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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

Ali Alkadhem
Jose Ignacio Bielma Velasco
Mohammed Albuali
Naydu Paola Zambrano Urrutia
Talal Aldugman

Related Publications

Monitoring Ni0 and Coke Evolution during the Deactivation of a Ni/La2O3-alpha-Al2O3 Catalyst in Ethanol Steam Reforming in a Fluidized Bed

by Montero, Ochoa, Castaño, Bilbao, Gayubo
J. Catal. Year: 2015

Abstract

This work studies the mechanism of coke deactivation of a Ni/La2O3–αAl2O3 catalyst in ethanol steam reforming conducted in a fluidized bed reactor under conditions of severe deactivation, at 500 °C. Deactivation takes place in three consecutive stages with time on stream, corresponding to increasing values of ethanol concentration in the reaction system and decreasing values for CH4 and CO byproducts. The analysis of the nature of coke by means of several techniques in the different deactivation stages shows that high conversion values (low ethanol concentrations in the medium) give way to filamentous coke (with CO and CH4 as precursor), which has little effect on deactivation. For a highly deactivated catalyst, ethanol concentration is high, and a nonfilamentous deactivating coke is formed (mainly due to the evolution of filamentous coke). X-ray diffraction analysis of Ni particles in different deactivation states shows that a fraction of Ni crystallites are dragged by filamentous coke and the fraction of Ni crystallites that remain supported are blocked by nonfilamentous coke. A scheme has been established to explain the evolution of Ni and coke, the interaction between both dynamics, and its effect on catalyst deactivation.

Keywords

REF ANW