Methods, Apparatus, and Systems for Producing Hydrogen and Non-Gaseous Products for Industrial Applications, Energy Production, and Related Power Generation - Patent application

Abstract

The present invention relates to the processing of carbonaceous materials, inter alia, for hydrogen production. In particular, the present invention relates to the production of hydrogen, for example as an input for industrial manufacturing applications or as a fuel source for associated power generation. In one form, the present invention provides a method of producing hydrogen, comprising reacting a combination of a solid carbonaceous material and a catalyst comprising an alpha-phase iron-based material adapted to undergo an exothermic reaction with the solid carbonaceous material.

Description

[Technical field]

[0001] Related Applications

[0001] This application claims priority to Australian Provisional Patent Application No. 2022900174, entitled "Method, Apparatus and System for Producing Hydrogen and Non-Gaseous Products for Industrial Applications, Energy Production, and Associated Electric Power Generation", filed on January 31, 2022 in the name of BXB Technologies Pty Ltd, Australian Provisional Patent Application No. 2022901378, entitled "PAK450 Metallic Material", filed on May 23, 2022 in the name of Henley-Smith et al., and Australian Provisional Patent Application No. 2022901396, entitled "Reduction of Metallic Ores", filed on May 24, 2022 in the name of Henley-Smith et al., the specifications of which are incorporated herein by reference in their entireties for all purposes.

[0002] The present invention relates inter alia to the processing of carbonaceous materials for hydrogen production. In particular, the present invention relates to the production of hydrogen, for example as an input for industrial manufacturing applications or as a fuel source for related power generation. For convenience, the present invention will be described below in terms of a thermal reaction between a carbonaceous material and an alpha-phase iron catalyst, which comprises one or a combination of ferrimagnetic oxides of iron and alpha ferrite, from which non-gaseous products and several gases are released, one of which is hydrogen for use as a fuel gas. However, it should be recognized that the present invention is not limited to only that use. [Background technology]

[0002]

[0003] Throughout this specification, use of the singular form "inventor" may be construed as a reference to one inventor or to more than one inventor (single inventor) of the invention.

[0003]

[0004] It will be appreciated that any discussion of documents, devices, acts or knowledge in this specification is included to explain the subject matter of the invention. Moreover, the discussion throughout this specification arises out of the inventor's recognition and / or the inventor's identification of problems in a particular related art field. Moreover, any discussion of materials such as documents, devices, acts or knowledge in this specification is included to explain the subject matter of the invention in terms of the inventor's knowledge and experimentation, and therefore any such discussion should not be construed as an admission that any of the materials form part of the prior art basis or common general knowledge in the relevant art field in Australia or elsewhere at or prior to the priority date of the present disclosure and claims herein.

[0004]

[0005] There are numerous methods known for producing hydrogen as a fuel and energy source. For example, "green" hydrogen production methodologies include electrolysis to produce hydrogen, which utilizes an electric current to split water into hydrogen and oxygen. If the electricity is produced by renewable sources, e.g., solar or wind, the resulting hydrogen is considered renewable as well. It has been stated that the green hydrogen market could generate at least 12 trillion US dollars in revenue by 2050, which is larger than any industry we currently have (Non-Patent Document 1). "Grey / brown" hydrogen production involves coal reforming / gasification in a process that converts lignite into carbon monoxide (CO), hydrogen (H2) and carbon dioxide (CO2). Typically, this is achieved by pyrolysis, where the materials react at about 900°C to about 1,150°C. As stated in Petrofac (Non-Patent Document 2), grey hydrogen production is essentially the same as "blue" hydrogen production, except that the CO2 by-product is released into the atmosphere. "Blue" hydrogen production typically involves natural gas reforming, where hydrogen is produced by reacting natural gas with high-temperature steam. This method is considered to be the cheapest, most efficient, and most common. Natural gas reforming accounts for approximately 70% or more of the hydrogen currently produced. Additionally, according to Petrofac, "pink" hydrogen production is the same as green hydrogen as it is produced via electrolysis, but uses nuclear power as the power source, and a further type of hydrogen produced by electrolysis is "yellow" hydrogen, where electrolysis is achieved solely by solar power, unlike green, which may use a combination of renewable energy sources such as wind and solar.

[0005]

[0006] Hydrogen is considered environmentally friendly, especially since its combustion by the end user does not produce any CO2 emissions. However, it should be noted that greenhouse gas emissions may occur during the production and supply of hydrogen.

[0006]

[0007] Hydrogen production using current technologies involves high capital expenditures (CAPEX), high operating costs (OPEX), high levels of CO2 emissions, high temperatures (approximately >900°C-1,000°C), and high electricity requirements per kg of hydrogen produced.

[0007]

[0008] Examples that demonstrate the shortcomings of current technologies used for renewable alternative energy production include: ·Solar and coal / gas with high CAPEX and high OPEX. · Coal and gas steam reforming of hydrogen which produces large amounts of CO2 emissions. - Huge energy input is required per kg of hydrogen produced. ·Minimal or no useful or commercial by-products. ·Large footprint and infrastructure required for wind-solar farms. Solar energy only works about 20-30% of the time, and wind power also has limited operating times. Depending on your location, the energy derived from solar panels and wind power is limited and otherwise subject to factors related to operating times. As such, solar panels only derive power when the sun is shining and turbines only operate when the wind is blowing. · New electricity distribution infrastructure is needed. Carbon capture and sequestration (CCS) increases the cost per kilogram and energy use. Electrolysis systems require the use of large amounts of specially treated water, which is an inefficient use of a valuable resource.

[0008]

[0009] Throughout the 1960s, 70s and 80s, research and development in coal hydrogenation has been carried out in parallel with both the polymer industry and the historic oil / energy crisis activities. This activity was mainly aimed at improved production of various types of alkanes. However, some work was also carried out on the reverse process of dehydrogenation of coal products, in which hydrogen is released (Non-Patent Document 3). An example of this activity is found in the publication by Yokono et al. (Non-Patent Document 4). This publication is directed to the evaluation of catalysts for use in coal liquefaction, i.e., converting coal into liquid hydrocarbons, i.e., liquid fuels and petrochemicals; to do this, Yokono et al. carried out a number of hydrogen-generating pyrolysis reactions at temperatures of about 450° C. on coal samples using various Fe2O3-metal-oxide catalysts, each in a weight ratio of 10:1, resulting in a yield of approximately one ton of coal per kg of hydrogen.

[0009]

[0010] In the 21st century, interest in the production of hydrogen for fuel has increased significantly. Huffman (Non-Patent Document 5) is a publication that discusses the production of H2 from C1, i.e., molecules with one carbon atom, namely methane (CH4), carbon monoxide (CO), carbon dioxide (CO2) and methanol (CH3OH). The publication shows that work has been carried out using catalysts for gaseous alkanes consisting of iron oxide / metal complexes in the form of Fe-M (M=Ni, Mo or Pd) that have shown excellent activity and life span for the non-oxidative dehydrogenation of the described gaseous alkanes, resulting in pure hydrogen in one step without producing CO or CO2. However, the process disclosed by Huffman is too insufficient to address an efficient way to produce H2 from solid carbonaceous materials.

[0010]

[0011] Examples of the many hydrogen production processes that have been developed are disclosed in U.S. Patent No. 7,588,676 (Reichman et al.), which is directed to the production of hydrogen from carbonaceous materials via an electrochemical reaction in the presence of a base catalyst, with carbonate and / or bicarbonate ions being produced as by-products.

[0011]

[0012] Conversion of natural gas to hydrogen has been contemplated by the Hazer Group (Non-Patent Document 6). However, the process disclosed by the Hazer Group involves the production of hydrogen from gaseous hydrocarbons using iron ore as a catalyst at high temperatures, and does not address the need to produce H2 from solid carbonaceous materials, such as coal or waste organic materials and plastics.

[0012]

[0013] Further examples of industrial processes that may form part of the relevant technical field are as follows:

[0013]

[0014] US Patent Publication No. 2011 / 0024687 (White et al.) is of general interest in the area of ​​catalysis. White et al. discloses a process that includes alternately contacting an oxygen-supported catalyst with a reducing agent or a lower partial pressure of an oxidizing gas, and then with an oxidizing gas or a higher partial pressure of an oxidizing gas, whereby the catalyst is alternately reduced and then regenerated to an oxidizing state. In certain embodiments disclosed by White et al., when a feedstock is treated in a reducing stage, carbon dioxide and hydrogen are produced as product gases. However, White et al. requires a reaction that includes an oxidizing catalyst, and further requires a pressurized environment.

[0014]

[0015] US Patent Application Publication No. US20140163120 (Kyle) is directed to a method for converting carbon-containing compounds, such as coal, methane or other hydrocarbons, into liquid hydrocarbon fuels. The process disclosed by Kyle utilizes a high-pressure, high-temperature reactor that operates on blending carbon compounds, including Co2 and a carbon source, a catalyst and steam. Microwave power is directed into the reactor. A catalyst, preferably magnetite, acts as a heating medium for the microwave power, and the temperature of the reactor is raised to a level that efficiently converts the carbon and steam into hydrogen and carbon monoxide.

[0015]

[0016] US Patent Application Publication No. 2018 / 0195006 (Dayton et al.) is directed to a process for converting biomass to hydrocarbon fuels using pyrolysis. Dayton et al. disclose a process for converting biomass starting materials (e.g., lignocellulosic materials) to stable liquid intermediates with low oxygen content that can be reformed to make liquid hydrocarbon fuels. More specifically, the process can be a catalytic biomass pyrolysis process in which an oxygen removal catalyst is used in the reactor and the biomass is subjected to pyrolysis conditions. The stream exiting the pyrolysis reactor contains bio-oil with low oxygen content, and such streams may be subjected to further steps such as separation and / or condensation to isolate the bio-oil.

[0016]

[0017] European Patent Application No. EP 3138892 (Synthopetrol et al.) is directed to the production of liquid biofuels and discloses the use of a heterogeneous solid catalyst comprising or consisting of a metal complex bound by covalent bonds and / or van der Waals type interactions to a magnetic carrier for carrying out a hydrotreating reaction of a gas derived from the pyrolysis of a substrate, said hydrotreating reaction being carried out with hydrogen and said gas in the presence of said catalyst resulting in a gas phase which by a cooling step produces a liquid phase formed of the liquid biofuel.

[0017]

[0018] U.S. Patent No. 10,106,407 (Siriwardane et al.) is directed to producing synthesis gas from methane via oxidation. The embodiments disclosed in Siriwardane et al. x O y(1≦x≦3, and 3≦y≦5, and M comprises a Group II alkaline earth metal) to a fuel reactor; delivering a gas stream containing methane to the metal ferrite oxygen carrier in the fuel reactor; and maintaining the fuel reactor at a reducing temperature sufficient to reduce a portion of the metal ferrite oxygen carrier and oxidize a portion of the methane containing gas stream. An embodiment includes the steps of producing a gas product containing H2 and CO gases in the fuel reactor; withdrawing a product stream from the fuel reactor, the gas product comprising the product stream, at least >50% by volume of the product stream comprising CO and H2; and oxidizing the reducing support in an oxidation reactor by contacting the reducing support and an oxidizing gas at an oxidation temperature, the oxidizing gas being comprised of oxygen, the oxidation temperature being sufficient to produce an oxidation reaction, and further comprising reactants of the oxidation reaction comprising a portion of the oxygen, a portion of the M component, and Fe c O d The product of the oxidation reaction is MFe x O y and transferring heat generated in the oxidation reactor to a fuel reactor for reaction of the metal ferrite with methane.

[0018]

[0019] CN101891149A (ENN Science and Technology Development Co Ltd) relates to a continuous method for preparing a flammable gas from a high concentration slurry of carbon-containing organic material. The method can be carried out continuously by reducing pressure and continuously discharging the reaction product. The reduction in pressure and continuous discharging operation is carried out by fitting at least two buffer tanks operated in parallel or at least one pressure reducing valve. The disclosure of CN101891149A also relates to an apparatus for preparing a flammable gas from a high concentration slurry of carbon-containing organic material.

[0019]

[0020] A method for producing hydrogen and nanocarbon by catalytic decomposition of methane (CDM) is described in Qian et al., "Methane decomposition to produce CO x -free hydrogen and nano-carbon over metal catalysts: A review, International Journal of Hydrogen Energy, 2020, Vol. 45, pp. 7981-8001. However, it should be noted that CDM for COx-free hydrogen production is still in its infancy. The urgency of CDM to industrial scale is more important than ever in the current situation of huge COx emissions. This review investigates CDM development on Ni-based catalysts, precious metal catalysts, carbon catalysts, and Fe-based catalysts, especially the inexpensive Fe-based catalyst, and shows that CDM is a promising and viable method for large-scale hydrogen production at moderately low cost. Others review recent progress in reaction mechanism and kinetic studies on metal catalysts, showing that catalyst deactivation rate becomes more rapid with increasing temperature than in CDM rate. This review also evaluates the role of various parameters on CDM catalyst performance, such as metal loading effect, support influence, hydrogen reduction, methane reduction, and methane / hydrogen carburization. Catalyst deactivation due to carbon deposition is a major challenge found in CDM processes, and an interesting approach has been proposed: molten metal reactors, which continuously remove floating surface solid carbon, to overcome the drawbacks of deactivation. Furthermore, specific CDM reactors using alternative heat sources, e.g., plasma and solar, are exemplified in detail in this study, in addition to the common electrical heating of fixed-bed and fluidized-bed reactors. Development of highly efficient catalysts and optimization of reactors are essential for industrial-scale production of CDM.

[0020]

[0021] A discussion of ferrites as catalysts for steam reforming of ethanol is disclosed in Stolyarchuk et al., "FERRITES MFe2O4 (M=Mg, Mn, Fe, Zn) AS CATALYSTS FOR STEAM REFORMING OF ETHANOL." Theoretical and Experimental Chemistry, 2016, Vol. 52, No. 4, pp. 246-251. As discussed by Stolyarchuk et al., steam reforming of ethanol (SRE) over composite magnesium, manganese, iron and zinc oxides at 823 K was investigated. X-ray phase analysis showed that the catalytically active phases consisted of ferrites of the respective metals with a spinel structure. The yield of hydrogen over manganese and magnesium ferrites was greater than 80% and no CO was present in the reaction products.

[0021]

[0022] The production of pure hydrogen from methane mediated by the redox of Ni- and Cr-added iron oxides has been discussed in Takenaka et al., "Production of pure hydrogen from methane mediated by the redox of Ni- and Cr-added iron oxides," Journal of Catalysis. 2004, Vol. 228, pp. 405-416. In this study, the favorable effect of the addition of Ni and Cr species to iron oxides on the redox reaction is reported. Iron oxides containing both Ni and Cr species can repeatedly produce pure hydrogen through reduction with methane and subsequent oxidation with water vapor at lower temperatures compared to iron oxides with both Cu and Cr species. Furthermore, the role of Ni and Cr species added to iron oxide samples in the redox reaction was examined based on the local structure of these additives.

[0022]

[0023] US Pat. No. 8,920,525 (Despen et al.) discloses a process and system for converting biomass into high carbon biogenic reagents in the form of pyrolytic solids.

[0023]

[0024] The foregoing discussion of the background art is intended only to facilitate an understanding of the present invention. The discussion is not an admission or acknowledgement that any of the material referred to is or was part of the common general knowledge at the priority date of this application. [Prior art documents] [Patent documents]

[0024] [Patent Document 1] U.S. Patent Publication No. 2011 / 0024687 [Patent Document 2] US Patent Application Publication No. 20140163120 [Patent Document 3] US Patent Application Publication No. 2018 / 0195006 [Patent Document 4] European Patent Application No. 3138892 [Patent Document 5] U.S. Patent No. 10,106,407 [Patent Document 6] CN101891149A [Patent Document 7] U.S. Patent No. 8,920,525 [Non-patent literature]

[0025] [Non-Patent Document 1] Andrew Forrest, Fortescue Metals Group, on the ABC (Australian Broadcasting Corporation) Boyer Lectures, January 2021 [Non-Patent Document 2] https: / / www.petrofac.com / media / stories-and-opinion / the-difference-between-green-hydrogen-and-blue-hydrogen / [Non-Patent Document 3] See Chapter 12: Dehydrogenation of Alkanes (2005) [Non-Patent Document 4] Tetsuro YOKONO, Shoichi IYAMA, Yuzo SANADA, Tsutomo YAMAGUCHI and Tokio IIZUKA, "Dehydrogenation of Coal over Catalysts: Evaluation of Catalysts for Liquefaction", (1982), Journal of Japan Petroleum Institute, Vol. 27, No. 6, 1984. [Non-Patent Document 5] Gerald P. Huffman, University of Kentucky, Consortium for Fossil Fuel Sciences (CFFS), "Production and Storage of Hydrogen Using C1 Chemistry" (April 19, 2006). [Non-Patent Document 6] https: / / hazergroup.com.au / about / #hazerprocess [Non-Patent Document 7] Qian et al., “Methane decomposition to produce COx-free hydrogen and nano-carbon over metal catalysts: A review” International Journal of Hydrogen Energy, 2020, Vol. 45, pp. 7981-8001 [Non-Patent Document 8] Stolyarchuk et al., "FERRITES MFe2O4 (M=Mg, Mn, Fe, Zn) AS CATALYSTS FOR STEAM REFORMING OF ETHANOL." Theoretical and Experimental Chemistry, 2016, Vol. 52, No. 4, pp. 246-251 [Non-Patent Document 9] Takenaka et al., "Production of pure hydrogen from methane mediated by the redox of Ni- and Cr-added iron oxides," Journal of Catalysis. 2004, Vol. 228, pp. 405-416 Summary of the Invention [Problem to be solved by the invention]

[0026]

[0025] It is an object of the present invention to alleviate at least one disadvantage associated with the related art. [Means for solving the problem]

[0027] In general, the present invention provides a method for producing hydrogen, comprising the steps of: reacting a combination of a solid carbonaceous material and a catalyst comprising an alpha-phase iron-based material adapted to produce an exothermic reaction with the solid carbonaceous material. The present invention provides a method comprising:

[0028] The method comprises: combining a mixture of solid carbonaceous material and a catalyst; reacting the mixture by heating the mixture to a temperature of at least about 100° C.; may include:

[0029] In a preferred embodiment of the present invention, the catalyst comprises alpha ferrite.

[0030] The catalyst is Ferrimagnetic oxide of iron, Ferrite, Magnetite may include one or a combination of the above.

[0031]

[0030] Preferably, the magnetite comprises Fe3O4 and the ferrite comprises FeO.

[0032] The mixture of the solid carbonaceous material and the catalyst is about 90% by weight of a solid carbonaceous material; and Approximately 10% by weight of catalyst may include:

[0033] The step of reacting the mixture may include heating the mixture to a temperature up to about 1,000°C.

[0034] The method comprises: reacting the mixture of solid carbonaceous material and catalyst to produce a feed of alpha ferrite for further catalyzing the reaction. It may further include.

[0035] The reacting step may be carried out in a furnace, in a reaction chamber or in a retort.

[0036] The method comprises: operating the furnace at a temperature of about 1,000° C. or less to maintain an exothermic reaction of the mixture of the solid carbonaceous material and the catalyst. It may further include.

[0037] The method comprises: drying the mixture prior to reacting the mixture to produce an anhydrous mixture of the carbonaceous material and the catalyst. It may further include.

[0038]

[0037] The drying step may be carried out at about 35°C.

[0039] The method comprises: extruding the mixture to form the mixture into pellets prior to the drying step; prior to the drying step, molding the mixture to form the mixture into a molded shape to optimize heat transfer. The method may further include one or more of:

[0040]

[0039] The solid carbonaceous material is coal, sugar and / or sugarcane, Corn, plastic, Rubber, Waste pit sludge, and Waste materials may include one or a combination of the above.

[0041]

[0040] The above plastics are Polyvinyl chloride (PVC), Polyethylene terephthalate (PET), Low density polyethylene (LDPE), and High Density Polyethylene (HDPE) may include one or a combination of the above.

[0042]

[0041] The above coal is Pete, Lignite, and Subbituminous coal may include one or a combination of the above.

[0043]

[0042] The waste materials mentioned above are Rubber products, Food and organic waste, and Plastic waste may include one or a combination of the above.

[0044] Preferably, in the case of lignite, a typical analysis is as follows:

[0045] [Table 1]

[0046]

[0044] Preferably, the mixture further comprises about 2% by weight of a binder. The binder is then cement, flour, Sodium silicate. Corn flour may include one or a combination of the above.

[0047]

[0045] The binder is It may be formed from an aqueous solution of sodium silicate, including Na2SiO4, mixed in a typical ratio of about 100 g to 1 liter of water at about 60°C.

[0048]

[0046] The by-products of the reacting step include hydrogen (H2), and Carbon monoxide (CO), Carbon dioxide (CO2), Methane (CH4), Ethane (C2H6), and Carburizing Coke or a combination thereof.

[0049] The method comprises: extracting the by-products of reacting the mixture as synthesis gas and solid by-products, respectively; cooling the synthesis gas; Separating hydrogen from the synthesis gas. It may further include.

[0050] The step of separating hydrogen from the synthesis gas comprises: Liquefaction technology, Membrane and filtration technologies; Steam and vapor phase recovery technologies; Enrichment and separation techniques involving chemicals that catalyze reactions may include one or a combination of the above.

[0051] The combining step comprises: mixing a combination comprising a solid carbonaceous material, a catalyst and a binder until the combination has a thick paste-like consistency; extruding the combination having a paste-like consistency into pellets; and / or Molding the combination, which has a paste-like consistency, into a molded shape to optimize heat transfer. may include:

[0052] In general, the present invention also provides an apparatus for producing hydrogen, comprising: a reactor having a furnace and a reaction chamber adapted to react an anhydrous mixture of a solid carbonaceous material and a catalyst comprising an alpha-phase iron-based material adapted to undergo an exothermic reaction with the solid carbonaceous material by heating the mixture to a temperature of at least about 100° C. to at most about 1,000° C. to produce a synthesis gas and a solid by-product; a cooling system for cooling the synthesis gas; a collection system for separating hydrogen from the synthesis gas and collecting the separated hydrogen; An apparatus comprising:

[0053]

[0051] In the device disclosed herein, the catalyst preferably comprises alpha ferrite. Further, the catalyst comprises: Ferromagnetic oxide of iron, Ferrite, Magnetite may include one or a combination of the above.

[0054]

[0052] As with the methods disclosed herein, in the use of the apparatus as disclosed, the magnetite may include Fe3O4 and the ferrite may include FeO. Similarly, in the use of the apparatus, the mixture may include about 90% by weight of the solid carbonaceous material, and about 10% by weight of the catalyst.

[0055]

[0053] The apparatus may include a conveyor for processing the solid by-product, the conveyor comprising: Use as an industrial ingredient; and Their reuse as catalysts a magnetizing roller for separating magnetic particles from non-magnetic particles for one or a combination of the above.

[0056]

[0054] The apparatus may further comprise a control system operatively connected to one or more of the reactor, the cooling system, and the collection system, the control system comprising: a furnace burner or heating element controller operatively connected to at least one temperature sensor disposed within the reaction chamber to control the reaction temperature of the anhydrous mixture of the carbonaceous material and the catalyst; at least one temperature sensor disposed between the cooling system and the collection system for measuring the temperature of the synthesis gas at the point of collection; at least one pressure gauge disposed within the collection system; and a display for displaying operating parameters of the device based on measurements from one or a combination of the temperature sensor and the pressure gauge; Includes.

[0057] In general, the present invention also relates to a coal-fired power plant comprising an input coal fuel processor, a generator adapted for first connection to a turbine driving the generator and for second connection to an electrical grid for distribution of electricity generated by the generator; The present invention provides an adaptation in a coal fired power plant, characterized in that it comprises an apparatus according to any one of claims 23, 27 or 28 in a first operative connection with an input coal fuel processor as a supply of carbonaceous material, and in a second operative connection with a turbine for supplying separated hydrogen.

[0058] An embodiment of the present invention is a control device adapted to control the production of hydrogen, comprising: A control device comprising processor means adapted to operate according to a predetermined instruction set, which in conjunction with said instruction set is adapted to carry out and control the method steps as disclosed herein.

[0059] The control device preferably comprises: the temperature of at least one of the reaction mixture and the furnace; a gas product stream of the reacting step; analyzing the gas products of the reacting step; Pressure, as well as The mechanical speed of the plant equipment utilized to perform the method steps as disclosed herein. or a combination thereof.

[0060]

[0058] The embodiment also comprises: A computer usable medium having computer readable program code and computer readable system code embodied thereon for controlling the production of hydrogen in a data processing system - Patent 7326963 A computer program product comprising: The present invention may also include a computer program product comprising computer readable code in said computer usable medium for performing the method steps disclosed herein.

[0061]

[0059] A computer program product comprising: the temperature of at least one of the reaction mixture and the furnace; a gas product stream of the reacting step; analyzing the gas products of the reacting step; Pressure, as well as The mechanical speed of the plant equipment utilized to perform the method steps as disclosed herein. The signal may be adapted to control one or a combination of:

[0062] A further embodiment is a method for producing hydrogen, comprising the steps of: combining a mixture of carbonaceous material and a catalyst including one or a combination of ferrimagnetic oxides of iron and ferrite; reacting the mixture by heating the mixture to a temperature of at least about 100° C.; A method may be provided, comprising:

[0063]

[0061] Preferably, the step of reacting the mixture includes heating the mixture to a temperature between about 110°C and about 1,000°C or less.

[0064]

[0062] In a preferred embodiment, the catalyst comprises one or a combination of magnetite and alpha ferrite. Magnetite may comprise Fe3O4 and alpha ferrite may comprise FeO.

[0065]

[0063] Preferably, the mixture comprises about 90% by weight of the carbonaceous material and about 10% by weight of the catalyst.

[0066]

[0064] In a preferred embodiment, the method may further include the step of reacting the mixture of carbonaceous material and magnetite to produce a feed of alpha ferrite.

[0067] The step of reacting the mixture may be carried out in a furnace in a reaction chamber or retort. The furnace may be operated up to a temperature of about 1,000° C. The reaction of the mixture is an exothermic reaction.

[0068]

[0066] A further embodiment of the invention includes drying the mixture to produce a combined anhydrate comprising the carbonaceous material and catalyst prior to reacting the mixture. The drying step may be carried out at about 35°C. Prior to the drying step, the mixture is prepared or molded into a shape that promotes optimal heat transfer. Preferably, the mixture is extruded and formed into pellets prior to the drying step. Alternatively, the mixture may be chopped and prepared for molding into other shapes.

[0069] According to an embodiment of the present invention, the carbonaceous material is coal, sugar and / or sugarcane, Corn, Plastics, such as polyvinyl chloride (PVC), polyethylene terephthalate (PET), low density polyethylene (LDPE) and high density polyethylene (HDPE), Rubber, Waste pit sludge, and Waste materials or a combination thereof.

[0070]

[0068] The waste materials may include food waste.

[0071] In a preferred embodiment, the coal comprises one or a combination of peat, lignite, and subbituminous coal.

[0072]

[0070] Preferably, the waste material is Rubber products, Food and organic waste, and Plastic waste or a combination thereof.

[0073]

[0071] In a preferred embodiment, for lignite, a typical analysis is as follows:

[0074] [Table 2]

[0075] In a preferred embodiment of the present invention, the mixture further comprises 2% by weight of a binder. cement, flour, Sodium silicate, Corn flour may include one or a combination of the above.

[0076]

[0073] The binder is preferably formed from an aqueous solution of sodium silicate, including Na2SiO4, mixed in a typical ratio of about 100g per liter of water at about 60°C.

[0077] The products of the step of reacting the mixture include hydrogen (H2), and water, Carbon monoxide (CO), Carbon dioxide (CO2), Methane (CH4), Ethane (C2H6), and Carburizing Coke or a combination thereof.

[0078]

[0075] In a preferred embodiment, methane produced during the course of the process, in addition to the main reaction, further reacts with a catalyst to break down CH4 molecules to produce hydrogen.

[0079] In a preferred embodiment, the method comprises the steps of: extracting products of the reacting step as synthesis gas and solid by-products; cooling the synthesis gas; Separating hydrogen from the synthesis gas. It may further include.

[0080] The step of separating hydrogen from the synthesis gas comprises: Liquefaction technology, Membrane and filtration technologies; Steam and vapor phase recovery technologies; Enrichment and separation techniques involving chemicals that catalyze reactions may include one or a combination of the above.

[0081]

[0078] Preferably, the combining step comprises: mixing a combination including the carbonaceous material, the catalyst, and the binder until the combination has a thick paste-like consistency; Extruding the combination having a paste-like consistency into pellets. Includes.

[0082] An embodiment of the present invention also provides an apparatus for producing hydrogen, comprising: a reactor having a furnace and a reaction chamber adapted to react an anhydrous mixture of a carbonaceous material and a catalyst comprising one or a combination of a ferrimagnetic oxide of iron and a ferrite by heating the mixture to a temperature of at least about 100° C. and not more than about 1,000° C. to produce a synthesis gas and solid by-products; a cooling system for cooling the synthesis gas; a collection system for separating hydrogen from the synthesis gas and collecting the separated hydrogen; An apparatus comprising:

[0083]

[0080] The disclosed apparatus is adapted to carry out the methods of the embodiments of the present invention as described herein.

[0084]

[0081] Preferably, the apparatus comprises a conveyor for handling the solid by-product, the conveyor comprising: Use as an industrial ingredient; and Their reuse as catalysts or a combination thereof.

[0085]

[0082] The apparatus may further comprise a control system operatively connected to one or more of the reactor, the cooling system, and the collection system, the control system comprising: a furnace burner controller operatively connected to at least one temperature sensor disposed within the reaction chamber to control the reaction temperature of the anhydrous mixture of the carbonaceous material and the catalyst; at least one temperature sensor disposed between the cooling system and the collection system for measuring the temperature of the synthesis gas at the point of collection; at least one pressure gauge disposed within the collection system; and a display for displaying operating parameters of the device based on measurements from one or a combination of the temperature sensor and the pressure gauge; Includes.

[0086]

[0083] An embodiment of the present invention also provides a coal-fired power plant comprising an input coal fuel processor and a generator adapted for a first connection to a turbine that drives the generator and a second connection to a power grid for distributing electrical power generated by the generator; The application may provide for an adaptation in a coal fired power plant, characterized in that it comprises an apparatus of an embodiment disclosed herein in a first operative connection with an input coal fuel processor as a supply of carbonaceous material, and in a second operative connection with a turbine for supplying separated hydrogen.

[0087] An embodiment of the present invention is a control device adapted to control the production of hydrogen, comprising: There is provided a control device comprising processor means adapted to operate according to a predetermined instruction set, and adapted in conjunction with said instruction set to carry out and control the method steps as disclosed herein.

[0088]

[0085] Preferably, the control device comprises: the temperature of at least one of the reaction mixture and the furnace; a gas product stream of the reacting step; analyzing the gas products of the reacting step; Pressure, as well as The mechanical speed of the plant equipment utilized to carry out the method steps according to any one of claims 1 to 22. or a combination thereof.

[0089] A preferred embodiment also comprises: A computer usable medium having computer readable program code and computer readable system code embodied thereon for controlling the production of hydrogen in a data processing system - Patent 7326963 A computer program product comprising: A computer program product is provided comprising computer readable code in said computer usable medium for performing the method steps as disclosed herein. Preferably, the computer program product comprises: the temperature of at least one of the reaction mixture and the furnace; a gas product stream of the reacting step; analyzing the gas products of the reacting step; Pressure, as well as The mechanical speed of the plant equipment utilized to perform the method steps as disclosed herein. or a combination thereof.

[0090] Essentially, the present embodiment stems from the observation that by selecting an alpha-phase iron-based catalyst that promotes an exothermic reaction with carbonaceous materials, a H2-rich feed can be generated at low temperatures. In the course of conducting reduction experiments for mining applications with various ore types, the inventors utilized a mixture of catalysts including a variety of coal types and at least one or more combinations of ferromagnetic oxides of iron and ferrite, i.e., alpha ferrite. Thus, the inventors tried a wide variety of ratios of alpha ferrite and Fe3O4 in combination as ferrite and / or magnetite-based catalysts at various temperatures to successfully generate H2 feed from a number of carbonaceous materials.

[0091]

[0088] Other aspects and preferred embodiments are disclosed herein and / or defined in the appended claims, which form part of the description of the invention. Effect of the Invention

[0092] Advantages provided by embodiments of the present invention include: Low operating costs (OPEX) and low capital expenditures (CAPEX) can be realized due to the low complexity of the equipment and chemical processes involved. ·Higher yields (kWhH2 / kg coal) than other coal-based processes. · Less power consumption per kilogram of H21. The process involves very low CO2 emissions, which can be obtained by separation of the gas at the end of the process. Current coke production systems emit high levels of CO2, but the preferred embodiment will emit low levels of CO2. · Ultra-pure water by-product for advanced industries such as semiconductor manufacturing. The solid by-products can be used for improved industrial applications, for example improved components in catalytic converters. - Preferred embodiments include processes that are exothermic and thus reduce the processing energy involved. Production rates can be scaled up to production volumes consistent with any known steam reforming and wind or solar system. Unlike other "green" technologies that may have energy production components that may be comprised of significant rare earth metals, the amount of rare earth metals that make up the components implemented for embodiments of the present invention is minimal. A relatively low amount of energy is required to produce hydrogen, for example around 5kW per kilogram of H2, compared to around 65kW per kilogram of H2 required to produce "green, brown and blue hydrogen". No CO2 is released into the atmosphere, compared to the large amounts of CO2 indirectly released into the atmosphere in known "brown and blue hydrogen" production technologies. · Pure water, CO2 and clean coke are produced as by-products, whereas known "green hydrogen" production technologies produce little or no useful by-products. No new electricity distribution infrastructure is required. A production plant according to the preferred embodiment can run 24 / 7.

[0093] Further scope of applicability of the embodiments of the present invention will become apparent from the detailed description set forth hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the present disclosure herein will become apparent to those skilled in the art from this detailed description.

[0094]

[0091] Further disclosure, objects, advantages and aspects of other preferred embodiments of the present invention may be better understood by those skilled in the relevant art by reference to the following description of the embodiments taken in conjunction with the accompanying drawings, which are given by way of example only and, therefore, are not limiting of the present disclosure herein. [Brief description of the drawings]

[0095] [Figure 1] 1 is a process flow diagram illustrating a preferred embodiment of the present invention. [Diagram 2] FIG. 1 is a schematic diagram of an apparatus utilized to practice a preferred embodiment of the present invention. [Diagram 3] FIG. 3 is a schematic diagram of the apparatus of FIG. 2 including a control and monitoring device according to a preferred embodiment of the present invention. [Figure 4] FIG. 2 is a schematic diagram of the equipment utilized to recover catalyst and solid by-product materials in accordance with a preferred embodiment of the present invention. [Diagram 5] FIG. 2 is a schematic diagram of heat exchange equipment utilized to recover the synthesis gas product in accordance with a preferred embodiment of the present invention. [Figure 6A] FIG. 1 illustrates an existing electrical infrastructure according to the prior art. [Figure 6B] FIG. 1 illustrates the adaptation of an existing electrical infrastructure according to a preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0096]

[0092] An embodiment of the present invention utilizes the release of hydrogen from hydrocarbon compounds involving a catalytically enhanced chemical reaction at a relatively low temperature of about 110°C. The catalytic reaction produces a synthesis gas that can be separated into pure carbon-containing solids and, among other things, hydrogen. Small amounts of other gases, such as methane CH4, carbon monoxide CO, carbon dioxide CO2, and ethane C2H4, are therefore easily collected. As one skilled in the art will recognize, this separation of gases can be efficiently carried out by one or a combination of liquefaction techniques, membrane and filtration techniques, steam and vapor phase recovery techniques, and enrichment and separation techniques involving additive elements such as platinum, palladium, cobalt, and nickel to catalyze the reaction. By-products of the process include ultra-pure water for some carbonaceous materials and coke. In the context of this description, the term "ultrapure water" is used with respect to the preferred embodiment utilizing lignite as the feedstock carbonaceous material and refers to the water removed from old lignite when drying and preparing it for the catalytic process. The ultrapure water removed from lignite has the highest level of purity for all contaminant types including organic and inorganic compounds, dissolved particulate matter, volatile and nonvolatile, reactive and inert, hydrophilic and hydrophobic, and dissolved gases.

[0097] In one aspect, a preferred embodiment of the invention involves the thermochemical catalysis of lignite as the preferred coal-derived carbonaceous material reactant for the production of hydrogen. In another aspect, a preferred embodiment of the invention involves the helio-chemical catalysis of fresh foodstuffs such as plastics, rubber, corn and sugarcane, and / or other organic wastes as the preferred waste-derived carbonaceous material reactants for the production of hydrogen.

[0098] In a preferred embodiment, the method for producing hydrogen gas comprises using coal, particularly lignite, and exploits the chemical reactivity of lignite. The use of certain catalytic compounds at low temperatures promotes the release of hydrogen gas. The process is preferably carried out at low temperatures using a chemical process, which uses an alpha-phase iron-based catalyst, and the preferred catalyst may include one or a combination of alpha ferrite and at least a ferromagnetic oxide of iron, or a combination of a ferromagnetic oxide of iron and ferrite, to induce an exothermic reaction. This reaction produces hydrogen in large quantities. An increase in the applied heat intensifies the catalytic process. When the temperature of the carbonaceous material and catalyst is increased above about 110°C, H2 generation may reach an optimum level of production as heat is increased, depending on the feedstock material being used.

[0099]

[0095] By comparison with known techniques for hydrogen production, the preferred embodiment of the present invention utilizes carbon-based precursors, catalysts, other organic raw materials, and recycled resources, which are heated to initiate a reaction at a temperature ranging from about 110°C to about 115°C, and then as the reaction temperature of the materials increases, the process becomes exothermic and produces H2 continuously without the need for further energy input. This is in contrast to known methods of hydrogen production, including the green, gray / brown, and blue production methods of hydrogen production. Furthermore, in the above process of the preferred embodiment, CO2 is produced at a level of about 1% to about 10%, and can be captured (e.g., bottled) for use as an industrial product.

[0100] A preferred embodiment involves the reaction of lignite or other carbonaceous material with a catalyst in the production of hydrogen fuel gas, the catalyst including one or more combinations of magnetite and ferrites including FeO, or preferably alpha ferrite, as a source of Fe3O4.

[0101]

[0097] The by-products obtained in the reaction in the preferred embodiment of the present invention include a material residue, which includes "coke", which is a carburized coke of various densities and weights depending on the feedstock carbonaceous material used. In the context of this description, the material residue is a coke material that is pure carbon and includes the remains of catalytic material and some ash. This residual coke material can be used for carburization in green steelmaking processes, filtration media, automotive catalytic converters, and the like. For example, the alpha ferrite component of this residual coke material can be isolated and used to replace platinum in catalytic converters. In this context, an improved catalytic converter utilizing the alpha ferrite material of the residual coke material would begin to react at an onset temperature of about 110°C, instead of the current 300°C in current implementations of conventional catalytic converters. In the preferred embodiment of the present invention, the alpha ferrite coke produced as a by-product is much less expensive and is a viable alternative to the way automotive catalytic converters are currently made and manufactured. Another component of the by-product residue is pure carbon, which can be used in steelmaking and filtration media as a cheaper alternative to the present manufacturing process. Additionally, the production of these carbon-based materials is carried out without the CO2 emissions of current methods of their production. Typical NATA laboratory spectrometer analysis results for the residual solids are shown in Table 1 below.

[0102] [Table 3]

[0103]

[0098] Referring to FIG. 1, which illustrates one embodiment of the present invention, an input raw material of an exemplary composition of alpha-phase iron-based catalyst, with alpha ferrite typically constituting about 10% of the components, along with lignite, typically about 90%, is mixed with water and a binder. Other embodiments may include an alpha-phase iron-based catalyst that includes a combination of magnetite and ferrite, i.e., alpha ferrite. The preferred binder for this reaction is a compound of sodium silicate mixed with water in a composition that constitutes about 2% of the total weight of the batch being produced. Several compositions for the binder have been tried, with compositions including cement, wheat flour, sodium silicate, and corn flour. In another embodiment utilizing organic waste instead of lignite as a reactant source for hydrogen, the preferred binder includes a solution of hot water at about 60°C and sodium silicate Na2SiO4 mixture in a ratio of 100 grams of Na2SiO4 to 1 liter of water. This water is used to add to the mixing process, but not all of it is always used, only added until the mixture is homogenous and firm and has the appropriate consistency for preparing the reactants.

[0104]

[0099] The lignite and catalyst components are weighed to achieve their respective percentages of the net weight of each process batch. The mixture is combined to form a homogeneous consistency, for example using a paddle mixer or the like, resulting in a consistency of about 60% moisture content per 5 tonne charge in 1 hour. In essence, the mixture forms a "dry mix" so that the mixture is ready when it can be formed into a homogeneous clay-like material that can be extruded through a die. At this consistency, the mixture is ready for further processing.

[0105]

[0100] To aid in efficient processing of the following steps, the combined mixture is then extruded in an extruder to produce a pelletized material ready for drying and heat treatment. When the mixture is homogenous and has the appropriate moisture content, the product is extruded to provide pellets of the desired size. As an example, the mixture may be processed in an extruder at a rate of 1 ton / hour through a die that produces 8 mm pellets. For example, in a laboratory-scale plant, 25 mm round pellets are produced. The combined mixture is then dried in an air recirculation drying cabinet or equivalent oven to the extent that the mixture contains less than about 5% moisture. In an example of drying, the pelletized mixture is placed on one or more trays with recirculating air at about 35°C until the mixture contains less than about 5% moisture. Preferably, the tray or trays are placed on shelves and designed so that free-flowing warm air (about 35°C) passes over the surface of the or each tray. Before heating, the dried mixture may be weighed again.

[0106]

[0101] With reference to both Figures 1 and 2, the dried combined mixture may then be heat treated and placed in a retort furnace, which is fired to an operating set point of about 110°C to about 1000°C and controlled to an optimum temperature for efficient generation of H2. In this regard, the hydrogen production reaction begins at a reactant temperature of approximately 100°C. In the heating process, a retort is placed in the furnace, and then the dried pellets are placed in the retort. A lid seal is then placed on the retort flange. The retort lid is then closed and bolted tightly for an airtight finish. The syngas outlet pipe is then connected to the cooling inlet, and finally, one or more thermocouples are connected to the retort lid. The control and monitoring of the process is shown in more detail in Figure 3. Figure 2 illustrates a suitable furnace as shown. The furnace may be an insulated steel construction with a suitable form of refractory insulation. An exemplary insulation may be alumina-based ceramic fiber. A suitable form of such insulation is commercially available Fibrefrax™ insulation.

[0107]

[0102] The raw materials are placed in a retort. The hermetically sealed retort is placed in a furnace. A gas burner is then fired to provide a flame at the bottom of the furnace chamber.

[0108]

[0103] The process acts to destroy the chemical composition of the hydrocarbons, releasing hydrogen and depositing carbon.

[0109]

[0104] As can be appreciated by those skilled in the art, the relative volumes of gas obtained are subject to optimization of the pressure, residence time and temperature of the system. The system should be optimized to produce the maximum amount of H2 and the minimum amount of CO2 and CO.

[0110]

[0105] In a preferred embodiment, the catalyst comprises magnetite, which consists essentially of Fe3O4, which may also be recoverable after the thermal process is completed. Figure 4 shows an exemplary configuration of a conveyor that may be used to recover the catalyst utilizing the properties of its constituent ferrimagnetic oxides of iron, a preferred embodiment comprising a magnetite catalyst. The magnetic particles are separated in and by the conveyor. Figure 4 shows an exemplary configuration of a conveyor that may be used to recover the catalyst from the reaction. As shown, a magnetic roller is utilized to separate the magnetic particles from the non-magnetic particles for recycling of the magnetic particles. The recovered iron mixture comprises a ferrite-based catalyst.

[0111]

[0106] In general, the products of the thermal chemical reactions that occur are as follows: High value solids as by-products including: ○Carburized coke - pure carbon A synthesis gas product, i.e. a synthesis gas or fuel gas mixture comprising: Carbon monoxide (CO), ○ Carbon dioxide CO2, Methane CH4, Ethane, C2H6, and ○Hydrogen H2.

[0112]

[0107] The ratio of the various products may vary with changes in the input reactants and conditions. Carbon monoxide CO is typically up to 10% of the products and may be bottled and sold to industry. Carbon dioxide CO2 is typically about 15%-24% and may also be bottled and sold to industry. Methane CH4 is typically up to about 40% and is produced at industrial purity and may also be recovered and sold to industry. Ethane C2H6 is typically up to about 8% and is also industrial purity and may also be recovered and sold to industry. Carburized coke is typically up to about 45% of the original mass and is also industrial purity and may also be recovered and sold to industry.

[0113]

[0108] The solid by-product may have numerous industrial applications due to its composition from the catalytic reaction. For example, this ferrite material component may be useful to replace platinum in automotive catalytic converters. Advantageously, the solid by-product used in catalytic converters begins to react at 110°C to destroy the hydrocarbons in the exhaust gas, compared to platinum, which begins to react at 300°C and exhausts hydrocarbons into the atmosphere during the warm-up of the automobile engine. The solid by-product may also be used as a carburizing agent in casting and steelmaking operations, replacing existing carburizing agents. One benefit is that the by-product may be safely loaded into the furnace charge along with the electromagnet. This may be used as a filtration compound in the water treatment and chemical manufacturing industries. It is also envisioned that the solid by-product may be useful as a source material for the production of graphene.

[0114]

[0109] Referring to Figures 2 or 3, a gas burner or heat source of any known configuration may be utilized in the H2 production process according to the preferred embodiment, as will be recognized by those skilled in the art. By way of example, a heat source utilizing induction or electric elements may be suitable as an alternative to a gas burner. The retort with reactant materials is then placed in the furnace. The furnace lid is bolted to the retort flange and sealed with a gasket. In operation, the burner flue gases exit the flue as shown in Figure 2. In operation, the following steps are performed according to the preferred embodiment:

[0115]

[0110] When the gas burner is ignited, the flame generates heat and transfers it to the shell of the retort, heating the contents inside the retort. The furnace controller adjusts the gas input to maintain the set temperature of the contents.

[0116]

[0111] A thermocouple measures the temperature of the contents inside the retort, as shown in Figure 3. The thermocouple is located 100 mm above the base of the retort, close to the top center of the sealing plate. As heat increases, evolved gases are forced out of the retort and piped to a cooling system, as shown in Figure 2. An exemplary cooling system is shown in Figure 5, in which the synthesis gas enters the cooling system at a gas inlet and passes through a gas cooling chamber. While passing through the gas cooling chamber, the synthesis gas is cooled by cooling water passing through an outer cooling medium chamber, which enters the outer cooling medium chamber at a cooling water inlet and exits the outer cooling medium chamber via a cooling water outlet.

[0117] After cooling, the gas passes through a hydroseal, which acts as a backflow prevention seal and a scrubber. Sampling of the generated gas can be performed using aluminum foil gas collection bags, as will be appreciated by those skilled in the art. Sampling was performed during the experiment according to the following design sheet:

[0118] [Table 4]

[0119]

[0113] During trial production, gases were collected as needed for analysis at a NATA accredited laboratory.

[0120] Experimental Results

[0114] The following is a typical report from a NATA accredited laboratory, providing experimental testing to demonstrate the correctness of the invention.

[0121]

[0115] Analysis of samples J / N 21920 Test 1 and J / N 21920 Test 2 sampled on 20 / 09 / 2021 was performed on 20 / 09 / 2021. 7 . Concentration (mol%) Composition J / N 21920 Test 1 Hydrogen 37.02 Methane 7.71 Ethane 0.14 C6+ 0.248 Carbon Dioxide 18.67 Oxygen and Argon * 1.43 Nitrogen 26.92 7 Reference Method: WI-UC-086: All results reported on a dry gas and sulfur free basis. Expanded uncertainties are estimated at ±3% (relative) for values ​​above 1 mol%, and ±10% (relative) or ±0.002 mol% (whichever is greater) for values ​​below 1 mol%, using a coverage factor of 2 to define intervals estimated to have a 95% confidence level. Samples Analyzed: 2021 / 09 / 20 Lab Request Number: 211215 HRL Sample ID: J / N 21920 BXB Test 1 211215-1, J / N 21920 BXB Test 2 211215-2

[0122]

[0116] As a precursor step, a ferrite-based catalyst can be produced by reacting a magnetite source of Fe3O4 with a carbonaceous material, namely coal in the form of lignite. This reaction creates the conditions for producing alpha iron ferrite, as illustrated in the iron-carbon phase diagram below.

[0123] [ka]

[0124] Another preferred embodiment of the present invention includes replacing lignite with a raw material input of waste materials including one or a combination of foodstuffs, tires or plastic processing. By way of example, it is envisioned that this embodiment may also be provided for extracting H2 from plastics and tires. In this embodiment, hydrogen may be produced from foodstuffs, tires and plastic waste using similar chemical reactions. This hydrogen production process also includes an input material of one or a combination of waste foodstuffs, tires and plastics combined with a magnetite catalyst having various binders better suited to bind with foodstuffs, tires and plastics instead of coal. In this regard, as mentioned above, utilizing organic waste instead of lignite as the reactant source of hydrogen, the preferred binder includes a solution of hot water at about 60°C and sodium silicate Na2SiO4 mixture in a ratio of 100 grams of Na2SiO4 to 1 liter of water. This water is used to add to the mixing process, but not all of it is always used, only added until the mixture becomes homogeneous and firm and has a suitable consistency for preparing the reactants.

[0125]

[0118] It will also be appreciated that embodiments of the present invention may be directly adapted to existing coal-fired power plants, with zero CO2 emissions compared to existing green energy solutions. With reference to Figures 6A and 6B, the envisaged adaptation of a coal-fired power plant and its infrastructure may take the form of a coal-fired power plant comprising an input coal fuel processor, a steam generating boiler adapted for a first connection to a steam turbine driving a generator and a second connection to a power grid for distributing electricity generated by the generator, characterized in that the adaptation comprises the apparatus of Figures 2 and / or 3, in a first operative connection with the input coal fuel processor as a supply of carbonaceous material, and in a second operative connection with the turbine for supplying separated hydrogen.

[0126]

[0119] The adaptation of the coal-fired power plant and its infrastructure illustrated in Figures 6A and 6B may be equipped with the apparatus described herein for similar industries that are required to remain operational on a 24 / 7 basis, helping to reduce the need for traditional forms of high carbon emitting fuels. Examples of this include, but are not limited to, industries such as galvanizing plants, cement manufacturing, aluminum smelting, steel plants (glass furnaces), etc. The process of converting carbonaceous materials to syngas or its by-products helps reduce the carbon footprint due to the hydrogen content of the syngas. The syngas can be blended into existing fuel supplies or dedicated to other plants and equipment as an alternative.

[0127]

[0120] The adaptation technique can be extended to include the installation of hydrogen injection systems on stationary and mobile diesel engines. Direct injection of syngas produced according to embodiments of the present invention to augment diesel injection reduces carbon emissions significantly (e.g., approximately 25%) compared to direct diesel emissions.

[0128]

[0121] Certain embodiments of the present invention may allow existing coal mining infrastructure to remain operational into the future, and instead of burning coal in coal-fired boilers, steam is made in steam turbines, which may be replaced with apparatus according to the preferred embodiment that converts the input coal to its equivalent mass of hydrogen, which is used in hydrogen-fired turbines to generate electricity. This allows the existing electricity distribution infrastructure, which currently extends from traditional coal-fired power plants, to also remain operational into the future.

[0129]

[0122] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications. This application is intended to cover any variations or adaptations of the invention which follow the principles of the invention generally and include departures from the present disclosure as known or customary within the art to which the invention pertains and as may be applied to the essential features set forth hereinabove.

[0130]

[0123] Since the present invention can be embodied in several forms without departing from the spirit of the essential features of the present invention, it should be understood that the above-described embodiments do not limit the present invention unless otherwise specified, but should rather be broadly interpreted within the spirit and scope of the present invention as defined in the appended claims. The described embodiments are considered in all respects only as examples and not as limitations.

[0131]

[0124] Various modifications and equivalent arrangements are intended to be within the spirit and scope of the present invention and the appended claims. Accordingly, the specific embodiments are understood to be illustrative of the many ways in which the principles of the present invention may be practiced. In the following claims, any means-function claim is intended to encompass the structure performing the defined function, and equivalent structures as well as structural equivalents. For example, nails and screws may not be structural equivalents in that nails use cylindrical surfaces to fasten wooden parts together, while screws use helical surfaces to fasten wooden parts together, but in the context of fastening wooden parts, nails and screws are equivalent structures. Furthermore, as examples of specific embodiments of the present invention, variations and modifications to the specific component ratios of the input reactant materials of the present invention are envisioned to provide optimal production of the resulting products of the present process in response to various conditions, such as those related to temperature and pressure.

[0132] Sections I-VII below provide guidance for interpreting this specification. I. Terminology

[0133]

[0125] The term "product" means any machine, manufacture and / or composition of matter, unless expressly specified otherwise.

[0134]

[0126] The term "process" means any industrial process, algorithm, methodology, etc., unless expressly specified otherwise.

[0135]

[0127] The term "anhydrous" refers to any combination or mixture of materials disclosed herein and means the absence of water, or at least, moisture up to a percentage weight percent of water of at least 5% or less.

[0136]

[0128] Each process (whether referred to as a method, algorithm, or otherwise) inherently includes one or more steps, and thus all references to a "step" or "steps" of a process have inherent antecedent in the mere description of the term "process" or similar term. Thus, any reference in a claim to a "step" or "steps" of a process has sufficient antecedent.

[0137]

[0129] The term "invention" and the like means "one or more inventions disclosed herein," unless expressly specified otherwise.

[0138]

[0130] "An embodiment," "one embodiment," "multiple embodiments," "the embodiment," "multiple embodiments of the embodiment," "one or more embodiments," "some embodiments," "a particular embodiment," "one embodiment," "another embodiment," and the like mean "one or more (but not all) embodiments of the invention(s) of the present disclosure," unless expressly specified otherwise.

[0139]

[0131] The term "variant" of an invention means an embodiment of the invention, unless expressly specified otherwise.

[0140]

[0132] A reference to "another embodiment" when describing an embodiment does not imply that the referenced embodiment is mutually exclusive with the other embodiment (e.g., an embodiment described before the referenced embodiment), unless expressly specified otherwise.

[0141]

[0133] "Including," "comprising," and variations thereof mean "including but not limited to," unless expressly specified otherwise.

[0142]

[0134] The terms "a," "an," and "the" mean "one or more," unless expressly specified otherwise.

[0143]

[0135] The term "plurality" means "two or more" unless expressly specified otherwise.

[0144]

[0136] The term "herein" means "the present specification, including anything that may be incorporated by reference," unless expressly specified otherwise.

[0145]

[0137] The phrase "at least one of," when such phrase modifies a plurality of things (e.g., an enumerated list of things), means any combination of one or more of those things, unless expressly specified otherwise. For example, the phrase "at least one of widgets, cars, and wheels" means either (i) widgets, (ii) cars, (iii) wheels, (iv) widgets and cars, (v) widgets and wheels, (vi) cars and wheels, or (vii) widgets, cars, and wheels. The phrase "at least one of," when such phrase modifies a plurality of things, does not mean "one of each of" the plurality of things.

[0146]

[0138] Numeric terms such as "one," "two," and the like, when used as a cardinality indicating a quantity of something (e.g., one widget, two widgets), refer to the amount indicated by the numerical term, but not to at least the amount indicated by the numerical term. For example, the phrase "one widget" does not mean "at least one widget," and thus the phrase "one widget," for example, does not encompass two widgets.

[0147]

[0139] The phrase "based on" does not mean "based only on," unless expressly specified otherwise. In other words, the phrase "based on" describes both "based only on" and "based at least on." The phrase "based at least on" is equivalent to the phrase "based at least in part on."

[0148]

[0140] The term "represents" and similar terms are not exclusive unless expressly specified otherwise. For example, the term "represents" does not mean "represents only" unless expressly specified otherwise. In other words, the phrase "The data represents a credit card number" describes both "The data represents only a credit card number" and "The data represents a credit card number, and the data also represents something else."

[0149]

[0141] The term "whereby" is used herein only preceding a clause or other set of words that express only the intended result, object, or consequence of something expressly recited above. Thus, when the term "whereby" is used in a claim, the clause or other word that it modifies does not establish any specific further limitation of that claim or any other limitation of the meaning or scope of that claim.

[0150]

[0142] The term "eg" and similar terms mean "for example," and thus do not limit the term or phrase it describes. For example, in the sentence "a computer sends data (e.g., instructions, data structures) over the Internet," the term "eg" explains that "instructions" are an example of "data" that a computer can send over the Internet, and that "data structures" are an example of "data" that a computer can send over the Internet. However, both "instructions" and "data structures" are merely examples of "data," and other things besides "instructions" and "data structures" can also be "data."

[0151]

[0143] The term "ie" and similar terms mean "that is," and thus limit the term or phrase it describes. For example, in the sentence "A computer sends data (i.e., instructions) over the Internet," the term "ie" describes that the "instructions" are the "data" that a computer sends over the Internet.

[0152]

[0144] Any given numerical range will include integers and fractions within that range. For example, the range "1 to 10" will be interpreted as specifically including integers between 1 and 10 (e.g., 2, 3, 4...9) and non-integer numbers (e.g., 1.1, 1.2...1.9).

[0153] II. Determining

[0145] The term "determining" and its grammatical variations (e.g., determining a price, determining a value, determining an object that meets certain criteria) are used in a very broad sense. The term "determining" encompasses a wide variety of actions, and thus "determining" can include calculating, computing, processing, deriving, examining, searching (e.g., searching a table, database or another data structure), ascertaining, and the like. Also, "determining" can include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory), and the like. Also, "determining" can include resolving, selecting, choosing, establishing, and the like.

[0154]

[0146] The term "determining" does not imply certainty or absolute precision; thus, "determining" can include estimating, extrapolating, predicting, inferring, and the like.

[0155]

[0147] The term "determining" does not imply that mathematical operations must be performed, it does not imply that numerical methods must be used, and it does not imply that an algorithm or process is used.

[0156]

[0148] The term "determining" does not imply that any particular device must be used - for example, a computer does not necessarily have to perform the determining.

[0157] III. Indication

[0149] The term "indication" is used in a very broad sense: it may encompass, among other things, a symbol, a sign, or any other token.

[0158]

[0150] The term "indication" may be used to refer to any markings and / or other information that indicate or relate to a subject, item, entity, and / or other object and / or concept.

[0159]

[0151] As used herein, the phrases "information indicative of" and "indicia" may be used to refer to any information that represents, describes, and / or otherwise relates to an associated entity, subject, or object.

[0160]

[0152] Information indicia may include, for example, a symbol, a code, a reference number, a link, a signal, an identifier, and / or any combination thereof, and / or any other information indicia associated with the information.

[0161] In some embodiments, the indicia of information (or indication of information) may be or include the information itself and / or any portion or component of the information. In some embodiments, the instructions may include requests, solicitations, broadcasts, and / or any other form of information gathering or dissemination.

[0162] IV. Sentence Morphology

[0154] Where a limitation of a first claim encompasses both one of the features and more than one of the features (e.g., a limitation such as "at least one widget" encompasses both one widget and more than one widget), and in a second claim that depends from the first claim, the second claim uses the definite article "the" to refer to the limitation (e.g., "the widget"), this does not imply that the first claim encompasses only one of the features, and this does not imply that the second claim encompasses only one of the features (e.g., "the widget" can encompass both one widget and more than one widget).

[0163]

[0155] When an ordinal number (e.g., "first," "second," "third," etc.) is used as an adjective before a term, the ordinal number is used (unless expressly specified otherwise) merely to indicate a particular feature, e.g., to distinguish that particular feature from another feature described by the same or a similar term. For example, a "first widget" may be so named merely to distinguish it from, e.g., a "second widget." Thus, the mere use of the ordinal numbers "first" and "second" before the term "widget" does not indicate any other relationship between the two widgets, nor does it similarly indicate any other features of either or both widgets. For example, the mere use of the ordinal numbers "first" and "second" before the term "widget" does not (1) indicate that any widget comes before or after any other in order or arrangement, (2) indicate that any widget occurs or acts before or after any other in time, or (3) indicate that any widget ranks above or below any other in importance or quality. In addition, the mere use of the ordinal numbers does not define a numerical limit for the feature identified by the ordinal number. For example, the mere use of the ordinal numbers "first" and "second" before the term "widget" does not indicate that there must be no more than two widgets.

[0164]

[0156] Where a single device or article is described herein, two or more devices / articles (whether they cooperate or not) may alternatively be used in place of the single device / article described. Thus, functionality described as being processed by a device may alternatively be possessed by two or more devices / articles (whether they cooperate or not).

[0165]

[0157] Similarly, where two or more devices or articles (whether they cooperate or not) are described herein, a single device / article may alternatively be used in place of two or more of the described devices or articles. For example, multiple computer-based devices may be replaced with a single computer-based device. Thus, various functionality that is described as being possessed by two or more devices or articles may alternatively be possessed by a single device / article.

[0166]

[0158] The functionality and / or features of a single device described may alternatively be implemented by one or more other devices that are described but are not explicitly described as having such functionality / features. Thus, other embodiments need not include the described device itself, but rather may include one or more other devices that may have such functionality / features in other embodiments.

[0167] V. Disclosed Examples and Terminology Are Not Limiting

[0159] Neither the title nor the Abstract herein is intended to be construed in any way as limiting the inventive scope of this disclosure. The titles and section headings provided herein are for convenience only and are not to be construed in any way as limiting this disclosure.

[0168]

[0160] Several embodiments are described in this application and are presented for illustrative purposes only. The described embodiments are not and are not intended to be limiting in any way. The invention of the present disclosure is broadly applicable to numerous embodiments, as is readily apparent from the present disclosure. Those skilled in the art will recognize that the invention of the present disclosure can be realized using various modifications and alterations, such as structural, logical, software and electrical modifications. Although certain features of the invention of the present disclosure may be described with reference to one or more specific embodiments and / or drawings, it should be understood that such features are not limited to use in one or more specific embodiments or drawings to which they are described by reference, unless expressly specified otherwise.

[0169]

[0161] This disclosure is not a literal description of all embodiments of the invention, nor is this disclosure a listing of features of the invention that must be present in all embodiments.

[0170]

[0162] Devices described as being connected to each other need not be continuously connected to each other unless expressly specified otherwise. In contrast, such devices need only communicate with each other as necessary or desired, and may in fact decline to exchange data or materials most of the time. For example, a machine connected to another machine via the Internet may not communicate data to the other machine for extended periods of time (e.g., weeks at a time). In addition, devices connected to each other may communicate directly or indirectly through one or more intermediaries. The same may be true of industrial machines and equipment.

[0171]

[0163] The description of an embodiment with several components or features does not imply that all or even any of such components / features are required. To the contrary, various optional components are described to illustrate the wide variety of possible embodiments of the invention. Unless expressly specified otherwise, no component / feature is essential or required.

[0172]

[0164] Although process steps, operations, algorithms, and the like may be described in a particular sequence order, such processes may be configured to work in different orders. In other words, any sequence or order of steps that may be explicitly described does not necessarily indicate a requirement that the steps be performed in that order. The steps of the processes described herein may be performed in any actual order. Furthermore, some steps may be performed simultaneously, regardless of whether they are described or implied as occurring non-concurrently (e.g., because one step is described after another step). Furthermore, the illustration of a process by its illustration in the drawings does not imply that the illustrated process is exclusive of other variations and modifications thereto, does not imply that the illustrated process or any of its steps are required for the invention, and does not imply that the illustrated process is preferred.

[0173] Although a process may be described as including a number of steps, this does not imply that all or any of the steps are preferred, essential, or required. Various other embodiments within the scope of the invention(s) described include other processes that omit some or all of the steps described. Unless expressly specified otherwise, no step is essential or required.

[0174]

[0166] Although a process may be described in isolation or without reference to other products or methods, in some embodiments the process may interact with other products or methods. For example, such interactions may include linking one business model to another. Such interactions may be provided to enhance the flexibility or desirability of the process.

[0175] Although a product may be described as including a number of ingredients, aspects, qualities, properties, and / or characteristics, this does not indicate that any or all of the plurality are preferred, essential, or required. Various other embodiments within the scope of the invention(s) described include other products that omit some or all of the plurality of the described.

[0176]

[0168] An enumerated list of items (which may be numbered or unnumbered) does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. Similarly, an enumerated list of items (which may be numbered or unnumbered) does not imply that any or all of the items are exhaustive of any category, unless expressly specified otherwise. For example, the enumerated list "computer, laptop, PDA" does not imply that any or all of the three items in the list are mutually exclusive, nor does it imply that any or all of the three items in the list are exhaustive of any category.

[0177]

[0169] An enumerated list of items (which may be numbered or unnumbered) does not imply that any or all of the items are equivalent to each other or readily substituted for one another.

[0178]

[0170] All embodiments are illustrative and do not imply that the invention or any embodiment has been made or performed in any case.

[0179]

[0171] "Comprises / comprising" and "includes / including," as used herein, specify the presence of stated features, integers, steps, or components, but do not exclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. Thus, unless the context clearly requires otherwise, throughout this description and claims, words such as "comprise," "comprising," "includes," "including," and the like, are to be interpreted in an inclusive sense, i.e., "including but not limited to," as opposed to an exclusive or exhaustive sense.

[0180] Process Authentication Example

[0172] Qualification test results for the implementation of an embodiment of the present invention are as follows for lignite and LDPE plastic feedstocks, respectively.

[0181] Hydrogen generation process from coal (lignite)

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[0183] Hydrogen generation process from LDPE plastics

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Claims

1. 1. A method for producing hydrogen, comprising: reacting a combination of a solid carbonaceous material and a catalyst comprising an alpha-phase iron-based material adapted to undergo an exothermic reaction with the solid carbonaceous material; A method comprising:

2. combining a mixture of solid carbonaceous material and catalyst; reacting the mixture by heating the mixture to a temperature of at least about 110°C; The method of claim 1 , comprising:

3. 3. The method of claim 1 or 2, wherein the catalyst comprises alpha ferrite.

4. The catalyst is ferrimagnetic oxide of iron, ferrite, Magnetite 4. The method of claim 3, comprising one or a combination of:

5. Magnetite is Fe ３ O ４ 5. The method of claim 4, wherein the ferrite comprises FeO.

6. a mixture of the solid carbonaceous material and the catalyst; about 90% by weight of a solid carbonaceous material; and About 10% by weight of catalyst The method of claim 2 , comprising:

7. 3. The method of claim 2, wherein reacting the mixture comprises heating the mixture to a temperature of up to about 1,000°C.

8. 10. The method of claim 1, further comprising reacting the mixture of solid carbonaceous material and catalyst to produce a feed of alpha ferrite for further catalyzing the reaction.

9. 10. The method of claim 1, wherein the reacting step is carried out in a furnace in a reaction chamber or retort.

10. 10. The method of claim 9, further comprising operating the furnace at a temperature of about 1,000°C or less to maintain an exothermic reaction of the mixture of solid carbonaceous material and catalyst.

11. 3. The method of claim 2, further comprising drying the mixture prior to reacting the mixture to produce a combined anhydrate comprising the carbonaceous material and the catalyst.

12. 12. The method of claim 11, wherein the drying step is carried out at a temperature of about 35°C.

13. extruding the mixture to form the mixture into pellets prior to the drying step; molding the mixture to form it into a molded shape to optimize heat transfer before the drying step. The method of claim 11 , further comprising one or more of:

14. The solid carbonaceous material coal, sugar and / or sugarcane, corn, plastic, tires and rubber products, waste pit sludge, and waste materials 10. The method of claim 1, comprising one or a combination of:

15. Plastic, Polyvinyl chloride (PVC), polyethylene terephthalate (PET), Low density polyethylene (LDPE), and High density polyethylene (HDPE) 15. The method of claim 14, comprising one or a combination of:

16. Coal, Pete, lignite, and Subbituminous coal 15. The method of claim 14, comprising one or a combination of:

17. The waste material is tires and rubber products, food and organic waste, and plastic waste 15. The method of claim 14, comprising one or a combination of:

18. 17. The method of claim 16, wherein the lignite has the following compositional analysis: Moisture content at time of receipt (M%ar) 51.40% Approximate analysis: Ash content 5.40% db, Volatile matter 51.00% db, Fixed carbon 43.70% db, Elemental analysis: C 67.30%db, H 5.00% db, N 0.65% db, S 1.95% db, O 19.80% db, and Heat output: Total dry matter 26.60 MJ / kg; Total wet matter 12.90 MJ / kg; Net wet matter 11.30 MJ / kg

19. The method of claim 2 , wherein the mixture further comprises about 2% by weight of a binder.

20. The binder cement, flour, sodium silicate, corn flour 17. The method of claim 16, comprising one or a combination of:

21. The binder was mixed in a typical ratio of about 100 g NaOH to 1 liter of water at about 60°C. ２ SiO ４ 17. The method of claim 16, wherein the silicate is formed from an aqueous solution of sodium silicate comprising:

22. A by-product of the reacting step is hydrogen (H ２ ), and carbon monoxide (CO), Carbon dioxide (CO ２ ), Methane (CH ４ ), Ethane (C ２ H ６ ), and Carburizing Coke 10. The method of claim 1, comprising one or a combination of:

23. and reacting the mixture with a synthesis gas and a solid by-product, respectively. and extracting the cooling the synthesis gas; separating hydrogen from the synthesis gas; 23. The method of claim 22, further comprising:

24. separating hydrogen from the synthesis gas, Liquefaction technology, and membrane and filtration technologies; Steam and vapor phase recovery technologies, Enrichment and separation techniques, including chemicals that catalyze reactions 24. The method of claim 23, comprising one or a combination of:

25. The matching step is mixing a combination comprising the solid carbonaceous material, the catalyst, and the binder until the combination has a thick paste-like consistency; extruding the combination having a paste-like consistency into pellets; and / or forming the combination, which has a paste-like consistency, into a molded shape to optimize heat transfer; 20. The method of claim 19, comprising:

26. 1. An apparatus for producing hydrogen, comprising: a reactor having a furnace and a reaction chamber adapted to react an anhydrous mixture of a solid carbonaceous material and a catalyst comprising an alpha-phase iron-based material adapted to undergo an exothermic reaction with the solid carbonaceous material by heating the mixture to a temperature of at least about 110° C. and up to about 1,000° C. to produce a synthesis gas and solid by-products; a cooling system for cooling the synthesis gas; a collection system for separating hydrogen from the synthesis gas and collecting the separated hydrogen; An apparatus comprising:

27. 27. The apparatus of claim 26, wherein the catalyst comprises alpha ferrite.

28. The catalyst is ferrimagnetic oxide of iron, ferrite, Magnetite 28. The method of claim 26 or 27, comprising one or a combination of:

29. Magnetite is Fe ３ O ４ 29. The apparatus of claim 28, comprising:

30. The mixture is about 90% by weight of a solid carbonaceous material; and About 10% by weight of catalyst 27. The apparatus of claim 26, comprising:

31. a conveyor for processing the solid by-product, the conveyor comprising: Use as an industrial ingredient, and Their reuse as catalysts 27. The apparatus of claim 26, comprising a magnetizing roller for separating magnetic particles from non-magnetic particles for one or a combination thereof.

32. a control system operatively connected to one or more of the reactor, the cooling system, and the collection system, the control system comprising: a furnace burner or heating element controller operatively connected to at least one temperature sensor disposed within the reaction chamber to control the reaction temperature of the anhydrous mixture of carbonaceous material and catalyst; at least one temperature sensor disposed between the cooling system and the collection system for measuring the temperature of the synthesis gas at the point of collection; at least one pressure gauge disposed within the collection system; and 27. The device of claim 26, including a display for displaying operating parameters of the device based on measurements from one or a combination of a temperature sensor and a pressure gauge.

33. 1. An adaptation of a coal-fired power plant, the coal-fired power plant comprising: an input coal fuel processor; a generator adapted for first connection to a turbine that drives a generator; and a second connection to an electrical grid for distribution of electricity generated by the generator; 27. The adaptation comprising the apparatus of claim 26, wherein the adaptation is in first operative connection with an input coal fuel processor as a supply of carbonaceous material, and in second operative connection with a turbine for supplying separated hydrogen.

34. 1. A controller adapted to control the production of hydrogen, comprising: A control device comprising processor means adapted to operate in accordance with a predetermined instruction set, and adapted in conjunction with said instruction set to implement and control the method steps of claim 1.

35. the temperature of at least one of the reaction mixture and the furnace; a gas product stream of the reacting step; analyzing the gas products of the reacting step; pressure, and The mechanical speed of the plant equipment utilized to perform the method steps of claim 1.

35. The control device of claim 34 adapted to control one or a combination of:

36. 1. A computer program product including a computer usable medium having computer readable program code and computer readable system code embodied on the medium for controlling the production of hydrogen in a data processing system, the computer program product comprising:

10. A computer program product comprising computer readable code in said computer usable medium for performing the method steps of claim 1.

37. the temperature of at least one of the reaction mixture and the furnace; a gas product stream of the reacting step; analyzing the gas products of the reacting step; pressure, and 37. The computer program product of claim 36 adapted to control one or a combination of machine speeds of plant equipment utilized to perform the method steps of claim 1.

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