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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

NiFeMnBaPr perovskite Pre-Catalysts for stable steam reforming of heavy crude oil

by Albuali, Mohamed, Ramos-Fernandez, Morlanes, Rendón-Patiño, Alahmadi, Bai, Castaño
Fuel Year: 2025 DOI: https://doi.org/10.1016/j.fuel.2025.134560

Abstract

This study evaluates the stability and activity of Pr0.5Ba0.5Mn0.8Ni0.15Fe0.05O3 perovskite pre-catalyst, demonstrating its capability to resist deactivation and produce hydrogen under the challenging conditions required for reforming heavy crude oil. Operating at 800 °C, the catalyst achieved an 88 % conversion, yielding a hydrogen-rich gas stream (54 mol% H2) with minimal pressure buildup, outperforming the “traditional” NiCoCeMgAl catalysts (stable for 3 h) by maintaining stability for 30 h. The catalyst resistance against carbon deposition and sulfur is enhanced through a unique composition, which enables efficient coke gasification and the formation of phases that keep the activity. These phases formed during the reaction (NiSx, NiC, Fe2O3, FeC, and MnOx) contribute to prolonged activity by releasing oxygen to react with carbonaceous deposits. Our work highlights the potential for hydrogen production from heavy crude oil and establishes a pathway for developing highly durable catalysts for industrial applications.

Keywords

HCE C2H