CPC C01B 3/26 (2013.01) [B01J 6/008 (2013.01); B01J 21/185 (2013.01); B01J 23/892 (2013.01); C01B 32/05 (2017.08); H05B 6/647 (2013.01); C01B 2203/0277 (2013.01); C01B 2203/0855 (2013.01); C01B 2203/1064 (2013.01); C01B 2203/1082 (2013.01); C01B 2203/1241 (2013.01)] | 18 Claims |
1. A method for producing hydrogen and crystalline carbon materials from methane, the method comprising:
a. conveying a process gas comprising methane to a chemical reactor; wherein the reactor comprises a catalyst material comprising Ni—Pd, Ni—Cu, Co, Fe, or a combination thereof and a catalyst support comprising a solid carbon material;
b. heating the catalyst with a thermal fluid and microwave irradiation using a hybrid heating device;
c. contacting the catalyst with the process gas; wherein the methane undergoes pyrolysis, thereby forming hydrogen and at least one solid carbon product; and
d. collecting the hydrogen;
wherein hybrid heating device comprises:
a process gas reactor;
wherein the process gas reactor has a thermally heated reactor surface;
wherein the thermally heated reactor surface is in contact with a catalyst bed within the process gas reactor;
a heating system comprising a thermal fluid heating system and a microwave heating system;
wherein the thermal fluid heating system comprises a thermal fluid inlet for conveying the thermal fluid to the thermal fluid heating system and a thermal fluid outlet for conveying the thermal fluid from the thermal fluid heating system;
wherein the thermal fluid heating system transfers heat to the thermally heated reactor surface;
wherein the microwave heating system comprises a microwave generator and a microwave tuner;
wherein the microwave generator is positioned to irradiate the catalyst bed;
a process gas inlet for conveying a process gas to the process gas reactor;
wherein the process gas is conveyed to be in contact with the catalyst bed;
a process gas outlet for conveying unreacted process gas and reactant gas out from the process gas reactor.
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