Catalytic Cracking Reactor with Leaching for Pure Hydrogen and Carbon
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Solution Overview
Problem
Current technologies for catalytic cracking of light hydrocarbons, such as steam methane reforming with or without carbon capture sequestration, produce high carbon emissions and are inefficient in producing high purity hydrogen and solid carbon, while reactor design and engineering difficulties hinder cost-effective processes.
Innovation Solution
A reactor system and process that includes a carbon supported metal catalyst for catalytic cracking, followed by a leaching system to solubilize active metal compounds from spent catalyst, and a separation system to produce high purity solid carbon, with heat integration and product effluent separation to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If steam methane reforming with carbon capture sequestration is used, then hydrogen production is achieved, but carbon emissions are high and production cost is increased
Solution Approach 1:
The patent extracts and removes carbon deposits from the spent catalyst through leaching processes, separating the harmful carbon byproduct from the valuable metal catalyst components. This extraction approach converts the carbon emission problem into a resource recovery opportunity, producing high-purity solid carbon while regenerating the catalyst.
Solution Approach 2:
The patent changes the chemical parameters of the spent catalyst through sequential leaching treatments with different solutions (acidic, basic, complexing agents) to selectively dissolve and remove carbon deposits while preserving the active metal compounds, thereby transforming the waste material into valuable products.
2Object-generated harmful factors
If catalytic cracking is used to produce hydrogen and solid carbon, then carbon emissions are reduced, but manufacturing precision and product purity are challenging
Solution Approach 1:
The patent segments the spent catalyst treatment into multiple sequential leaching steps, each targeting specific components (carbon deposits, metal oxides, support materials) with different chemical solutions. This segmented approach enables progressive purification and achieves high product purity through controlled separation of each component.
Solution Approach 2:
The patent introduces intermediary leaching solutions (acids, bases, complexing agents) that mediate the separation between the spent catalyst components and the desired products. These intermediaries selectively interact with specific components to facilitate precise purification while maintaining overall process efficiency.
3Device complexity
If spent catalyst is directly disposed, then process simplicity is maintained, but resource loss and environmental harm occur
Solution Approach 1:
The patent implements a recovery system that captures and regenerates valuable metal compounds from the spent catalyst through leaching and precipitation processes. Instead of direct disposal, the system recovers precious metals and reusable catalyst components, converting waste into valuable resources while maintaining economic sustainability.
Solution Approach 2:
The patent enables the spent catalyst to serve itself by using its own structural properties and compositional features to facilitate its own regeneration. The leaching process exploits the inherent characteristics of the spent catalyst material to enable selective dissolution and recovery of its components, reducing the need for external intervention and complex processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Produces high purity hydrogen and solid carbon with significantly lower carbon emissions, optimizing temperature control and catalyst regeneration for cost-effective production.
Implementation Method 1
catalytic cracking of light hydrocarbons such as, for example, methane, ethane, natural gas, etc.
Implementation Method 2
contacting a first portion of a spent carbon supported metal catalyst with a leaching solution to solubilize the one or more active metal compounds from the first portion of the spent carbon supported metal catalyst
Data Source
AI summary
A process for producing high purity solid carbon includes contacting a first portion of a spent carbon supported metal catalyst comprising one or more active metal compounds and solid carbon deposits derived from catalytically cracking a light hydrocarbon feedstock in the presence of a carbon supported metal catalyst comprising one or more active metal compounds in a reactor with a leaching solution to solubilize the one or more active metal compounds from the first portion of the spent carbon supported metal catalyst to generate a solubilized leaching solution comprising solubilized one or more active metal compounds and a solid carbon product, and separating the solid carbon product from the solubilized leaching solution to generate the solid carbon product and a separated solubilized leaching solution comprising the solubilized one or more active metal compounds. The solid carbon product is a high purity solid carbon product.