US 11,939,218 B2
Methods and compositions for production of hydrogen and carbon nanomaterials by catalytic methane pyrolysis using microwave-thermal hybrid heating
Jianli Hu, Morgantown, WV (US); and Brandon Robinson, Morgantown, WV (US)
Assigned to West Virginia University Board of Governors on Behalf of West Virginia University, Morgantown, WV (US)
Filed by West Virginia University Board of Governors on Behalf of West Virginia University, Morgantown, WV (US)
Filed on Aug. 30, 2022, as Appl. No. 17/823,290.
Claims priority of provisional application 63/399,930, filed on Aug. 22, 2022.
Prior Publication US 2024/0059559 A1, Feb. 22, 2024
Int. Cl. C01B 3/26 (2006.01); B01J 6/00 (2006.01); B01J 21/18 (2006.01); B01J 23/89 (2006.01); C01B 32/05 (2017.01); H05B 6/64 (2006.01)
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
OG exemplary drawing
 
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.