US 11,680,299 B2
Process and system for steel and hydrogen production using recycled ferrous scrap and natural gas
Divyaraj Desai, Hayward, CA (US); Jessica Louis Baker Rivest, Palo Alto, CA (US); Dane Andrew Boysen, Anchorage, AK (US); Rahul Pandey, San Jose, CA (US); and Eugene Shin Ming Beh, Menlo Park, CA (US)
Assigned to Palo Alto Research Center Incorporated, Palo Alto, CA (US)
Filed by Palo Alto Research Center Incorporated, Palo Alto, CA (US)
Filed on Sep. 4, 2019, as Appl. No. 16/560,627.
Prior Publication US 2021/0062279 A1, Mar. 4, 2021
Int. Cl. C21B 13/00 (2006.01); C01B 3/00 (2006.01)
CPC C21B 13/0013 (2013.01) [C01B 3/0031 (2013.01); C01B 2203/06 (2013.01); C21B 2400/032 (2018.08)] 9 Claims
OG exemplary drawing
 
1. A method for producing a homogeneous molten composition and a fluid product, comprising:
producing a first molten metal composition in an enclosed volume, wherein the first molten metal composition comprises iron and a metal, wherein the metal comprises at least one of: iron, nickel, manganese, cobalt, scandium, or lanthanum;
contacting a hydrocarbon reactant with the first molten metal composition;
decomposing the hydrocarbon reactant into at least one fluid product and carbon in a solid phase;
dissolving the carbon in the solid phase into the first molten metal to form a metal alloy from a mixture of the carbon and the first molten metal composition;
separating a homogenous second molten composition from the metal alloy; and
removing the at least one fluid product and the homogenous second molten composition from the enclosed volume.