WO2023053149A1

WO2023053149A1 - A method and device for onsite generation of hydrogen fuel

Info

Publication number: WO2023053149A1
Application number: PCT/IN2022/051115
Authority: WO
Inventors: Harjinder Singh Cheema; J.P. Kundra
Original assignee: Cheema, Guramrit
Priority date: 2022-01-11
Filing date: 2022-12-22
Publication date: 2023-04-06

Abstract

Eco-friendly method and device for onsite generation of hydrogen fuel relates to an onsite device for production of gaseous mixture containing a substantial proportion of hydrogen by reaction of methane with superheated steam in the presence of a catalyst, and a method thereof. The present invention also enables capture and usage of carbon as carbon nanoparticles for further use in industry. The present invention substitutes the combustion of fossil fuels with hydrogen to release no greenhouse gases. The invention provides a cost effective, eco-friendly, and easy to install alternative to cut down industry's carbon emissions.

Description

TITLE OF THE INVENTION A METHOD AND DEVICE FOR ONSITE GENERATION OF HYDROGEN FUEL TECHNICAL FIELD [001] The present invention relates to the fuel generation. More particularly it relates to the highly efficient and eco-friendly hydrogen fuel generation. BACKGROUND ART [002] Hydrogen fuel is a zero-carbon fuel that is burned with oxygen; provided it is created in a zero-carbon way. [003] Hydrogen is the lightest and first element of periodic table. Since the weight of hydrogen is less than air, it rises in the atmosphere and is therefore rarely found in its pure form, H₂. In a flame of pure hydrogen gas, burning in air, the hydrogen (H₂) reacts with oxygen (O₂) to form water (H₂O) and releases energy. 2H₂ (g) +O₂ (g) → 2H₂O (g) + energy [004] The energy released enables hydrogen to act as a fuel. In atmospheric air instead of pure oxygen, hydrogen combustion may yield lesser amounts of inox gases, along with the water vapour. [005] Hydrogen is usually considered an energy carrier, like electricity when it is produced from a primary energy source such as solar energy, biomass, electricity, or hydrocarbons such as natural gas or coal. [006] Conventional hydrogen production using natural gas induces significant environmental impacts; as with the use of any hydrocarbon, carbon dioxide is emitted. At the same time, the addition of 20% of hydrogen to natural gas can reduce CO₂ emissions caused by heating and cooking. [007] Hydrogen fuel can be produced from methane or by electrolysis of water. However, most of the hydrogen is produced by steam methane reforming process. Only a small quantity is made by alternative routes such as biomass gasification or electrolysis of water or solar thermochemistry. The reason behind is steam methane reforming directly uses natural gas whereas electrolysis process requires electricity and the cost of producing electricity is more than natural gas. [008] Steam-methane reforming, involves the extraction of hydrogen from methane. However, this reaction releases fossil carbon dioxide and carbon monoxide into the atmosphere which is greenhouse gases exogenous to the natural carbon cycle, and thus contribute to climate change. [009] Another problem of using hydrogen as fuel is “It is difficult to store it in either a high-pressure tank or a cryogenic tank.” [010] Hydrogen has a high energy content per unit mass. However, at room temperature and atmospheric pressure, it has a very low energy content per unit volume, compared to liquid fuels or even to natural gas. For this reason, it is usually either compressed or liquefied by lowering its temperature to less than 33K. [011] Therefore, to overcome the problems encountered in present day systems require a complete elimination of harmful gases produced during hydrogen fuel consumption. The present invention provides an eco-friendly hydrogen fuel method, device, and its method of operation. [012] The novelty resides in the construction and mode of action of the device which produces the high yield of hydrogen and oxygen molecules to be successively used as energy fuel. [013] The present invention describes eco-friendly method and device for onsite generation of hydrogen fuel, generator working at temperatures between 700- 1500 °C. Once produced, hydrogen can be used in much the same way as natural gas. It can be used to fuel cells to generate electricity and heat, used in a combined cycle gas turbine to produce larger quantities of centrally produced electricity or burned to run a combustion engine. The device producing no carbon or methane emissions in environment. In the device hydrogen is combined with oxygen to form water. This is also one of its most important advantages as hydrogen fuel is environmentally friendly. The heat in a hydrogen flame is a radiant emission from the newly formed water molecules. The water molecules are in an excited state on the initial formation and then transition to a ground state; the transition releasing thermal radiation. The said system and method are more energy efficient, cost effective and environment friendly. The said method and device are unique in terms of its simplicity, expandability, multiple utility etc. DISCLOSURE OF THE INVENTION [014] The present invention disclosing eco-friendly method and device for onsite generation of hydrogen fuel generator working at temperatures between 700- 1600 °C. [015] The work involves the splitting of Hydrogen from methane and steam & firing the same in boiler to produce steam thus reducing the fuel consumption of machine and reducing the content of carbon in Air thereby using atomic grade carbon. There by increasing the heat value of fuel by burning hydrogen instead of methane. Presently the splitting is done with electrolysis process which is power consuming & unviable process. These processes are only suitable for low volume of hydrogen. It fails when we need more than 20 litres. /sec. of hydrogen. Therefore, the disclosed invention will reduce the fuel consumption of all machines and reduces the air pollution drastically. BRIEF DESCRIPTION OF THE DRAWING [016] The present invention will become more understandable from the description given herein and the accompanying drawings below. These are given by way of illustration only and therefore not limited to present invention and wherein: [017] Figure 1 illustrates the device for onsite generation of hydrogen as fuel. BEST MODE(S) FOR CARRYING OUT THE INVENTION [018] The following presents a simplified description of the invention in order to provide a basic understanding of some aspects of the invention. This description is not an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form. [019] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well- known functions and constructions are omitted for clarity and conciseness. [020] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments. [021] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. [022] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. [023] By the term “substantially” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide. [024] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. [025] It should be emphasized that the term “eco-friendly” when used in this specification is taken to specify the materials that are earth-friendly or not harmful to the environment. [026] It should be emphasized that the term “onsite generation” when used in this specification is taken to specify the production of energy at the point of use i.e., the site where it is to be consumed. [027] It should be emphasized that the term “fuel” when used in this specification is taken to specify the material to produce heat or power. [028] It should be emphasized that the term “catalyst” when used in this specification is taken to specify any substance that increases the rate of a reaction without itself being consumed. [029] It should be emphasized that the term “self-assembly” when used in this specification is taken to specify a process in which a disordered system of pre- existing components forms an organized structure or pattern as a consequence of specific, local interactions among the components themselves, without external direction. [030] It should be emphasized that the term “self-assembled carbon structures” when used in this specification is taken to specify the structures made by self- assembly of carbon atoms or molecules. [031] It should be emphasized that the term “electrostatic deposition” when used in this specification is taken to specify a process to deposit thin and/or thick layers of a coating onto various substrates. [032] It should be emphasized that the term “de-carbonization” when used in this specification is taken to specify the reduction of carbon content. [033] It should be emphasized that the term “valve” when used in this specification is taken to specify a device that regulates, controls, or directs the flow of steam or gas or fluid by opening, closing, or partially/completely obstructing fluid/gas flow. [034] Disclosing eco-friendly method and device for onsite generation of hydrogen fuel generator working at temperatures between 700-1600 °C. Once produced, hydrogen can be used in much the same way as natural gas - it can be used to fuel cells to generate electricity and heat, used in a combined cycle gas turbine to produce larger quantities of centrally produced electricity or burned to run a combustion engine; The generator producing no carbon or methane emissions in environment. In the generator hydrogen is combined with oxygen to form water. This is also one of its most important advantages as hydrogen fuel is environmentally friendly. The heat in a hydrogen flame is a radiant emission from the newly formed water molecules. The water molecules are in an excited state on the initial formation and then transition to a ground state; the transition releasing thermal radiation. [035] The invention disclosing an eco-friendly method for onsite generation of hydrogen fuel involves the interaction of methane with high temperature steam. [036] In the method, the methane and steam are interacted in 1: 2 molar ratios. [037] In the method, the methane and steam are interacted in the presence of catalyst. [038] In the method, four molecules of hydrogen, one molecule of oxygen and carbon are produced after interaction of one molecule of methane and two molecules of water (steam). [039] In the method, the carbon atom of methane is collected in the form of self- assembled carbon structures. [040] In the method, the catalyst is an inorganic compound. [041] In an embodiment in the method the catalyst is selected from the group comprises of iron and nickel. [042] In the method, the carbon is collected in the form of self-assembled structures by cyclonic filtration, mechanical membrane separation, electrostatic deposition etc. [043] In the method, the atoms of the carbon are self-assembled in to carbon nanotubes, buckyballs, fullerenes, carbon dots, diamond, graphite, graphene, graphene oxide and/or carbon black. [044] The invention further disclosing an eco-friendly device for onsite generation of hydrogen fuel comprises at least one steam generator, furnace, mixing chamber and cyclone separator connected to each other. [045] The device further comprising of steam trail containing steam carrying source and steam control valve, gas control valves, drain and vents, temperature sensor and controllers etc. [046] In the device, the mixing chamber is feed with piped natural gas to react with the steam generated in the furnace to generate onsite hydrogen fuel. [047] In the device, the onsite hydrogen fuel is a mixture of gases containing 90%- 97% of hydrogen and 3% -10% oxygen. [048] In an embodiment, in the device alumina supported nickel-iron wool acts as a catalyst and also adsorbs the negatively charged carbon intermediate species produced as a result of the reaction between superheated steam and methane/natural gas. [049] In an embodiment in the device, the rate of generation of hydrogen fuel is from 100 litre/hour to 1500 litre/hour depending on the boiler design and capacity. [050] In an embodiment in the device, the rate of generation of hydrogen fuel is from 100 litre/hour to 1000 litre/hour depending on the boiler design and capacity. [051] In an embodiment in the device, the rate of generation of hydrogen fuel is from 100 litre/hour to 400 litre/hour depending on the boiler design and capacity. [052] In an embodiment the steam generator (102) can be of any shape such as rectangle, square, trapezoid, tapered, circular etc. or combination thereof. [053] In an embodiment the steam generator (102) can be of sufficient size to heat the water for the proper functioning of the system. [054] In an embodiment the steam generator (102) can be made of any material such as natural, artificial or combination thereof. [055] In an embodiment the mixing chamber (104) can be of any shape such as rectangle, square, trapezoid, tapered, circular etc. or combination thereof. [056] In an embodiment the mixing chamber can be of sufficient size to mix the methane and steam for the proper functioning of the system. [057] In an embodiment the mixing chamber (104) can be made of any material such as natural, artificial or combination thereof. [058] In an embodiment the steam generator (102) and mixing chamber (104) surface can be coated with the protected material to increase the shelf life. [059] In embodiments the steam carrying sources can be of any shape and size which serves the purpose of invention. [060] In preferred embodiments the steam carrying sources are of elongated, tube-like structure with or without bends. [061] In preferred embodiments the steam carrying sources are pipes. [062] In embodiments the steam carrying sources can be made of any material such as natural, synthetic, semi-synthetic or combination thereof. [063] The system (100) comprising the multiple valves to control the circulation of the steam, air, fuel in the system. [064] In an embodiment the valves can be of any type such as Ball, Butterfly, Check, Diaphragm, Gate, Globe, Knife Gate, Parallel Slide, Pinch, Piston, Plug, Sluice, etc. but not limited to these only. [065] In an embodiment the valves can be manual, automatic, or semi-automatic operated. [066] In an embodiment in the system all the valves can be of different in terms of its functionality, material. [067] In an embodiment in the system at least two valves can be the same in terms of its functionality, material. [068] In a preferred embodiment in the system all valves are solenoid valves. [069] In a preferred embodiment in the system all the solenoid valves are operated through an automatic programmable controller. [070] Referring to Figure 1 providing, the device (100) comprising steam generator (102), furnace (104), mixing chamber (106), cyclone separator (108), dust/ carbon collector (110), gas burner (112), gas inlet (114), steam super-heated coils (116), flame (118), water inlet (120), steam outlet (122), steam control valve (124, 128), air vent (126), gas control valve (130), temperature indicator (132), fuel carrying source (134). [071] WORKING OF THE DEVICE 1) Firstly, in the device (100) the steam generator (102) is filled with water by opening the water inlet (120). The furnace (104) is heated using gas burner (112) to generate the steam (100°C-200°C) in the steam generator (102). 2) The produced steam is carried from the steam generator (102) to mixing chamber (106) through the pipes and during the passage the steam become superheated steam (700°C - 1500°C) when it passed through the super-heated coils (116) located over the furnace (104). 3) In the device (100) the flow of the steam is regulated with steam control valves (124, 128). 4) The mixing chamber (106) is feed with methane/natural gas through gas inlet (114) to react with the super-heated steam. 5) In the mixing chamber (106) the methane/natural gas and superheated steam are mixed in the ratio of 1:2 and moved to cyclone separator (108). 6) In the cyclone separator (108) methane gas and superheated steam are interacted with each other which involves the splitting of hydrogen from methane and steam in the presence of catalyst. 7) In the reaction mixture hydrogen, oxygen and carbon are produced after interaction of methane and water in steam form. 8) The carbon atom of methane is collected in carbon collector (110), in the form of self-assembled carbon structures by cyclonic filtration, mechanical membrane separation and/or electrostatic deposition. 9) The generated hydrogen fuel which is the mixture of gases containing 90%- 97% of hydrogen and 3% -10% oxygen is moved through hydrogen fuel outlet pipe (132) to gas burner (112). 10) The generated hydrogen fuel is successively used in gas burner (112) to generate flame (118), which is further used to heat the furnace (104). 11) The rate of generation of hydrogen fuel is from 100 litre/hour to 1000 litre/hour depending on the device design and capacity. 12) Along with heating the coils, the generated fuel is further used for heating of steam generator (102) for other industrial and domestic applications. 13) The hydrogen fuel can be used in much the same way as natural gas. It can be used to fuel cells to generate electricity and heat, used in a combined cycle gas turbine to produce larger quantities of centrally produced electricity or burned to run a combustion engine. [072] The device producing no carbon or methane emissions in environment. The foremost advantage of system is to generate the green hydrogen fuel in a facile manner, which has high industrial applicability and also eco-friendly. [073] The disclosed system and method is more energy efficient, cost effective and environment friendly. The said method and device is unique in terms of its simplicity, expandability, multiple utility etc. [074] The processes described above is described as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be rearranged, or some steps may be performed simultaneously. [075] Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. [076] Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read therefore going description. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications; these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention. INDUSTRIAL APPLICABILITY [077] The present invention provides an eco-friendly hydrogen fuel method, device, and its method of operation. [078] The present invention describes eco-friendly method and device for onsite generation of hydrogen fuel, generator working at temperatures between 700- 1500 °C. Once produced, hydrogen can be used in much the same way as natural gas. It can be used to fuel cells to generate electricity and heat, used in a combined cycle gas turbine to produce larger quantities of centrally produced electricity or burned to run a combustion engine. [079] The said system and method are more energy efficient, cost effective and environment friendly. The said method and device are unique in terms of its simplicity, expandability, multiple utility etc. [080] The device producing no carbon or methane emissions in environment. The foremost advantage of system is to generate the green hydrogen fuel in a facile manner, which has high industrial applicability and also eco-friendly.

Claims

CLAIMS We/I claim 1. A method for onsite generation of hydrogen fuel comprising interaction of methane with high temperature steam wherein i. the methane and steam are interacted in 1: 2 molar ratios; ii. the methane and steam are interacted in the presence of catalyst; iii. four molecules of hydrogen, one molecule of oxygen and carbon are produced after interaction of one molecule of methane and two molecules of water in steam form; and iv. the carbon atom of methane is collected in the form of self- assembled carbon structures.

2. The method for onsite generation of hydrogen fuel as claimed in claim 1 wherein, the catalyst is an inorganic compound selected from the group comprises of alumina supported iron and nickel.

3. The method for onsite generation of hydrogen as fuel as claimed in claim 1 wherein, produced four molecules of hydrogen, one molecule of oxygen are successively used as a fuel.

4. The method for onsite generation of hydrogen fuel as claimed in claim 1 wherein, the carbon is collected in the form of self- assembled structures by cyclonic filtration, mechanical membrane separation and/or electrostatic deposition.

5. The method for onsite generation of hydrogen fuel as claimed in claim 1 wherein, the atoms of the carbon are self-assembled in to carbon nano-tubes, buckyballs, fullerenes, carbon dots, diamond, graphite, graphene, graphene oxide and/or carbon black.

6. The method for onsite generation of hydrogen as fuel as claimed in claim 1 wherein, the onsite hydrogen fuel is a mixture of gases containing 90%-97% of hydrogen and 3% -10% oxygen.

7. A device (100) for onsite generation of hydrogen fuel comprising at least one steam generator (102), furnace (104), mixing chamber (106), cyclone separator (108); wherein the cyclone separator is further comprising a carbon collector (110).

8. The device (100) for onsite generation of hydrogen as claimed in claim 7 further comprises of at least one, gas burner (112), gas inlet (114), steam super- heated coils (116), flame (118), water inlet (120), steam outlet (122), steam control valve (124, 128), air vent (126), gas control valve (130), temperature indicator (132), and fuel carrying source (134).

9. The device (100) for onsite generation of hydrogen fuel as claimed in claim 7, employed comprising; i. firstly, in the device (100) the steam generator (102) is filled with water by opening the water inlet (120); ii. the furnace (104) is heated using gas burner (112) to generate the steam (100°c-200°c) in the steam generator (102); iii. the produced steam is carried from the steam generator (102) to mixing chamber (106) through the pipes and during the passage the steam become superheated steam (700°c - 1500°c) when it passed through the super- heated coils (116) located over the furnace (104); iv. the mixing chamber (106) is feed with methane/natural gas through gas inlet (114) to react with the super-heated steam; v. in the mixing chamber (106) the methane/natural gas and superheated steam are mixed in the ratio of 1:2 and moved to cyclone separator (108); vi. in the cyclone separator (108) methane gas and superheated steam are interacted with each other which involves the splitting of hydrogen from methane and steam in the presence of catalyst; vii. in the reaction mixture hydrogen, oxygen and carbon are produced after interaction of methane and water in steam form; viii. the carbon atom of methane is collected in carbon collector (110), in the form of self-assembled carbon structures by cyclonic filtration, mechanical membrane separation and/or electrostatic deposition; ix. the generated hydrogen fuel which is the mixture of gases containing 90%- 97% of hydrogen and 3% -10% oxygen is moved through hydrogen fuel outlet pipe (132) to gas burner (112); x. the generated hydrogen fuel is successively used in gas burner (112) to generate flame (118), which is further used to heat the furnace (104); the generated fuel is further used for heating of steam generator (102) for other industrial and domestic applications.

10. The device (100) for onsite generation of hydrogen as claimed in claim 7 wherein, the rate of generation of hydrogen fuel is from 100 litre/hour to 1000 litre/hour.