Process for producing hydrogen and graphitic carbon from hydrocarbons

Abstract

In accordance with the present invention, there is provided a process for producing hydrogen and graphitic carbon from a hydrocarbon gas comprising: contacting at a temperature between 600° C. and 1000° C. the catalyst with the hydrocarbon gas to catalytically convert at least a portion of the hydrocarbon gas to hydrogen and graphitic carbon, wherein the catalyst is a low grade iron oxide.

1 . A process for producing hydrogen and graphitic carbon from a hydrocarbon gas comprising:
 contacting at a temperature between 600° C. and 1000° C. the catalyst with the hydrocarbon gas to catalytically convert at least a portion of the hydrocarbon gas to hydrogen and graphitic carbon,   
       wherein the catalyst is a low grade iron oxide. 
     
     
         2 . A process for producing hydrogen and graphitic carbon according to  claim 1 , wherein the pressure is greater than atmospheric pressure. 
     
     
         3 . A process for producing hydrogen and graphitic carbon according to  claim 1 , wherein the pressure is 0 bar to 100 bar. 
     
     
         4 . A process for producing hydrogen and graphitic carbon according to any one of the preceding claims, wherein the temperature is between 700° C. and 950° C. 
     
     
         5 . A process for producing hydrogen and graphitic carbon according to any one of  claims 1  to  4 , wherein the temperature is between 800° C. and 900° C. 
     
     
         6 . A process for producing hydrogen and graphitic carbon according to any one of  claims 1  to  4 , wherein the temperature is between 650° C. and 750° C. 
     
     
         7 . A process for producing hydrogen and graphitic carbon according to any one of the preceding claims, wherein the hydrocarbon gas is methane. 
     
     
         8 . A process for producing hydrogen and graphitic carbon according to any one of  claims 1  to  9 , wherein the hydrocarbon gas is natural gas. 
     
     
         9 . A process for producing hydrogen and graphitic carbon according to any one of the preceding claims, wherein, the step of contacting the catalyst with the hydrocarbon gas is performed in a plurality of pressurised reactors arranged in series. 
     
     
         10 . A process for producing hydrogen and graphitic carbon according to  claim 9 , wherein the arrangement of the reactors in series allows gas to flow from a first reactor to a subsequent reactor and each subsequent reactor in the series operates at a lower pressure than the preceding reactor, allowing gas to travel to reactors of lower pressure. 
     
     
         11 . A process for producing hydrogen and graphitic carbon according to  claim 10 , wherein each reactor is provided with unreacted catalyst. 
     
     
         12 . A process for producing hydrogen and graphitic carbon according to  claim 9 , wherein the arrangement of the reactors in series allows catalyst to flow from a first reactor to a subsequent reactor and each subsequent reactor in the series is operated at a higher pressure than the preceding reactor, allowing catalyst to travel to reactors of higher pressure. 
     
     
         13 . A process for producing hydrogen and graphitic carbon according to  claim 12 , wherein unreacted hydrocarbon gas is provided to each reactor. 
     
     
         14 . A process for producing hydrogen and graphitic carbon according to  claim 9 , wherein the arrangement of the reactors in series allows for both the hydrocarbon gas and catalyst to flow between reactors in opposite directions. 
     
     
         15 . A process for producing hydrogen and graphitic carbon according to  claim 14 , wherein unreacted catalyst is provided in the lowest pressure reactor and unreacted hydrocarbon gas is provided in the highest pressure reactor and catalyst is transferred between the chambers of increasing pressure counter-currently to the gas flow between the chambers. 
     
     
         16 . A method for the beneficiation of catalytic metal containing ore, the method comprising contacting at a temperature between 600° C. and 1000° C. the catalytic metal containing ore with a hydrocarbon gas to form a carbon-coated metal species. 
     
     
         17 . A method for the beneficiation of catalytic metal containing ore according to  claim 16 , wherein the carbon-coated metal species is a graphite coated metal species. 
     
     
         18 . A method for the beneficiation of catalytic metal containing ore according to  claim 16  or  claim 17 , wherein the catalytic metal containing ore is iron ore. 
     
     
         19 . A method for the beneficiation of catalytic metal containing ore according to any one of  claims 16  to  18 , wherein the pressure is greater than atmospheric pressure. 
     
     
         20 . A method for the beneficiation of catalytic metal containing ore according to any one of  claims 16  to  18 . wherein the pressure is 0 bar to 100 bar. 
     
     
         21 . A method for the beneficiation of catalytic metal containing ore according to any one of  claims 16  to  19 , wherein the temperature is between 700° C. and 950° C. 
     
     
         22 . A method for the beneficiation of catalytic metal containing ore according to any one of  claims 16  to  21 , wherein the graphite is removed from the graphite coated metal species by contacting at temperature of 700° C. to 900° C. the graphite coated metal species with hydrogen gas. 
     
     
         23 . A method for the beneficiation of catalytic metal containing ore according to any one of  claims 16  to  22 , wherein the removal of the graphite from the graphite coated metal species is performed in a pressurised reduction reactor at a pressure of 0 bar to 100 bar. 
     
     
         24 . A method for the beneficiation of catalytic metal containing ore according to any one of  claims 16  to  23 , wherein the step of contacting at temperature of 700° C. to 900° C., the graphite coated metal species with hydrogen gas produces methane which is recycled to produce hydrogen. 
     
     
         25 . A method for the beneficiation of catalytic metal containing ore according to  claim 24 , wherein the hydrogen produced in the step of recycling the methane is used in the step of contacting at temperature of 700° C. to 900° C. the graphite coated metal species with hydrogen gas to remove the graphite from the graphite coated metal species.