Catalyst, method and arrangement for a chemical reaction, and use

Abstract

The application relates to a catalyst, a method and an arrangement for a chemical reaction forming one or more reaction products in solid form. The catalyst is formed of catalyst material, and the catalyst comprises at least one surface for the chemical reaction, attachment means for attaching the catalyst, and at least one functional element, which is selected from the group consisting of an integrated thermal element, integrated catalyst regeneration element, reactor cleaning element and their combinations. Further, the application relates to the use of the catalyst.

Description

[0001]CATALYST, METHOD AND ARRANGEMENT FOR A CHEMICAL REAC-TION, AND USEFIELD The application relates to a catalyst definedin claim 1, a method defined in claim 9 and an arrange-ment defined in claim 17 for a chemical reaction formingone or more reaction products in solid form. Further,the application relates to a use of the catalyst definedin claim 20. BACKGROUND It is known different catalysts for producingdifferent products. For example, different catalyst par- ticles are used in processes, e.g. fluidized processes, where hydrogen is formed. The thermal management and regeneration of currently used fluidized catalysts are challenging. OBJECTIVE An objective is to alleviate the disadvantagesmentioned above. In particular, the objective is to dis-close a novel type of catalyst with functional and op- erational properties. Further, the objective is to dis-close a novel type of 3D printed catalyst. Further, theobjective is to achieve an effective process for formingsolid products and / or hydrogen. Further, the objectiveis to provide a solution for regeneration of the cata-lyst. SUMMARY The catalyst, method, arrangement and use arecharacterized by what are presented in the claims.A catalyst for a chemical reaction forming re-action products is formed of catalyst material, and thecatalyst comprises at least one surface for the chemical reaction, attachment means for attaching the catalyst and at least one functional element, which is selected from the group consisting of an integrated thermal el- ement, integrated catalyst regeneration element, reac-tor cleaning element and their combinations. Preferably,at least the integrated catalyst regeneration element is used as the functional element. The method and arrangement for producing thereaction products comprise the defined catalyst. DETAILED DESCRIPTION A catalyst for a chemical reaction forming one or more reaction products, preferably comprising atleast carbon, in solid form is formed of catalyst mate-rial, and the catalyst has a catalyst structure and thecatalyst comprises at least one surface, such as cata-lyst surface, for the chemical reaction, attachmentmeans for attaching the catalyst, e.g. to an arrange-ment, and at least one functional element, which isselected from the group consisting of an integratedthermal element(s), integrated catalyst regenerationelement(s), reactor cleaning element(s) and their com-binations, and the catalyst comprises at least inte- grated catalyst regeneration element which is arrangedto the catalyst structure. In one embodiment, the cat-alyst comprises more than one functional elements. Pref-erably, the catalyst is free of a catalyst support.In this context, the catalyst has a structure,and the catalyst means any catalyst structure which isformed of catalyst material comprising at least one cat-alytic agent. Preferably, the catalyst is a fixed cat-alyst. The catalyst material may be formed of one ormore components, e.g. catalytic agents. The catalystmaterial may contain catalytically active metals, car-bon, other catalytically active agent or any combinationthereof, as the catalytic agent. In one embodiment, the catalyst material is formed of one or more catalyticagent. In one embodiment, the catalyst consists of thecatalyst material. The catalyst comprises the at least one surface, such as catalyst surface, for the chemical reaction. In one embodiment, the at least one surface for the chemical reaction comprises one or more cata-lytic agent. In one embodiment, the at least one surfacefor the chemical reaction is formed of a composite,preferably comprising at least two catalytic agents. Inone embodiment, the at least one surface for the chem- ical reaction is made of one or more catalytically ac-tive metals, carbon, or is a composite. In one embodi-ment, the at least one surface of the catalyst is formed of a composition of the catalyst material which differs from the other catalyst material, and the said surface is arranged onto the other catalyst material. In one embodiment, the whole catalyst is formed of the samecatalyst material. The catalyst has a three-dimensionalstructure with predetermined dimensions, e.g. length, width, depth and / or diameter, and with predeterminedshape. In one embodiment, the appearance structure ofthe catalyst is tubular. Further, the catalyst has apredetermined cross-section. In one embodiment, the cat- alyst has a predetermined pattern of the cross-section,e.g. honeycomb pattern or lattice pattern. In one em-bodiment, the catalyst has a honeycomb structure, lat- tice structure, spiral structure, screw structure, tubestructure, rod structure, platy structure, sheet struc-ture, structure comprising parallel sheets, other struc-ture through which gas can flow, or other suitablestructure. In one embodiment, the catalyst is porous.In one embodiment, the catalyst is transporous. In oneembodiment, the catalyst is non-porous. In one embodi-ment, the catalyst has a surface area of at least 2 -30 m2 / g, in one embodiment 5 – 25 m2 / g. In one embodiment, the catalyst material and / or the at least one surface for the chemical reaction is made of one or more catalytically active metals selected from the group consisting of nickel, copper, iron, al-uminium, titanium, cobalt, manganese, chromium, sili-con, carbon, or an oxide thereof, or any combinationthereof. In one embodiment, the catalyst material and / orthe at least one surface for the chemical reaction is made of one or more catalytically active metals selected from the group consisting of nickel, copper, iron, al-uminium, titanium, cobalt, manganese, chromium, sili-con, carbon, and any combination thereof. In one embod-iment, the at least one surface for the chemical reac- tion is made of two catalytically active metals, wherein the two catalytically active metals are selected from the group consisting of nickel, copper, iron, aluminium,titanium, cobalt, manganese, chromium, silicon, carbon,and any combination thereof. In one embodiment, the cat-alyst material and / or the at least one surface for the chemical reaction is made of a metal alloy. In one embodiment, the catalyst is a monolith. In one embodiment, the surface of the catalyst comprisesone or more surface irregularities. In one embodiment,the catalyst has a specific pressure profile which isdetermined based on a flow in the catalyst. In one em-bodiment, the catalyst is a monolith comprising one or more surface irregularities for providing an uneven sur- face pressure profile. In one embodiment, the surface comprises pores and / or protrusions to form surface ir-regularities. In one embodiment the catalyst, preferablythe surface, comprises microstructures, such as spikes, protruding from the surface of the catalyst. The spikesmay enable carbon nanotube and / or carbon nanofiber for-mation. In one embodiment, the spikes are used for car-bon nanotube and / or carbon nanofiber formation. In oneembodiment, microstructures, such as spikes, can contain different metals than the rest of the catalyst struc- ture. In one embodiment, the catalyst is formed from the catalyst material, such as from powder of the cat-alyst material. In one embodiment, the catalyst isformed from powder of the catalyst material to form athree-dimensional catalyst. In one embodiment, the cat-alyst is formed from a metal alloy, preferably powderof the metal alloy. In one embodiment, the catalyst isformed by printing, 3D-printing, direct metal laser sin-tering (DMLS), selective laser sintering (SLS), laser-based powder bed fusion technology (L-PFB), stereo-lithography, and / or extrusion printing, or any combina-tion thereof. In one embodiment, the catalyst is formedby printing. In one embodiment, the catalyst is formedusing the 3D-printing from the catalyst material. In oneembodiment, the 3D-printing is selected from the group consisting of binder jetting, directed energy deposi- tion, material extrusion, powder bed fusion, sheet lam-ination, vat polymerisation, laser-based powder bed fu-sion technology (L-PFB), and wire arc additive manufac-turing, or any combination thereof. In one embodiment,the catalyst is formed by printing, coating, depositing, extruding, rolling, cutting, laser cutting, or typical metal production methods, where metal powder is used, or any combination thereof. In one embodiment, the cat- alyst is formed by printing, coating, depositing, ex- truding, or by any another suitable method. In one em- bodiment, the coating of the catalyst is carried out by heat spraying, porous plating, metal plating, blast pro- cessing, other suitable coating, or any combinationthereof. The desired structure and shape of the catalystis provided during the manufacture of the catalyst, e.g.during the printing or other manufacturing method.The catalyst comprises at least one functional element, which is selected from the group consisting of an integrated thermal element, integrated catalyst re- generation element, reactor cleaning element and theircombinations. In this context, the functional elementmeans any element by which the catalyst can be operated,e.g. by regenerating, heating or cleaning. The func-tional element is arranged to the catalyst structure during the manufacture of the catalyst. In one embodi-ment, the functional element is a channel, passage, ductor the like. In one embodiment, the functional elementis the channel in the catalyst structure. In one embod- iment, the functional element is the duct or channel inside the catalyst. In one embodiment, the functional element is arranged parallel with a direction of flowin the catalyst. In one embodiment, the functional el-ement is arranged crosswise with relation to a direction of flow in the catalyst. In one embodiment, the catalyst is pre-treated before the use, e.g. before an attachment to an arrange-ment, to modify the surface of the catalyst and / or toimprove the activity of the catalyst. In one embodiment,the catalyst is acid-treated. In one embodiment, thesurface of the catalyst is modified such that surface irregularities, e.g. microstructures, spikes, protrud- ing from the surface, pores or the like, are arranged onto the catalyst, preferably to the surface. The catalyst can be attached by means of the attachment means to an arrangement, e.g. reactor. In this context, the arrangement means any arrangement, de-vice, apparatus, reactor or the like or any combinationthereof, which preferably comprises the catalyst. In oneembodiment, the arrangement comprises at least the reac-tor. In the arrangement for a chemical reactionforming one or more reaction products, preferably com-prising at least carbon, in solid form, the arrangementcomprises the catalyst as defined in this description. In one embodiment, the arrangement further com- prises a reaction chamber for receiving the catalyst. In one embodiment, the reaction chamber comprises the attachment means for attaching the catalyst to the re- action chamber. In this context, the attachment means is under-stood to mean any attachment means, shape or profile ofthe catalyst or shape or profile of the arrangement, e.g.reactor. Any attachment means can be used to attach the catalyst to the arrangement. In one embodiment, the at-tachment means for attaching the catalyst to an arrange-ment is an integrated part of the catalyst. In one em-bodiment, the catalyst is attached to the arrangementwalls by the attachment means. In one embodiment, theattachment is selected from the group consisting of hooks, connectors, other connecting element, or any com-bination thereof. In one embodiment, the catalyst isshaped such that the shape of the catalyst comprises the attachment means. In one embodiment, the catalyst or its external appearance is shaped such that the catalyst can be placed and locked into the arrangement, e.g. into the reactor, i.e. the catalyst comprises the external appear- ance as the attachment means. In one embodiment, the arrangement, e.g. the reactor, or its inner appearance is shaped such that the catalyst can be placed and lockedinto the arrangement, and the catalyst has suitable shapeto be locked into the arrangement. Preferably, the cata-lyst can be easily replaced or removed from the arrange- ment, e.g. for regeneration purposes. In one embodiment, the catalyst is a detachable catalyst, i.e. the catalyst can be easily detached from the arrangement, e.g. from the reactor. In one embodiment, the catalyst has a structurewhich is formed from more than one parts and in which the parts can be detached and attached. In one embodiment, the catalyst has a block structure. In one embodiment, the parts are arranged one on the other, and preferably combined to form the catalyst structure. In one embodi- ment, the parts are arranged in parallel, e.g. as halves, to form a combined catalyst structure. In one embodiment, the parts, and preferably each part, are detachable fromother parts. Then dirty and / or worn out part or parts canbe removed and regenerated or replaced with a new part. In one embodiment, the catalyst consists of solid free- forming interlockable and stackable halves, e.g. inside the reactor, so that the halves are made of catalyst material, e.g. alloy / composite. The halves are arranged by orienting them opposite to each other, e.g. to form a grid structure. The reactant, such as reaction gas,can flow through the catalyst structure, and a catalyt-ical reaction will occur on the surfaces of the cata-lyst. In one embodiment the parts, e.g. several half-cells, may be stacked upon each other to obtain desiredheight, and to make sure that all reactants, such asreaction gas, are consumed before it escapes the reac-tor. The advantage of this design is two-fold: (1) the product removal, e.g. carbon, is made easier as the twohalves can be pulled apart and cleaned and / or regeratedchemically, e.g. by hydrogen or acid, or mechanically,and / or e.g. by using ultrasound, microwave or vibration means or other means. Besides, (2) the catalytic reac-tion is expected to eventually consume the catalyst ma-terial, e.g. alloy / composite, thinning the catalyticsurfaces. The erosion is likely higher at the place of fastest growth, i.e. gas inlet, so these places will wear out first. A modular design, i.e. combined parts,will allow removing wasted parts and replacing freshones on the top, minimizing material loss. The dimen- sions can be worked out based on the expected carbon growth, gas flow, and desired wall thickness. The predetermined chemical reaction is per- formed by the catalyst. The chemical reaction can be performed in the arrangement, e.g. in the reactor. In one embodiment, the chemical reaction is performed at apressure between 0 – 5 bars and / or at a temperaturebetween 600 - 900 °C. In one embodiment, the catalystmaterial is selected such that the catalyst decomposesless than 60 %, less than 50 %, less than 30 %, less than 10 %, less than 5 %, or less than 1 % during thereaction. In one embodiment, the chemical reaction form-ing one or more reaction products in solid form is a chemical reaction selected from the group consisting ofcatalysed pyrolysis, catalysed hydrocarbon pyrolysis,catalysed methane pyrolysis, catalytic methane decompo-sition, catalysed methane splitting, chemical vapor dep-osition, other reaction, or any combination thereof. Inone embodiment, hydrocarbon pyrolysis is the reaction, in which the hydrocarbon is selected from the group of C1-10-alkanes, such as methane and ethane, C2-10-alkenes and C2-10-alkynes. In the method for producing one or more reac-tion products comprising at least carbon in solid formby a chemical reaction, a catalyst, which has a catalyststructure, is formed from catalyst material, wherein thecatalyst comprises at least one surface for the chemical reaction, attachment means and at least one functional element, which is selected from the group consisting of an integrated thermal element, integrated catalyst re- generation element, reactor cleaning element and their combinations, and the catalyst comprises at least inte- grated catalyst regeneration element which is arranged to the catalyst structure, and the catalyst is attachedby means of the attachment means to an arrangement, areactant is fed to the arrangement and the chemicalreaction is performed in the arrangement, and at leastone solid reaction product is recovered. Preferably, atleast carbon is recovered as the solid reaction product.Preferably, the reactant is arranged to contact with thecatalyst in the arrangement, e.g. in the reactor. In oneembodiment, the steps comprising the feeding of the re- actant, the performance of the chemical reaction and the recovery of the products can be repeated one or more times. In this context, the reactant means any suit- able reactant, which can be treated in the method with the defined catalyst. In one embodiment, the reactant is a hydrocarbon selected from the group of C1-10-alkanes such as methane and ethane, C2-10-alkenes, and C2-10-al- kynes. In one embodiment, the chemical reaction isperformed at a reaction temperature of between 600 – 900°C. In one embodiment, the chemical reaction is per-formed under the pressure of between 0 – 5 bars. In oneembodiment, the contact time of the reactant with thecatalyst is selected based on the reactant and the cat-alyst. In one embodiment, the method comprises: i)providing a catalyst as defined; ii) letting the cata-lyst to contact a reactant at a predefined reaction temperature, wherein the predefined reaction tempera- ture is selected based on the catalyst and the reactant, thereby forming one or more reaction products in solidform; and iii) collecting the formed one or more reac-tion products in solid form. In one embodiment, hydrogenis formed in ii), and the formed hydrogen is collected. In one embodiment, in ii), the predefined reaction tem-perature is between 600 – 900 °C. In one embodiment, inii), the pressure is between 0 – 5 bars. In one embod-iment, the steps ii) and iii) are repeated one or moretimes. The reaction product in the solid form com- prises carbon. In one embodiment, the reaction productin solid form and hydrogen are produced. In one embodi-ment, the one or more reaction products in solid form comprises, or consists essentially of, carbon. In oneembodiment, the reaction product in solid form comprisesan allotrope of carbon, e.g. carbon nanotube, carbonnanofiber, graphite, graphene, and / or carbon black. Inone embodiment, the one or more reaction products insolid form consists of an allotrope of carbon, prefer-ably consists essentially of carbon nanotube and carbonnanofiber. In one embodiment, hydrogen and the one ormore reaction products in solid form, wherein the one or more reaction products in solid form comprises, or consists essentially of, carbon, are formed in the chem- ical reaction, and preferably are recovered. The catalyst can be treated, regenerated, heated and / or cleaned by the at least one functional element. The functional element can be an integrated thermal element, integrated catalyst regeneration ele- ment, reactor cleaning element or any combination thereof. In one embodiment, the catalyst is a regener- able catalyst, which can be easily regenerated. In one embodiment, the formed carbon may block up the catalyst,i.e. the pores or passages in the catalyst, and then itis important that the catalyst can be regenerated. Inone embodiment, the catalyst is detached from the ar- rangement, e.g. from the reactor, before treating, re- generating, heating and / or cleaning. In one embodiment, the catalyst is treated in the arrangement. Preferably, the catalyst comprises the inte-grated catalyst regeneration element, arranged to thecatalyst structure, e.g. in the catalyst structure. Inone embodiment, the integrated catalyst regenerationelement is selected from the group consisting of one ormore channels, one or more means for microwave irradi- ation, one or more means for ultrasound irradiation, one or more means for vibration, and any combinationthereof. In one embodiment, the integrated catalyst re-generation element is selected from one or morechannels, one or more means, e.g. device, for microwaveirradiation, one or more means, e.g. device, for ultra-sound irradiation, one or more means, e.g. device, forvibration, one or more means, e.g. device, for gaspulse, or any combination thereof. In one embodiment,the integrated catalyst regeneration element is selected from one or more of one or more open ended channels, one or more means for microwave irradiation, one or more means for ultrasound irradiation, and one or more meansfor gas pulse. In one embodiment, the catalyst comprisesat least one or more channels. In one embodiment, thecatalyst comprises one or more open ended channels, andone or more means for microwave irradiation. In oneembodiment, the catalyst comprises one or more tubes formicrowaves. In one embodiment, the catalyst comprisesone or more open ended channels, and one or more meansfor ultrasound irradiation. In one embodiment, the cat-alyst comprises one or more means for vibration. In oneembodiment, the catalyst comprises one or more means for gas pulse. In one embodiment, the catalyst comprises one or more open ended channels, and one or more means forgas pulse. In one embodiment, the one or more open endedchannels are arranged to receive a fluid and / or a gasfrom the arrangement. In one embodiment, hydrogen and / ornitrogen is blown through the channels to remove carbonfrom the catalyst. In one embodiment, hydrogen with tem-perature causes reaction to go backwards, such as C +2H2 -> CH4, which cleans the catalyst surfaces. In oneembodiment, the catalyst can be regenerated using an acid, e.g. via the channels, i.e. the catalyst can be re-activated by the acid. In one embodiment, the inte- grated catalyst regeneration element is a combined cat- alyst regeneration and cleaning element. In one embod- iment, the catalyst regeneration element comprises at least one cleaning element. In one embodiment, the cleaning element is a mechanical cleaning means or de- vice, e.g. a blade, such as a movable blade. In one embodiment, the catalyst comprises theintegrated thermal element. In one embodiment, the in-tegrated thermal element is selected from one or more channels, one or more heating devices, and one or more duct for heating the catalyst by a heated medium, andany combination thereof. In one embodiment, the inte-grated thermal element comprises one or more heating tubes. In one embodiment, the catalyst comprises theintegrated reactor cleaning element. In one embodiment,the integrated reactor cleaning element is selected from one or more channels, one or more means for ultrasoundirradiation, one or more means for vibration, one ormore mechanical cleaning means, and one or more ducts,e.g. comprising holes, for cleaning or washing the cat-alyst by a cleaning medium, e.g. hydrogen or water, andany combination thereof. In one embodiment, the catalystor reactor is cleaned by hydrogen flow. In one embodi- ment, the catalyst or reactor is cleaned by ultrasound. In one embodiment, the catalyst or reactor are cleanedby vibration. In one embodiment, the catalyst or reactoris cleaned mechanically, e.g. mechanical cleaning meansor device. In one embodiment, the catalyst regenerationelement comprises at least one cleaning element, e.g. mechanical cleaning means or device. In one embodiment,the mechanical cleaning means is a blade, e.g. a movableblade. In the method embodiment, the catalyst can betreated, regenerated, heated and / or cleaned by the atleast one functional element. In one embodiment, thecatalyst is detached from the arrangement, e.g. from thereactor, and the catalyst is treated, regenerated,heated and / or cleaned by the at least one functionalelement. In one embodiment, the method further comprises: irradiating the catalyst using the means for microwave irradiation and / or the means for ultrasound irradiation. In one embodiment, the method further com- prises: irradiating the catalyst using the means for microwave irradiation. In one embodiment, the method further comprises: irradiating the catalyst using theone or more means for ultrasound irradiation. In oneembodiment, the method further comprises: irradiating the catalyst using the means for microwave irradiation and / or the one or more means for ultrasound irradiation. In one embodiment, the method further comprises: irradiating the catalyst and / or the reactant and / or the one or more reaction products in solid form using the means for microwave irradiation, and / or the one or more means for ultrasound irradiation. In oneembodiment, the method further comprises: irradiatingthe catalyst and / or the reactant using the means for microwave irradiation. In one embodiment, the method further comprises: treating or exposing the catalyst and the one or more reaction products in solid form with a gas, such as hydrogen, noble gas, or air, and / or a fluid, such as water, via the one or more channels, e.g. open ended channels. In one embodiment, the method further comprises: treating or exposing the catalyst and the one or more reaction products in solid form with a gas, such as hydrogen, noble gas, or air, and / or a fluid, such aswater, via the one or more channels, e.g. open endedchannels; and irradiating the catalyst, the one or more reaction products, and the gas and / or the fluid using the means for microwave irradiation, and / or the one or more means for ultrasound irradiation. In one embodiment, the method further comprises: treating the catalyst and the one or more reaction products by vibrating using the means for vibration. In one method for the preparation of the cat-alyst, the method comprises: providing one or more cat-alyst components, e.g. catalyst agents, to form the cat- alyst material; depositing the catalyst material andforming the catalyst from the catalyst material, andarranging attachment means and at least one functionalelement, which is selected from the group consisting of an integrated thermal element, integrated catalyst re- generation element, reactor cleaning element and theircombinations to the catalyst. In one embodiment,the catalyst is pre-treated before the chemical reac- tion. In one embodiment, the depositing is additivemanufacturing such as 3D-printing, direct metal lasersintering (DMLS), selective laser sintering (SLS), la-ser-based powder bed fusion technology (L-PFB), stere-olithography, and / or extrusion printing, or any combi-nation thereof. In one embodiment, the 3D-printing isselected from the group consisting of binder jetting, directed energy deposition, material extrusion, powder bed fusion, sheet lamination, vat polymerisation, and wire arc additive manufacturing, or any combination thereof. In one embodiment, the catalyst can be obtained by the method as above defined. The catalyst can be used in a desired arrange-ment and / or in a desired method. In one embodiment, thecatalyst is used in a catalysed pyrolysis, catalysedhydrocarbon pyrolysis, catalysed methane pyrolysis,catalytic methane decomposition, catalysed methanesplitting, chemical vapor deposition, other reaction,or any combination thereof. Thanks to the invention the high quality cat-alyst with operational functions can be provided. Fur-ther, 3D printing catalyst can be prepared easily. Thethree-dimensional catalyst geometry enables integrated thermal management, e.g. with channels or addition of microwave. The integration of microwaves, ultrasound and / or channels for purge gas provides easy soot blowing and catalyst regeneration. Further, gas flow management and pressure optimization can be achieved, and various pressure zones across the catalyst are possible. The invention offers a possibility to achievea catalyst with good properties easily. The catalyst canbe prepared with low material costs, with better me-chanical strength and with long lifetime. The catalystis easy to regenerate and operate in connection withproduction processes. By means of the catalyst simplerbalance of the process can be achieved. Further, the catalyst has a lower carbon footprint over lifetime. EXAMPLES The catalyst for a chemical reaction is formedof catalyst material, and the catalyst comprises atleast one surface for the chemical reaction, attachment means for attaching the catalyst to an arrangement and at least one functional element. The functional element is selected from the group consisting of an integrated thermal element, integrated catalyst regeneration ele- ment, reactor cleaning element and their combinations. The catalyst consists of the catalyst material, such as metal alloy, and the catalyst is free of acatalyst support. The catalyst is prepared by 3D-print-ing from the metal alloy powder to form a fixed catalyst having desired structure and dimensions. Further, chan- nels are formed in the catalyst. In the chemical reaction, solid reaction prod- ucts, such as at least carbon, and also hydrogen are formed by using the catalyst in the arrangement. Thearrangement is a reactor with the fixed catalyst asdefined above. The catalyst can be detached from the arrange-ment, and the catalyst can be treated, regenerated,heated and / or cleaned by the functional element. Thefunctional element comprises the channels in the cata-lyst. The catalyst can be treated by blowing a gas, e.g.hydrogen, and / or supplying a fluid, e.g. water, throughthe one or more channels. Further, or optionally, thecatalyst can be irradiated using the means for microwaveirradiation and / or the means for ultrasound irradiation. Then the catalyst can be regenerated easily. Example 1 In this example, a fixed catalyst with channelswas manufactured. The catalyst was formed by 3D-printing from the metal alloy powder. The catalyst has honeycomb structure. The catalyst is the regenerable catalyst. Typ- ically, the formed carbon blocks up the catalyst, such as the pores or passages in the catalyst. The catalystcomprises the channels as integrated catalyst regener-ation elements, and the catalyst can be regenerated eas- ily. Hydrogen can be blown through the channels, and simultaneously carbon can be removed from the catalyst. It was observed that the catalyst can be used in the chemical reaction to form solid carbon product and hydrogen. Example 2 In this example, the arrangement comprises thecatalyst according to example 1. The arrangement is areactor in a catalysed pyrolysis. The catalyst can beattached by means of the attachments means to the ar- rangement. Example 3 In this example, reaction products in solidform are produced by a chemical reaction by using thecatalyst according to example 1 in the arrangement ac- cording to example 2. A reactant comprising hydrocarbons is fed to the arrangement and the chemical reaction isperformed in the arrangement. The reactant is arrangedto contact with the catalyst in the arrangement. Atleast carbon is recovered as the solid reaction product. Further hydrogen is formed and recovered. Example 4 In this example, the catalyst of example 1 isregenerated using the integrated catalyst regenerationelements. The catalyst comprises the channels. Further, the catalyst comprises means for microwave irradiation, means for ultrasound irradiation, means for vibrationand / or means for gas pulse as the integrated catalystregeneration elements. The cleaning of catalyst surfacescan be improved by means of microwave irradiation, ul-trasound irradiation, vibration and / or gas pulse, andthus the catalyst can be regenerated easily and effec-tively. Example 5 In this example, the catalyst of example 1 is regenerated using the integrated catalyst regenerationelements. The catalyst comprises the channels, and fur-ther at least one cleaning element, which is a mechan- ical cleaning element, such as a blade or a movableblade. Then the solid carbon product can be removedmechanically from the surface(s) of the catalyst struc-ture by the mechanical cleaning element. Example 6 In this example, the catalyst is regenerated using the integrated catalyst regeneration elements. Thecatalyst has a plate structure in this example. The sur-faces of the plates are treated with an acid.In the tests, the carbon was produced in a ther- mal catalytic decomposition process of methane, and the carbon yield was 83 g carbon / g catalyst (run time of 66.5 hours). After the first run, the catalyst was re-acti- vated by dipping the plates in HNO3and by calcining. A new reaction run was performed, and the carbon yield was 54 g carbon / g catalyst (run time of 51 hours). It was observed from the tests that the catalyst can be re-activated by means of the acid. Thus, the cat- alyst can be regenerated easily and effectively. The catalyst is suitable in different embodi-ments for different uses. Further, the invention issuitable in different embodiments for producing differ-ent products.The invention is not limited merely to the ex-amples referred to above; instead, many variations arepossible within the scope of the inventive idea defined by the claims.

Claims

CLAIMS 1. A catalyst for a chemical reaction formingone or more reaction products comprising at least carbonin solid form, c h a r a c t e r i z e d in that the cat-alyst has a catalyst structure which is formed of cat-alyst material, and the catalyst comprises at least onesurface for the chemical reaction, attachment means forattaching the catalyst, and at least one functional el-ement, which is selected from the group consisting ofan integrated thermal element, integrated catalyst re-generation element, reactor cleaning element and theircombinations, and the catalyst comprises at least inte- grated catalyst regeneration element which is arrangedto the catalyst structure.

2. The catalyst according to claim 1, c h a r -a c t e r i z e d in that the at least one surface forthe chemical reaction is made of one or more catalyti- cally active metals, carbon, or is a composite.

3. The catalyst according to claim 1 or 2,c h a r a c t e r i z e d in that the at least one surfacefor the chemical reaction is made of one or more cata- lytically active metals selected from the group con- sisting of nickel, copper, iron, aluminium, titanium,cobalt, manganese, chromium, silicon, and carbon, or anoxide thereof, or any combination thereof.

4. The catalyst according to any one of claims1 to 3, c h a r a c t e r i z e d in that the reactionproduct in solid form comprises an allotrope of carbon.

5. The catalyst according to any of claims 1to 4, c h a r a c t e r i z e d in that the integratedcatalyst regeneration element is selected from one or more of one or more open ended channels, one or more means for microwave irradiation, one or more means for ultrasound irradiation, one or more means for vibration, and one or more means for gas pulse.

6. The catalyst according to any one of claims1 to 5, c h a r a c t e r i z e d in that the catalyst isformed from powder of the catalyst material to form athree-dimensional catalyst.

7. The catalyst according to any one of claims1 to 6, c h a r a c t e r i z e d in that the catalyst isformed by printing, 3D-printing, direct metal laser sin-tering (DMLS), selective laser sintering (SLS), laser-based powder bed fusion technology (L-PFB), stereo-lithography, and / or extrusion printing, or any combina- tion thereof.

8. The catalyst according to any one of claims1 to 7, c h a r a c t e r i z e d in that the attachmentmeans for attaching the catalyst to an arrangement is an integrated part of the catalyst.

9. A method for producing one or more reactionproducts comprising at least carbon in solid form by achemical reaction, c h a r a c t e r i z e d in that themethod comprises -forming a catalyst, which has a catalyst structure,from catalyst material, wherein the catalyst com-prises at least one surface for the chemical reac- tion, attachment means and at least one functionalelement, which is selected from the group consist- ing of an integrated thermal element, integrated catalyst regeneration element, reactor cleaning element and their combinations, and the catalyst comprises at least integrated catalyst regenera- tion element which is arranged to the catalyst structure; -attaching the catalyst by means of the attachmentmeans to an arrangement; -feeding a reactant to the arrangement and perform-ing the chemical reaction in the arrangement; and- recovering at least one solid reaction product.

10. The method according to claim 9, c h a r -a c t e r i z e d in that hydrogen and the one or morereaction products in solid form, which comprises carbon,are formed in the chemical reaction and recovered.

11. The method according to claim 9 or 10,c h a r a c t e r i z e d in that the reactant is a hydro-carbon selected from the group of C1-10-alkanes, C2-10- alkenes, and C2-10-alkynes.

12. The method according to any one of claims9 to 11, c h a r a c t e r i z e d in that the chemicalreaction is performed at a reaction temperature of be-tween 600 – 900 °C.

13. The method according to any one of claims9 to 12, c h a r a c t e r i z e d in that the chemicalreaction is performed under the pressure of between 0 –5 bars.

14. The method according to any one of claims9 to 13, c h a r a c t e r i z e d in that the catalystis detached from the arrangement, and the catalyst istreated, regenerated, heated and / or cleaned by the at least one functional element.

15. The method according to any one of claims9 to 14, c h a r a c t e r i z e d in that the methodfurther comprises: treating the catalyst and the one or more reaction products in solid form with a gas and / or a fluid via the one or more channels.

16. The method according to any one of claims9 to 15, c h a r a c t e r i z e d in that the methodfurther comprises: irradiating the catalyst using the means for microwave irradiation and / or the means for ultrasound irradiation.

17. An arrangement for a chemical reactionforming one or more reaction products comprising atleast carbon in solid form, c h a r a c t e r i z e d inthat the arrangement comprises at least a catalyst whichhas a catalyst structure formed of catalyst material andwhich comprises at least one surface for the chemical reaction, attachment means for attaching the catalyst to the arrangement and at least one functional element, which is selected from the group consisting of an inte- grated thermal element, integrated catalyst regenera- tion element, reactor cleaning element and their combi- nations, and the catalyst comprises at least integrated catalyst regeneration element which is arranged to the catalyst structure.

18. The arrangement according to claim 17,c h a r a c t e r i z e d in that the arrangement furthercomprises a reaction chamber for receiving the catalyst.

19. The arrangement according to claim 17 or18, c h a r a c t e r i z e d in that the arrangement isa device, apparatus, reactor or any combination thereof.

20. A use of the catalyst according to any oneof claims 1 to 8, c h a r a c t e r i z e d in that thecatalyst is used in a catalysed pyrolysis, catalysedhydrocarbon pyrolysis, catalysed methane pyrolysis,catalytic methane decomposition, catalysed methanesplitting, chemical vapor deposition, other reaction,or any combination thereof.