This new Iron-based catalyst will enable a one-step process to produce hydrogen - a promising energy source that is also environmentally benign - by directly converting methane. The catalyst will eliminate the need to first create syngas and then remove carbon dioxide. In addition to creating hydrogen, carbon, which is also a useful commodity is created as a by-product. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge
The traditional commercial methods of forming hydrogen from methane are based on steam methane reforming, coal or bio-mass gasification, electrolysis, and thermo-chemical processes. Some of these methods are cost-effective, but each requires that syngas first be created and the water gas shift reaction be used to convert syngas to hydrogen and carbon dioxide. From there, the hydrogen must be purified using pressure swing adsorption to separate the hydrogen for the carbon dioxide. Developing a method that avoids these intermediate steps would reduce the cost of producing valuable hydrogen.

This invention describes a novel catalytic method combined with a chemical looping process to produce a hydrogen (H₂)-rich synthesis gas (syngas) stream free of the nitrogen from coal. The catalytic process uses reduced metal oxide/coal/steam to produce a H₂-rich syngas stream that is free of nitrogen (N₂) from coal while the chemical looping combustion (CLC) of fuel with the metal oxide is used for production of the heat required for the catalytic process. CLC processes also produce a concentrated stream of carbon dioxide (CO₂) that is ready for sequestration. This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Challenge

Traditional coal gasification requires an expensive air separation unit to produce N₂-free syngas. However, NETL’s novel catalytic process using reduced metal oxide/coal/steam does not require an air separation unit for production of nitrogen free syngas stream. Heat is traditionally produced via fuel combustion, which generates a CO₂ stream mixed with N_2. This stream requires expensive separation technologies for CO₂ sequestration. The novel catalytic process uses the heat from CLC of fuel, which generates a sequestration ready CO₂ stream. Integration of the processes, addressing contaminant issues and scaling up the technology for commercialization are necessary.

This technology provides an advantageous means to convert syngas into a class of chemicals known as higher oxygenates, as well as other long-chain hydrocarbons. Research is currently active on this technology "Method of CO and/or CO₂ Hydrogenation Using Doped Mixed Metal Oxides." This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Research is currently active on the patented technology "A Process for the Mixing of Heavy Solid Particulate Matter in a Lighter Liquid Carrier Fluid Using an Inverted Pulsed Jet Mixing Apparatus." The technology is available for licensing and/or further collaborative research from the U.S. Department of Energy's National Energy Technology Laboratory.

The Department of Energy’s National Energy Technology Laboratory (NETL) is seeking collaborative research and licensing partners interested in implementing United States Non-provisional Patent Application entitled "Rapid Gas Hydrate Formation Process." Disclosed in this application is a method and device for producing gas hydrates from a two-phase mixture of water and a hydrate forming gas such as methane (CH₄) or carbon dioxide (CO₂). The two-phase mixture is created in a mixing zone, which may be contained within the body of the spray nozzle. The two-phase mixture is subsequently sprayed into a reaction vessel, under pressure and temperature conditions suitable for gas hydrate formation. The reaction zone pressure is less than the mixing zone pressure so that expansion of the hydrate-forming gas in the mixture provides a degree of cooling and better mixing between the water and the hydrate-forming gas. The result of the process is the continuous formation of gas hydrates with a greatly reduced induction time for gas hydrate crystal formation. This invention may have utility in natural gas / CH₄ storage and transport, CO₂ sequestration, cold energy storage, transportation fuels, and desalination.

Research is currently active on the patented technology titled, "Kick Detection at the Bit Using Wellbore Geophysics." This technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Research is active on the development of techniques for the economic recovery of valuable metals from petroleum gasification waste products. This invention is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Research is currently active on the patented technology titled, "Regenerable Immobilized Aminosilane Sorbents for Carbon Dioxide Capture." The technology is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

This technology, "Regenerable Mixed Copper-Iron-Inert Support Oxygen Carriers for Solid Fuel Chemical Looping Combustion Process," provides a metal-oxide oxygen carrier for application in fuel combustion processes that use oxygen. This technology is available for licensing and/or further collaborative research with the U.S. Department of Energy’s National Energy Technology Laboratory.

The innovation represents a BIAS particle sorbent suspended in a non-aqueous fluid carrier (slurry) that is capable of CO₂ sorption, is easy to incorporate into established power plants, and can minimize energy and infrastructure requirements.

Challenge

Carbon sequestration can reduce the emissions of CO₂ from large point sources and holds potential to provide deep reductions in greenhouse gas emissions. Amine-based solid sorbents are effective and economical agents for CO₂ capture from gaseous mixtures. However, because of the high concentration of CO₂ in many feed streams, a large quantity of the gas often reacts with the sorbent exothermically to produce excessive heat, which must be removed from the sorbent to prevent temperature instability within the reactor and to eliminate potential degradation of the sorbent. Reducing the damage to sorbents with this technology and method can increase efficiency and reduce replacement costs faced by industries.