Patent ID: 7588746

Claim:
A method for producing hydrogen and carbon by sustainable, in-situ decomposition of hydrocarbon feedstock over carbon aerosol particles using a continuous process comprising the steps of: a) selecting a reactor vessel consisting essentially of two compartments, a first reaction compartment for generating in-situ catalytically active aerosol carbon particles connected to a second reaction compartment that is a catalytic reactor for in-situ dissociation of hydrocarbon feedstock into hydrogen gas and elemental carbon; b) selecting a carbonaceous material that can be converted to catalytically active aerosol carbon particles; c) transporting the carbonaceous material of step b) to the first reaction compartment where the carbonaceous material is exposed to an energy input that produces an outgoing steam of catalytically active aerosol carbon particles that become airborne; d) directing the outgoing stream of airborne, catalytically active aerosol carbon particles to the second reaction compartment; e) sending a stream of hydrocarbon feedstock to the second reaction compartment where in-situ dissociation of the hydrocarbon feedstock occurs over the surface of catalytically active aerosol carbon particles from step d) acting as catalyst for the dissociation of the hydrocarbon feedstock; and f) collecting hydrogen gas from a first outlet and elemental carbon from a second outlet of the second reaction compartment in a continuous process without catalyst regeneration.