Induction Heated Carbon Catalyst for Hydrogen Production

The patent employs an inert atmosphere by using nitrogen or carbon dioxide as a diluent gas in the methane decomposition process. This inert environment prevents complete oxidation of carbon to CO2, instead favoring the formation of solid carbon deposits on the catalyst surface. The inert atmosphere thus enables hydrogen production while minimizing CO2 emissions, directly resolving the technical contradiction between productivity and harmful emissions.

The patent extracts the oxygen element from the reaction system by operating under oxygen-free or oxygen-limited conditions. Instead of using steam reforming where oxygen is present and leads to CO2 formation, the process removes oxygen entirely and uses thermal decomposition. This extraction of the harmful element (oxygen) prevents CO2 generation while maintaining hydrogen production capability.

The patent changes the reaction parameters from high-temperature steam reforming (700-1100°C with steam) to moderate-temperature dry reforming (400-600°C with CO2). By changing the temperature parameter and the reacting gas composition, the process achieves comparable hydrogen production rates with significantly lower energy input and operating costs.

The patent introduces a solid carbon catalyst as an intermediary medium to facilitate the methane decomposition reaction at lower temperatures. The catalyst provides active sites that lower the activation energy barrier, enabling the reaction to proceed efficiently at 400-600°C instead of requiring the high temperatures of conventional steam reforming, thus reducing energy consumption.

The patent implements a catalyst regeneration cycle where the spent catalyst, deactivated by carbon deposition, is periodically removed from the reactor and subjected to oxidative treatment to burn off the accumulated carbon. The regenerated catalyst is then returned to service. This discarding of the deactivated state and recovery of the active catalyst maintains long-term reliability while sustaining the low CO2 emission benefits.

The patent employs periodic operation cycles alternating between the decomposition phase (where hydrogen is produced and carbon deposits form) and the regeneration phase (where carbon is removed oxidatively). This periodic action allows the catalyst to maintain its activity over extended periods by systematically removing deactivating carbon deposits, thus resolving the reliability issue while preserving the environmental benefits.