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Process development and deployment for the direct reforming of crude oil to hydrogen and carbon materials

Problem statement

Hydrogen is a clean energy source and carrier because of its non−polluting combustion, making it an excellent alternative to the current fossil fuel-dominated energy scenario. Nonetheless, there are several critical challenges to implementing a broad sustainable use of hydrogen. In this project, we develop a laboratory−scale setup with stable operation and high hydrogen production.

We aim at assessing (i) different hydrocarbon feedstock (from n-heptane to crude oil) fed to the reactor with water as emulsions, carried by steam or vaporized; (ii) steam reforming (SR) and auto thermal reforming (ATR); and (iii) stable and energy efficient catalysts for the efficient production of hydrogen inside packed, fluidized, and multifunctional reactors. These, coupled with carbon capture technologies, minimize the carbon footprint of the overall process.

We support our research with simulations and techno−economic analysis to assess the approach's feasibility. C2H can use the current refinery infrastructure to reduce costs and the impact of market volatility on refinery operations.

Goals

  • Develop and scale up advanced catalysts and reactors for converting crude to hydrogen
  • Model process simulations to analyze the viability of the process 
  • Scaling the technical catalysts for their demanding application: endothermic process, poisoning, massive coke deposition, and fluidized-bed reactors
  • Analyze different process conditions to optimize hydrogen production and stability in the process
C2H-REF2023

Related People

Related Publications

Catalytic conversion of crude oil to hydrogen by a one-step process via steam reforming
Int. J. Hydrog. Energy Year: 2024 DOI:https://doi.org/10.1016/j.ijhydene.2024.03.121
Authors: Albuali, Morlanes, Rendón-Patiño, Castaño, Gascon
  • CRE
  • O2H
  • REF
Effect of Thermal, Acid, and Alkaline Treatments over SAPO-34 and Its Agglomerated Catalysts: Property Modification and Methanol-to-Olefin Reaction Performance
Ind. Eng. Chem. Res. Year: 2024 DOI:https://doi.org/10.1021/acs.iecr.3c03956
Authors: Zapater, Lasobras, Zambrano, Hita, Castaño, Soler, Herguido, Menendez
  • HCE
  • C2H
Isolating the effect of Co and Ce on Ni–X–Y/Al2O3 bi- and trimetallic reforming catalysts for hydrogen generation
Int. J. Hydrog. Energy Year: 2024 DOI:https://doi.org/10.1016/j.ijhydene.2023.10.257
Authors: Mohamed, Kulkarni, Velisoju, Zhang, Yerrayya, Bai, Kolubah, Yao, Morlanes, Castaño
  • HCE
  • REF
A holistic approach to include SiC and design the optimal extrudate catalyst for hydrogen production–reforming routes
Fuel Year: 2023 DOI:https://doi.org/10.1016/j.fuel.2023.128717
Authors: Alkadhem, Tavares, Realpe, Lezcano, Yudhanto, Subah, Manaças, Osinski, Lubineau, Castaño
  • REF
  • HCE
Decreasing the coking and deactivation of a reforming Ni-Ce/Al2O3 catalyst with intraparticle SiC in hydrogen production routes
Fuel Year: 2023 DOI:https://doi.org/10.1016/j.fuel.2022.127058
Authors: Tavares, Mohamed, Kulkarni, Morlanes, Castaño
  • REF
  • HCE
Silicon carbide in catalysis: from inert bed filler to catalytic support and multifunctional material
Catal. Rev. Year: 2023 DOI:https://doi.org/10.1080/01614940.2022.2025670
Authors: Kulkarni, Velisoju, Tavares, Dikhtiarenko, Gascon, Castaño
  • CO2
  • CHA
  • REF
  • HCE
Improving robustness of kinetic models for steam reforming based on artificial neural networks and ab initio calculations
Chem. Eng. J. Year: 2022 DOI:https://doi.org/10.1016/j.cej.2021.133201
Authors: Morlanes, Lezcano, Yerrayya, Mazumder, Castaño
  • C2H
  • REF
  • MKM
Polymeric Waste Valorization at a Crossroads: Ten Ways to Bridge Research on Model and Complex/Real Feedstock
Green Chem. Year: 2021
Authors: Hita, Sarathy, Castaño
  • FCC
  • REF
  • HPC
  • W2C
  • ANW
Oxidative Steam Reforming of Raw Bio-Oil over Supported and Bulk Ni Catalysts for Hydrogen Production
Catalysts Year: 2018
Authors: Arandia, Remiro, Garcia, Castaño, Bilbao, Gayubo
Open Access.
  • REF
  • W2C
  • HCE
Coking and Sintering Progress of a Ni Supported Catalyst in the Steam Reforming of Biomass Pyrolysis Volatiles
Appl. Catal. B: Environ. Year: 2018
Authors: Ochoa, Arregi, Amutio, Gayubo, Olazar, Bilbao, Castaño
  • REF
  • W2C
  • ANW
  • CRE