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

Abstract

The present invention relates to a process and system for producing clean hydrogen gas from a gaseous biomass source such as methane gas using pyrolysis and a catalyst gas such as xenon in a plasma-driven pyrolysis system having an integrated carbon removal step. More specifically, the pyrolysis step is carried out within the plasma decomposition system, resulting in the release of hydrogen and catalyst gas, which are captured by a cooling pressure control system processing system using the transition boiling point (liquefaction) of xenon, while carbon byproducts are removed. An advantage of the above method and system is that the catalyst gas xenon can be filtered during cooling and recycled as a primary catalyst for continuous reuse.

Description

Technical Field

[0001] Cross - reference to related applications This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 453,292, filed Mar. 20, 2024, the entire content of which is hereby incorporated by reference in its entirety.

[0002] Figures selected for publication Figure 1

[0003] Field of the Invention The present invention relates to a method for producing clean hydrogen gas from a liquefied or gaseous biomass source. More specifically, the present invention relates to a method and system for producing clean hydrogen gas using plasma - driven pyrolysis and xenon gas as a catalyst.

Background Art

[0004] Description of related technology This section of the specification provides context for, and / or introduces information about, technologies that may be related to the subject matter described and / or claimed herein. Background information is provided to facilitate a better understanding of various aspects of the present invention. This is a discussion of “related” technologies. That such technologies are related does not in any way imply that they are also “prior” art. Related technologies may or may not be prior art. The discussion in this section of the specification should be read in this light and should not be construed as an admission of prior art.

[0005] Fossil fuels (liquid, solid, and gaseous) are common in both industrial and transportation sectors, and unfortunately have the effect of releasing multiple carbon species into the atmosphere during processing. At the same time, fossil fuels and petroleum are abundant, reasonably inexpensive, and remain essential precursors for many fields of business and industry, and will continue to be so for some time to come. Currently, the increasing use of electric-powered transport vehicles (electric cars, buses, scooters, trams, and aircraft, etc.) is being emphasized to mitigate the gaseous release of carbon and the adverse effects of carbon-containing gases on the atmosphere. Unfortunately, challenges remain, including the inherent dangers and high costs of handling high-pressure / low-temperature hydrogen and oxygen gas sources. The use of fuel cell technology, including the reaction of hydrogen and oxygen gases in vehicles, is in its early stages, and only aviation, aerospace, and high-value transport can utilize such fuel cells. A further challenge in the fuel cell field is the strong detrimental effects of impurities on fuel cell components.

[0006] One method for separating hydrogen gas from fossil fuels is the Kraener process, which uses an endothermic reaction and a plasma burner to produce carbon black (carbon) and hydrogen gas (and other biogas) in a pyrolysis process, resulting in carbon particles and hydrogen (and other biogas) in an aerosol. The carbon forms nanocone deposits and tar on the surface, and no greenhouse gases are released. This process is inherently inefficient, resulting in considerable losses and non-conversion.

[0007] Other forms of carbon chemical nucleation or deposition systems are known from so-called chemical vapor deposition (CVD) or plasma chemical vapor deposition (PECVD) techniques, in which polycrystalline diamond films or carbon compositions (including graphene) are grown from hydrocarbon feedstock in a reactor. These processes are inherently inefficient and generally require the use of gas additions, resulting in vapor errors, improper deposition, and associated quality losses in the process.

[0008] Noble gases were considered chemically inert for many years. Xenon, a noble gas, has the most extensive chemistry in Group 18 of the periodic table, with many oxidation states. Unfortunately, as one might expect, xenon compounds are inadequate oxidizing agents for many compounds, making it difficult to work with them. Therefore, currently known xenon chemistry often involves fluorides and oxofluorides due to strong reactions that impose other disadvantages when achieving results requiring ion donors. Xenon is also used in anesthetic closed-rebreathing circuits, but unfortunately, this requires complex CO2 / Xe or N2 / Xe molecular sieve membranes.

[0009] Therefore, the need for an improved process that addresses one or more of the above challenges has been proposed. [Overview of the project]

[0010] This disclosure relates to a process and system for producing clean hydrogen gas from a gaseous or liquid-to-gas gaseous biomass source such as methane gas, using pyrolysis and xenon as a catalyst, in a plasma-driven pyrolysis system having an optionally integrated carbon removal step. More specifically, the pyrolysis step is carried out in a plasma decomposition system, resulting in the release of hydrogen and catalyst gas, which are captured by a cooling pressure-controlled processing system using the liquid point of xenon, while carbon byproducts and hydrogen are removed. An advantage of the above method and system is that the catalyst gas xenon can be filtered during cooling and recycled as a primary catalyst for continuous reuse.

[0011] In another alternative and adaptable embodiment of the present invention, processes, methods, and systems are provided for reducing the costs associated with hydrogen separation from alkane gas.

[0012] In another alternative and adaptable embodiment of the present invention, a process is provided for using a plasma-driven pyrolysis system to produce hydrogen from an alkane gas using a noble gas as a catalyst.

[0013] According to another alternative and adaptable embodiment, a process is provided for producing purified hydrogen, carbon, and xenon for use in downstream fuel cell technology that utilizes a gaseous biomass source to generate electricity together with pure water as a byproduct using pure hydrogen and oxygen.

[0014] According to another alternative and adaptable embodiment, a process is provided for producing purified hydrogen for use in vehicle transport and, alternatively, in personal vehicle transport, using a gaseous biomass source (or liquid-to-gas sources such as liquefied methane or other alkane gases). Carbon and xenon are reusable.

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

[0016] According to another alternative and adaptable embodiment of the present invention, a system (and means thereof) for recycling and reusing xenon gas for further use is provided by a simple cooling / liquefaction process that utilizes the liquid point of xenon (-108.1 degrees Celsius (-108.1°C) / -162.6 degrees Fahrenheit (-162.6°F)) (or as otherwise known in the art).

[0017] According to another alternative and adaptable embodiment of the present invention, a process, method, and system are provided that provides pure hydrogen for use in a fuel cell, thereby producing electricity and pure water as another by-product.

[0018] According to another alternative and adaptable embodiment of the present invention, a method for producing hydrogen gas using a catalyst gas, The steps include providing an alkane supply tank for storing alkane gas and for releasing alkane gas into a gas mixing system, The step of providing a catalyst supply tank for storing catalyst gas and for releasing catalyst gas into a gas mixing system, The steps include operating a gas mixing system to receive alkane gas and catalyst gas as a gas mixture, The steps include maintaining the operational mixing temperature and mixing pressure of the gas mixture within the gas mixing system, The steps include providing a gas mixture from a gas mixing system to a pump system, The pump system receives a gas mixture and maintains the operational pump pressure. The steps include operating a plasma torch system using a gas mixture as a carrier gas from a pump system, and generating plasma from the plasma torch system, A step of providing a pyrolysis reactor that receives plasma from a plasma torch system and operates at pyrolysis reactor temperature and pressure, wherein the plasma torch system and the pyrolysis reactor decompose an alkane gas with a catalytic gas to form a carbon-catalyst gas and a hydrogen-catalyst gas. A step of cooling a carbon-catalyst gas and a hydrogen-catalyst gas in a pyrolysis reactor to separate the carbon from the catalyst gas and separate the catalyst gas from the hydrogen, wherein the pyrolysis reactor includes a carbon sequester system for sealing the carbon during cooling. The steps include providing a gas separator module for separating hydrogen gas and catalyst gas, The step of providing a catalyst gas receiver system that receives catalyst gas from a gas separator module and returns the catalyst gas in situ to a catalyst supply tank, The steps include providing a hydrogen gas receiver that receives hydrogen gas from a gas separator module and stores the hydrogen gas, A method including this is provided.

[0019] According to another alternative and adaptable embodiment of the present invention, a method is provided in which the catalyst gas is a noble gas.

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

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

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

[0023] According to another alternative and adaptable embodiment of the present invention, a method is provided that further includes the step of operating the plasma torch system, which includes the step of providing a power control system and a cooling and safety system in the operation control of the plasma torch system.

[0024] According to another alternative and adaptable embodiment of the present invention, a method further includes the step of providing a gas condensation system for the catalyst gas receiver system, wherein the step of returning in situ to the catalyst supply tank includes returning the condensed catalyst gas to the catalyst supply tank.

[0025] According to another alternative and adaptable embodiment of the present invention, the catalyst gas is xenon, the alkane gas is methane, and the method further includes the step of providing a gas condensation system for the catalyst gas receiver system. The step of returning in situ to the catalyst supply tank includes returning the condensed catalyst gas to the catalyst supply tank. The step of cooling the carbon-catalyst gas and the hydrogen-catalyst gas in the pyrolysis reactor includes the step of controlling the temperature and pressure in the pyrolysis reactor and further includes the step of providing a heat exchange system having a pressure and temperature control module and at least one cooling element.

[0026] According to another alternative and adaptable embodiment of the present invention, a system for producing hydrogen gas using a catalyst gas, An alkane supply tank that stores alkane gas and releases alkane gas into a gas mixing system, A catalyst supply tank for storing catalyst gas and releasing catalyst gas to a gas mixing system, wherein the gas mixing system receives alkane gas and catalyst gas as a gas mixture and maintains the operating mixing temperature and mixing pressure of the gas mixture within the gas mixing system. A pump system that receives the gas mixture from the gas mixing system and maintains the operating pressure, A plasma torch system, which receives a gas mixture as a carrier gas from a pump system and generates plasma from the plasma torch system, A pyrolysis reactor that receives plasma from a plasma torch system and operates at pyrolysis reactor temperature and pressure, wherein the plasma torch system and the pyrolysis reactor decompose an alkane gas with a catalytic gas to form a carbon-catalyst gas and a hydrogen-catalyst gas, A heat exchange system that controls the temperature and pressure inside a pyrolysis reactor according to a pressure and temperature control module, wherein the pyrolysis reactor separates carbon from catalyst gas and separates catalyst gas from hydrogen, and the heat exchange system A carbon sealing system in a pyrolysis reactor that seals carbon during cooling, A gas separator module that separates hydrogen gas and catalyst gas, A catalyst gas receiver system that receives catalyst gas from a gas separator module and returns the catalyst gas to the catalyst supply tank in situ, A hydrogen gas receiver receives hydrogen gas from the gas separator module and stores the hydrogen gas, A system equipped with the above features is provided.

[0027] According to another alternative and adaptable embodiment of the present invention, the catalyst gas is a noble gas, and the alkane gas is one of methane, ethane, propane, and butane. A gas condensation system within a catalytic gas receiver system, in which the condensed noble gas is returned in situ to the catalyst supply tank, is a gas condensation system that returns the condensed noble gas to the catalyst supply tank. A heat exchange system having a pressure and temperature control module and at least one cooling element, which controls the temperature and pressure inside the pyrolysis reactor. A system that further includes this is provided.

[0028] According to another alternative and adaptable embodiment of the present invention, a system is provided in which the noble gas is xenon and the alkane gas is methane.

[0029] According to another alternative and adaptable embodiment of the present invention, an apparatus for producing hydrogen gas using a catalyst gas, An alkane supply tank that stores alkane gas and releases alkane gas into a gas mixing system, A catalyst supply tank for storing catalyst gas and releasing catalyst gas to a gas mixing system, wherein the gas mixing system receives alkane gas and catalyst gas as a gas mixture and maintains the operating mixing temperature and mixing pressure of the gas mixture within the gas mixing system. A pump system that receives the gas mixture from the gas mixing system and maintains the operating pressure, A plasma torch system, which receives a gas mixture as a carrier gas from a pump system and generates plasma from the plasma torch system, A pyrolysis reactor that receives plasma from a plasma torch system and operates at pyrolysis reactor temperature and pressure, wherein the plasma torch system and the pyrolysis reactor decompose an alkane gas with a catalytic gas to form a carbon-catalyst gas and a hydrogen-catalyst gas, A heat exchange system that controls the temperature and pressure inside a pyrolysis reactor according to a pressure and temperature control module, wherein the pyrolysis reactor separates carbon from catalyst gas and separates catalyst gas from hydrogen, and the heat exchange system A carbon sealing system in a pyrolysis reactor that seals carbon during cooling, A gas separator module that separates hydrogen gas and catalyst gas, A catalyst gas receiver system that receives catalyst gas from a gas separator module and returns the catalyst gas to the catalyst supply tank in situ, A hydrogen gas receiver receives hydrogen gas from the gas separator module and stores the hydrogen gas, A device is provided that includes the following.

[0030] According to another alternative and adaptable embodiment of the present invention, the catalyst gas is a noble gas, and the alkane gas is one of methane, ethane, propane, and butane. A gas condensation system within a catalytic gas receiver system, in which the condensed noble gas is returned in situ to the catalyst supply tank, is a gas condensation system that returns the condensed noble gas to the catalyst supply tank. A heat exchange system having a pressure and temperature control module and at least one cooling element, which controls the temperature and pressure inside the pyrolysis reactor. A device further equipped with the following is provided.

[0031] According to another alternative and adaptable embodiment of the present invention, an apparatus is provided in which the noble gas is xenon and the alkane gas is methane.

[0032] According to another alternative and adaptable embodiment of the present invention, a method for producing hydrogen by methane gas pyrolysis using xenon gas as a catalyst is provided, comprising the following steps or selected from the following steps: (1) A step of providing a mixing chamber for mixing alkane gas and xenon gas in a predetermined proportion at a suitable pressure and temperature. (2) Passing the mixed gas through a DC plasma torch at a suitable heat to cause thermal decomposition and separation of the alkane gas (for example, the plasma temperature varies depending on the gas composition and is not limited herein, for example, it is known that temperatures of up to 10,000 to 15,000°F or higher / or approximately 5,000 to 10,000°C or higher can occur in the plasma (such temperatures are not limited in this disclosure)), (3) A step of thermally decomposing an alkane using xenon to form short-lived precursor products of XeH and XeC, (4) Cooling the gas to release hydrogen (H2) and xenon (Xe) from XeH, (5) Cooling to release xenon gas (Xe) and carbon (C) from XeC, and accumulating carbon (C) as a solid carbon byproduct. Optionally, (5a) a step of filtering and separating hydrogen gas molecules for use in subsequent processing (including fuel cells), or (5b) a step of filtering and separating xenon gas by cooling it, condensing the xenon into a liquid, and recirculating it to a primary xenon supply for a mixing chamber.

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

[0034] The above description provides a basic understanding of some aspects of the present invention, and below is a simplified summary of the claimed invention. This summary is not an exhaustive overview of the invention. It is not intended to identify the main or important elements of the invention or to define its scope. Its sole purpose is to present some concepts in a simplified form as a prelude to a more detailed explanation that will follow. [Brief explanation of the drawing]

[0035] [Figure 1] Figure 1 is a pictogram flow chart of the system according to the present invention.

[0036] [Figure 2] Figure 2 is a detailed process flow diagram of one alternative embodiment of the present invention. [Modes for carrying out the invention]

[0037] While the disclosed subject matter is subject to various modifications and alternative forms, the drawings illustrate specific embodiments described in detail as examples. However, it should be understood that the description of specific embodiments herein is not intended to limit the claims to the specific forms disclosed, but rather to encompass all modifications, equivalents, and alternatives that fall within the spirit and scope of the appended claims.

[0038] Embodiments of the present invention are referred to in detail here. Wherever possible, the same or similar reference numerals are used in the drawings and description to refer to the same or similar parts or steps. The drawings are simplified and not to exact scale. The word “couple” and similar terms do not necessarily indicate a direct and immediate connection, but also include connections via intermediate elements or devices. For convenience and clarity only, terms relating to direction (e.g., up / down) or motion (e.g., forward / backward) may be used in reference to the drawings. These and similar directional terms should not be construed as limiting the scope in any way. It will also be understood that other embodiments may be utilized without departing from the scope of the present invention, that the detailed description should not be construed as limiting, and that elements may be arranged differently or described as described in the appended claims without requiring the requirements described in the specification.

[0039] Various operations can be described sequentially as multiple separate operations so as to be helpful in understanding embodiments of the present invention; however, the order of the description should not be interpreted as indicating that these operations are order-dependent.

[0040] Referring here to Figure 1, the schematic flow process 500 of this system is provided for the production of hydrogen by alkane gas pyrolysis using a catalyst gas (xenon gas), with the recovery of carbon, hydrogen gas, and catalyst gas (xenon gas). More specifically, the process provides a system for producing hydrogen gas on demand and continuously by pyrolysis of light carbon alkanes such as methane, ethane, propane, and butane, produced by plasma-driven gas-phase pyrolysis of alkanes, using xenon gas as a catalyst. Unlike other methods, the process includes the removal of solid-phase carbon byproducts by using a solid-phase plasma-induced carbon crystal growth deposition and screening / filtration recovery process. Also, unlike other processes, the catalyst gas (xenon gas) can be purified and recycled in a continuous (in situ) process loop and then reused. As described below, the xenon receiver systems 14, 14A, 14B or the catalyst gas receiver systems 14, 14A, 14B (referred to substituted and collectively as 14 in Figure 2) may optionally include a liquid nitrogen cooling system (liquid N2) for further cooling and liquefying the xenon below its transition temperature and returning it in situ via the process feed / process flow P6, as described herein and below.

[0041] The flow process 500 comprises an alkane supply unit 100 that provides a supply of alkane gas to the mixing system 102 at a suitable pressure and in a suitable form, as will be further described below, and a catalyst supply unit (here, a xenon supply unit 101) similarly provides a supply of catalyst gas (here, xenon gas) to the mixing system 102 at a suitable pressure and in a suitable form. Preferred alkanes are light carbon alkanes such as methane, ethane, propane, and butane, and others, preferably having single-bonded carbon / hydrogen chains, but not limited thereto, and it will be understood that branched alkanes, cycloalkanes, three-group-chain alkanes, and other carbon-hydrogen gases (or liquids that can be converted into gases) are also included, without any limitations other than the reduction in system efficiency due to the relative carbon:hydrogen ratio (e.g., methane as CH4 has the highest such ratio). The mixing system 102 safely supplies the suitably mixed alkane / catalyst gas (xenon gas) to the plasma system 103 (e.g., a DC plasma jet system) at a suitable pressure. The plasma system 103 is sealed (free from unintended external gases) and is suitably cooled to allow it to operate continuously at a plasma temperature suitable for the alkane-xenon system (which can exceed 5,000 to 15,000°C depending on the gas composition involved). As described herein, the plasma system 103 (having a DC plasma jet) operates at a suitable temperature based on the input carrier gas (the gas supplied to the plasma jet 103) (an alkane gas including methane and xenon), without departing from the scope of the invention, and therefore there are no limitations on a specific temperature. The plasma jet (not shown, but located within the plasma system 103) receives a mixed gas under pressure in an energy-supplied manner, provides a plasma jet with the mixed gas, and uses a catalyst gas (preferably xenon as a catalyst) to thermally decompose and decompose the alkane gas (e.g., methane) to form XeH and XeC (from CH4 (or other alkanes) and Xe) as the resulting products, which are received in a temperature and pressure-controlled pyrolysis reactor 104.

[0042] As further shown in Figure 1, the product gases (XeH and XeC) present in the pyrolysis reactor 104 are temperature and pressure regulated and released during the transition via the following associated recovery systems: (i) carbon recovery step 107 (from XeC to Xe and C) as carbon deposition (e.g., onto one or more carbon nucleating plates on which carbon atoms are added as seed sites / crystals) which can be periodically recovered from the pyrolysis reactor 104 during washing in waste step 108; and (ii) xenon recovery step 105 and hydrogen recovery step 106 (from XeH to Xe and H) as gaseous products removed from the pyrolysis reactor 104 by cooling condensation and pressure condensation along the reactor 104 and linked to recovery steps 105, 106 and 107. For example, there is a temperature gradient along the pyrolysis reactor 104 (from the high-temperature plasma side to the relatively low-temperature recovery side), which aids in separation and recovery. During normal cooling and pressure adjustment, carbon is separated (carbon recovery step 107) leaving gaseous components XeH and Xe. In the xenon recovery step 105, a liquid nitrogen (N2) temperature control jacket may be included (for example). Since the liquefaction temperature of xenon is relatively "warm" (-108.1°C / -162.6°F) compared to the liquefaction temperature of hydrogen (-253°C / -423°F) under cooling and pressure adjustment, liquefied xenon (Xe) readily breaks hydrogen bonds through the respective xenon recovery step 105 and the respective hydrogen recovery step 106, releasing scavengable hydrogen gas (H2).

[0043] Throughout this specification, all temperatures (regardless of the scale of plasma (F / C) or various liquid temperatures (F / C)) are relative and not absolute, and are generally known to those skilled in the art. Therefore, by reviewing and understanding this disclosure, any modifications will be readily understood, and it will be understood that the invention and claims are fully disclosed and supported.

[0044] As will be understood by those skilled in the art who recognize and fully understand the full scope of the present invention, the recovered xenon (in step 105) may be returned to the xenon supply unit 101 for reuse in a continuous in-situ recovery step (e.g., during the process), providing a continuous hydrogen production method operating through a flow process 500 and a hydrogen production system 200, as will be further described in combination below.

[0045] As long as the flow process 500 and system 200 continuously maintain / supply alkane gas (preferably methane via alkane supply unit 100) to the mixing system 102, plasma system 104 and pyrolysis reactor 104 for pyrolysis using xenon (provided via xenon supply unit 101 and xenon recovery unit 105), it will be further and additionally understood by those skilled in the art who recognize and fully understand the full scope of the present invention that the provided process, method and system provide clean hydrogen gas. Thus, it will be understood that the system provides continuous in situ gas conditioning of the alkane supply unit 100.

[0046] Referring further to Figure 2, a more detailed hydrogen production system 200 according to the present invention is provided, generally comprising an alkane tank 1 (preferably methane, but may be any alkane) having an access and pressure regulation control device 1A and a mixed discharge and pressure monitoring control 1B (and may also include a liquid-to-gas conversion system for conveniently storing liquefied alkanes (including methane) before conversion to gas for further processing). A catalyst tank 2 (here, optionally, and preferably, a xenon tank 2) comprises an access and pressure regulation control device 2A and a mixed discharge and pressure monitor 2B. Alkane tank 1 and xenon tank 2 together feed, via a first process feed P1, to a mixing manifold system and a pressure control module 3 for a mixing system 4 (also called a gas mixing system 4). The mixing system 4 operates in coordination with and is linked to the access, pressure, and temperature controller 4A, and further includes a temperature and pressure maintaining system 4B that maintains a suitable internal temperature and internal pressure for the mixed gas from the alkane tank 1 (methane tank 1) and the catalyst (xenon) tank 2. It will be further understood that the access, pressure, and temperature controller 4A monitors and maintains a suitable mixing ratio / blend of the gases in the mixing system 4 for downstream use.

[0047] As a non-limiting example, the mixed discharge and pressure monitors 1B, 2B, and the access, pressure, and temperature controller 4A, in combination, maintain a suitable pyrolysis gas mixture at a suitable pressure / temperature for further processing. In the case of pyrolysis (using methane, e.g., CH4), it will be understood that any number of xenon (Xe) atoms may be present depending on their respective atomic states. For example, if five xenon atoms are used for a complete conversion (CH4 + 5Xe to XeC + 4XeH) as described below herein, or if xenon + 4 (or other in another state) is used, atomic configurations within the scope of the present invention may exist. The mixing system 4 (for mixing and pressure control) is provided with an access port (not shown) for suitable testing and inspection, as will be understood in the art.

[0048] Pump system 5 receives a mixed gas from mixing system 4 in process feed P2. Pump system 5 includes a pump 5B and a pressurization, temperature and release control module 5A having suitable valves, backflow preventers and associated monitoring systems, and supplies the prepared process feed P3 (e.g., carrier gas) to the plasma torch system 7. Plasma torch system 7 includes a suitable power controller system and module 7A for energizing the mixed gas in process feed P3, and associated cooling and safety systems 7B for maintaining continuous and safe operation of the plasma torch system 7 at a suitable plasma temperature using a suitable plasma arc. It will be understood that the mixed gas in process feed P3 serves as the carrier or working gas for the plasma torch system 7 within a sealed system, so that the plasma torch system 7 can operate continuously without oxygen or other gases being supplied.

[0049] The pyrolysis reactor chamber 9 is gas-sealed to the plasma torch system 7 and receives a plasma jet from the plasma torch system 7, and the resulting pyrolysis (Xe + CH4 to XeC and XeH) yields relevant ratios depending on the alkane feed, catalyst feed, and mixing system 4 (also called the gas mixing system 4 or gas mixer 4). A pressure and temperature control module 10 monitors the reactor chamber 9 and controls the heat exchange system 10A, and any suitable form of cooling element 10B, 10B is coupled to a portion of the reactor chamber 9 to maintain the desired combination of temperature and pressure. The pressure and temperature control module 10 can provide a temperature gradient along the heat exchange system 10A downstream from a relatively high-temperature region adjacent to the plasma torch system 7 to a relatively low-temperature region adjacent to the carbon sealing system 12 (see the "temperature arrow graphic" in Figure 2 within the reactor chamber 9), and it will be understood that an associated cryogenic separator 11 having a cooling jacket module 11A is provided at the end of the reactor chamber 9.

[0050] The carbon sealing system 12 is provided within the reactor chamber 9 in any preferred form, but as shown, it may be a series of interchangeable carbon chemical vapor nucleation deposition plates (e.g., titanium, stainless steel, or ceramic (SiC)) in the form of plates or meshes, or in the form of a plug having a layer of carbon or CVD diamond on it). The sealing system 12 is provided in the path of the pyrolysis gas flow of XeC and XeH, and as understood, as the temperature gradient within the reaction chamber 9 begins to cool, carbon (C) begins to separate from XeC into C and Xe, which allows for a continuous process of depositing carbon on it and releasing Xe as a gas.

[0051] Adjacent to the end of the reactor chamber 9 is a cryogenic gas separator system 11 provided to receive hydrogen gas (H) (just separated from XeH) and Xe (and any remaining XeH), with a cooling jacket and module 11A (such as an electrostatic cooler or condensing gas cooler system) provided therewith, in communication with a heat exchange system 10A and cooling element 10B, to provide further controlled cooling so that H2 is formed and Xe and H2 are in gaseous form and reach a manifold and gas separator 13 that provides further low-pressure transition to separate H2 and Xe by any suitable means such as temperature / pressure control, electrostatic or fluid cooling, or other means. As a result, process feeds P4 for xenon and P5 for hydrogen (H2) are obtained.

[0052] Process feed P4 delivers xenon to a xenon receiver system 14 having a xenon pressurized liquefaction system 14A (e.g., a gas condenser system (and optionally a gas separator system)), the xenon receiver system 14 supplies a discharge and pressure monitoring valve system 14B that provides process feed P6, returning the purified xenon (gaseous, liquefied, or both) to the xenon tank 2 (also called catalyst tank 2) via an access and pressure regulating module 2A (thereby providing a continuous in situ / in-process system for returning the catalyst gas (xenon) to the catalyst tank 2). It will be understood that the compression and liquid transition processes of xenon perform further functions in purifying the gas / liquid for further use in the proposed system 200 / flow 500. Similarly, the manifold and gas separator module 13 provides a hydrogen flow via process flow P5 to a hydrogen receiver system 15, which includes temperature and pressure regulation and operations for safe storage, before further transport via process flow P7 for later hydrogen use (the hydrogen receiver system 15 may further include a hydrogen gas separator system within the scope of this disclosure). Furthermore, molecular sieves and other devices known in the field of gas separation may be included herein without departing from the scope and spirit of the invention. For example, for downstream convenience, an additional cooling element (using a liquid gas such as nitrogen (N2)) may be used to condense the catalyst gas (here xenon) (from gas to liquid).

[0053] A person skilled in the art who has studied and understood this disclosure will understand that the provided System 200 / Flow 500 may include additional safety and pressure control systems (not shown), sensors and monitors (not shown), and control systems for operation (not shown) without departing from the scope and spirit of the invention. For example, gas and pressure control systems include (optionally) pressure relief valves, one-way flow dividers, automatic aeration and release systems, and other safety features known to a person skilled in the art of such system design without departing from the scope of this specification.

[0054] As also shown in Figure 2, an exemplary fuel cell system 20 in an exemplary vehicle (represented exemplary by brackets 25) is connected in process to receive a hydrogen flow P7 and an external oxygen supply 21 and to produce direct current (DC) power 22 and purified water 23, as would be understood by those skilled in the art in the field of fuel cell operation. Such a vehicle 25 may further include associated systems and a crash protection system for commercial operation. The exemplary vehicle 25 may be any form of transport vehicle known as described above in this disclosure without departing from the scope and spirit of this disclosure.

[0055] As described above in this specification, the system 200 and process 500 efficiently generate up to 100% of the hydrogen (H2) from the alkane feed 100 that can be used in downstream reactions.

[0056] As will be further understood by those skilled in the art who have studied and understood this disclosure, the method for producing clean hydrogen gas is preferably intended for use in transport vehicles having a compressed alkane tank (e.g., a methane tank, or liquefied methane (liquid point -82.1 degrees Celsius (-82.1°C)) at standard pressure, although liquefaction occurs at higher pressures and temperatures, but its applications are adaptable to and not limited to transport vehicles. Similar analysis can be applied to propane or other alkane gases within the scope of the invention. For example, a commercial taxi or bus fleet running on such an alkane gas supply with a catalytic gas supply may, within the scope of the disclosure, continuously store the resulting product to operate such a system and for later use in a fuel cell or other power generation device.

[0057] Although only a few embodiments have been disclosed in detail above, other embodiments are possible and are intended to be incorporated herein. This specification describes specific technical solutions for solving the technical problems explicitly and essentially described in this application. This disclosure describes embodiments, and the claims are intended to encompass any modifications, substitutions, or generalizations of these embodiments that may be foreseeable to those skilled in the art.

[0058] Unless otherwise defined, all terms used herein, including technical and scientific terms, have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. Furthermore, unless otherwise defined, all terms as defined in commonly used dictionaries should not be interpreted excessively. Details are provided below to provide a more complete description of the embodiments. However, it will be obvious to those skilled in the art that embodiments can be carried out without these specific details. In other examples, well-known structures and devices are shown in block diagrams or schematic drawings rather than in detail, to avoid obscuring the embodiments. Also, features of the different embodiments described below may be combined with each other unless otherwise noted. For example, a variation or modification described with respect to one embodiment may be applicable to other embodiments unless otherwise stated.

[0059] Furthermore, equivalent or similar elements, or elements having equivalent or similar functions, are indicated by equivalent or similar reference numerals in the following descriptions. Since identical or functionally equivalent elements are given the same reference numeral in the drawings, repeated descriptions of elements with the same reference numeral may be omitted. Therefore, the descriptions provided for elements with the same or similar reference numerals are interchangeable.

[0060] When an element is referred to as being connected to or joined to another element, it will be understood that it can be directly connected to or joined to the other element, or that an intervening element may exist. In contrast, when an element is referred to as being "directly connected" or "directly joined" to another element, there is no intervening element. Other words used to describe the relationship between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.).

[0061] In this disclosure, expressions containing ordinal numbers such as “first” and “second” may modify various elements. However, such elements are not limited by the above expressions. For example, the above expressions do not limit the order and / or importance of the elements. The above expressions are used solely for the purpose of distinguishing one element from another. For example, the first box and the second box represent different boxes, but they may work together or be interconnected in a way that makes them appear sequential. In further examples, without departing from the scope of this disclosure, the first element may be called the second element, and similarly, the second element may also be called the first element.

[0062] Those skilled in the art who have studied and understood this disclosure will further understand that methods and means and other systems for cooling / pressure control can be provided in a variety of ways without departing from the scope and spirit of the invention. For example, the cooling and / or pressure control systems described may include, but are not limited to, any form of temperature control or cooling, including electrostatic or hydrostatic cooling, pressure fluctuation cooling / heating, and / or refrigeration via one or more suitable (unmixed) thermal transition interfaces or manifolds using other liquefied gases (liquid nitrogen N2 systems that cool the outside of the chamber below the liquid point).

[0063] As a further consequence of the above, those skilled in the art will recognize that various temperature and pressure maintenance systems, regulating controllers, and other operating modules are understood to operate and maintain operating conditions (e.g., desired pressure, temperature, etc., according to specific tank, mixing system, reactor module, or other requirements). Such matters are understood to be various pressures, temperatures, and operating parameters for continuous processes based on the respective gases and liquids used herein.

[0064] As a result of the above, those skilled in the art will recognize the improvements provided in this disclosure, which include, but are not limited to, the use of an in situ plasma-driven gas phase process for the pyrolysis of alkane gases, the use of a recirculating xenon recovery function in the operation of the process, the use of xenon as a catalytic function or operation in the process, and the use of pressure and temperature control of the resulting pyrolysis reactor gas to separate (and liquefy) xenon for recirculation.

[0065] Finally, it is recognized that in situ xenon plasma pyrolysis is used for the production of free hydrogen (H2) instead of some forms of petrochemical reactions or gas pressure cracking.

[0066] Similarly, as those skilled in the art will understand, the use of the phrase “in situ” is understood to refer to an in-process activity or process, such as the plasma-driven gas-phase pyrolysis of alkanes occurring within the path between the feed unit and the reactor that recovers xenon, rather than as a separate external process beyond the system and process. For example, here the pyrolysis reactor is “in situ” because it receives a mixed gas (alkanes, preferably methane and xenon) for a reaction therein that forms a decomposition without any external steps, and the catalyst gas is recovered for reuse.

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

[0068] As used herein, pyrolysis is the thermochemical decomposition of a biomass source (in this case, alkane gases such as methane, ethane, propane, butane, and others (including those having single-bonded carbon and hydrogen atoms)) having hydrogen and carbon in a certain ratio relative to the gas (methane (CH4) has the most favorable ratio) at high temperature in the absence of oxygen and in the presence of a catalyst gas, preferably xenon, but optionally argon or krypton. More specifically, the pyrolysis process is carried out by plasma-driven gas-phase pyrolysis of alkanes in the presence of xenon. Removal of carbon byproducts from the gas phase to the solid phase downstream is by the use of solid-phase plasma-induced carbon crystal growth via screening and filtration processes. A cooling process further separates and purifies the catalyst gas by utilizing the boiling point of the gas catalyst (xenon). This results in gaseous decomposition to gaseous hydrogen and carbon nucleation in a pressure and temperature-controlled chamber, as well as downstream gas-phase pyrolysis and separation.

[0069] Furthermore, the inventors intend that only claims using the phrase “means for” should be interpreted under Section 112 of the U.S. Patent Act. Moreover, limitations from the specification are not intended to be incorporated into any claim unless those limitations are expressly included in the claims.

[0070] Where a particular numerical value is mentioned herein, it should be understood that the value can be increased or decreased by 20%, while remaining within the scope of the teachings of this application, unless any different range is specifically mentioned. Where a particular logical meaning is used, it is intended that the opposite logical meaning is also included.

[0071] While at least one preferred embodiment of the present invention has been described with reference to the accompanying drawings, it will be apparent to those skilled in the art that the present invention is not limited to those exact embodiments, and that various modifications and variations can be made in the system of the present disclosure without departing from the scope or spirit of the invention. Therefore, the present disclosure is intended to encompass such modifications and variations, provided that they fall within the scope of the appended claims and their equivalents.

Claims

1. A method for producing hydrogen gas using a catalytic gas, The steps include providing an alkane supply tank for storing alkane gas and for releasing the alkane gas into a gas mixing system, The steps include providing a catalyst supply tank for storing the catalyst gas and for releasing the catalyst gas into the gas mixing system, The steps include operating the gas mixing system and receiving the alkane gas and the catalyst gas as a gas mixture, The steps include maintaining the operating mixing temperature and mixing pressure of the gas mixture in the gas mixing system, The steps include providing the gas mixture from the gas mixing system to the pump system, The pump system receives the gas mixture and maintains the operating pump pressure, The steps include operating the plasma torch system using the gas mixture as a carrier gas from the pump system and generating plasma from the plasma torch system, A step of providing a pyrolysis reactor that receives the plasma from the plasma torch system and operates at the pyrolysis reactor temperature and pressure, The plasma torch system and the pyrolysis reactor perform the steps of decomposing the alkane gas with the catalyst gas to form a carbon-catalyst gas and a hydrogen-catalyst gas, The steps include cooling the carbon-catalyst gas and the hydrogen-catalyst gas in the pyrolysis reactor, separating the carbon from the catalyst gas, and separating the catalyst gas from the hydrogen, The pyrolysis reactor includes a carbon sealing system for sealing the carbon during cooling, The steps include providing a gas separator module for separating the hydrogen gas and the catalyst gas, The step of providing a catalyst gas receiver system that receives the catalyst gas from the gas separator module and returns the catalyst gas in situ to the catalyst supply tank, The steps include providing a hydrogen gas receiver that receives the hydrogen gas from the gas separator module and stores the hydrogen gas, A method that includes this.

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

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

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

5. The catalyst gas is xenon, The method according to claim 1, wherein the alkane gas is methane.

6. The step of operating the plasma torch system is, The method according to claim 1, further comprising the step of providing a power control system and a cooling and safety system for controlling the operation of the plasma torch system.

7. The method according to claim 1, comprising the step of providing a gas condensation system for the catalyst gas receiver system, wherein the step of returning in situ to the catalyst supply tank further comprises the step of returning the condensed catalyst gas to the catalyst supply tank.

8. The catalyst gas is xenon, The alkane gas is methane, The method described above is The step further includes providing a gas condensation system for the catalyst gas receiver system, wherein the step of returning the condensed catalyst gas to the catalyst supply tank in situ is to return the condensed catalyst gas to the catalyst supply tank. The method according to claim 1, wherein the step of cooling the carbon-catalyst gas and the hydrogen-catalyst gas in the pyrolysis reactor further includes the step of providing a heat exchange system that controls the temperature and pressure in the pyrolysis reactor and has a pressure and temperature control module and at least one cooling element.

9. A system for producing hydrogen gas using a catalytic gas, An alkane supply tank for storing alkane gas and releasing the alkane gas into a gas mixing system, A catalyst supply tank for storing catalyst gas and releasing the catalyst gas to a gas mixing system, wherein the gas mixing system receives the alkane gas and the catalyst gas as a gas mixture and maintains the operating mixing temperature and mixing pressure of the gas mixture within the gas mixing system. A pump system that receives the gas mixture from the gas mixing system and maintains the operating pressure, A plasma torch system comprising: a plasma torch system that receives the gas mixture as a carrier gas from the pump system and generates plasma from the plasma torch system; A pyrolysis reactor that receives the plasma from the plasma torch system and operates at the pyrolysis reactor temperature and pressure, The plasma torch system and the pyrolysis reactor include a pyrolysis reactor which decomposes the alkane gas with the catalyst gas to form a carbon-catalyst gas and a hydrogen-catalyst gas, A heat exchange system that controls the temperature and pressure inside the pyrolysis reactor according to a pressure and temperature control module, The pyrolysis reactor includes a heat exchange system that separates the carbon from the catalyst gas and separates the catalyst gas from the hydrogen. A carbon sealing system in the pyrolysis reactor for sealing the carbon during the cooling process, A gas separator module for separating the hydrogen gas and the catalyst gas, A catalyst gas receiver system that receives the catalyst gas from the gas separator module and returns the catalyst gas in situ to the catalyst supply tank, A hydrogen gas receiver that receives the hydrogen gas from the gas separator module and stores the hydrogen gas, A system equipped with these features.

10. The catalyst gas is a noble gas, The alkane gas is one of methane, ethane, propane, and butane. The aforementioned system A gas condensation system within the catalyst gas receiver system, wherein the condensed noble gas is returned in situ to the catalyst supply tank, and the gas condensation system returns the condensed noble gas to the catalyst supply tank. A heat exchange system having a pressure and temperature control module and at least one cooling element controls the temperature and pressure inside the pyrolysis reactor. The system according to claim 9, further comprising the above.

11. The aforementioned noble gas is xenon, The system according to claim 10, wherein the alkane gas is methane.

12. An apparatus for producing hydrogen gas using a catalytic gas, An alkane supply tank for storing alkane gas and releasing the alkane gas into a gas mixing system, A catalyst supply tank for storing catalyst gas and releasing the catalyst gas to a gas mixing system, wherein the gas mixing system receives the alkane gas and the catalyst gas as a gas mixture and maintains the operating mixing temperature and mixing pressure of the gas mixture within the gas mixing system. A pump system that receives the gas mixture from the gas mixing system and maintains the operating pressure, A plasma torch system comprising: a plasma torch system that receives the gas mixture as a carrier gas from the pump system and generates plasma from the plasma torch system; A pyrolysis reactor that receives the plasma from the plasma torch system and operates at the pyrolysis reactor temperature and pressure, wherein the plasma torch system and the pyrolysis reactor decompose the alkane gas with the catalyst gas to form a carbon-catalyst gas and a hydrogen-catalyst gas, A heat exchange system that controls the temperature and pressure inside the pyrolysis reactor according to a pressure and temperature control module, The pyrolysis reactor includes a heat exchange system that separates the carbon from the catalyst gas and separates the catalyst gas from the hydrogen. A carbon sealing system in the pyrolysis reactor for sealing the carbon during the cooling process, A gas separator module for separating the hydrogen gas and the catalyst gas, A catalyst gas receiver system that receives the catalyst gas from the gas separator module and returns the catalyst gas in situ to the catalyst supply tank, A hydrogen gas receiver that receives the hydrogen gas from the gas separator module and stores the hydrogen gas, A device equipped with the following features.

13. The catalyst gas is a noble gas, The alkane gas is one of methane, ethane, propane, and butane. The aforementioned device A gas condensation system within the catalyst gas receiver system, wherein the condensed noble gas is returned in situ to the catalyst supply tank, and the gas condensation system returns the condensed noble gas to the catalyst supply tank. A heat exchange system having a pressure and temperature control module and at least one cooling element controls the temperature and pressure inside the pyrolysis reactor. The apparatus according to claim 12, further comprising the following:

14. The aforementioned noble gas is xenon, The apparatus according to claim 13, wherein the alkane gas is methane.

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