Process for producing hydrogen and graphitic carbon from hydrocarbons

Abstract

A process is provided for catalytically converting hydrocarbon gases to hydrogen and graphitic carbon using a low-grade catalyst. [Solution] A process for producing hydrogen and graphitic carbon from hydrocarbon gases, comprising contacting a catalyst with the hydrocarbon gas at between 600°C and 1,000°C to catalytically convert at least a portion of the hydrocarbon gas to hydrogen and graphitic carbon, wherein the catalyst is low-grade iron oxide. Also disclosed is a method for beneficiating catalytic metal containing ores, comprising contacting catalytic metal containing ores with a hydrocarbon gas at between 600°C and 1,000°C to form carbon-coated metal species.

Description

[Technical field]

[0001] The present invention relates to a process for producing hydrogen and graphitic carbon. [Background technology]

[0002] Hydrogen has many commercial applications, such as a clean and environmentally friendly alternative to fuels for internal combustion engines. Carbon, and more specifically graphite, is considered an important material in the emerging green technology market and has been shown to be useful in energy storage, electrical conduction devices, catalyst supports, lubricant additives, and modern electronic devices. All references to carbon in this patent relate to the graphitic form of carbon, and therefore these terms are used interchangeably throughout.

[0003] However, conventional methods for producing hydrogen from fossil fuels produce carbon dioxide, which is harmful to the environment (natural gas steam reforming and coal gasification).

[0004] Natural gas can be catalytically decomposed into hydrogen gas and solid carbon according to equation (1). CH4→C+2H2(1)

[0005] In such a process, carbon is deposited on the surface of the catalyst and hydrogen gas is released. There are many known catalysts for this process, including noble metal and carbon-based catalysts.

[0006] Although the above processes are known, they have not been commercially exploited for a number of economic reasons. Primarily, this is related to the cost of the underlying catalyst, both in the initial feed and in the recycle / regeneration. Most of the researchers in this field have used expensive complex supported catalysts, which, despite their high catalytic activity and product yields, result in very high catalyst turnover costs. Such costs are a significant barrier to commercializing the use of these catalysts. There is a significant need for new and improved processes and catalysts for the catalytic conversion of hydrocarbons to stable and commercially valuable hydrogen and solid carbon.

[0007] The above discussion of the background art is intended only to facilitate an understanding of the present invention. It should be understood that the above discussion does not constitute an affirmation or admission that any of the subject matter referred to was part of the common general knowledge in Australia at the priority date of this application. Summary of the Invention [Problem to be solved by the invention]

[0008] In its broadest aspect, the present invention provides a process for producing hydrogen and graphitic carbon from a hydrocarbon gas. In particular, the present invention provides a process for catalytically converting a hydrocarbon gas to hydrogen and graphitic carbon using a low-grade catalyst.

[0009] Throughout this specification, the term "low grade" will be understood to mean non-synthetic materials, unless the context otherwise requires. As will be understood by those skilled in the art, synthetic materials are produced by chemical reaction of precursor materials. A standard synthesis technique for catalysts that is excluded from this invention is, for example, impregnation of nano-sized catalytic elements onto an inert support. The term "low grade" includes naturally occurring materials, but should not be understood to exclude materials that have undergone physical beneficiation such as crushing and screening or classification.

[0010] Throughout this specification, unless otherwise stated, all pressures are given in bar (standard of measurement), with 0 bar being atmospheric pressure. [Means for solving the problem]

[0011] According to the present invention there is provided a process for producing hydrogen and graphitic carbon from a hydrocarbon gas comprising contacting a catalyst with the hydrocarbon gas at a temperature between 600°C and 1,000°C to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon, the catalyst being low grade iron oxide.

[0012] Preferably the pressure is greater than atmospheric pressure.

[0013] In one form of the invention, the step of catalytically converting at least a portion of the hydrocarbon gas to hydrogen and graphitic carbon by contacting the catalyst with the hydrocarbon gas at a temperature between 600° C. and 1,000° C. more specifically includes the steps of reducing at least a portion of the iron oxide to iron, decomposing the hydrocarbon gas to produce hydrogen gas and an iron carbide intermediate, and precipitating graphitic carbon on the surface of the iron.

[0014] In one embodiment of the invention, the step of contacting the catalyst with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. is carried out at a pressure between 0 bar and 100 bar. Preferably, the step of contacting the catalyst with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. is carried out at a pressure between 0 bar and 50 bar. More preferably, the step of contacting the catalyst with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. is carried out at a pressure between 0 bar and 20 bar. Even more preferably, the step of contacting the catalyst with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. is carried out at a pressure between 2 bar and 10 bar.

[0015] In one aspect of the invention, the step of contacting the catalyst with the hydrocarbon gas at a temperature between 600°C and 1,000°C to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon is preferably carried out at a temperature of from 700°C to 950°C.

[0016] In a second aspect of the invention, the step of contacting a catalyst with a hydrocarbon gas at a temperature between 600°C and 1,000°C to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon is preferably carried out at a temperature of from 800°C to 900°C.

[0017] In a third aspect of the invention, the step of contacting a catalyst with a hydrocarbon gas at a temperature between 600°C and 1,000°C to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon is preferably carried out at a temperature of from 650°C to 750°C.

[0018] We have discovered that the process of the present invention allows for the use of lean catalysts while still obtaining high conversions and yields.

[0019] Without wishing to be bound by theory, the inventors understand that the use of iron ore is advantageous because the metallic species catalyzes the cracking reaction and the catalytic elements are exposed to the hydrocarbon gases according to the mineralogy of the ore. Applicants understand that the force of precipitation of the graphite layer on the surface of the catalyst component is sufficient to crumble and dislodge the overlying catalyst particles from the catalyst, further exposing the iron oxide of the catalyst. Thus, the catalyst is self-supporting and does not require extensive preparation prior to use.

[0020] In one form of the invention, the hydrocarbon gas is methane. Preferably, the hydrocarbon gas is natural gas.

[0021] In one aspect of the invention, the catalyst is ground to a particle size of less than 20 mm. Preferably, the catalyst is ground to a particle size of less than 15 mm. More preferably, the catalyst is ground to a particle size of less than 10 mm. Even more preferably, the catalyst is ground to a particle size of less than 5 mm. Even more preferably, the catalyst is ground to a particle size of less than 1 mm. Even more preferably, the catalyst is ground to a particle size of less than 0.5 mm. Even more preferably, the catalyst is ground to a particle size of less than 0.1 mm.

[0022] In one aspect of the invention, the step of contacting the catalyst with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. is carried out in a pressurized reactor. Preferably, the pressurized reactor is selected from the group of a stationary bed reactor, a moving bed reactor, and a fluidized bed reactor.

[0023] In one form of the invention, the catalyst is disposed on a substantially horizontal surface of the reactor and exposed to a cross flow of the hydrocarbon gas. In a second embodiment of the invention, the catalyst is suspended in a fluidized bed reactor and the hydrocarbon gas is caused to flow through the fluidized bed.

[0024] In one aspect of the invention, the step of contacting the catalyst with the hydrocarbon gas is carried out in a plurality of pressurized reactors arranged in series.

[0025] In one aspect of the invention, a series arrangement of reactors allows gas to flow from a first reactor to a subsequent reactor. Preferably, each subsequent reactor in the series operates at a lower pressure than the preceding reactor to allow gas to pass to the lower pressure reactor. In a series arrangement, any unreacted hydrocarbon gas passes to the subsequent lower pressure reactor for further processing against additional catalyst to more completely convert the hydrocarbon gas to hydrogen and graphitic carbon.

[0026] In another aspect of the invention, a series arrangement of reactors allows for catalyst flow from the first reactor to the subsequent reactor. Preferably, each subsequent reactor in the series operates at a higher pressure than the preceding reactor to allow catalyst to move to the higher pressure reactor. At lower pressures, some portions of the catalyst may only be partially deactivated. In a series arrangement, the partially deactivated catalyst moves to the subsequent reactor at higher pressure where it is exposed to additional hydrocarbon gas for further processing to produce purer graphitic carbon. Applicant envisions placing the subsequent reactor below the preceding reactor so that the flow of catalyst between the reactors is gravity assisted. Applicant termed this a cascade arrangement.

[0027] In one form of the invention, two pressurized reactors are used in series. The first reactor is at a pressure between 15 and 25 bar. The second reactor is at a pressure between 0 and 1 bar.

[0028] In another embodiment of the present invention, three pressurized reactors are used in series. When three pressurized reactors are used in series, the first reactor is at a pressure between 15 and 25 bar; The second reactor is at a pressure between 5 and 10 bar, The third reactor is at a pressure between 0 and 1 bar.

[0029] In another embodiment of the present invention, four pressurized reactors are used in series. When four pressurized reactors are used in series, the first reactor is at a pressure between 20 and 30 bar; The second reactor is at a pressure between 5 and 15 bar, The third reactor is at a pressure between 4 and 6 bar; The fourth reactor is at a pressure between 0 and 1 bar.

[0030] In another embodiment of the present invention, five pressurized reactors are used in series. When five pressurized reactors are used in series, The first reactor is at a pressure between 25 and 35 bar; The second reactor is at a pressure between 10 and 20 bar, The third reactor is at a pressure between 5 bar and 10 bar, The fourth reactor is at a pressure between 4 and 6 bar; The fifth reactor is at a pressure between 0 and 1 bar.

[0031] The utility and economic drivers of converting hydrocarbon gases to hydrogen and graphitic carbon are competing kinetic and thermodynamic drivers of the reaction. As discussed above, the decomposition of the hydrocarbon gases eventually results in the precipitation of graphitic carbon on the surface of the metal particles of the catalyst. Precipitation continues until methane cannot penetrate the overlying graphite to reach the catalyst. Dynamically, increasing the reaction pressure drives the reaction because it allows better diffusion of methane to the graphitic structures overlying the active catalyst surface, leading to higher catalyst utilization. Higher catalyst utilization also leads to a higher purity graphitic product. A competing factor is that the thermodynamics of the reaction favors starting the reaction at lower pressures. Higher pressures result in higher product gas volumes (2 moles of hydrogen produced per mole of methane fed) and a more favorable equilibrium position for the initial reagents over the products. This equilibrium position limits the percentage of methane feed that can be converted to hydrogen. This is known in the art as the limit of thermodynamic equilibrium (TEL), which decreases with increasing reaction pressure.

[0032] The inventors have discovered that by using multiple reactors in series, the competing kinetic and thermodynamic drivers of the reaction can be controlled by varying the pressure of each subsequent reactor. This not only allows for higher catalyst activity at higher pressures, but also allows for higher conversion of the hydrocarbon gas feed in lower pressure reactors. The benefit of using multiple reactors in series is that increased reaction pressures can be used to increase product yields per unit of catalyst used (catalyst utilization) while maintaining a high methane conversion efficiency (TEL).

[0033] In one embodiment of the present invention, where multiple reactors are used in series to allow for gas flow between the reactors, each reactor is provided with unreacted catalyst. In this configuration, each reactor is filled with unreacted catalyst before contacting the hydrocarbon gas. A portion of the hydrocarbon gas is converted to hydrogen and graphitic carbon in the reactor with the highest pressure. The first reactor has an associated TEL, which results in underconversion of the hydrocarbon gas to hydrogen gas and carbon. The resulting hydrocarbon gas / hydrogen mixture is transferred to one or more subsequent lower pressure reactors. The lower pressure reactors have higher associated TELs, which allow for further conversion of the hydrocarbon gas to hydrogen gas and carbon. When unreacted catalyst is provided in each reactor, the applicant has named this configuration a parallel gas multiple pressure reactor (parallel gas MPR).

[0034] In a second embodiment of the invention, where multiple reactors are used in series to allow for catalyst flow between the reactors, each reactor is fed with unreacted hydrocarbon gas. In this configuration, the hydrocarbon gas flows continuously through the reactors. Unreacted catalyst is fed to the reactor with the lowest pressure, which catalytically converts methane and then produces partially deactivated catalyst. The partially deactivated catalyst is transferred to the next reactor in the series, which has a higher pressure, and further catalytically converts methane. The higher reactor pressure allows for further catalyst deactivation. The transfer of partially deactivated catalyst is repeated along the multiple reactors of increasing pressure. When unreacted hydrocarbon gas is fed to each reactor, the applicant has named this configuration a parallel catalyst multiple pressure reactor (parallel catalyst MPR).

[0035] In a third embodiment of the invention, multiple reactors are arranged in series to allow for counter flow of both hydrocarbon gas and catalyst between the reactors. In this configuration, unreacted catalyst is fed to the reactor with the lowest pressure and unreacted hydrocarbon gas is fed to the reactor with the highest pressure. The catalyst travels between the pressure chambers toward the higher pressure, counter flowing the gas flow between the chambers. Applicant has named this configuration the Counter Flow Multiple Pressure Reactor (Counter Flow MPR). Partially deactivated catalyst remains active in the higher pressure reactor and the resulting graphite product will be of higher purity (mass percent) and correspondingly more valuable.

[0036] The inventors have discovered that a counter-flow MPR configuration can provide more complete conversion of the hydrocarbon gas and a higher purity graphitic carbon product, and is much simpler to design than a counter-flow MPR since there is no catalyst flow in a parallel gas MPR or no gas flow in a parallel catalyst MPR.

[0037] In one aspect of the invention, the process is configured to preferentially produce either higher purity hydrogen or graphitic carbon. As will be appreciated by those skilled in the art, both hydrogen and graphitic carbon products are typically produced in a fixed ratio of 1:3 (carbon:graphitic carbon) on a mass basis as determined by fundamental reaction stoichiometry. Nonetheless, it is possible to favor a higher purity of one of the products over the other.

[0038] In one form of the invention where the process is tuned to preferentially produce higher purity hydrogen, the process comprises contacting a catalyst with a hydrocarbon gas at a temperature between 800° C. and 900° C. and atmospheric pressure to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon.

[0039] Preferably, the process is carried out in a single fluidized bed reactor.

[0040] If higher purity hydrogen is desired, conditions that increase the efficiency of methane conversion are strengthened. Increasing hydrogen purity in a single stage reactor typically involves lower pressures and higher temperatures, which thermodynamically maximize conversion. The tradeoff for higher conversion is lower graphite purity, resulting in higher catalyst consumption and lower yield per unit of catalyst.

[0041] In one form of the invention where the process is tailored to preferentially produce purer graphitic carbon, the process comprises contacting a catalyst with a hydrocarbon gas at a temperature between 650° C. and 950° C. and a pressure between 2 bar and 100 bar to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon.

[0042] Preferably, the process is carried out in a fluidized bed reactor.

[0043] If a purer graphitic carbon is desired, conditions that enhance catalyst utilization are intensified. Graphite quality is a function of purity relative to non-carbon content and crystallinity. When enhancing graphitic carbon purity in a single stage reactor, this typically involves broadening the temperature range and increasing pressure, which maximizes catalyst utilization.

[0044] According to a further aspect of the invention there is provided a method of beneficiating catalytic metal containing ore comprising contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600°C and 1,000°C to form carbon coated metal species.

[0045] Preferably the pressure is greater than atmospheric pressure.

[0046] In one form of the invention, the carbon coated metallic species is a graphite coated metallic species.

[0047] In one embodiment of the invention, the step of contacting a catalytic metal containing ore with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. to form a carbon coated metal species more specifically comprises: reducing at least a portion of the catalytic metal containing ore to catalytic metal species; decomposing a hydrocarbon gas to produce hydrogen gas and a catalytic metal carbide intermediate; precipitating graphitic carbon on the surface of the catalytic metal; Includes.

[0048] Without wishing to be bound by theory, applicants believe that the force with which the graphite layer precipitates on the surface of the catalyst component is sufficient to spall and dislodge the overlying catalyst particles from the remaining ore rock. As the overlying catalyst particles are spalled, additional catalyst components within the ore are exposed to the hydrocarbon gases.

[0049] In one form of the invention, the catalytic metal containing ore is iron ore.

[0050] As discussed above, the metallic species in the iron ore catalyze the decomposition reaction. Most of the iron on the Earth's crust exists in a form called banded iron formations (BIF), which consist of layers of iron separated by layers of non-ferrous minerals, typically SiO2. The benefit of this configuration is that the iron layers are never completely trapped in the non-ferrous species, so gas always has access to them. Furthermore, iron ore has a relatively high iron concentration. In contrast, catalytic elements in other ores are often trapped in the non-catalytic species, at very low concentrations and not stratified, so the process gas cannot come into contact with the catalytic elements to react.

[0051] In one form of the invention, the process is carried out in a pressurized dusting reactor, where catalytic metal containing ores are preferably contacted with a hydrocarbon gas to produce nano / micron sized graphite coated metal particles. The advantage is that larger (>1 mm) non-catalytic gangue species remain unchanged. This size difference allows the graphite coated metal species to be separated and removed from the gangue using physical separation techniques.

[0052] In one form of the invention, the dusting reactor is a fluidized bed reactor. The inventors have found that the advantage of using a fluidized bed reactor is that the nano / micron sized graphite coated metal particles are simultaneously separated from the larger gangue species during the beneficiation process. The smaller sized graphite coated metal particles are carried in the process gas stream and removed from the reactor by this gas stream, while the larger gangue particles remain in the reactor. In one form of the invention, the smaller graphite coated metal species are removed from the gas stream by a gas-solid separator that allows the particles to settle. The gangue can be continuously removed from the dusting reactor by periodic discharge by gravity.

[0053] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600°C and 1,000°C to form a carbon coated metal species is preferably carried out at a temperature of from 700°C to 950°C.

[0054] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600°C and 1,000°C to form a carbon coated metal species is preferably carried out at a temperature of 800°C to 900°C.

[0055] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600°C and 1,000°C to form a carbon coated metal species is preferably carried out at a temperature of 650°C to 750°C.

[0056] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. to form a carbon coated metal species is carried out at a pressure between 0 bar and 100 bar.

[0057] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. to form a carbon coated metal species is carried out at a pressure between 0 bar and 50 bar.

[0058] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. to form a carbon coated metal species is carried out at a pressure of 0 bar to 20 bar.

[0059] In one form of the invention, the step of contacting the catalytic metal containing ore with a hydrocarbon gas at a temperature between 600° C. and 1,000° C. to form a carbon coated metal species is carried out at a pressure of 0 bar to 10 bar.

[0060] In one form of the invention, graphite is removed from the graphite coated metallic species by contacting the graphite coated metallic species with hydrogen gas at a temperature of from 700° C. to 900° C. Preferably, the step of contacting the graphite coated metallic species with hydrogen gas at a temperature of from 700° C. to 900° C. is carried out in a pressurized reduction reactor.

[0061] In one aspect of the invention, the removal of graphite from the graphite-coated metallic species is carried out in a pressurized reduction reactor at a pressure between 0 and 100 bar. The inventors have realised that the higher the pressure, the more favourable the removal of graphite. In a preferred aspect of the invention, the removal of graphite from the graphite-coated metallic species is carried out in a pressurized reduction reactor at a pressure between 10 and 20 bar.

[0062] Contacting the graphite-coated metal species with hydrogen gas at a temperature between 700° C. and 900° C. produces methane. In one aspect of the invention, the methane is recycled to produce hydrogen. More specifically, the methane recycling step comprises contacting a low-grade iron ore catalyst with the methane at a temperature between 600° C. and 1,000° C. to catalytically convert at least a portion of the methane to hydrogen and graphitic carbon.

[0063] In one form of the invention, the hydrogen produced in the methane recycling step is used in a step of removing graphite from the graphite coated metal species by contacting the graphite coated metal species with hydrogen gas at a temperature of 700°C to 900°C.

[0064] When iron ore is beneficiated, the graphite is removed in a reduction reaction leaving the metallic species in a highly pure form, often as ferrous metal. [Brief description of the drawings]

[0065] Further features of the present invention are described more fully in the following description of several non-limiting embodiments of the present invention, which is included for illustrative purposes only and should not be understood as a limitation to the broad summary, disclosure, or description of the present invention set forth above. The description is made with reference to the accompanying drawings. [Figure 1] FIG. 1 shows a schematic diagram of a process for producing hydrogen and graphite according to countercurrent MPR of the present invention. [Diagram 2] FIG. 2 shows a schematic diagram of a process for producing hydrogen and graphite according to the parallel gas MPR of the present invention. [Diagram 3] FIG. 3 shows a schematic diagram of a process for producing hydrogen and graphite according to parallel catalytic MPR of the present invention. [Figure 4] FIG. 4 shows a schematic diagram of a process for beneficiating catalytic metal containing ore according to a first embodiment. [Diagram 5] FIG. 5 is a graphical representation of XRD plots of analytical grade iron oxide and iron ore catalyst samples. [Figure 6] FIG. 6 is a graphical representation of the carbon purity (wt %) and carbon yield (grams of carbon per gram of iron-GC / GFe) of the iron oxide catalyst after the reaction. [Figure 7] FIG. 7 is a schematic diagram of a three-stage cascade countercurrent flow system. [Figure 8A] FIG. 8A shows a schematic diagram of the experimental conditions used to test the methane conversion of an MPR system with three reactors in series using a stationary fixed-bed reactor. [Figure 8B]FIG. 8B shows a schematic diagram of the experimental conditions used to test the methane conversion of an MPR system with three reactors in series using a stationary fixed-bed reactor. [Figure 9] FIG. 9 is a graph of methane conversion results of hematite catalyst at different reaction pressures. [Figure 10] FIG. 10 is a graphical representation of carbon purity (% critical) and carbon yield (grams of carbon per gram of iron-GC / GFe) of hematite catalyst at different reaction pressures. [Figure 11] FIG. 11 shows a schematic diagram of variables for the mass balance calculation of a counterflow MPR system. [Figure 12] FIG. 12 is a graphical representation of the mass balance calculations for both the countercurrent and parallel MPR showing the catalyst mass flow rate required for a balanced system with a hydrogen production rate of 2,000 m3 / hr. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0066] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. The invention includes all such variations and modifications. The invention also includes all steps, features, formulations, and compounds referred to or shown in the specification, individually or collectively, in any combination, or any two or more steps or features.

[0067] Each document, reference, patent application, or patent cited in this text is expressly incorporated herein by reference in its entirety. This means that they should be read and considered by the reader as part of this text. It is for the sake of brevity only that documents, references, patent applications, or patents cited in this text are not repeated in this text. However, neither the cited material nor the information contained therein should be taken as common general knowledge.

[0068] Manufacturers' manuals, instructions, product specifications, and product sheets for any products mentioned in this specification, or in any document incorporated by reference herein, are hereby incorporated by reference and may be employed in the practice of the invention.

[0069] The present invention is not to be limited in scope by any of the specific embodiments described herein, which are intended as examples only. Functionally equivalent products, formulations, and methods are clearly within the scope of the invention described herein.

[0070] The invention described herein may include one or more ranges of values ​​(e.g., size, concentration, etc.) A range of values ​​is understood to include all values ​​within the range, including the values ​​defining the range and values ​​adjacent to the range that lead to the same or substantially the same result as the values ​​immediately adjacent to the values ​​defining the boundaries of the range.

[0071] Throughout the specification, unless the context otherwise requires, the word "comprise" or variations of "comprises" or "comprising" are understood to mean the inclusion of a stated integer or group of integers but not to the exclusion of any other integer or group of integers.

[0072] Other definitions of selected terms used herein may be found within the Detailed Description of the Invention and are applicable throughout. Unless otherwise defined, all other scientific and technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs.

[0073] Features of the invention will now be described with reference to the following non-limiting descriptions and examples.

[0074] In a general form, the invention relates to a process for producing hydrogen and graphitic carbon from hydrocarbon gases. In particular, the invention provides a process for catalytically converting hydrocarbon gases to hydrogen and graphitic carbon using a low grade iron oxide containing catalyst.

[0075] The hydrocarbon gas may be any gas stream that contains light hydrocarbons. Illustrative examples of hydrocarbon gas include, but are not limited to, natural gas, coal seam gas, landfill gas, and biogas. The composition of the hydrocarbon gas varies widely, but generally includes one or more light hydrocarbons in the group including methane, ethane, ethylene, propane, and butane.

[0076] In a preferred embodiment of the present invention, the hydrocarbon gas is natural gas.

[0077] A process for producing hydrogen and graphitic carbon from natural gas includes contacting a hydrocarbon gas with a catalyst at a temperature between 600° C. and 1,000° C. to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon, the catalyst being low-grade iron oxide.

[0078] Referring to FIG. 1, a countercurrent MPR process 10 using three fluidized bed reactors to produce hydrogen 12 and graphitic carbon 14 from a hydrocarbon gas, for example natural gas 16, is described.

[0079] In the embodiment shown in Figure 1, the process uses three reactors operating at different pressures: a high pressure reactor 18 under 18 bar, a medium pressure reactor 20 under 6 bar, and a low pressure reactor 22 under 1 bar. The reactor temperatures are each 850°C. The reactors 18, 20, and 22 are arranged in series, with hydrogen and unreacted hydrocarbon natural gas being transferred between adjacent reactors, for example, from the high pressure reactor 18 to the medium pressure reactor 20 and from the medium pressure reactor 20 to the low pressure reactor 22.

[0080] Each reactor 22, 20, and 18 is loaded with low grade iron oxide catalyst, e.g., iron ore 24", 24', and 24, respectively. 24 is unused, unreacted catalyst, while 24' and 24" are successively more used, with more graphitic carbon attached and less overall residual catalytic activity. Stream 14 contains only traces of fully spent catalyst, with the majority of this stream (>90 wt. % at the 850° C. reaction temperature) being graphitic carbon.

[0081] The amount of catalyst required for this reaction is related to the amount of hydrogen required, the process conditions, and the type of catalyst. Three 2,000m reactors were operated under the above conditions. 3 / hr hydrogen production plant requires about 14 kg / hr of iron.

[0082] Natural gas 16 is passed through a series of reactors, from a high pressure reactor 18 to a medium pressure reactor 20 and a low pressure reactor 22. Each reactor converts a portion of the natural gas to hydrogen, and each subsequent gas stream 28, 30, and 12 contains more hydrogen. The virgin natural gas 16 first contacts the catalyst 24" in the high pressure reactor 18 at a temperature of 850°C and a pressure of 18 bar, and a portion of the natural gas is converted to hydrogen, so that the corresponding gas stream 28 is a mixture containing hydrogen and unreacted natural gas. This reactor also deposits some graphitic carbon on the catalyst 24", which contributes to the total amount of graphitic carbon in stream 14.

[0083] Gas stream 28 travels to the medium pressure reactor 20 where it contacts catalyst 24' at a temperature of 850° C. and a pressure of 6 bar, converting the natural gas to hydrogen and carbon. The lower pressure of the medium pressure reactor 20 allows for the conversion of gas stream 28, which contributes to the total hydrogen amount 12. The process deposits graphitic carbon on the catalyst 24', which contributes to the total graphitic carbon stream 14. A portion of the natural gas in gas stream 28 remains unreacted and mixes with the produced hydrogen gas to form gas stream 30.

[0084] Gas stream 30 travels to low pressure reactor 22 where it contacts catalyst 24 at a temperature of 850° C. and a pressure of 1 bar (atmospheric pressure). The lower pressure in low pressure reactor 22 allows the thermodynamic equilibrium of the reaction to favor the decomposition direction of the reaction, allowing further conversion of second gas stream 30 to carbon and hydrogen gas. The process deposits graphitic carbon on catalyst 24, contributing to the total graphitic carbon stream 14. This reactor also contributes hydrogen gas in the total hydrogen stream 12, which exits the reactor for use or further processing.

[0085] Theoretical empirical calculations determine that reactors 18, 20, and 22 have conversion efficiencies of 54%, 75%, and 94%, respectively, and correspondingly gas streams 28, 30, and 12 have hydrogen concentrations of 70%, 86%, and 97% by weight, respectively.

[0086] The percentage of graphitic carbon in iron oxide streams 24, 24', 24'', and 14 is 0%, 91%, 95%, and 98%, respectively.

[0087] In the embodiment shown in Figure 1, when natural gas 16 contacts catalyst 24 at high temperature to produce hydrogen gas 12 and carbon 14, catalyst 24 is consumed to form partially deactivated catalyst 24'. The partially deactivated catalyst 24' travels countercurrent to the flow of natural gas 16 between the reactors. Catalyst 24 is introduced into reactor 22, which has the lowest pressure, and then passes to the higher pressure reactor. Thus, the partially deactivated catalyst 24' retains activity in the higher pressure reactor 20, and the resulting graphitic carbon 14 has a higher carbon purity (as a percentage by mass) and a correspondingly higher value.

[0088] 2, a parallel gas MPR process 50 is shown. The parallel gas MPR process 50 has features in common with the countercurrent MPR process 10, and like reference numbers refer to like parts.

[0089] In the embodiment shown in Figure 2, the process uses three reactors operating at different pressures: a high pressure reactor 18 under 18 bar, a medium pressure reactor 20 under 6 bar, and a low pressure reactor 22 under 1 bar. The reactor temperatures are each 850°C. The reactors 18, 20, and 22 are arranged in series, allowing unreacted hydrocarbon natural gas to be transferred between adjacent reactors, for example from the high pressure reactor 18 to the medium pressure reactor 20 and from the medium pressure reactor 20 to the low pressure reactor 22.

[0090] Each reactor 18, 20, and 22 is respectively loaded with iron ore catalyst 52. In contrast to the previously described countercurrent MPR process 10, each reactor 22, 20, and 18 is fed with unreacted catalyst 52 prior to contacting the hydrocarbon gas.

[0091] The amount of catalyst required for this reaction is related to the amount of hydrogen required, the process conditions, and the type of catalyst. Three reactors were used to operate a 2,000m 3 / hr hydrogen production plant requires about 27 kg / hr of iron.

[0092] Natural gas 16 is passed through a series of reactors, from high pressure reactor 18 to intermediate pressure reactor 20 to low pressure reactor 22. Each reactor converts a portion of the natural gas to hydrogen, with each subsequent gas stream 28, 30, and 12 containing more hydrogen. Unreacted natural gas 16 first contacts catalyst 34 in high pressure reactor 18 at a temperature of 850° C. and a pressure of 18 bar, which converts a portion of the natural gas into hydrogen and produces gas stream 28, which is a mixture of hydrogen and unreacted natural gas. Graphite also deposits on catalyst 34, producing partial graphite stream 54.

[0093] Gas stream 28 passes to the medium pressure reactor 20 where it contacts catalyst 52 at a temperature of 850° C. and a pressure of 6 bar, converting the natural gas into hydrogen and carbon. The lower pressure of the medium pressure reactor 20 allows for further conversion of gas stream 28, contributing to the total hydrogen stream 12. The process deposits carbon on the catalyst 52, producing partial graphite stream 56. A portion of the natural gas in gas stream 28 remains unreacted and mixes with the produced hydrogen gas to form gas stream 30.

[0094] The gas stream 30 passes to the low pressure reactor 22 where it contacts the catalyst 52 at a temperature of 850° C. and a pressure of 1 bar (atmospheric pressure). The lower pressure in the low pressure reactor 22 allows the thermodynamic equilibrium of the reaction to favor the decomposition direction of the reaction, allowing the conversion of the natural gas in the second gas stream 30 to carbon and hydrogen gas. The process deposits carbon on the catalyst 52 and a partial graphite stream 58 is produced. This reactor also contributes hydrogen gas in the total hydrogen stream 12, which exits the reactor for use or further processing.

[0095] Partial graphite streams 54, 56, and 58 contain a mixture of unreacted iron ore and graphitic material. Given the different pressures in each reactor 22, 20, and 18, each partial graphite stream has a different conversion. Partial graphite stream 58 has the most iron impurities, followed by partial graphite stream 56 and partial graphite stream 54.

[0096] In experiments, reactors 18, 20, and 22 had conversion efficiencies of 54%, 75%, and 94%, respectively, and correspondingly gas streams 28, 30, and 12 had hydrogen concentrations of 70%, 86%, and 97% by weight, respectively.

[0097] 3, a parallel catalytic MPR process 60 is shown. The parallel MPR process 60 has features in common with the countercurrent MPR process 10, and like reference numbers refer to like parts.

[0098] In the embodiment shown in Figure 3, the process uses three reactors operating at different pressures: a high pressure reactor 18 under 18 bar, a medium pressure reactor 20 under 6 bar, and a low pressure reactor 22 under 1 bar. The temperature of the reactors is 850°C each.

[0099] Each reactor 18, 20, and 22 is loaded with low grade iron oxide containing catalyst, e.g., iron ore 24", 24', and 24, respectively. 24 is unreacted catalyst, while 24' and 24" are successively more used, with more carbon deposited and less overall catalytic activity remaining. Stream 14 contains only traces of fully consumed catalyst, with the majority of this stream (>90 wt. % at the 850° C. reaction temperature) being graphite.

[0100] Reactors 18, 20, and 22 are arranged in series with catalyst 24", 24', and 24 being transferred between adjacent reactors, for example, from low pressure reactor 22 to medium pressure reactor 20, and from medium pressure reactor 20 to high pressure reactor 18.

[0101] In contrast to the previously described countercurrent MPR process 10 , unreacted natural gas 16 is fed to each of the reactors 22 , 20 , and 18 .

[0102] In the embodiment shown in FIG. 3, when natural gas 16 contacts catalyst 24 at elevated temperatures to produce hydrogen gas 12 and carbon 14, catalyst 24 is depleted to form partially deactivated catalyst 24'. The partially deactivated catalysts 24' and 24" are transferred between the reactors. Catalyst 24 is introduced into the lowest pressure reactor 22 and then passed to the higher pressure reactors 20 and 18. Thus, the partially deactivated catalyst 24' retains activity in the higher pressure reactor 20 and the resulting carbon 14 has a higher carbon purity (as a percentage of mass) and a correspondingly higher value.

[0103] Natural gas 16 contacts catalyst 24 in low pressure reactor 22 at a temperature of 850° C. and a pressure of 18 bar to convert a portion of natural gas 16 into hydrogen and produce gas stream 68, which is a mixture containing hydrogen and unreacted natural gas. Graphitic carbon deposits on catalyst 24, producing catalyst 24′, which contributes to the total carbon in stream 14.

[0104] Natural gas 16 contacts catalyst 24' in medium pressure reactor 20 at a temperature of 850° C. and a pressure of 6 bar to convert natural gas 16 to hydrogen and produce gas stream 64, which is a mixture containing hydrogen and unreacted natural gas. Graphitic carbon deposits on catalyst 24' to produce catalyst 24'', which contributes to the total carbon in stream 14.

[0105] The natural gas 16 contacts the catalyst 24'' in the high pressure reactor 18 at a temperature of 850°C and a pressure of 18 bar, converting a portion of the natural gas 16 into hydrogen and producing a gas stream 62 which is a mixture containing hydrogen and unreacted natural gas. Graphitic carbon deposits on the catalyst 2'' to produce catalytic graphitic carbon 14.

[0106] Referring to FIG. 4, a process 100 for beneficiating catalytic metal containing ore, for example iron ore 102, is described.

[0107] Low grade iron ore 102 passes through a surge bin 104 to a dusting reactor 106. In the dusting reactor 106, the iron ore 102 contacts a hydrocarbon gas 108 at a temperature of 850° C. and a pressure between 10 and 20 bar to produce a graphite coated iron stream 110 and a waste stream 112 containing larger (>1 mm) gangue particles. The size difference between the graphite coated iron stream 110 and the waste stream 112 separates the streams. The graphite coated iron stream 110 passes through a gas / solids separator 114, where a gas stream 116 is separated from a solids stream 118, which is passed to a reduction reactor 120.

[0108] In the reduction reactor 120, the graphite coated iron particles of the solids stream 118 are contacted with hydrogen gas 122 at a temperature between 800° C. and 900° C. and a pressure between 10 and 20 bar to remove the carbon coating, leaving an iron concentrate stream 124. The reaction also forms a methane gas stream 126, which is recycled to other parts of the process. In the embodiment shown in FIG. 2, the methane gas stream 126 is further contacted with the iron ore 102 passing through a surge bin 130 at a temperature between 800° C. and 900° C. in a hydrogen reactor 127 to produce hydrogen gas 122 and graphite powder 128. As shown in FIG. 4, the hydrogen gas 122 is returned to the reduction reactor 120. [Example] [Example 1]

[0109] Use of iron ore as a catalyst for the economical production of hydrogen and graphite via the thermocatalytic decomposition of methane. [Experiment details]

[0110] The present invention provides a method that allows low grade iron oxide to be used as a catalyst for the decomposition of methane. To demonstrate the catalytic activity of the low grade iron oxide catalyst of the present invention, a sample of low grade iron oxide was compared to a high grade iron oxide sample. Two high grade iron oxides were tested: hematite (99%, <5 μm, Sigma-Aldrich) and magnetite (95%, <5 μm, Sigma-Aldrich); and two iron ore samples: hematite ore (Pilbara mine) and goosite ore (Yandi mine). The ore samples were crushed to <150 μm and were otherwise unprocessed. The compositional data, particle size distribution and surface area of ​​all samples "as received" are detailed in Table 1. [Table 1] Table 1 - Composition, particle size, and surface area data for iron oxide samples

[0111] Each sample was placed in a separate single stage reactor. The reactor was a vertical 1 / 2" diameter stainless steel (SS316 Swagelok) tube with a 3 / 8" quartz tube inner liner. The quartz tube inner liner reduces the catalytic effect of the stainless steel reactor walls by limiting contact with the reacting methane gas. 20g catalyst samples were placed in a 3 / 8" "test tube" quartz chamber.

[0112] The XRD plots of the high grade iron oxide catalyst samples, namely analytical grade (hematite and magnetite), and the low grade iron oxide catalyst samples (hematite and gousite) are shown in FIG.

[0113] Each sample was reacted at temperatures ranging from 750°C to 950°C with 10 sccm of pure methane (UHP) at reaction pressures between 1 and 9 bar (absolute). After complete inertization (approximately 19 hours), the reaction was terminated and the sample was cooled with 20 sccm of pure nitrogen (UHP). The resulting carbon (and embedded catalyst particles) was weighed to determine the total carbon yield per gram of iron catalyst used.

[0114] Figure 6 shows the results of these experiments at reaction conditions of 850°C and atmospheric pressure. The results show that the low-grade iron ore samples performed nearly as well as the high-grade oxides, with carbon yields ranging from 9.2 to 8.9 grams per gram of iron, and corresponding carbon purities of 90% to 89% by weight, respectively. These values ​​were shown to correlate closely with those derived by quantitative XRD, differing by less than 2% by weight (shown as hollow shapes in Figure 6).

[0115] As will be appreciated by those skilled in the art, a common method to increase the activity of a catalyst is to make it very pure to increase the reaction area. Iron oxide catalysts, such as the high grade iron oxide samples tested, must be specifically synthesized to be greater than 99% pure. The results of this experiment show that the specific process conditions of the present invention allow high conversions and yields to be obtained using low grade catalysts. [Example 2] Thermocatalytic methane decomposition using counterflow MPR Countercurrent

[0116] A three-reactor countercurrent flow MPR was assembled in a cascade configuration as shown in the schematic diagram of FIG.

[0117] An experimental evaluation of the counterflow MPR system was conducted using a static (non-continuous) system by testing the effect of pressure on methane conversion efficiency and carbon yield. The results confirmed that increasing pressure reduced methane conversion and increased carbon yield, and conversely, lower pressure increased methane conversion and decreased total carbon yield. [Experiment details]

[0118] Effect of reaction pressure on the limits of methane conversion.

[0119] The reactor setup included three independent reactor stages (3×½” OD316SS Swagelok, 70 mm length) with different back pressure settings (12 bar, 4 bar, and atmospheric) and isothermal at 850° C. Instead of connecting the reactors in series, they were fed and analyzed separately to assess their individual performance. The feed gas composition of each reactor was set to induce operation of each reactor in series, and each reactor was operated at the theoretical maximum conversion possible at the reaction pressure (Table 2). The performance of each stage was determined by monitoring the effluent from each reactor using a gas chromatograph (GC). A schematic of this process is shown in FIG. 8. Excess iron oxide was used to induce conditions for continuous catalyst flow in this quiescent system, providing a momentary glimpse of the expected steady-state continuous operation. [Table 2] Table 2 - Process conditions for MPR experiments

[0120] The results from this experiment are shown in Figure 9 and correlate well with theoretical expectations, validating the theory. The three reactor stages correlated well with the expected limits of thermodynamic equilibrium (shown by the dashed lines) for a period of more than 20 hours, after which the reaction was terminated. It is clear that using the MPR system, high hydrogen concentrations do not affect the ability of the reaction to achieve conversion at the limits of thermodynamic equilibrium.

[0121] These results demonstrate that the continuous MPR system is capable of maintaining stable conversion at the limit of thermodynamic equilibrium, regardless of the hydrogen level. [Effect of pressure on product yield]

[0122] The effect of reaction pressure was tested using 20 mg of catalyst at a pressure interval of 1 bar, with all other reaction conditions remaining identical to the previous experiment (i.e., 850° C., 20 sccm methane, autoreduction, and 19 h duration).

[0123] The results indicate that there is a positive linear relationship between reaction pressure and total carbon yield. As shown in Figure 10, the profile indicates that the carbon yield per gram of iron increases from 9 g to 22 g over the pressure range from atmospheric to 9 bar absolute, corresponding to carbon purities of 90% to 96%, respectively. [Empirical calculation of catalyst flow rate]

[0124] The overall feasibility of an MPR system depends on mass flow balance. This is especially important for counterflow MPR because the mass flow rate of the catalyst is strictly interdependent with (1) the number of pressure reactor stages, (2) the pressure range, and (3) the carbon capacity profile of the catalyst. Empirical mass balance calculations were performed to determine the feasibility of achieving balance.

[0125] The catalyst flow rate in each reactor can be determined by dividing the carbon deposition rate of each reactor by the catalyst utilization, both bounded by the pressure range of the reactor.

number

[0126] The biggest constraint in a counterflow MPR configuration is balancing the catalyst mass flow rate among all reactor stages to allow for continuous operation. The catalyst flow rate required at each stage depends on (1) the number of reactor stages, and (2) the catalyst carbon content profile versus pressure. This balance is shown in Figure 11.

[0127] The objective of this calculation is to determine, for a given catalyst carbon capacity profile and reaction temperature (assuming isothermal conditions), the number of pressure stages that will balance the catalyst flow rate among all stages.

[0128] If the mass flow rate of the catalyst is set so that it is completely deactivated upon exiting each reactor stage, then the catalyst utilization at each stage is the difference between the total catalyst utilization at the reactor pressure and the adjacent lower pressure reactor. Thus,

number

[0129] 'n' is the reactor number (n=1 is the reactor with the lowest pressure).

[0130] Therefore, the mass flow rate of catalyst in each reactor stage is:

number

[0131] In a reactor system having only one reactor (n=1), the stages of reactor (n-1) and reactor (n+1) do not exist, so

number

[0132] Similarly, in the case of a two-stage reactor, the reactor (n-1) and the reactor (n+2) do not exist, and in the case of a three-stage reactor, the reactor (n-1) and the reactor (n+3) do not exist. [Catalyst mass flow balance]

[0133] For a multi-stage process to be continuous, the catalyst flow rates must be equivalent.

number

number

[0134] For isothermal conditions, this is

number

[0135] If the reactor 'R1' operates at atmospheric pressure and is operated at TEL, then ξ R1 is known, and ξ R2 can be solved using the equation above. This solution will solve for the pressure required for reactor 2 to have equal catalyst flow.

[0136] This is done similarly for larger numbers of reactors. Number of reactor stages: 3:

number

number

[0137] The above can be extrapolated to additional reactor stages. [result]

[0138] Empirical results, with linear extrapolation for pressures above 9 bar (absolute), are shown graphically in FIG. 12. These results indicate that countercurrent MPR will consume significantly less catalyst than a parallel flow process in all cases. A countercurrent process with five reaction stages requires only 19% of the catalyst required in a single reactor, compared to 42% for a parallel flow process with the same number of stages. However, a countercurrent process can only have a maximum of five reaction stages to ensure a constant catalyst mass flow rate through all stages. In contrast, a parallel flow process has an unlimited number of stages. However, it will be appreciated that there is a diminishing return for each stage, and overall the catalyst required is significantly more than for the countercurrent option. The catalyst mass flow rate is 2,000 m 3 Calculated based on an assumed hydrogen output flow rate of 1000 / hr. [Example 3] Iron ore beneficiation Experimental details

[0139] Typical low-grade iron ore rocks consist of clearly distinguishable sections of high-grade iron oxide and low-grade equivalents. This type of rock is known as banded iron formation (BIF). A 6.39g sample of BIF iron ore was prepared and the properties analyzed are shown in Table 3. [Table 3] Table 3 - Sample Analysis

[0140] The samples were packed into a bed of a static reactor and exposed to methane gas for 4 hours at 900° C. and atmospheric pressure. After reaction, the high-grade iron oxide streaks were crushed, whereas the low-grade counterparts were largely unaffected.

[0141] Without wishing to be bound by theory, the inventors understand that the initial reaction is the reduction of the agglomerated iron oxide species ore to iron carbide, releasing water vapor, H2, CO2, and traces of CO. As the reaction continues, the agglomerated iron carbide is broken down by metal dusting (as described above), and in the absence of oxides, the system releases only H2 gas. In this dusting, all the iron species are broken down into micron and nano-sized fragments by the graphite layer that encapsulates them. The iron ore gangue (usually a highly stable mineral containing SiO2 and Al2O3) is not affected by these process conditions and remains intact and intact. Thus, the product of this process is the larger gangue agglomerates and the fine particles of ferric iron / iron carbide surrounded by graphite. The size and density differences between the iron species and the gangue can then be exploited to separate the two species by physical screening.

[0142] Compositional data for the samples after reaction and physical separation by size is shown in Table 4. [Table 4] Table 4 - Sample Analysis

[0143] Analysis shows that it is possible to separate most of the iron species by size separation, with sample A corresponding to the majority of the iron. The compositional data was determined by XRF analysis, which requires prior oxidation of the sample, so that any iron species are shown as oxides and not ferrite. Energy dispersive X-ray spectroscopy analysis performed prior to calcination showed the iron species to be ferrite. Empirically, we can calculate that removing this oxide from the iron composition allows the process to extract a product that is 85% iron by weight from the original overall rock composition, which is approximately 35% by weight.

[0144] It is hypothesized that the graphitic carbon can then be removed from the ferric iron / carbide surrounded by graphite by a process called methanation, in which the iron / carbon particles are exposed to hydrogen gas at high temperatures to form methane gas via reaction 2 below. C+2H2→CH4(2)

[0145] Because the iron particles are very small and the reaction is exothermic, the iron particles agglomerate to form larger particles of pure iron.

[0146] It is envisaged that the graphitic carbon can then be removed from the graphite-encased ferric iron / carbide by contacting the graphite-encased ferric iron / carbide with hydrogen gas at 800° C. and 20 bar.

[0147] The advantage of the present invention over conventional iron ore beneficiation methods is that in addition to removing gangue, the iron oxide species produced are reduced (oxygen is removed leaving ferric iron). This reduced iron is 90% to 95% iron by weight, whereas high-grade iron ore is typically 55% to 63% by weight (70% is the theoretical maximum). Reduced iron is a higher quality product compared to iron ore and is therefore more expensive. Also, since ballast oxygen is not transported, the transportation costs of the reduced iron product are likely to be lower, saving 30% to 40% by weight and up to 50% by volume. Conventional beneficiation processes used in the iron ore industry include crushing, magnetic separation, flotation, gravity separation, thickening / filtration, and agglomeration.

[0148] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described, and the invention includes all such variations and modifications, and the invention includes all steps, features, formulations, and compounds, individually or collectively, referred to or shown in the specification.

Claims

1. 1. A process for producing hydrogen and graphitic carbon from a hydrocarbon gas, comprising the steps of: contacting a catalyst with the hydrocarbon gas at a temperature between 600° C. and 1,000° C. and a pressure between 0 bar (g) and 10 bar (g) to catalytically convert at least a portion of the hydrocarbon gas into hydrogen and graphitic carbon; the catalyst is a low-grade iron oxide, the hydrocarbon gas is selected from the group consisting of methane, ethane, ethylene, propane, and / or butane; and Upon contact with said hydrocarbon gas, all of the iron oxide in said catalyst is encapsulated by said graphitic carbon and broken down into micron- and nano-scale fragments.

2. 2. The process of claim 1, wherein the pressure is from 1 bar(g) to 10 bar(g).

3. 3. The process of claim 1 or 2, wherein the temperature is between 700°C and 950°C.

4. 4. The process of claim 1, wherein the temperature is between 800° C. and 900° C.

5. 3. The process of claim 1 or 2, wherein the temperature is between 650°C and 750°C.

6. 6. The process of claim 1, wherein the hydrocarbon gas is methane.

Images