the pyrolysis reactor 104 are temperature and pressure conditioned and release in transition(s) via related recovery systems: (i) the carbon recovery step 107PATENT 14 BURLA.01953.P3PCT (XeC to Xe and C) as a carbon (for example onto one or more carbon nucleation plates impregnated on a surface with carbon atoms as seed sites / crystals) that may be periodically recovered from pyrolysis reactor 104 during cleaning in a disposal step 108, and (ii) the xenon recovery step 105 and hydrogen recovery step 106 (XeH to Xe and H) as gaseous products that are removed from pyrolysis reactor 104 by cooling- and pressure-condensing along the reactor 104 and linked with recovery steps 105, 106, and 107. For example, there is a temperature gradient along the pyrolysis reactor 104 (from the high temperature plasma side to the relatively lower temperature recovery side) and this aids separation and recovery. During normal cooling and pressure adjustment carbon separates (carbon recovery step 107) leaving gas components XeH and Xe, and in xenon recovery step 105 a liquid nitrogen (N2) temperature control jacket may be included (for example), and since the liquification temperature of xenon is relatively ‘warm’ (-108.1 degrees Celsius (-108.1°C) / -162.6 degrees Fahrenheit (- 162.6°F)) compared with that of hydrogen (-253 degrees Celsius (-253°C) / -423 degrees Fahrenheit (-423°F)) under cooling-and-pressure-conditioning the liquifying xenon (Xe) readily surrenders the hydrogen bond releasing capturable hydrogen gas (H2) via the respective xenon recovery step 105 and the respective hydrogen recover step 106.

[0043] It will be understood herein and throughout that all of the temperatures (for plasma in whatever scale (F / C) or the various liquid temperatures (F / C) are relative, not absolute, and are generally known to those of skill in the art so that upon review and appreciation of the disclosure any variation will be readily understood and there will remain complete disclosure and support for the present invention and the claims.

[0044] As will be understood by one of skill in this art having appreciated and fully understood the full scope of the present invention; the recovered xenon (in step 105) may be returned to xenon supply 101 for reuse in a continuous in-situPATENT 15 BURLA.01953.P3PCT (e.g., in process) recovery step, for a continuous hydrogen production method operating through flow process 500 and the hydrogen production system 200, as will be discussed on combination further below.

[0045] It will be further and additionally understood by one of skill in this art having appreciated and fully understood the full scope of the present invention that the provided process, method, and system provides clean hydrogen gas as long as the present flow process 500 and system 200 continuously maintains / provides an alkane gas (preferably methane via alkane supply 100) for pyrolysis with xenon (provided via xenon supply 101 and xenon recovery 105) to mixing system 102, plasma system 104 and pyrolysis reactor 104. In this manner, the present system will be understood to provide a continuous in-situ gas conditioning of the alkane supply 100.

[0046] Additionally referring now to FIG. 2, a more detailed hydrogen production system 200 is provided according to the present invention and generally includes an alkane tank 1 (preferably methane but may be any alkane) (and may include a liquid-to-gas conversion system for storing conveniently a liquified alkane (including methane) before converting to gas for further processing) having an access and pressure regulation control 1A and a mixing release and pressure monitor control 1B. A catalyst tank 2 (here optionally and preferably a xenon tank 2) includes an access and pressure regulation control 2A and a mixing release and pressure monitor 2B. Together alkane tank 1 and xenon tank 2 feed a mixing manifold system and pressure control module 3 for a mixing system 4 (also termed a gas mixing system 4) via a first process feed P1. Mixing system 4 further includes a temperature and pressure maintenance system 4B operative in concert with and linked with an access, pressure, and temperature controller 4A to maintain a suitable internal temperature and internal pressure for the mixed gases from alkane tank 1 (methane tank 1) and catalyst (xenon) tank 2. It will be further understood that access, pressure, and temperature controller 4A monitors andPATENT 16 BURLA.01953.P3PCT maintains a suitable mixing of the gases in mixing system 4 for downstream use.

[0047] For a non-limiting example, in combination, mixing release and pressure monitors 1B, 2B, and access, pressure, and temperature controller 4A maintain the suitable pyrolysis gas mixture at a suitable pressure / temperature for further processing. It will be understood that for the pyrolysis (using methane for example CH4), there may be any number of xenon (Xe) atoms depending upon the respective atomic states; e.g., five (5) xenon atoms for full conversion (CH4+ 5Xe -to- XeC + 4XeH) as will be discussed herein and below, or if xenon+4 (or other in another state) is used there may be atomic arrangements within the scope of this disclosure. Mixing system 4 (for mixing and pressure control) includes (not shown) access ports for suitable testing and inspection as will be understood in the art.

[0048] A pump system 5 receives the mixed gases in a process feed P2 from mixing system 4. Pump system 5 includes a pump 5B and a pressurization, temperature, and release control module 5A having suitable valving, back-flow preventers, and related monitoring systems to provide a prepared process feed P3 (e.g., a carrier gas) to plasma torch system 7. Plasma torch system 7 includes a suitable power controller system and module 7A to energize the mixed gases in process feed P3 and a related cooling and safety system 7B to maintain continuous and safe operation of plasma torch system 7 at a suitable plasma temperature with a suitable plasma arc. It will be understood that the mixed gases in process feed P3 serve as the carrier-or-working gas of the plasma torch system 7 in a sealed system so that no oxygen or other gas is provided and the plasma torch system 7 may run continuously.

[0049] A pyrolysis reactor chamber 9 is in a gas sealed connection with plasma torch system 7 and receives the plasma jet from plasma torch system 7 and the resulting pyrolysis results (Xe + CH4 to XeC and XeH) in a related ratioPATENT 17 BURLA.01953.P3PCT depending upon the alkane supply, supply, and mixing system 4 (also called gas mixing system 4 or gas mixer 4). A pressure and temperature control module 10 monitors reactor chamber 9 and controls a heat exchange system 10A, with any form of suitable cooling elements 10B, 10B bounding a portion of reactor chamber 9 to maintain, a desired combination of temperature and pressure. It will be understood that pressure and temperature control module 10 is able to provide a temperature gradient (see ‘temperature arrow graphic’ in Fig. 2 within reactor chamber 9) along the heat exchange system 10A from the relatively higher temperature region proximate plasma torch system 7 down-stream towards a relatively lower temperature region proximate carbon sequester system 12, and related low temperature separator 11 with cooling jacket modules 11A provided at the end of reactor chamber 9.

[0050] A carbon sequester system 12 is provided in reactor chamber 9, in any suitable form, but as shown is a series of replaceable carbon chemical vapor nucleation deposition plates (for example titanium, stainless steel or ceramic (SiC)) plates or a mesh form or a plug form with a layer of carbon or CVD diamond thereon). Sequester system 12 is provided within the pathway of the pyrolyzed gas flow of XeC and XeH; and as will be understood, as the temperature gradient within reactor chamber 9 begins to cool carbon (C) begins to separate from XeC-to-C and Xe and this allows carbon to deposit thereon releasing Xe as a gas in a continuous process.

[0051] Proximate the terminus of reactor chamber 9 is low temperature gas separator system 11 provided to receive the hydrogen gas (H) (just separated from XeH) and Xe (and any remaining XeH) and a cooling jacket and module 11A (such as an electrostatic cooler or condensed gas cooler system) is provided therewith and in communication with heat exchange system 10A and cooling elements 10B provides a further controlled cooling so that H2forms and Xe and H2are in gaseous form and reach a manifold and gas separator 13 providing a further low pressure transition separating H2and Xe by any suitable means suchPATENT 18 BURLA.01953.P3PCT as temperature / pressure control, static or hydro static cooling, or other means; resulting in a process feed P4 for Xenon and a process feed P5 for Hydrogen (H2).

[0052] Process feed P4 transmits xenon to a xenon receiver system 14 having a xenon pressurization and liquefier system 14A (e.g., a gas condenser system (and optionally a gas separator system)) feeding to a release and pressure monitoring valve system 14B that provides a process feed P6 to return purified xenon (gaseous or liquified or both) to xenon tank 2 (also called catalyst tank 2) via access and pressure regulation module 2A (thereby providing the continuous in situ / in-process system to return the catalyst gas (xenon) to catalyst tank 2). It will be understood that in the process of compression and liquid transition for xenon further serves to purify the gas / liquid for further use in the proposed system 200 / flow 500. Similarly, manifold and gas separator module 13 provides the hydrogen flow via process flow P5 to a hydrogen receiver system 15 including operations for temperature and pressure regulation and safe storage before further transport via a process flow P7 for later hydrogen use (hydrogen receiver system 15 may further include a hydrogen gas separator system within the scope of the present disclosure). Additionally, molecular sieves and other devices known in the art of gas separation may be included herewith without departing from the scope and spirit of the present invention. For example, further cooling elements (using liquid gases such as Nitrogen (N2) may be used to condense (from gas to liquid) the catalyst gas (here xenon) for downstream convenience.

[0053] It will be understood by those of skill in the art, having studied and appreciated the enclosed disclosure, that the provided system 200 / flow 500 additional safety and pressure control systems (not show), sensors and monitors (not shown) and controlling systems for operations (not shown) may be included and understood without departing from the scope and spirit of the present invention. For example, the gas and pressure control systems include (optionally) pressure release valving, one-way flow diverters, automatic venting and releasePATENT 19 BURLA.01953.P3PCT systems and other safety features to those of such system designs without departing from the scope herein.

[0054] As also shown in Fig. 2, an exemplary fuel cell system 20 in an exemplary vehicle (illustratively represented by bracket 25) connected in process to receive a hydrogen flow P7, and an external oxygen supply 21 and to produce direct current (DC) power 22 and purified water 23 as will be understood by those of skill in the arts of fuel cell operation. Such a vehicle 25 would further include related system systems and crash protection systems to operate in commerce. Illustratively represented vehicle 25 may be any form of transport vehicle known and noted herein above without departing from the scope and spirit herein.

[0055] As noted herein, and above, the present system 200 and process 500 generates up to 100% of the hydrogen (H2) from the alkane supply 100, without waste, that may be used for downstream reactions.

[0056] As will be further appreciated by one of skill in the art having studied and appreciated the disclosure the method of producing clean hydrogen gas is suitably intended for use transportation vehicles having compressed alkane tanks (e.g., methane tanks, or liquified methane (liquid point is -82.1 degrees Celsius(- 82.1°C)) at standard pressures, but under increased pressures will liquify at a higher temperature, but its applications are adaptable and not limited to transportation vehicles. A similar analysis may be used for propane or other alkane gases within the scope of the present invention; e.g., a commercial taxi or bus fleet running on such an alkane gas supply with a catalyst gas supply may operate such a system and store the resultant products continuously within the scope of the present disclosure for later use in a fuel cell or other electrical generation device.

[0057] Although only a few embodiments have been disclosed in detail above,PATENT 20 BURLA.01953.P3PCT other embodiments are possible and inventors intend these to be encompassed within this specification. The specification describes certain technological solutions to solve the technical problems that are described expressly and inherently in this application. This disclosure describes embodiments, and the claims are intended to cover any modification or alternative or generalization of these embodiments which might be predictable to a person having ordinary skill in the art.

[0058] Unless otherwise defined, all terms including technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. In addition, unless otherwise defined, all terms defined in generally used dictionaries may not be overly interpreted. In the following, details are set forth to provide a more thorough explanation of the embodiments. However, it will be apparent to those skilled in the art that embodiments may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form or in a schematic view rather than in detail in order to avoid obscuring the embodiments. In addition, features of the different embodiments described hereinafter may be combined with each other, unless specifically noted otherwise. For example, variations or modifications described with respect to one of the embodiments may also be applicable to other embodiments unless noted to the contrary.

[0059] Further, equivalent or like elements or elements with equivalent or like functionality are denoted in the following description with equivalent or like reference numerals. As the same or functionally equivalent elements are given the same reference numbers in the figures, a repeated description for elements provided with the same reference numbers may be omitted. Hence, descriptions provided for elements having the same or like reference numbers are mutually exchangeable.PATENT 21 BURLA.01953.P3PCT

[0060] It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.).

[0061] In the present disclosure, expressions including ordinal numbers, such as "first", "second", and / or the like, may modify various elements. However, such elements are not limited by the above expressions. For example, the above expressions do not limit the sequence and / or importance of the elements. The above expressions are used merely for the purpose of distinguishing an element from the other elements. For example, a first box and a second box indicate different boxes, but they may operate together or interconnected in a manner that seems continuous. For further example, a first element could be termed a second element, and similarly, a second element could also be termed a first element without departing from the scope of the present disclosure.

[0062] It will be further understood by those of skill in the art having studied and appreciated the disclosure that the method and means for cooling / pressure control and other systems may be provided in various ways without departing from the scope and spirit of the present invention For example, the discussed cooling and / or pressure control systems may include any form of temperature-control or cooling including without limit electrostatic or hydrostatic cooling, pressure variation cooling / heating and / or refrigeration via one or more suitable (non- mixing) thermal transfers interfaces or manifolds using other liquified gases (such as liquid nitrogen N2systems cooling an exterior of a chamber to below a liquidPATENT 22 BURLA.01953.P3PCT point.).

[0063] As a further consequence of the above, those of skill in this art will recognize that the various temperature and pressure maintenance systems, regulation controllers and other operational modules will be understood to operate and maintain an operational status (e.g., a desired pressure, temperature, etc. according to the requirements of the particular tank, mixing system, reactor module, or otherwise). Such matters will be understood to be the operational parameters for the continuous process based upon the various pressures, temperatures, and the respective gases and liquids employed herein.

[0064] As a consequence of the above, those of skill in this art will recognize the improvements provided herein; which include but are not limited to, the use of an in-situ plasma-driven gas-phase process for thermal decomposition of alkane gases, the use of a re-circulating xenon recovery feature in operating the process; the use of xenon as a catalytic feature or operation in the process; and the use of pressure and temperature conditioning of the resultant pyrolysis reactor gases separates (and liquefies) the xenon for re-circulation.

[0065] Finally, it is recognized that for the generation of free hydrogen (H2) we are using an in-situ xenon plasma pyrolysis instead of some form of petrochemical reaction, or gaseous-pressure-cracking.

[0066] Similarly, as will be understood by those of skill in the art, the use of the phrase ‘in situ’ shall be recognized and referring to an in-process activity or process, such as plasma-driven gas-phase thermal decomposition of alkanes that occurs in a pathway between supplies and a reactor that recovers the xenon, and not as a separate external process beyond the systems and process. For example, here, pyrolysis reactor is ‘in situ’ because it receives mixed gases (alkane- preferably methane and xenon) for reaction therein forming decomposition without external steps and the catalytic gas is recovered for re-use.PATENT 23 BURLA.01953.P3PCT

[0067] Beneficial products produced by the above described system and method include gases (Xe and H) that are of high purity and may be readily used in a downstream fuel cell system (either directly or via a pre-storage step).

[0068] As used herein pyrolysis is a thermo-chemical decomposition of biomass sources (in this case Alkane gases such as methane, ethane, propane, butane, etc. and others (inclusively, including those with single-bonded carbon and hydrogen atoms)) that have hydrogen and carbon in a ratio (with methane (CH4) having the most advantageous ratio)) to a gas at an elevated temperature in the absence of oxygen and in the presence of a catalyst gas, preferably xenon, but optionally argon or krypton. More particularly, the pyrolysis process is produced by a plasma-driven gas-phase thermal decomposition of alkanes in the presence of xenon. The removal of down-stream gas-to-solid-phase carbon by-product is by use of solid-phase plasma induced carbon crystal growth via a screening and filtering process. The cooling process utilizes the boiling point of the gas catalyst (xenon) to further separate and purify the catalyst gas. The result being a gaseous decomposition into gaseous hydrogen and carbon nucleation in a pressure and temperature control chamber and downstream gas-phase thermal decomposition and separation.

[0069] Also, the inventors intend that only those claims which use the words "means for" are intended to be interpreted under 35 USC 112. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims.

[0070] Where a specific numerical value is mentioned herein, it should be considered that the value may be increased or decreased by 20%, while still staying within the teachings of the present application, unless some different range is specifically mentioned. Where a specified logical sense is used, thePATENT 24 BURLA.01953.P3PCT opposite logical sense is also intended be encompassed.

[0071] Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed system without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure covers modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.

Claims

PATENT 25 BURLA.01953.P3PCT WHAT IS CLAIMED IS:

1. A method for producing a hydrogen gas using a catalyst gas, the method comprising the steps of: providing an alkane supply tank for storing an alkane gas and for releasing said alkane gas to a gas mixing system; providing a catalyst supply tank for storing a catalyst gas and for releasing said catalyst gas to said gas mixing system; operating said gas mixing system to receive said alkane gas and said catalyst gas as a gas mixture; maintaining an operational mixing temperature and mixing pressure of said gas mixture in said gas mixing system; providing said gas mixture from said gas mixing system to a pump system; receiving said gas mixture at said pump system and maintaining an operational pump pressure; operating a plasma torch system with said gas mixture as a carrier gas from said pump system and producing a plasma from said plasma torch system; providing a pyrolysis reactor that receives said plasma from said plasma torch system and operates at a pyrolysis reactor temperature and pressure; said plasma torch system and said pyrolysis reactor cracking said alkane gas with said catalyst gas and forming a carbon-catalyst gas and a hydrogen- catalyst gas; cooling said carbon-catalyst gas and said hydrogen-catalyst gas in said pyrolysis reactor and separating said catalyst gas from said carbon and separating said hydrogen from said catalyst gas; said pyrolysis reactor including a carbon sequester system that sequesters said carbon during said cooling; providing a gas separator module for separating said catalyst gas from said hydrogen gas;PATENT 26 BURLA.01953.P3PCT providing a catalyst gas system that receives said catalyst gas from said gas separator module and in situ returns said catalyst gas to said catalyst supply tank; and providing a hydrogen gas receiver that receives said hydrogen gas from said gas separator module and stores said hydrogen gas.

2. The method, according to claim 1, wherein: said catalyst gas is a noble gas.

3. The method, according to claim 2, wherein: said alkane gas is one of methane, ethane, propane and butane.

4. The method, according to claim 2, wherein, the step of cooling said carbon-catalyst gas and said hydrogen-catalyst gas in said pyrolysis reactor, further comprises the step of: providing a heat exchange system controlling a temperature and a pressure in said pyrolysis reactor and having a pressure and temperature control module and at least one cooling element.

5. The method, according to claim 1, wherein: said catalyst gas is xenon; and said alkane gas is methane.

6. The method, according to claim 1, said step of operating said plasma torch system further comprises the step of: providing a power control system and a cooling and safety system in operative control of said plasma torch system.

7. The method, according to claim 1, further comprising the step of:PATENT 27 BURLA.01953.P3PCT providing a gas condensing for said catalyst gas receiver system, whereby said step of in situ returning to said catalyst supply tank returns a condensed catalyst gas to said catalyst supply tank.

8. The method, according to claim 1, wherein: said catalyst gas is xenon; said alkane gas is methane; and further comprising the step of: providing a gas condensing system for said catalyst gas receiver system, whereby said step of in situ returning to said catalyst supply tank returns a condensed catalyst gas to said catalyst supply tank; and the step of cooling said carbon-catalyst gas and said hydrogen-catalyst gas in said pyrolysis reactor, further comprises the step of: providing a heat exchange system controlling a temperature and a pressure in said pyrolysis reactor and having a pressure and temperature control module and at least one cooling element.

9. A system for producing hydrogen gas using a catalyst gas, the system comprising: an alkane supply tank that stores an alkane gas and releases said alkane gas to a gas mixing system; a catalyst supply tank that stores a catalyst gas and releases said catalyst gas to said gas mixing system; said gas mixing system receiving said alkane gas and said catalyst gas as a gas mixture and maintaining an operational mixing temperature and mixing pressure of said gas mixture in said gas mixing system; a pump system for receiving said gas mixture from said gas mixing system and maintaining an operational pressure; a plasma torch system that receives said gas mixture as a carrier gas from said pump system and produces a plasma from said plasma torch system;PATENT 28 BURLA.01953.P3PCT a pyrolysis reactor that said plasma from said plasma torch system and operates at a pyrolysis reactor temperature and pressure; said plasma torch system and said pyrolysis reactor cracking said alkane gas with said catalyst gas and forming a carbon-catalyst gas and a hydrogen- catalyst gas; a heat exchange system that controls a temperature and a pressure in said pyrolysis reactor according to a pressure and temperature control module; said pyrolysis reactor separates said catalyst gas from said carbon and separates said hydrogen from said catalyst gas; a carbon sequester system in said pyrolysis reactor that sequesters said carbon during said cooling; a gas separator module separates said catalyst gas from said hydrogen gas; a catalyst gas receiver system receives said catalyst gas from said gas separator module and in situ returns said catalyst gas to said catalyst supply tank; and a hydrogen gas receiver that receives said hydrogen gas from said gas separator module and stores said hydrogen gas.

10. The system, according to claim 9, wherein: said catalyst gas is a noble gas; said alkane gas is one of methane, ethane, propane and butane; and further comprising: a gas condensing system in said catalyst gas receiver system, whereby said in situ returns to said catalyst supply tank returns a condensed said noble gas to said catalyst supply tank; and a heat exchange system that controls a temperature and a pressure in said pyrolysis reactor and has a pressure and temperature control module and at least one cooling element.

11. The system, according to claim 10, wherein:PATENT 29 BURLA.01953.P3PCT said noble gas is xenon; and said alkane gas is methane.

12. An apparatus for producing a hydrogen gas using a catalyst gas, said apparatus comprising: an alkane supply tank that stores an alkane gas and releases said alkane gas to a gas mixing system; a catalyst supply tank that stores a catalyst gas and releases said catalyst gas to said gas mixing system; said gas mixing system receiving said alkane gas and said catalyst gas as a gas mixture and maintaining an operational mixing temperature and mixing pressure of said gas mixture in said gas mixing system; a pump system for receiving said gas mixture from said gas mixing system and maintaining an operational pressure; a plasma torch system that receives said gas mixture as a carrier gas from said pump system and produces a plasma from said plasma torch system; a pyrolysis reactor that receives said plasma from said plasma torch system and operates at a pyrolysis reactor temperature and pressure; said plasma torch system and said pyrolysis reactor cracking said alkane gas with said catalyst gas and forming a carbon-catalyst gas and a hydrogen- catalyst gas; a heat exchange system that controls a temperature and a pressure in said pyrolysis reactor according to a pressure and temperature control module; said pyrolysis reactor separates said catalyst gas from said carbon and separates said hydrogen from said catalyst gas; a carbon sequester system in said pyrolysis reactor that sequesters said carbon during said cooling; a gas separator module separates said catalyst gas from said hydrogen gas;PATENT 30 BURLA.01953.P3PCT a catalyst gas receiver said catalyst gas from said gas separator module and in situ returns said catalyst gas to said catalyst supply tank; and a hydrogen gas receiver that receives said hydrogen gas from said gas separator module and stores said hydrogen gas.

13. The apparatus, according to claim 12, wherein: said catalyst gas is a noble gas; said alkane gas is one of methane, ethane, propane and butane; and further comprising: a gas condensing system in said catalyst gas receiver system, whereby said in situ return to said catalyst supply tank returns a condensed said noble gas to said catalyst supply tank; and a heat exchange system that controls a temperature and a pressure in said pyrolysis reactor and has a pressure and temperature control module and at least one cooling element.

14. The apparatus, according to claim 13, wherein: said noble gas is xenon; and said alkane gas is methane.

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