Method and apparatus for processing hydrocarbons using pyrolysis

Abstract

A method for processing a hydrocarbon (101), specifically a hydrocarbon gas, is described, the method comprising: i) preheating said hydrocarbons (101) in a preheating device (110); ii) feeding the preheated hydrocarbon to a liquid metal bath (125) in a reactor (120), wherein the liquid metal bath (125) comprises at least one catalyst; and iii) carrying out a pyrolysis reaction with said hydrocarbon in said liquid metal bath (125) resulting in a carbon phase and a hydrogen phase.

Description

[Technical field]

[0001] The present invention relates to a method for treating hydrocarbons using a pyrolysis process, in particular in a liquid metal bath, and furthermore to an apparatus adapted to carry out said method. [Background technology]

[0002] To combat the progression of climate change and its impacts on ecosystems, the aim is to minimize carbon dioxide (CO2) emissions by further developing energy generation systems on a global scale. It is envisaged that hydrogen could play a central role in future CO2-minimized energy generation systems. Nevertheless, the question remains how to produce large amounts of hydrogen in an environmentally friendly way. For example, hydrogen can be produced from water by electrolysis (2H2O<->O2+2H2), which requires a large amount of energy.

[0003] Methane (CH4) is similar to another promising source for hydrogen formation. For example, hydrogen can be obtained from methane by steam reforming, but in this process CO2 will be produced (CH4+2H2O<->CO2+4H2). Another idea to obtain hydrogen from methane is the pyrolysis of methane into hydrogen and carbon (CH4<->2H2+C). Pyrolysis may be considered a particularly interesting technology since it requires significantly less energy as in the case of electrolysis, while no CO2 is produced as in reforming. The reaction of methane gas into hydrogen gas and solid carbon may be improved by using catalysts, especially in the liquid bath. Nevertheless, it may still be considered a challenge to provide an energy-efficient and environmentally friendly pyrolysis process. Summary of the Invention

[0004] In particular, there may be a need to process hydrocarbons in an efficient, energy-saving and environmentally friendly manner to produce hydrogen.

[0005] A description of manufacturing methods and apparatus is provided.

[0006] According to an aspect of the present invention, a method for processing hydrocarbons, specifically hydrocarbon gases, is described, the method comprising: i) preheating said hydrocarbons in a preheating device; ii) feeding the preheated hydrocarbon to a liquid metal bath in a reactor, wherein the liquid metal bath comprises at least one catalyst, particularly a metal catalyst; and iii) carrying out a pyrolysis reaction with the hydrocarbon in the liquid metal bath, resulting in a carbon phase (e.g., a solid carbon phase) and a hydrogen phase (e.g., a gaseous hydrogen phase).

[0007] According to a further aspect of the present invention there is described an apparatus for processing hydrocarbons, the apparatus comprising: i) a preheating device for preheating said hydrocarbons; ii) a reaction device coupled to the preheating device and configured to carry out a pyrolysis reaction with the preheated hydrocarbon in a liquid metal bath, thereby obtaining a carbon phase and a hydrogen phase.

[0008] According to a further aspect of the present invention, a method for processing hydrocarbons, in particular hydrocarbon gases, is described, the method comprising: i) feeding the (preferably preheated) hydrocarbon to a liquid metal bath in a reactor, the liquid metal bath comprising at least one catalyst; and ii) carrying out a pyrolysis reaction with the hydrocarbon in the liquid metal bath, resulting in a carbon phase (e.g., a solid carbon phase) and a hydrogen phase (e.g., a gaseous hydrogen phase).

[0009] In the present context, the term "hydrocarbon" may refer in particular to organic compounds / substances (which may be solid, liquid, or gaseous) that (substantially) contain hydrogen and carbon. In one example, the hydrocarbon may only contain hydrogen and carbon, while in another example, the hydrocarbon may contain further chemical elements, such as oxygen or nitrogen. Nevertheless, hydrogen and carbon are generally the main components of the hydrocarbon. The hydrocarbon may comprise or consist of gas, liquid, solid, or mixtures thereof. Examples of hydrocarbons may include methane, biogas, natural gas, pyrolysis gas, carbonized gas from scrap pyrolysis, pre-pyrolysis gas, landfill gas, crude oil, mineral oil, pyrolysis oil, bio-oil, liquid industrial waste hydrocarbons, plastic waste, industrial residues, organically contaminated metal scrap. In a specific example, the hydrocarbon may be primarily solid or liquid, but may be transformed into gaseous hydrocarbons during the pre-pyrolysis reaction.

[0010] In the present context, the term "liquid metal bath" may refer in particular to a mass of metal that is fully or partially molten. In certain instances, the liquid metal bath includes a base metal (e.g., copper, iron) with at least one active metal, in which case the active metal is a metal catalyst (e.g., nickel). The metal bath may include primarily metal, but may also contain additional substances. In the present context, the term "reaction equipment" may refer to any equipment suitable for containing (and carrying out a pyrolysis reaction therein) a liquid metal bath. Hydrocarbons may be introduced into the metal bath as reactants and undergo a pyrolysis reaction caused by heat (and thus pressure) and the metal catalyst. In certain instances, the hydrocarbons may be transported through the bath (in particular, vertically from below to above), thereby constantly undergoing a pyrolysis reaction. In a specific instance, the hydrocarbons are thereby reacted into a solid phase and a gas phase. As a result, the gas phase may be transported through the metal bath as bubbles, while the solid phase may form a layer on top of the liquid metal bath.

[0011] In the present context, the term "catalyst" may refer to a substance that increases the rate of a chemical reaction, especially when added to a substance to be chemically reacted. If the catalytic substance comprises or consists of one or more metals, it may be referred to as a "metal catalyst". For example, the metal catalyst may be mono-component, e.g. nickel. Furthermore, the metal catalyst may also be poly-component. In certain embodiments, the liquid metal bath comprises or consists of a metal catalyst body. Thus, the pyrolysis reaction in the reaction device may occur (substantially) within the liquid metal bath. The reaction may occur only within the bath or also (at least partially) outside (above) the bath. Within the bath, the catalyst (e.g. metal and / or (solid) carbon) may be completely or partially liquid.

[0012] In the present context, the term "pyrolysis reaction" may refer in particular to any reaction involving the decomposition of a substance caused by heat. Pyrolysis may be understood as the thermal decomposition of a substance / material at high temperatures, which may involve a change in the chemical composition of the substance. In the present context, the term pyrolysis may also include thermolysis, which may be a specific pyrolysis aimed at producing specific products by thermolysis (rather than simply decomposing all the substance). A specific example in the present context may include the pyrolysis of a hydrocarbon, such as methane, into a carbon phase and a hydrogen phase.

[0013] In the context of this document, the term "preheating equipment" may denote any equipment suitable for heating hydrocarbons, in particular to a certain temperature. The preheating equipment may be coupled to the reaction equipment and may heat the hydrocarbons, so that the preheated hydrocarbons can be supplied to the reaction equipment. The preheating equipment may be (directly) coupled to the reaction equipment. Furthermore, the preheating equipment may be configured as a transport line. The preheating equipment may, for example, comprise or be coupled to (encapsulated) heating lines, (porous) heat exchangers, (graphite) chutes. In another example, the hydrocarbons may first be preheated and then secondly transported to the reaction equipment. The temperature in the preheating equipment may be of the same order of magnitude as the temperature of the reaction equipment, but may also be lower or even higher. The skilled person knows many ways how to design a heating equipment, according to which heating by inductor coils may be a preferred solution. The preheating equipment may comprise an inlet for the hydrocarbons and an outlet for the preheated hydrocarbons. The latter may be coupled or integrated with the inlet of the reaction equipment, for example a gas purging unit.

[0014] In the present context, the term "hydrogen phase" may refer to a phase that comprises or consists of hydrogen. While in one example, the hydrogen phase may contain only (gaseous) hydrogen, in another example, the hydrogen phase contains further substances. Other substances (e.g. polyaromatic hydrocarbons (PAHs) as by-products from CH4 decomposition (e.g. acetylene->benzene->PAHs)) may be removed during the subsequent purification process.

[0015] In certain instances, three different hydrogen-rich phases may exist during the described process: - A hydrogen-rich gas stream, specifically a gas phase that may be loaded with solid carbon dust and / or metal particles / droplets. A hydrogen-rich gas stream may be present right after the liquid metal bath (and up to the (hot gas) filtration process stage). - A hydrogen-rich gas phase, in particular the gas phase after the (hot gas) filter which contains hydrogen and further gaseous components (e.g. incomplete CH4 decomposition). The hydrogen-rich gas phase can be further processed, for example by a condenser and / or a membrane. - a hydrogen-rich phase containing hydrogen of high purity, which may occur in the described process after the membrane treatment stage.

[0016] In the present context, the term "carbon phase" may refer to a phase that comprises or consists of carbon, specifically solid carbon. In one example, the carbon phase comprises only carbon, while in another example, the carbon phase further comprises other substances.

[0017] According to an exemplary embodiment, the present invention may be based on the idea that a hydrogen-rich phase can be produced from hydrocarbons in an efficient, energy-saving and environmentally friendly manner if the hydrocarbons are fed to a pre-heating process before being pyrolyzed in a liquid bath containing a metal catalyst.

[0018] It has been discovered by the inventors that the efficiency of the pyrolysis reaction can be significantly improved by preheating the hydrocarbons before introducing them into the pyrolysis reactor. As a result, the objective can be to design a hydrocarbon process that is as energy efficient as possible, thereby reducing the required materials to a minimum. When the preheated hydrocarbons are introduced into a liquid metal bath together with the metal catalyst body, they can react immediately into hydrogen and carbon phases. These phases rise (e.g., with (in) gas bubbles) in the liquid metal bath and can be recovered for further purification processes. By carrying out substantially the entire pyrolysis reaction with preheated hydrocarbons in the liquid metal bath, the yield (of the pyrolysis reaction) can be maximized while the energy requirements can be minimized. Since the process is carried out under industrially relevant conditions (e.g., 900-1600°C, <50 bar (5 MPa)), the described measures can be implemented in a simple manner in existing metallurgical plants. Upscaling can therefore be carried out in a straightforward manner.

[0019] It can be seen that the main advantage of this process is that it requires significantly less energy, which can be supplied from renewable sources (or even other metallurgical plant processes), and as a result, the CO2 emissions for the hydrogen produced in this way are much lower compared to, for example, steam reforming. Description of exemplary embodiments

[0020] According to an embodiment, the method further comprises a step of heating the liquid metal bath and / or the preheating device by induction, in particular to induce motions in the liquid metal bath. Through a defined arrangement and control of the induction coils, electromagnetic forces can be applied, thereby providing the desired parameters (bath motion, bubble size, and residence time of the gas in the bath). Thus, heating by induction can not only heat the metal bath in an efficient manner, but it can also allow selective adjustment of advantageous parameters that further improve the efficiency of the process. The preheated hydrocarbons can thereby directly participate in the induced motions without cooling down / slowing down the dynamics in the metal bath.

[0021] According to a further embodiment, the method further comprises applying a coating layer above the liquid metal bath, in particular comprising at least one of the following: slag, stable oxide, solid oxide (e.g., spheres of Al2O3), molten salt, carbon. By applying a coating layer on the surface of the metal bath, it may be possible to control the emission behavior of the hydrocarbon-containing gas as well as the resulting solids. This may provide the advantage of avoiding metal droplets from leaving the metal bath, thereby saving resources.

[0022] According to a further embodiment, the step of supplying the hydrocarbon further comprises a step of injecting the hydrocarbon into the reactor by at least one of the group consisting of: a lance, a porous tube, a purge block, an impeller. Different systems for gas injection (as well as electromagnetic forces by induction) can make it possible to influence the bath motion, the bubble size and the gas residence time, which can ensure a significant increase in the conversion rate of the exhaust gas. The input of the hydrocarbon (containing gas) into the liquid metal bath can be carried out through one or more units, including different gas injection systems such as a lance, a purge block, an impeller or a porous tube, as well as a system for gas preheating. The configuration of these units can be variable, which can make it possible to make a targeted influence on the bath motion, the bubble size and the residence time of the gas in the bath.

[0023] According to further embodiments, the pyrolysis reaction is carried out at a temperature of 1600° C. or lower, particularly in the range of 600° C. to 1600° C., more particularly in the range of 900° C. to 1400° C., and even more particularly in the range of 1000° C. to 1200° C. In other examples, in the range of 900° C. to 1200° C., or in the range of 600° C. to 900° C. Thus, energy- and reaction-efficient temperatures can be advantageously adapted to the required needs.

[0024] In one example, for tin (Sn) as the base metal, a range of 600°C to 900°C may be applied, for copper as the base metal, a range of 900°C to 1200°C may be applied, and for iron or nickel as the base metal, a range of 1200°C to 1600°C may be applied. Thus, the temperature can be precisely tailored to the requirements of the applied base metal. While a lower temperature may primarily save energy, a higher temperature may allow for faster reactions and / or higher yields, thus potentially saving more energy over a longer time scale.

[0025] According to a further embodiment, the preheating step is carried out at a temperature of 900°C or lower, in particular in the range of 600°C to 900°C. Thus, the hydrocarbon can be brought to a temperature equal to or at least close to the temperature of the liquid metal bath. This can provide the advantage of increasing the reaction yield while saving energy costs. In some examples, the preheating temperature is lower than the temperature of the liquid metal bath. Preheating the input gas by using process heat from the pyrolysis process or another process can save costs. In other examples, the thermal energy from the melt is used only or mainly for CH4 decomposition and not for heating the gas to the process temperature.

[0026] According to a further embodiment, the pyrolysis reaction is carried out in a technical vacuum or at a pressure of 1 bar (0.1 MPa) or higher, in particular at a pressure of 5 bar (0.5 MPa) or higher, in particular at a pressure of 10 bar (1 MPa) or higher, in particular at a pressure of 40 bar (4 MPa) or higher, more particularly at a pressure of 50 bar (5 MPa) or lower. In some instances, the pressure may be in the range of 1 to 60 bar (0.1 to 6 MPa), in particular at a pressure of 5 to 60 bar (0.5 to 6 MPa), in particular at a pressure of 10 to 50 bar (1 to 5 MPa). Depending on the applied pressure, the reaction may be advantageously accelerated.

[0027] According to a further embodiment, the method further comprises injecting the preheated hydrocarbon as a gas into an inlet of the reactor, where the preheated hydrocarbon forms bubbles that rise in the liquid metal bath. As can be seen in FIG. 1, in one example, the bubbles may have a small size near the inlet, while their size continuously expands while moving up in the liquid metal bath. During the pyrolysis reaction, the hydrocarbon produces a solid carbon phase that may precipitate at the surface of the bath, and a gas phase that includes gas and solids and moves with (within) the bubbles to the surface of the liquid metal bath. Carbon may stick to (attach to) the bubbles (flotation effect) and / or be present inside the bubbles. In the metal bath, a reaction of CH4 to 2H2 may occur, which reduces the metal static pressure, increases the temperature, and causes solidification. In certain instances, the bubbles may shrink during the rise due to H2 or CH4 solubility in the metal bath catalyst or by reaching a critical size.

[0028] According to a further embodiment, at least a part of the carbon phase is in solid form and floats on the liquid metal bath, the method further comprising a step of discharging the carbon phase, in particular by at least one of mechanical, pneumatic and gravity conveyance. As explained above, the carbon phase may at least partially precipitate / float on the bath, thereby forming a coating layer. The coating layer may have a beneficial effect on the liquid metal bath (e.g., avoiding material (metal droplets, particles, etc.) from leaving the metal bath) and may be recovered in a simple manner.

[0029] According to a further embodiment, the method further comprises a step of separating said carbon phase in solid form from the hydrogen-rich gas stream, in particular by at least one of a filter, in particular a hot gas filter, a gravity separator. As explained above, the hydrogen-rich gas stream (after the metal bath) may contain solids (carbon phase) and gas (hydrogen phase) (in other words a hydrogen-containing gas mixture and a carbon-containing solid fraction), whereby the solids are transported in the gas to the surface of the bath as in the stream. This may provide the advantage that the (main) solid part (a further part may remain at the bottom and / or in suspension) does not remain in the bath but is transported to the surface, where it can be efficiently separated from the hydrogen phase. In this way, it is possible to prevent the catalyst from being deactivated / contaminated. For this purpose, known established means may be applied, such as (hot gas) filtration and / or gravity separation.

[0030] According to a further embodiment, the method further comprises a step of treating said hydrogen-rich gas stream (for example to obtain a hydrogen-rich gas phase, specifically hydrogen gas), specifically by at least one of filtration, condensation, compression, membrane separation, quenching. In addition to or instead of the above-described processes, the hydrogen-rich gas stream (hydrogen phase to be treated) can be (further) treated, for example, by a condenser (see FIG. 1) (and optionally a polys filter). The hydrogen-rich gas phase can be configured as a gas phase that may be contaminated with solid carbon dust and / or metal particles / droplets. A filter / condenser can be applied to efficiently separate the hydrogen (phase) from the solid carbon phase (dust) and / or metal particles / droplets and / or gaseous synthesis products that arise as solid or liquid condensates in the condenser. A bypass gas (for example nitrogen) can be applied as a cleaning gas to transport the carbon phase from the metal bath surface.

[0031] According to an illustrative example, the resulting solid fraction is separated from the product gas stream via a hot gas filter. Further processing of the produced gas includes process steps such as quenching to condense certain hydrocarbons, compression, and separation of the residual gas from the hydrogen via a membrane.

[0032] According to further embodiments, the (metal) catalyst comprises at least one of the group consisting of Cu, Ni, Sn, Al, Ga, In, Bi, Fe, Co, Si, C, Pt, Rh, Ir, Pd, Au, Ag, or mixtures thereof. Industrially relevant materials can therefore be applied directly as catalytic bodies in liquid metal baths. The pyrolysis reaction is based on the thermal decomposition of the catalytically active pure metals listed above, or of the introduced (gaseous) components in a multi-substance system, which may contain binary, ternary and quaternary combinations of metals. The metals may be present, for example, in elemental form, oxides, sulfides or carbides. The use of combinations of the mentioned metals may allow optimal catalytic treatment effects.

[0033] According to further embodiments, the (metal) catalyst comprises or consists of one of a binary, ternary, or quaternary system. According to further embodiments, the metal catalyst comprises at least one catalytically active metal within at least one base metal (e.g., at least one of tin, copper, and iron). In another example, the metal catalyst comprises only catalytically active metals.

[0034] According to a further embodiment, the (metal) catalyst is not substantially deactivated or consumed during the pyrolysis reaction.

[0035] According to further embodiments, the reactor is configured as a bubble column reactor or as a hearth furnace. Industrially relevant and established technologies can therefore be directly applied to the described measures. Simple adaptation of existing systems, e.g. metallurgical plants, can be made possible. The associated processes can be carried out in an induction heating unit, which can be designed as a bubble column reactor or as a hearth furnace. These units can be operated independently or (at least partially) in series.

[0036] According to further embodiments, the hydrocarbon comprises (or consists of) gases including or consisting of at least one of methane, biogas, natural gas, pyrolysis gas, carbonization gas from scrap pyrolysis, landfill gas, etc. Thus, multiple hydrocarbon gases can be introduced directly into the pyrolysis process.

[0037] According to further embodiments, the hydrocarbons comprise or consist of liquids including or consisting of at least one of the following: crude oil, mineral oil, pyrolysis oil, bio-oil, liquid industrial waste hydrocarbons. Thus, multiple liquid hydrocarbons (even waste materials) can be introduced into the pyrolysis process.

[0038] According to further embodiments, the hydrocarbons comprise or consist of solids including or consisting of at least one of the following: plastic waste, industrial residues, organically contaminated metal scrap. Thus, multiple solid hydrocarbons (as well as waste materials) can be introduced into the pyrolysis process.

[0039] According to a further embodiment, the method further comprises: i) feeding the hydrocarbon containing solids and / or liquids to a pre-pyrolysis device; ii) carrying out a pre-pyrolysis (carbonization) reaction in the pre-pyrolysis device, thereby obtaining a (pre-pyrolyzed) gas-containing hydrocarbon; and iii) feeding the (pre-pyrolyzed) gas-containing hydrocarbon (produced in the pre-pyrolysis device) to a pre-heating device and / or a reaction device. This may provide the advantage that the solid / liquid hydrocarbons may be fed to the described pyrolysis in a particularly efficient manner. Pre-pyrolysis may produce gaseous hydrocarbons, which may be introduced into the pre-heating device / reaction device together with or instead of the usual gaseous hydrocarbons. The pre-pyrolysis device may be configured as a pre-heating device that generates a particularly high temperature (and pressure) to enable the pre-pyrolysis reaction. In another example, the pre-pyrolysis device may contain a (metal) catalyst body, in particular in a further liquid metal bath (e.g. a two-stage process, in particular where the pre-pyrolysis device is configured as a further reaction device).

[0040] According to a further embodiment, the method further comprises a step of feeding the hydrocarbons having solids, in particular particles, and / or liquids, through a feeding device to the liquid metal bath of the reaction device (or to the preliminary pyrolysis device, or to the preheating device). In particular, this is carried out by at least one of mechanical conveying, pneumatic conveying, and gravity conveying. This may provide the advantage that the solid / liquid hydrocarbons may be fed to the described pyrolysis in a particularly efficient manner. In addition to or instead of the preliminary pyrolysis, the hydrocarbons may be introduced directly into the metal bath. The feeding device may, for example, comprise a hopper and / or an extruder, which may be particularly suitable when the hydrocarbon solids comprise particles. The hydrocarbons may not be further processed in the feeding device. Nevertheless, the feeding device may also comprise a pretreatment means, for example the feeding device may be combined with a preheating device.

[0041] According to further embodiments, the method is carried out continuously or discontinuously (batchwise), and variations may occur between the continuous and discontinuous operation times, although both modes of operation may offer certain advantages.

[0042] According to a further embodiment, the method further comprises at least partially treating said carbon phase, in particular the solid fraction of said carbon phase, more particularly by at least one of classification, sorting, metallurgical refining, activation.

[0043] According to a further embodiment, the method further comprises adjusting the morphology of the solid fraction of the carbon phase, in particular by at least one of the following: introducing solid carbon particles, changing the alloy, changing the temperature, changing the pressure, changing the residence time of the hydrocarbons in the reactor, changing the coating layer.

[0044] According to a further embodiment, the method is carried out in an industrial metallurgical plant, the method further comprising using excess thermal energy from at least one further unit of said industrial metallurgical plant. This measure may allow a particularly efficient energy management and may be environmentally friendly. In certain instances, known and established industrial metallurgical plants may be adapted to the described method in a simple manner, thereby saving costs and efforts. [Brief description of the drawings]

[0045] The above-defined and further aspects of the invention are apparent from and will be elucidated with reference to the example embodiments described hereinafter.

[0046] [Figure 1] 1 illustrates an apparatus for processing hydrocarbons according to an exemplary embodiment of the present invention.

[0047] [Diagram 2] 3 shows an apparatus for processing hydrocarbons according to a further exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] The illustration in the figures is schematic. In different drawings, similar or identical elements are provided with the same reference signs.

[0049] Before describing the exemplary embodiments in more detail with reference to the figures, some basic considerations will be summarized based on which the exemplary embodiments of the present invention were developed.

[0050] According to an exemplary embodiment, pure metals such as, for example, Cu, Ni, Sn, Al, Ga, In, Bi, Fe, Si, or multi-component systems containing binary, ternary and quaternary combinations of the above elements, as well as their sulfide or carbide compounds, act as catalysts (or heat transfer media for initiating the pyrolysis reaction). These metals can act as heat exchangers and also have a catalytic effect, which promotes pyrolysis with less energy demands. The temperature of the metal bath is, for example, 900°C to 1600°C, and the pressure in the furnace chamber can increase up to 50 bar (5 MPa) in some cases. The introduction of the hydrocarbon containing gas into the molten bath is carried out by one or more units including different methods of gas introduction, such as lances, purge blocks, impellers or porous tubes, as well as a system for gas preheating. The following gases can be introduced into the metal bath reactor: methane, biogas, natural gas, pyrolysis gases or carbide gases from scrap pyrolysis. The bath motion, bubble size, and residence time of the gas within the melt can be influenced, among other things, by the defined placement of the purge unit and the positioning and control of the induction coil.

[0051] FIG. 1 shows an apparatus 100 for processing hydrocarbons 101 according to an exemplary embodiment of the present invention. The hydrocarbons 101 may be provided in this example preferably in gaseous form. In the exemplary example described herein, the hydrocarbons are provided as methane gas. The hydrocarbons 101 are introduced into a preheating device 110 via a compressor. The preheating device 110 includes a preheating vessel 111 defining a preheating chamber 112 in which the hydrocarbons (gas) 101 are preheated. In this example, the preheating device 110 further includes an inductor coil 113 arranged around the preheating chamber 112 and configured to heat the hydrocarbons 101 in the chamber 112. The hydrocarbons may be preheated, for example, to a temperature of 900° C. or lower.

[0052] The preheated hydrocarbons 101 are then transferred to the reactor 120 via an inlet or purge block 121. The reactor 120 is here configured as a bubble column reactor. The reactor 120 includes a reaction vessel 124 that defines a reaction chamber, which is then filled with a liquid metal bath 125. Said bath 125 includes a metal catalyst body for supporting the actual pyrolysis reaction of the preheated hydrocarbons 101 in said bath 125. Similar to the preheating device 110, the reactor 120 includes an inductor coil 123 around the reaction chamber. The coil 123 is configured to provide heat for melting the metal, thereby providing the molten metal liquid bath 125, and establishing a certain desired reaction temperature, for example 1600° C. or lower. Furthermore, the coil 123 can introduce motion into the liquid metal bath 125, thereby promoting the pyrolysis reaction. The reaction apparatus 120 further comprises an agitation / impeller unit 122 which introduces further motion and distribution of the hydrocarbons 101 in the liquid metal bath 125. Furthermore, the agitation / impeller unit 122 comprises in this example a further hydrocarbon (gas) input 101. The preheated hydrocarbons form gas bubbles 126 at the inlet 121 which rise in the liquid metal bath 125. The pyrolysis reaction is carried out in the liquid metal bath 125 substantially in a technical vacuum or at a pressure of 10 bar (1 MPa) or higher (or 10 bar (1 MPa) or lower).

[0053] Furthermore, to avoid losing parts of the liquid metal bath 125, specifically the catalyst body, a coating layer 128 is formed above the liquid metal bath 125. In the example shown, the coating layer 128 comprises a layer of solid carbon 105a from the pyrolysis reaction floating on the surface of the liquid metal bath 125. In addition to the solid carbon floating on the liquid metal bath 125, the pyrolysis reaction produces a hydrogen-rich gas stream. This hydrogen-rich gas stream can partially expel the solid carbon, resulting in a mixture of solid carbon and hydrogen-rich gas phase. The carbon can be part of the gas phase, but it can form a gas-solid mixture with the hydrogen-rich gas phase, which can expel part of the carbon. This can depend on the form and fineness of the carbon.

[0054] Said gas (hydrogen-rich gas stream) is transferred to a filtering device 130 via a gas and carbon discharge 131. The filtering device 130 comprises a hot gas filter 132 configured to filter and send the discharged solid carbon phase 105b to storage. The obtained hydrogen phase 141 is subject to further processing since it contains by-products in addition to hydrogen gas 106. The hydrogen phase 141 to be processed is therefore transferred to a condensing device 140, where it is cooled to a certain temperature in a condensing plate 142. To condense gaseous substances (intermediate products, synthesis products) of the hydrogen phase 141 to be processed, temperatures between +300° C. and −50° C. may be suitable. Furthermore, the condensing device 140 may be configured as a condensing tower, which may allow fractionation of said substances, for example PAK.

[0055] This processing may result in separation 145 of certain components of the hydrogen-rich gas phase as a treated liquid or solid condensate 141. For further gas scrubbing, the treated hydrogen-rich gas phase 141 is compressed (at 151) and fed to a membrane separation device 150. A membrane separation process 152 separates additional by-products 154 and produces the desired pure hydrogen gas 106 (hydrogen-rich phase).

[0056] Figure 2 shows an apparatus 200 for processing hydrocarbons 101 according to a further exemplary embodiment of the present invention. The apparatus 200 is very similar to that described with respect to Figure 1 above. However, while the apparatus 100 of Figure 1 is primarily configured to process gas-containing hydrocarbons 101 (gaseous hydrocarbons), the apparatus 200 of Figure 2 is inter alia configured to also process hydrocarbons containing solids and / or liquids.

[0057] The apparatus 200 comprises a pre-pyrolysis device 160 arranged before the (upstream process of) the pre-heating device 110. The gaseous hydrocarbons 101 are directly introduced into the pre-heating device 110, while the hydrocarbons 103a having solid / liquid (e.g. plastic waste, oil, etc.) contents are fed to the pre-pyrolysis device 160. Therein, a pre-pyrolysis reaction is carried out, resulting in the substantially gaseous pre-pyrolyzed hydrocarbons 103b, therefore also indicated as 101. The obtained hydrocarbons 103b produced in the pre-pyrolysis device 160 are then introduced into the pre-heating device 110 together with the gaseous hydrocarbons 101.

[0058] Additionally or alternatively, the apparatus 200 further comprises a feed device 170 for feeding the hydrocarbons with solids / liquids directly to the liquid metal bath 125 of the reaction device 120. In the illustrated example, the hydrocarbons 104 comprise solids in the form of fine particles, which are fed to a feed extruder 172 through a hopper 171. A siphon 173 is disposed between the side walls of the reaction device 120, so that the extruder 172 can transport the fine particle hydrocarbons 104 directly (by a combination of mechanical and gravity conveyance) to the liquid metal bath 125 through the siphon 173. While the apparatus 100 comprises a pneumatic discharge 131 for gases and carbon between the reaction device 120 and the filtering device 130, the apparatus 200 of FIG. 2 comprises an air mechanical discharge 133 for gases and carbon, where the carbon is continuously discharged by mechanical conveyance.

[0059] It should be noted that the word "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality, and elements described in association with different embodiments may be combined.

[0060] It should also be noted that reference signs in the claims shall not be construed as limiting the scope of the claims.

[0061] The implementation of the invention is not limited to the preferred embodiment shown in the drawings and described above: instead, many variations are possible that use the solutions shown and the principles according to the invention, even in the case of radically different embodiments. Reference sign 100 devices 101 Hydrocarbons 102 Mass flow control equipment 103a Solid / liquid hydrocarbons 103b Pre-pyrolyzed hydrocarbons 104 Hydrocarbons with solid particles 105a Carbonaceous phase, suspended solids 105b Carbon phase, storage solids 106 Hydrogen phase, gaseous 110 Preheating Equipment 111 Preheating container 112 Preheating reaction chamber, preheated hydrocarbon 113 Preheating inductor coil 120 Reaction Equipment 121 Inlet, purge block 122 Mixing or propelling units 123 Reaction inductor coil 124 Reaction vessel 125 Liquid metal bath 126 Bubbles 128 Protective / Coating Layer 130 Filtration equipment 131 Gas and carbon exhaust 132 Hot Gas Filter 133 Discharge section 140 Condensing Equipment 141 Hydrogen phase to be treated 142 Condenser plate 145 Condensate, oil 150 Membrane filtration equipment 151 Gas Cleaning Compressor 152 Membrane separator 154 By-product gas 160 Pre-pyrolysis equipment 170 Supply equipment 171 Hopper 172 Extruder 173 Supply Siphon 200 Further Equipment (Other possible items) (Item 1) A method for treating a hydrocarbon (101), specifically a hydrocarbon gas, comprising: preheating said hydrocarbon (101) in a preheating device (110); feeding the preheated hydrocarbon to a liquid metal bath (125) in a reactor (120), wherein the liquid metal bath (125) has at least one catalyst, specifically a metal catalyst; and carrying out a pyrolysis reaction with said hydrocarbon (101) in said liquid metal bath (125) to obtain a carbon phase and a hydrogen phase. A method for providing the above. (Item 2) heating the liquid metal bath (125) and / or the preheating device (120) by induction (113, 123); Specifically, thereby inducing motion within said liquid metal bath (125). 2. The method of claim 1, further comprising: (Item 3) applying a coating layer (128) above said liquid metal bath (125), in particular comprising at least one of slag, molten oxide, molten salt, and carbon; 3. The method according to claim 1 or 2, further comprising: (Item 4) The step of supplying a hydrocarbon (101) comprises: injecting the hydrocarbon (101) into the reactor (120) by at least one of the group consisting of a lance, a porous tube, a purge block (121), and an impeller (122); 4. The method according to any one of items 1 to 3, further comprising: (Item 5) The pyrolysis reaction is carried out at a temperature of 1600° C. or less, specifically in the range of 600° C. to 1600° C., more specifically in the range of 900° C. to 1400° C., and more specifically in the range of 1000° C. to 1200° C. 5. The method according to any one of items 1 to 4. (Item 6) The preheating step is carried out at a temperature of 900° C. or less. 6. The method according to any one of items 1 to 5. (Item 7) The pyrolysis reaction is carried out in a technical vacuum 7. The method according to any one of items 1 to 6. (Item 8) The pyrolysis reaction is carried out at a pressure of 1 bar (0.1 MPa) or higher, specifically at a pressure of 5 bar (0.5 MPa) or higher, specifically at a pressure of 10 bar (1 MPa) or higher, more specifically at a pressure of 40 bar (4 MPa) or higher, more specifically at a pressure of 50 bar (5 MPa) or lower. 8. The method according to any one of items 1 to 7. (Item 9) further comprising the step of injecting the preheated hydrocarbon (101) as a gas into an inlet (121) of the reactor (120); Here, the preheated hydrocarbon forms bubbles (126) at the inlet (121) that rise within the liquid metal bath (125). 9. The method according to any one of items 1 to 8. (Item 10) at least a portion of the carbon phase is in solid form (105a) and is suspended on the liquid metal bath (125); Discharging the carbon phase (105a, 105b), in particular by at least one of mechanical conveying, pneumatic conveying and gravity conveying. 10. The method of any one of items 1 to 9, further comprising: (Item 11) Separating said carbon phase (105a, 105b) in solid form from a hydrogen-rich gas stream (131), Specifically, separating by a filter (132), specifically at least one of a hot gas filter and a gravity separator. 11. The method of any one of items 1 to 10, further comprising: (Item 12) treating said hydrogen-rich gas stream (132); Specifically, the process includes at least one of filtering, condensing (142), compressing, membrane separation (152), and quenching. 12. The method of claim 11, further comprising: (Item 13) The catalyst comprises at least one of the group consisting of Cu, Ni, Sn, Al, Ga, In, Bi, Fe, Si, Co, C, Pt, Rh, Ir, Pd, Au, Ag, or mixtures thereof. 13. The method according to any one of items 1 to 12. (Item 14) The catalyst comprises or consists of one of a binary, ternary, or quaternary system; Specifically, the metal catalyst comprises at least one catalytically active metal within at least one base metal. 14. The method according to any one of items 1 to 13. (Item 15) The catalyst is not substantially deactivated during the pyrolysis reaction. 15. The method according to any one of items 1 to 14. (Item 16) The reaction apparatus (120) may be configured as a bubble column reactor or as a hearth furnace. 16. The method according to any one of items 1 to 15. (Item 17) The hydrocarbons (101) comprise gases, in particular gases including or consisting of at least one of methane, biogas, natural gas, pyrolysis gas, carbonized gas from scrap pyrolysis, pre-pyrolysis gas, and landfill gas. 17. The method according to any one of items 1 to 16. (Item 18) The hydrocarbons (101) comprise liquids, in particular liquids comprising or consisting of at least one of the following: crude oil, mineral oil, pyrolysis oil, bio-oil, liquid industrial waste hydrocarbons. 18. The method according to any one of items 1 to 17. (Item 19) The hydrocarbon (101) comprises solids, in particular comprising or consisting of at least one of the following: plastic waste, industrial residues, and organically contaminated scrap metal. 19. The method according to any one of items 1 to 18. (Item 20) feeding hydrocarbons (103a) having solids and / or liquids to a pre-pyrolysis apparatus (160); carrying out a pre-pyrolysis reaction in said pre-pyrolysis equipment (160) to obtain pre-pyrolyzed hydrocarbons (103b); and feeding the pre-pyrolyzed hydrocarbons (103b) to the pre-heating device (110) and / or the reaction device (120); 20. The method according to claim 18 or 19, further comprising: (Item 21) Supplying hydrocarbons (103, 104) bearing solids, in particular particles, and / or liquids, through a supply device (170) to the liquid metal bath (125) of the reactor (120), Specifically, the step of feeding by at least one of mechanical conveyance, pneumatic conveyance, and gravity conveyance. The method according to any one of Items 18 to 20, further comprising: (Item 22) The process may be carried out continuously or batchwise. 22. The method according to any one of items 1 to 21. (Item 23) At least partially processing said carbon phase, in particular the solid fraction of said carbon phase, more particularly by at least one of classification, sorting, metallurgical refining, and activation. 23. The method of any one of items 1 to 22, further comprising: (Item 24) adjusting the morphology of the solid fraction of the carbon phase; Specifically, adjusting by at least one of the following: introducing solid carbon particles, changing the alloy, changing the temperature, and changing the pressure. 24. The method of claim 23, further comprising: (Item 25) 25. The method according to any one of items 1 to 24, wherein the method is carried out in an industrial metallurgical plant, using excess thermal energy from at least one further unit of said industrial metallurgical plant. The method further comprises: (Item 26) An apparatus (100) for processing hydrocarbons (101), comprising: a preheating device (110) for preheating the hydrocarbon (101); a reactor (120) coupled to the preheater (110) and configured to carry out a pyrolysis reaction with the preheated hydrocarbon in a liquid metal bath (125) to result in a carbon phase and a hydrogen phase; An apparatus (100) comprising:

Claims

1. A method for treating hydrocarbons (101), in particular hydrocarbon gases, comprising: preheating the hydrocarbon (101) in a preheating device; feeding the preheated hydrocarbon to a liquid metal bath in a reactor, the liquid metal bath having at least one catalyst, particularly a metal catalyst; and carrying out a pyrolysis reaction with said hydrocarbon (101) in said liquid metal bath, resulting in a carbon phase and a hydrogen phase; A method for providing the above.

2. heating the liquid metal bath and / or the preheating device by induction; Specifically, thereby inducing motion within said liquid metal bath. The method of claim 1 further comprising:

3. applying a coating layer above said liquid metal bath, in particular comprising at least one of slag, molten oxide, molten salt, and carbon; The method of claim 1 or 2, further comprising:

4. The step of supplying the hydrocarbon (101) comprises: injecting the hydrocarbon (101) into the reactor by at least one of the group consisting of a lance, a porous tube, a purge block, and an impeller. The method according to claim 1 , further comprising:

5. The pyrolysis reaction is carried out at a temperature of 1600° C. or less, specifically in the range of 600° C. to 1600° C., more specifically in the range of 900° C. to 1400° C., and more specifically in the range of 1000° C. to 1200° C.

5. The method according to any one of claims 1 to 4.

6. The preheating step is carried out at a temperature of 900° C. or less.

6. The method according to any one of claims 1 to 5.

7. The pyrolysis reaction is carried out in a technical vacuum 7. The method according to any one of claims 1 to 6.

8. The pyrolysis reaction is carried out at a pressure of 1 bar (0.1 MPa) or higher, specifically at a pressure of 5 bar (0.5 MPa) or higher, specifically at a pressure of 10 bar (1 MPa) or higher, more specifically at a pressure of 40 bar (4 MPa) or higher, more specifically at a pressure of 50 bar (5 MPa) or lower.

8. The method according to any one of claims 1 to 7.

9. further comprising the step of injecting the preheated hydrocarbon (101) as a gas into an inlet of the reactor, Here, the preheated hydrocarbon forms bubbles at the inlet that rise through the liquid metal bath.

9. The method according to any one of claims 1 to 8.

10. at least a portion of the carbon phase is in solid form and suspended on the liquid metal bath; Discharging the carbon phase, in particular by at least one of mechanical conveying, pneumatic conveying, and gravity conveying. The method of claim 1 , further comprising:

11. separating said carbon phase in solid form from the hydrogen-rich gas stream; Specifically, separating by at least one of a filter, specifically a hot gas filter, and a gravity separator. The method of claim 1 , further comprising:

12. treating said hydrogen-rich gas stream; Specifically, the process includes at least one of filtering, condensing, compressing, membrane separation, and quenching. The method of claim 11 further comprising:

13. The catalyst comprises at least one of the group consisting of Cu, Ni, Sn, Al, Ga, In, Bi, Fe, Si, Co, C, Pt, Rh, Ir, Pd, Au, Ag, or mixtures thereof.

13. The method according to any one of claims 1 to 12.

14. The catalyst comprises or consists of one of a binary, ternary, or quaternary system; Specifically, the metal catalyst comprises at least one catalytically active metal within at least one base metal.

14. The method according to any one of claims 1 to 13.

15. The catalyst is not substantially deactivated during the pyrolysis reaction.

15. The method according to any one of claims 1 to 14.

16. The reactor is configured as a bubble column reactor or as a hearth furnace.

16. The method according to any one of claims 1 to 15.

17. The hydrocarbons (101) comprise gases, in particular gases including or consisting of at least one of methane, biogas, natural gas, pyrolysis gas, carbonization gas from scrap pyrolysis, pre-pyrolysis gas, landfill gas.

17. The method according to any one of claims 1 to 16.

18. The hydrocarbons (101) comprise liquids, in particular comprising or consisting of at least one of the following: crude oil, mineral oil, pyrolysis oil, bio-oil, liquid industrial waste hydrocarbons.

18. The method according to any one of claims 1 to 17.

19. The hydrocarbons (101) comprise solids, in particular solids comprising or consisting of at least one of the following: plastic waste, industrial residues, organically contaminated scrap metal.

19. The method according to any one of claims 1 to 18.

20. feeding hydrocarbons (103a) having solids and / or liquids to a pre-pyrolysis device; carrying out a pre-pyrolysis reaction in said pre-pyrolysis equipment, thereby obtaining pre-pyrolyzed hydrocarbons (103b); and feeding the pre-pyrolyzed hydrocarbons (103b) to the pre-heating device and / or the reaction device; 20. The method of claim 18 or 19, further comprising:

21. Supplying a hydrocarbon (103, 104) having solids, in particular particles, and / or liquids, through a supply device to the liquid metal bath of the reactor, Specifically, the step of feeding by at least one of mechanical conveyance, pneumatic conveyance, and gravity conveyance. The method of any one of claims 18 to 20, further comprising:

22. The process may be carried out continuously or batchwise.

22. The method of any one of claims 1 to 21.

23. At least partially processing said carbon phase, in particular the solid fraction of said carbon phase, more particularly by at least one of classification, sorting, metallurgical refining, and activation.

23. The method of any one of claims 1 to 22, further comprising:

24. adjusting the morphology of the solid fraction of the carbon phase; Specifically, adjusting by at least one of the following: introducing solid carbon particles, changing the alloy, changing the temperature, and changing the pressure.

24. The method of claim 23, further comprising:

25. 25. The method according to any one of claims 1 to 24, wherein the method is carried out in an industrial metallurgical plant, using excess thermal energy from at least one further unit of said industrial metallurgical plant. The method further comprises:

26. An apparatus for processing a hydrocarbon (101), comprising: a preheating device for preheating the hydrocarbon (101); a reaction device coupled to the preheating device and configured to carry out a pyrolysis reaction with the preheated hydrocarbon in a liquid metal bath to result in a carbon phase and a hydrogen phase; An apparatus comprising:

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