Fuel reformer catalyst and absorbent materials
First Claim
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1. A method for the conversion of a carbon-based fuel to a H2-rich product gas, comprising the steps of:
- (a) providing a carbon-based fuel;
(b) converting said carbon-based fuel to an intermediate gas product by contacting said carbon-based fuel with at least a first conversion catalyst;
(c) contacting said intermediate gas product with an absorbent material to absorb CO2 and form a H2-rich gas, said absorbent material having a theoretical absorption capacity for CO2;
(d) extracting said H2-rich gas from said contacting step;
(e) regenerating said absorbent; and
(f) repeating said steps (a), (b), (c), (d) and (e) at least 10 times, wherein said absorbent material retains at least about 50 mol. % of said theoretical absorption capacity after each of said repeating steps.
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Abstract
Materials that are useful for absorption enhanced reforming (AER) of a fuel, including absorbent materials and catalyst materials. The materials can be fabricated by spray processing. The use of the materials in AER can produce a H2 product gas having a high H2 content and a low level of carbon oxides.
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Citations
202 Claims
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1. A method for the conversion of a carbon-based fuel to a H2-rich product gas, comprising the steps of:
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(a) providing a carbon-based fuel;
(b) converting said carbon-based fuel to an intermediate gas product by contacting said carbon-based fuel with at least a first conversion catalyst;
(c) contacting said intermediate gas product with an absorbent material to absorb CO2 and form a H2-rich gas, said absorbent material having a theoretical absorption capacity for CO2;
(d) extracting said H2-rich gas from said contacting step;
(e) regenerating said absorbent; and
(f) repeating said steps (a), (b), (c), (d) and (e) at least 10 times, wherein said absorbent material retains at least about 50 mol. % of said theoretical absorption capacity after each of said repeating steps. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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29. A method for the conversion of a carbon-based fuel to a H2-rich product gas, comprising the steps of:
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(a) providing a carbon-based fuel;
(b) converting said carbon-based fuel to an intermediate gas product by contacting said carbon-based fuel with at least a first conversion catalyst;
(c) contacting said intermediate gas product with an absorbent material to absorb CO2 and form a H2-rich gas, said absorbent material having an theoretical absorption capacity for CO2;
(d) extracting said H2-rich gas from said contacting step;
1-0 (e) regenerating said absorbent; and
(f) repeating said steps (a), (b), (c), (d) and (e) at least 10 times, wherein said total mass of absorbent material retains at least about 10 grams CO2 per 100 grams unreacted absorbent after each of said repeating steps. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61)
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62. A method for the conversion of a carbon-based fuel to a H2-rich gas, comprising the steps of:
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(a) providing a carbon-based fuel and steam;
(b) converting said carbon-based fuel and said steam to an intermediate gas product by contacting with at least a first conversion catalyst;
(c) contacting said intermediate gas product with an absorbent material to absorb CO2 and form an H2-rich gas, said absorbent material having a theoretical absorption capacity and wherein at least said absorbent material is pelletized;
(d) extracting said H2-rich gas from said contacting step;
(e) regenerating said absorbent; and
(f) repeating said steps (a), (b), (c), (d) and (e) at least 50 times, wherein said absorbent material retains at least about 20 mol. % of its theoretical CO2 absorption capacity after each of said repeating steps. - View Dependent Claims (63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83)
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84. A method for absorption enhanced reforming of a carbon-based fuel, comprising the steps of:
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(a) providing a carbon-based fuel;
(b) contacting said carbon-based fuel with at least a first conversion catalyst to catalyze the formation of an intermediate gas product;
(c) contacting said intermediate gas product with a pelletized absorbent compound having a first bulk density, wherein said pelletized absorbent is converted to a carbonized absorbent having a second bulk density; and
(d) regenerating said carbonized absorbent to form a regenerated absorbent having a third bulk density, wherein said third bulk density is greater than said first bulk density. - View Dependent Claims (85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98)
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99. A steam-reforming catalyst, comprising:
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(a) a particulate support structure; and
(b) a metal dispersed on said support structure, wherein said reforming catalyst achieves at least about 90% of the theoretical thermodynamic conversion of methane to hydrogen at a temperature of 600°
C., a H2O;
C ratio of 3;
1 and a gas hour space velocity (GHSV) of 5000 hour−
1 in the absence of an absorbent for CO2. - View Dependent Claims (100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110)
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111. A particulate composite material, said particulates comprising:
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(a) an absorbent phase adapted to absorb CO2; and
(b) a catalyst phase selected from the group consisting of a reforming catalyst phase and a water-gas shift catalyst phase. - View Dependent Claims (112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134)
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135. A method for the fabrication of supported reforming catalyst particles, comprising the steps of:
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(a) forming a precursor solution comprising a metal precursor and an alumina precursor;
(b) atomizing said precursor solution to form precursor droplets;
(c) heating said precursor droplets to convert at least said metal precursor to metal-containing clusters dispersed on said alumina. - View Dependent Claims (136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148)
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149. A method for the fabrication of composite particles including an absorbent phase and a catalyst phase comprising the steps of:
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(a) forming a precursor solution, said precursor solution comprising;
(i) a liquid;
(ii) a precursor to an absorbent phase; and
(iii) a precursor to a catalyst phase;
(b) atomizing said precursor solution to form precursor droplets; and
(c) heating said precursor droplets to remove said liquid and form composite particles. - View Dependent Claims (150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162)
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163. A method for the fabrication of composite particles including an absorbent phase and a catalyst phase, comprising the steps of:
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(a) forming a particulate suspension, said particulate suspension comprising;
(i) a liquid;
(ii) a first particulate phase comprising an absorbent phase or an intermediate precursor to an absorbent phase; and
(iii) a second particulate phase comprising a catalyst phase;
(b) atomizing said particulate suspension to form suspension droplets; and
(c) heating said suspension droplets to remove said liquid and form composite particles. - View Dependent Claims (164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178)
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179. A pellet adapted for absorption enhanced reforming of a carbon-based fuel, said pellet comprising:
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(a) a particulate absorbent material; and
(b) a particulate catalyst material. - View Dependent Claims (180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190)
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- 191. A pellet adapted for absorption enhanced reforming of a carbon-based fuel, said pellet comprising composite particulates including an absorbent phase adapted to absorb CO2 and a catalyst phase selected from the group consisting of a reforming catalyst and a water-gas shift catalyst.
Specification