US 12,473,199 B2
Co-production of hydrogen, carbon, electricity, and carbon monoxide with carbon dioxide capture for refining of crude oil
Omar David Hurtado Perez, Dhahran (SA); and Sai P. Katikaneni, Dhahran (SA)
Assigned to Saudi Arabian Oil Company, Dhahran (SA)
Filed by Saudi Arabian Oil Company, Dhahran (SA)
Filed on Sep. 28, 2022, as Appl. No. 17/954,945.
Prior Publication US 2024/0101415 A1, Mar. 28, 2024
Int. Cl. C01B 3/32 (2006.01); C01B 3/24 (2006.01); C01B 32/50 (2017.01); C25B 1/04 (2021.01)
CPC C01B 3/326 (2013.01) [C01B 3/24 (2013.01); C01B 32/50 (2017.08); C25B 1/04 (2013.01); C01B 2203/0233 (2013.01); C01B 2203/0238 (2013.01); C01B 2203/043 (2013.01); C01B 2203/0475 (2013.01); C01B 2203/061 (2013.01); C01B 2203/067 (2013.01); C01B 2203/0883 (2013.01); C01B 2203/84 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method comprising:
processing a crude oil to separate the crude oil into a liquid hydrocarbon stream, a first gas stream, and a first solids stream, the first solids stream comprising carbon, the first gas stream comprising hydrogen and methane;
combining a first portion of the first gas stream and the liquid hydrocarbon stream to form a hydrocarbon feed stream;
exposing the hydrocarbon feed stream to heat in an absence of oxygen to convert the hydrocarbon feed stream into a second solids stream and a second gas stream, the second solids stream comprising carbon, the second gas stream comprising hydrogen;
separating the second gas stream into an exhaust gas stream and a first hydrogen stream comprising at least a portion of the hydrogen from the second gas stream;
separating the carbon from the second solids stream to produce a carbon stream;
performing electrolysis on a water stream comprising water to produce an oxygen stream and a second hydrogen stream, the oxygen stream comprising oxygen, the second hydrogen stream comprising hydrogen;
combining at least a portion of the oxygen of the oxygen stream and a second portion of the carbon of the carbon stream to generate power and a carbon dioxide stream comprising carbon dioxide; and
contacting the carbon dioxide stream and a second portion of the first gas stream with a dry reforming catalyst under dry reforming conditions to form a syngas stream comprising carbon monoxide and hydrogen, wherein a first portion of the generated power is used to perform electrolysis on the water stream, a second portion of the generated power is used to expose the hydrocarbon feed stream to heat, and a third portion of the generated power is used to provide heat to produce the dry reforming conditions.