Synergetic hydrogen generation and sand enhancement method and system

Abstract

A method for generating hydrogen while depositing carbon material on sand includes inputting (1100) sand grains (310, 316) into a reaction chamber (210), wherein the sand grains (310, 316) are either natural sand grains (310) that include a natural metal containing substance (312) or enhanced sand (316) that includes an added metal containing substance (314); inputting (1102) a carbon source (214) into the reaction chamber (210) to react with the sand grains (310, 316); controlling (1104) a temperature inside the reaction chamber (210) to achieve catalytic decomposition of the carbon source (214), which results in generation of hydrogen (222) and solid carbon (224), which grows on the sand grains (310, 316) to form carbonaceous treated sand (420); and collecting (1106) the hydrogen (222) outside the reaction chamber (210).

Description

SYNERGETIC HYDROGEN GENERATION AND SAND ENHANCEMENT METHOD AND SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 608,997, filed on December 12, 2023, entitled “CARBON IN SAND, PROCESS AND UTILIZATION,” and U.S. Provisional Patent Application No.63 / 671 ,511 , filed on July 15, 2024, entitled “SYNERGETIC HYDROGEN GENERATION AND SAND ENHANCEMENT METHOD AND SYSTEM,” the disclosures of which are incorporated herein by reference in their entirety.BACKGROUND OF THE INVENTIONTECHNICAL FIELD

[0002] Embodiments of the subject matter disclosed herein generally relate to a system and method for converting a carbon source into hydrogen while enhancing sand properties for selected applications, and more particularly, to using thermocatalytic decomposition of the carbon source (e.g., methane) to generate the hydrogen and using a sand-based catalyst so that the sand properties are enhanced by carbon deposition from the carbon source.DISCUSSION OF THE BACKGROUND

[0003] Transitioning to hydrogen fuel holds the potential to offer significant environmental and human health benefits, primarily by addressing issues related to air quality, reducing greenhouse gas emissions, and promoting sustainable energypractices. One advantage of the hydrogen fuel is the improved air quality. The combustion of hydrogen does not produce harmful pollutants such as particulate matter, nitrogen oxides (NOx), or sulfur dioxide (SO2). This is particularly relevant for urban areas experiencing air pollution, as the use of hydrogen fuel in transportation and industries can lead to cleaner air, reducing respiratory illnesses, and other health problems associated with poor air quality.

[0004] In addition, hydrogen fuel cells can be more energy-efficient than traditional combustion engines, especially in certain applications. The conversion of hydrogen into electricity within fuel cells is more efficient and cleaner than burning fossil fuels, leading to a more sustainable and resource-efficient energy system. Further, the generated hydrogen can serve as an energy carrier and storage solution, addressing the intermittent nature of renewable energy sources. Excess energy generated during periods of high renewable energy availability can be used to produce hydrogen through various processes, which can later be converted back to electricity when demand is high. This contributes to grid stability and enhances the overall reliability of renewable energy systems.

[0005] Transitioning to hydrogen as a fuel source diversifies the energy mix, reducing dependence on finite fossil fuel resources. This diversification enhances energy security, as hydrogen can be produced from a variety of sources, including water, biomass, and waste, in addition to renewable energy. Additionally, carbon capture and storage (CCS) technologies can be integrated into hydrogen production from carbon fuels, mitigating the environmental impact by capturing and storing the carbon dioxide emissions. This addresses one of the major concerns associated withfossil fuel-based processes, helping to bridge the gap between the current reliance on carbon-intensive industries and the transition to a more sustainable energy landscape. The utilization of existing assets in the carbon fuel industry, coupled with CCS, can serve as a transitional solution to meet the growing demand for hydrogen while minimizing the overall carbon footprint.

[0006] Generating hydrogen from carbon fuel, specifically through processes like catalytic decomposition of methane (CDM), or steam methane reforming (SMR) or gasification, has both advantages and drawbacks. One of the primary benefits is the existing infrastructure and expertise in the fossil fuel industry, making the transition to hydrogen production more feasible and cost-effective in the short term. By leveraging the well-established network of natural gas pipelines and refining facilities, the initial investment required for building new infrastructure is significantly reduced compared to other green hydrogen production methods.

[0007] Thus, there is a strong push today for moving away from fossil fuels and embracing alternative fuels, such as hydrogen. However, one obstacle in the large scale deployment of these processes to generate hydrogen from a carbon source is their high operating cost, as these processes require high temperatures (e.g., CDM), and a large amount of electricity might be needed (e.g., water electrolysis).

[0008] Therefore, there is a need for a new or improved process and system that offsets the high amount of energy necessary for generating the hydrogen from a carbon source.SUMMARY OF THE INVENTION

[0009] According to an embodiment, there is a method for generating hydrogen while depositing carbon material on sand. The method includes inputting sand grains into a reaction chamber, wherein the sand grains are either natural sand grains that include a natural metal containing substance or enhanced sand that includes an added metal containing substance, inputting a carbon source into the reaction chamber to react with the sand grains, controlling a temperature inside the reaction chamber to achieve catalytic decomposition of the carbon source, which results in generation of hydrogen and solid carbon, which grows on the sand grains to form carbonaceous treated sand, and collecting the hydrogen outside the reaction chamber.

[0010] According to another embodiment, there is a carbonaceous treated sand that includes natural sand grains, metal atoms attached to surfaces of the natural sand grains and carbon material attached to the metal atoms.

[0011] According to yet another embodiment, there is a system for generating hydrogen while depositing carbon material on sand, and the system includes a reaction chamber having a first input port configured to receive sand grains, where the natural sand grains are either natural sand grains that include a natural metal containing substance or enhanced sand that includes an added metal containing substance, a second input port configured to receive a carbon source to react with the sand grains, and a first output port configured to collect hydrogen, which is produced by a catalytic decomposition of the carbon source. The system furtherincludes a heater configured to heat the reaction chamber so that the catalytic decomposition of the carbon source takes place, and solid carbon is formed, which grows on the sand grains to form carbonaceous treated sand. The reaction chamber further includes a second output port configured to collect the carbonaceous treated sand.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0013] FIGs. 1 A and 1 B list various catalysts used in CDM for generating hydrogen and their capabilities;

[0014] FIG. 2 is a schematic diagram of a reactor configured to generate hydrogen while enhancing sand properties;

[0015] FIG. 3 schematically illustrates a catalytic compound used in the reactor of FIG. 2 for generating hydrogen;

[0016] FIG. 4 schematically illustrates a reaction chamber of the reactor having a conveyor system for catalyst supply;

[0017] FIGs. 5A and 5B are scanning electron microscopy (SEM) images of the enhanced sand;

[0018] FIG. 6 schematically illustrates the growing of carbon on the sand due to the hydrogen generation process in the reactor of FIG. 2;

[0019] FIG. 7 illustrates the thermogravimetric analysis of the carbonaceous treated sand;

[0020] FIG. 8 illustrates the X-ray diffraction analysis of the carbonaceous treated sand;

[0021] FIGs. 9A and 9B illustrate the liquid components found in the reactor after hydrogen generation;

[0022] FIG. 10 is a table comparing a strength of concrete made with the enhanced sand and concrete made with other sand and carbon material; and

[0023] FIG. 11 is a flow chart of a method for generating the hydrogen and enhanced sand.DETAILED DESCRIPTION OF THE INVENTION

[0024] The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to methane-based hydrogen generation and carbonaceous sand enhancements. However, the embodiments to be discussed next are not limited to hydrogen, methane, and sand enhancements, but may be applied to other types of fuel, other types of carbon sources, and / or other aggregate materials.

[0025] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

[0026] According to an embodiment, a method and system for synergistically generating a fuel from a carbon source and enhancing the properties of an aggregate material based on the same carbon source is introduced. The method may simultaneously generate the fuel and enhance the aggregate material based onthe various parts of the carbon source. In one application, the aggregate material is used as a base for a catalyst that is used to decompose the carbon source. The soiling of the catalyst becomes part of the aggregate material, which enhances the aggregate material’s properties. Thus, for this embodiment, the soiling of the catalyst is a positive outcome of the reaction and there is no need for catalyst regeneration as more aggregate material is treated during catalyst decomposition process. This synergy between fuel generation and catalyst based enhancement of the aggregate material reduces the cost of generating the fuel, as the enhanced aggregate material may be used in the construction field or soil enhancement field. Details of the processes and systems for generating these materials are now discussed with regard to the figures.

[0027] The inventors of this patent application have realized that one downside of the CDM process is the quick deactivation of the catalyst (especially metal catalyst) due to the encapsulation of the catalyst by deposited carbon or deposition of coke over the pores and internal cavities of the catalyst. Typical catalysts used for the CDM process are illustrated in the table of FIGs. 1 A and 1 B. However, the inventors have also realized that sand used for concrete applications needs to have specific qualities, e.g., roughness and / or minimum size, for being suitable as a building material, and most of the existing sand, for example, desert sand, is not suitable for such purposes.

[0028] In this regard, fine aggregate (sand), coarse aggregate (gravel), and a hydraulic binder (cement) are the main raw materials used for the production of concrete and mortar which, when combined with water, produce very commonconstruction materials. Of these three raw materials, the aggregates - sand and gravel - make up the largest percentage of the primary material inputs and are the most extracted group of materials worldwide. The sand is not homogeneous and can be classified by shape, with shapes and features varying from oblong, sharply angular to nearly spherical and smooth. Medium to coarse sand with rough surfaces and a sharply angular shape, such as river-bank sand or costal sand grain are favorable for making concrete. Desert and other fine sands, on the other hand, are classified as nearly oblong, spherical shape and a smooth surface; these are considered unsuitable for using in concrete and cement, or banking up new land in the sea.

[0029] The grain sizes or particle sizes of the sand is another parameter that is considered when determining the conforming properties of the sand. While coarse sand has a grain size of about 2.0 - 4.0 mm and is used as a base material for construction projects like roads and foundations, fine sand (typically desert sand) has a grain size of about 0.075 - 0.25 mm and is used in sandblasting to clean and etch surfaces. It is suitable for making mortar and stucco, and also in sand filters for water purification. However, it is not suitable for concrete applications.

[0030] Thus, the inventors have sought a single process that simultaneously addresses both (1 ) the fuel generation from a carbon source, and (2) enhancing the properties of non-conforming sand for making it appropriate for better applications (e.g., concrete applications) so that the two aspects are mutually enhanced. In one embodiment, such a process is the CDM with a sand-based catalyst. While the following embodiments focus on the generation of H2 and the enhanced sand, thoseskilled in the art would understand that other processes may be used, the fuel may be something different than H2, and the aggregate material may be different from sand.

[0031] According to the embodiment illustrated in FIG. 2, a system 200 for generating H2 and enhancing sand (e.g., making it rougher and / or increasing or decreasing its grain size) in a synergetic approach includes a reactor 202, which has a reaction chamber 210. The reaction chamber may have any size and may be configured to receive at a first input port 212 the carbon source 214, which in this case, is methane (CPU). As noted above, other carbon sources may be used, for example, methanol, kerosene, hydrocarbons, etc. While FIG. 2 shows the first input port 212 being located at the bottom of the reaction chamber 210, the first input port 212 may also be placed on a side or at the top of the reaction chamber. In one application, plural input ports may be configured, at one or various locations of the chamber. For controlling a temperature inside the reaction chamber 210, one or more heaters 216 may be located around the chamber, inside or outside it.

[0032] Inside the reaction chamber 210, a catalyst compound 220 is provided. The catalyst compound 220 may be placed at a single or multiple locations inside the reaction chamber, and may be shaped to have various forms, for example, a slab, a wire, plural pellets, a large amount of grains, etc. In one embodiment, the catalyst compound may be configured to continuously move through reaction chamber. In another embodiment the catalyst compound stands for a certain time inside the reaction chamber and then is replaced with a fresh one.

[0033] The catalyst compound 220 is illustrated in FIG. 3 as including plural natural sand grains 310, one or more grains including a certain amount of natural metal containing substance 312, and optionally, added metal containing substance 314. While the natural metal containing substance 312 is attached to the natural sand grains 310, the added metal containing substance 314 is just interspersed with the natural sand 310. Note that the natural sand may include various elements, but the most common one is silica (silicon dioxide), usually in the form of quartz. The natural sand may also include other elements, for example, potassium, sodium, and calcium based substances. The natural and / or added metal containing substances 312 and 314 may have the metal being iron, and thus, the natural and added iron containing substances may be an iron salt, iron oxide, or metallic iron in this embodiment. However, in another embodiment, the added metal containing substance may include another metal, for example, Ni, Cu, Al, La, Al, Mo, Co, T, Ce, W, Zr, or any combination of these metals. In one embodiment, oxides or salts of these metals may be used. In yet another embodiment, one or more of these metals may be combined with non-metal elements, for example, Si.

[0034] If the enhanced sand 316 (i.e., natural sand 310 with natural metal containing substances 312 and added metal containing substance 314) obtained in this process is intended to be used in the construction industry, then it is desired to use a metal that is not toxic or does not negatively affect humans, as they may enter in direct contact with this enhanced sand. Thus, for this purpose, the added metal containing substance 314 is chosen in this embodiment to be an iron containing substance.

[0035] The natural sand grains 310 of the catalyst compound 220 may naturally include iron or iron containing substances 312, i.e., iron minerals. However, according to the embodiment illustrated in FIG. 2, the natural sand grains 310 are processed prior to being input into the reaction chamber 210 to further increase their iron content. Note that this is an optional step and the process to be discussed with regard to the reaction chamber 210 also works only with natural sand 310 and natural metal based substance 312.

[0036] As shown in FIG. 2, the natural sand 310 and the natural iron based substance 312 (i.e., sand without the added metal containing substance 314) may be supplied to a mixing chamber 230, together with the added metal containing substance 314, where a mixer 232 is used to combine the natural sand 310, the added metal containing substance 312, and the added metal containing substance 314 to obtain the enhanced sand 316. After this treatment, the added metal containing substance to the natural sand can vary from 0.01% to 99.99%. The process may be performed at various temperatures, for example, from -100 to 1000 °C. In one application, a bonding material may be added to bond the added iron containing substance 314 to the natural sand 310. The process may be performed at any pressure, for example, between 0 to 10 atm. In this embodiment, the temperature is room temperature and the pressure is ambient pressure.

[0037] The enhanced sand 316 may then be used as the catalyst compound 220. In one application, other substances (for example, Al) may be added to the enhanced sand 316 to form the catalyst compound 220. Note that the enhanced sand 316 may be used as is, i.e., as grains, or may be formed into a specific shape,i.e., may be treated with a light adhesive to form a desired shape, for example, wires, foils, etc. The carbon source 214, methane in this embodiment, enters the reaction chamber 210 at the first input port 212 and reacts in the presence of the enhanced sand 316, which results in hydrogen 222, solid carbon 224, and other carbon products 225. The hydrogen 222, which is a gas, can be extracted from the reaction chamber at a first output port 226, while the solid carbon 224 is deposited on the surface of the enhanced sand 316. The other carbon products 225, which may be hydrocarbons as naphthalene, may be fluid and may be extracted at a second output port 228. Note that the location of the output ports in FIG. 2 is not necessary at scale, as the second output port 228 may be located at the bottom or side of the reaction chamber 210. The conversion of the carbon source 214 may range from zero to 100%.

[0038] The enhanced sand 316 may enter through a second input port 229 into the reaction chamber 210. The enhanced sand 316 may enter chamber 210 in batches, be used for the CDM reaction for a given time (minutes or hours), and then be removed while another batch is brought in. The enhanced sand 316 may enter from top to bottom, bottom to top, side to side, a combination of these configurations, or any other possible configuration. The carbon source may similarly enter in any of these configurations. If the enhanced sand is standing in the reaction chamber and does not flow through it, the enhanced sand may be configured to sit on a porous material (e.g., pores having a diameter between 100 nm and 1 cm) in order to allow the gas to methane to pass through it. The reaction process in the reaction chambermay be performed at different temperatures and pressures, for example, from 20 to 1500 °C, and from 0 to 30 atm.

[0039] In another embodiment, the enhanced sand 316 continuously enters the reaction chamber and, as it is being soiled due to the catalytic decomposition of the methane, it is also continuously removed from the reaction chamber. For this case, the enhanced sand may be provided and removed by a conveyor system 410 into and from the reaction chamber, as illustrated in FIG. 4. Note that the enhanced sand 316 enters the reaction chamber 210 on the conveyor belt 412, of the conveyor system 414, and after reacting with the methane 214, acquires the solid carbon 224 and becomes carbonaceous treated sand 420.

[0040] As shown in FIGs. 5A and 5B, which are SEM images of the carbonaceous treated sand 420, the solid carbon 224 is deposited as “onions” 224A and “tubes” 224B on the surface 316A of one or more enhanced sand grains 316. FIG. 6 shows, as a cartoon type illustration, the reaction experienced by the enhanced sand 316 in the presence of methane at a temperature between 500 and 1000 °C. The iron atoms 314A of the metal containing substance 314 can be found, at the end of the reaction, as being directly attached to the external surface of the grain sand 310, while the solid carbon 224 is shown as being attached, mainly to the iron atoms 314A, as onions 224A and / or tubes 224B. The carbonaceous treated sand 420 may only include, after the CDM process, the sand grains 310, iron atoms 314A directly attached to the surface of the sand grains 310, and the carbon material 224 (tubes and onions) directly attached to the iron atoms.

[0041] The carbonaceous treated sand 420 extracted from the reaction chamber 210, at output port 227 in FIG. 2, is then used either as a soil enhancer 430 (i.e., to be mixed up with poor soil for agricultural purposes), and / or as sand for making concrete 440. For this last application, the natural sand 310 or even the enhanced sand 316 may not be appropriate for concrete applications. However, after enhancing the natural sand with the carbonaceous material, the carbonaceous treated sand 420 has a large enough size and a good enough roughness, due to the deposited solid carbon 224, so that it becomes appropriate for concrete applications. Thus, the carbonaceous treated sand 420 may be mixed in a concrete mixer 442 with gravel and cement for obtaining the concrete 440. In one application, the carbonaceous treated sand 420 may be mixed with other types of sand (e.g., river sand) for obtaining the concrete 440. In one application, the carbonaceous treated sand 420 is between 5 and 20% of the total sand being added to the concrete 440. In another application, the carbonaceous treated sand 420 is between 20 and 40% of the total sand added to the concrete 440. In another application, the carbonaceous treated sand 420 is between 40 and 60% of the total sand added to the concrete 440. In another application, the carbonaceous treated sand 420 is between 60 and 80% of the total sand added to the concrete 440. In another application, the carbonaceous treated sand 420 is between 80 and 100% of the total sand added to the concrete 440. Note that the above noted ranges include the end values of the respective ranges.

[0042] On the other hand, the generated H2 may be used for powering various engines. Thus, the processes discussed with regard to FIGs. 2 and 6 simultaneouslygenerate hydrogen from a carbon source, and enhance poor quality sand (and even good quality sand) with solid carbon based on the same carbon source so that the poor quality sand can be used in concrete. At the same time, the poor sand acts as the catalyst of the hydrogen generation process, due to its natural and / or added iron content. Instead of cleaning this catalyst for reuse, as the traditional CDM processes are doing, the soiled catalyst becomes appropriate for concrete applications. In other words, the soiling of the catalyst generates the carbonaceous treated sand 420, which works to the advantage of the disclosed method, while in the traditional reactions, the soiling of the catalyst is an undesirable process.

[0043] The inventors have performed various experiments for confirming the presence of the solid carbon on the natural sand. In this regard, FIG. 7 shows the thermogravimetric analysis of the carbonaceous treated sand 420. Line 700 shows the loss of weight versus temperature. The weight loss of the carbonaceous treated sand 420 represents the carbon content. While line 700 shows about 10% carbon content, it is possible to obtain a carbon content in the original sand from 0.1 to 100%, depending on the conditions applied in the reaction chamber 210.

[0044] An x-ray diffraction analysis (XRD) was also performed, as shown in FIG. 8, to show the presence of carbon in the carbonaceous treated sand 420. The figure shows the content of the original sand 310 and the carbonaceous treated sand 420. It is noted that the carbon content of the carbonaceous treated sand 420 is highly increased when compared to the original sand. The inventors also performed a liquid analysis of the other carbon products 225 generated in the reaction chamber 210. FIGs. 9A and 9B illustrate the various components identified in the other carbonproducts 225, with the main component being naphthalene. The table in FIG. 9B illustrates the main components of the other carbon products 225. It is noted that the other carbon products 225 are useful by-products instead of contaminating byproducts.

[0045] Turning to the carbonaceous treated sand 420, one of the problems experienced by those that are generating these materials (by means different from the one discussed herein) is the non-uniform distribution of the carbon material in the mix for concrete production. Contrary to this, the methods discussed herein obtain a uniform distribution of the carbon material directly on the surface of the sand grains.

[0046] Because sand is going to be one of the main aggregates during the concrete production, and a high dispersion of the sand is found all over the concrete, the inventors have obtained a final product with good carbon distribution. If the carbon concrete 440 obtained with the process described herein is compared with other carbon concretes, for example, one where petroleum coke (petcoke) was used, it can be observed (not shown) that by adding the material (petcoke) directly to the concrete mix achieves a worse distribution of carbon in the final product.

[0047] Experiments performed by the inventors for concrete including the carbonaceous treated sand 420 (referred to as C1 ), and concrete not including such sand (referred to as C2) show the C1 concrete having a better or equal compressive strength performance, as illustrated in the table of FIG. 10. The higher performance of the carbon concrete made with the novel carbonaceous treated sand 420 might be explained due to the filling of pores and cracks by the carbon material, which acts as filling material between hydration products and bridging in micro-cracks.

[0048] Based on the above discussed embodiments, a method for simultaneously generating hydrogen and making the carbonaceous treated sand 420 is summarized as illustrated in FIG. 11 . The method includes a step 1100 of inputing sand grains into a reaction chamber, where the sand grains are either natural sand grains 310 that include a natural metal containing substance 312, or enhanced sand 316 that includes an added metal containing substance, a step 1102 of inputing a carbon source into the reaction chamber to react with the sand grains, a step 1104 of controlling a temperature inside the reaction chamber to achieve catalytic decomposition of the carbon source, which results in generation of hydrogen and solid carbon, which grows on the sand grains to form carbonaceous treated sand, and a step 1106 of collecting the hydrogen outside the reaction chamber.

[0049] In one application, the metal is iron. The carbonaceous treated sand has the solid carbon grown as tubes and onions on an external surface. The method may further include collecting a carbon-based fluid from the reaction chamber, where the carbon source is methane. The method may further include continuously providing the sand grains to the reaction chamber, and continuously extracting soiled sand grains from the reaction chamber, wherein the soiled sand grains include the natural metal containing substance soiled with products from the carbon source, as the natural metal containing substance acts as a catalyst of the reaction between the carbon source and the sand grains.

[0050] The method may further include continuously providing the sand grains to the reaction chamber, and continuously extracting soiled sand grains from the reaction chamber, wherein the soiled sand grains include the natural and addedmetal containing substances soiled with products from the carbon source, as the natural and added metal containing substances act as a catalyst of the reaction between the carbon source and the sand grains.

[0051] In one embodiment, an external surface of the carbonaceous treated sand includes metal atoms, and the solid carbon grows as tubes and onions on the metal atoms. The method may further include mixing the carbonaceous treated sand with gravel and cement to obtain concrete. In one embodiment, the sand grains are not suitable for concrete while the carbonaceous treated sand is suitable for concrete.

[0052] The term “about” is used in this application to mean a variation of up to 20% of the parameter characterized by this term. It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first object or step could be termed a second object or step, and, similarly, a second object or step could be termed a first object or step, without departing from the scope of the present disclosure. The first object or step, and the second object or step, are both, objects or steps, respectively, but they are not to be considered the same object or step.

[0053] The terminology used in the description herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used in this description and the appended claims, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and / or" as used herein refers toand encompasses any possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Further, as used herein, the term "if" may be construed to mean "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context.

[0054] The disclosed embodiments provide a method and system for generating hydrogen from a carbon source while enhancing the properties of a sand that might not be suitable for concrete applications. It should be understood that this description is not intended to limit the invention. On the contrary, the embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.

[0055] Although the features and elements of the present embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.

[0056] This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.

Claims

WHAT IS CLAIMED IS:1 . A method for generating hydrogen while depositing carbon material on sand, the method comprising: inputting (1100) sand grains (310, 316) into a reaction chamber (210), wherein the sand grains (310, 316) are either natural sand grains (310) that include a natural metal containing substance (312) or enhanced sand (316) that includes an added metal containing substance (314); inputting (1102) a carbon source (214) into the reaction chamber (210) to react with the sand grains (310, 316); controlling (1104) a temperature inside the reaction chamber (210) to achieve catalytic decomposition of the carbon source (214), which results in generation of hydrogen (222) and solid carbon (224), which grows on the sand grains (310, 316) to form carbonaceous treated sand (420); and collecting (1106) the hydrogen (222) outside the reaction chamber (210).

2. The method of Claim 1 , wherein the metal is iron.

3. The method of Claim 1 , wherein the carbonaceous treated sand (420) has the solid carbon grown as tubes and onions on an external surface.

4. The method of Claim 1 , further comprising: collecting a carbon-based fluid from the reaction chamber.

5. The method of Claim 1 , wherein the carbon source is methane.

6. The method of Claim 1 , further comprising: continuously providing the sand grains to the reaction chamber; and continuously extracting soiled sand grains from the reaction chamber, wherein the soiled sand grains include the natural metal containing substance soiled with elements from the carbon source, as the natural metal containing substance acts as a catalyst of the decomposition reaction of the carbon source.

7. The method of Claim 1 , further comprising: continuously providing the sand grains to the reaction chamber; and continuously extracting soiled sand grains from the reaction chamber, wherein the soiled sand grains include the natural and added metal containing substances soiled with elements from the carbon source, as the natural and added metal containing substances act as a catalyst of the decomposition reaction of the carbon source.

8. The method of Claim 1 , wherein an external surface of the carbonaceous treated sand includes metal atoms, and the solid carbon grows as tubes and onions on the metal atoms.

9. The method of Claim 1 , further comprising: mixing the carbonaceous treated sand with gravel and cement to obtain concrete.

10. The method of Claim 1 , wherein the sand grains are not suitable for concrete while the carbonaceous treated sand is suitable for concrete.11 . A carbonaceous treated sand (420) comprising: natural sand grains (310); metal atoms (314A) attached to surfaces of the natural sand grains (310); and carbon material (224) attached to the metal atoms (314A).

12. The carbonaceous treated sand of Claim 11 , wherein the carbon material is only attached to the metal atoms.

13. The carbonaceous treated sand of Claim 11 , wherein the carbon material is shaped as tubes and onions.

14. The carbonaceous treated sand of Claim 11 , wherein the natural sand grains are not suitable for concrete applications while the carbonaceous treated sand is suitable for the concrete applications.

15. The carbonaceous treated sand of Claim 11 , wherein the carbon material is uniformly distributed over the surfaces of the natural sand grains.

16. A system (200) for generating hydrogen while depositing carbon material on sand, the system (200) comprising: a reaction chamber (210) having, a first input port (229) configured to receive sand grains (310, 316), wherein the natural sand grains (310, 316) are either natural sand grains (310) that include a natural metal containing substance (312) or enhanced sand (316) that includes an added metal containing substance (314), a second input port (212) configured to receive a carbon source (214) to react with the sand grains (310, 316), and a first output port (226) configured to collect hydrogen (222), which is produced by a catalytic decomposition of the carbon source (214); and a heater (216) configured to heat the reaction chamber (210) so that the catalytic decomposition of the carbon source (214) takes place, and solid carbon (224) is formed, which grows on the sand grains (310, 316) to form carbonaceous treated sand (420), wherein the reaction chamber (210) further includes a second output port (227) configured to collect the carbonaceous treated sand (420).

17. The system of Claim 16, wherein the metal is iron.

18. The system of Claim 16, wherein the carbonaceous treated sand (420) has the solid carbon grown as tubes and onions on an external surface.

19. The system of Claim 16, wherein the carbon source is methane.

20. The system of Claim 16, further comprising: a conveyor system configured to continuously supply the sand grains to the reaction chamber and continuously extract soiled sand grains from the reaction chamber, wherein the soiled sand grains include the natural metal containing substance soiled with elements from the carbon source, as the natural metal containing substance acts as a catalyst of the decomposition reaction of the carbon source.

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