Hydrocarbon decomposition with aerosolized catalyst

WO2026101561A3PCT designated stage Publication Date: 2026-07-16JOHNS HOPKINS UNIVERSITY
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Patent Information

Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
JOHNS HOPKINS UNIVERSITY
Filing Date
2025-04-22
Publication Date
2026-07-16

AI Technical Summary

Technical Problem

Existing hydrocarbon decomposition methods face challenges in achieving efficient temperature control, uniformity of powder morphology, and reducing fouling in heat exchangers, leading to reduced system efficiency and increased operational costs.

Method used

The use of aerosolized catalyst powder entrained in an inlet gas stream within a reactor, combined with multiple heating zones and recuperative heat exchange, allows for controlled temperature profiles, uniform powder distribution, and minimizes fouling by depositing carbon on catalyst particles rather than heat exchanger walls.

Benefits of technology

This approach enhances thermal efficiency by up to 25% and maintains reactor performance by reducing fouling, while allowing for efficient recycling and reuse of catalyst particles.

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Abstract

Producing hydrogen gas includes combining a gaseous feedstock stream with a particulate catalyst, wherein the gaseous feedstock stream comprises a gaseous hydrocarbon, and the particulate catalyst is selected to promote decomposition of the gaseous hydrocarbon; entraining the particulate catalyst in the gaseous feedstock stream to yield an aerosolized reaction mixture comprising aerosolized catalyst particles; and heating the aerosolized reaction mixture to decompose the gaseous hydrocarbon, thereby yielding a product stream comprising elemental carbon and hydrogen gas.
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