SUSTAINABLE HYDROGEN GENERATION FROM MILD STEEL SCRAP AND INDUSTRY EFFLUENTS AND THEREOF

Abstract

This invention relates to using mild steel scrap and industry effluent spent acid for production of clean hydrogen and value-added products thereof.

Specification

Description:Ramesh K. Guduru & Krishnaveni Adepu Attorney Docket No.
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SUSTAINABLE HYDROGEN GENERATION FROM
MILD STEEL SCRAP AND INDUSTRY EFFLUENTS AND THEREOF
FIELD
[0001]
Present disclosure relates to the method of producing clean and sustainable hydrogen and value added products and thereof while utilizing mild steel scrap and industry effluent, such as spent acid and/or acidic natured industry effluent.
BACKGROUND
[0002]
This section offers contextual information relevant to the present disclosure, which may not constitute prior art.
[0003]
Hydrogen is a clean fuel with high calorific value, and is a great green energy source as well as chemical resource that can be used to power vehicles, generate electricity, and hydrogenation of oils, reducing metal oxides or ores into metals, and utilized in pharmaceuticals, chemical processing and other fuel production as well.
[0004]
Application of hydrogen in industry furnaces and automobiles, wherever it is applicable as a fuel replacement to the existing fossil fuels will help reduce the greenhouse gas emissions and thereby it would play a key role in the future green economy, offering significant potential to reduce CO2 levels while meeting the growing global energy demand.
[0005]
Hydrogen production technologies are well-established and utilize various methods, such as steam reforming, partial oxidation of oil, coal gasification, ammonia cracking, and electrolysis. However, with the exception of electrolysis, all of these methods result in direct carbon emissions.
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[0006]
In contrast, the environmental impact of hydrogen production via electrolysis largely depends on the electricity source used. When powered by fossil fuel-based electricity, electrolysis indirectly contributes to carbon emissions, whereas using renewable energy like solar, wind, or tidal can significantly reduce its carbon footprint. However, the intermittent nature of renewable energy requires battery storage, which introduces its own carbon footprint concerns due to the production and disposal of batteries. Moreover, electrolysis requires large amounts of purified or deionized water, with one ton of hydrogen needing at least nine tons of deionized water, which in turn requires over 27 tons of fresh water. This high water demand can exacerbate global freshwater shortages, especially in regions already facing water scarcity. Additionally, the processes used to produce deionized water can lead to carbon emissions and wastewater, further complicating the sustainability of hydrogen production through electrolysis.
[0007]
While this water-intensive demand for hydrogen production presents a significant crisis, many industries simultaneously struggle with the disposal of wastewater, effluent liquids, and spent acid solutions, which contribute to severe environmental contamination. These industrial discharges often lead to water and soil pollution, exacerbating the degradation of ecosystems, and promote the leaching of harmful heavy metals into natural resources. The challenge lies in balancing these conflicting issues-on one hand, the need for large quantities of purified water for clean energy production, and on the other, the proper treatment and disposal of industrial waste that continues to strain the environment.
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[0008]
Although technologies for acid recovery and reuse exist, their adoption is limited due to high costs and technological gaps. Globally, stricter regulations and the export of hazardous waste to developing countries pose additional challenges, with slow integration of circular economy practices hindering sustainable solutions.
[0009]
The growing shortage of water resources and declining availability of fresh water, coupled with the strain caused by industrial effluents, pose a significant threat to the environment, economy, and ecosystems. Industrial discharges not only contaminate vital water sources but also contribute to soil degradation and biodiversity loss. This double-edged crisis intensifies the need for sustainable solutions. By adopting circular economy principles-such as recycling water, treating effluents for reuse, and repurposing industrial byproducts-industries can mitigate their environmental impact, conserve resources, and create economic value, turning waste into opportunity. Without this shift, the long-term viability of both natural resources and industrial growth is at risk. Integrating circular economy principles, where industrial effluents and waste liquids can be utilized in hydrogen production processes, could offer a promising solution to both these crises by reducing water demand while mitigating pollution.
[0010]
At this juncture, producing hydrogen without harming the environment or depleting natural resources, while utilizing industry waste liquids or effluents, along with other waste materials that have lost their utility, presents a significant advantage for sustainable hydrogen production. This approach not only addresses waste management but also promotes resource efficiency and reduces the carbon footprint of hydrogen generation. Integrating such processes into the industrial landscape aligns with circular economy principles, enabling cleaner energy production while minimizing environmental
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impact and conserving critical resources like water and raw materials. This creates a
sustainable pathway for the future of hydrogen energy.
[0011]
Several patents detail innovative methods for hydrogen production without external energy, but they face critical limitations. European Patent EP 1997774B1 outlines hydrogen generation via the galvanic corrosion of scrap magnesium alloys in water, and similarly, Korean Patent KR 101100578B1 uses a composite of anode and cathode metals immersed in an electrolyte, both without energy input. US Patent US 7521038 B2 describes a process involving molten magnesium scrap and a platinum mesh in NaCl solution, while US Patent US 11198923 B2 leverages nanogalvanic alloys of aluminum with metals like lead or gallium to spontaneously produce hydrogen upon contact with water. Despite avoiding external power and reducing emissions, these techniques often rely on costly materials like magnesium alloys or require complex preparation, making them less feasible for large-scale or low-cost applications. Additionally, they overlook the potential of utilizing industrial effluents or waste materials, missing the opportunity to integrate circular economy principles and generate valuable byproducts alongside hydrogen production. This highlights the need for more sustainable and resource-efficient hydrogen production technologies that make use of industry waste streams.
[0012]
Although weak acidic waste liquids or effluents typically do not promote rapid hydrogen production through galvanic corrosion or hydrogen replacement reactions with their acidic or water content, leveraging these effluents in innovative ways can significantly accelerate the process. By utilizing specific catalysts, additives, or optimizing reaction conditions, it is possible to enhance the efficiency of hydrogen generation from
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such waste liquids. This approach not only accelerates hydrogen production but also
provides a sustainable solution for managing industrial effluents, converting them from a disposal challenge into a valuable resource for clean energy. This dual benefit of waste reduction and hydrogen generation aligns with circular economy principles, making it a promising pathway for more environmentally friendly and resource-efficient hydrogen production technologies.
[0013]
There is a pressing need for innovative technologies that are both environmentally friendly-reducing carbon emissions and conserving water-and economically viable. Ideally, these technologies should also generate additional valuable byproducts, making the overall process more sustainable and cost-effective.
[0014]
This patent introduces a method for rapidly producing substantial quantities of hydrogen, ranging from several hundred to thousands of liters per hour, by utilizing acid-based industrial effluents in combination with metal scrap that has reached the end of its useful life. By harnessing the chemical reactions between these waste materials, the process efficiently generates hydrogen. This approach not only offers a cost-effective and sustainable method of hydrogen production but also provides a solution for managing industrial waste. By repurposing metal scrap and effluents that would otherwise be pollutants, this technology supports both waste reduction and clean energy generation, embodying the principles of a circular economy.
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SUMMARY
[0015]
This section provides a concise summary of the disclosure and does not cover the complete range or all aspects of the invention.
[0016]
This disclosure presents innovative techniques, equipment, and compositions for generating hydrogen along with other valuable byproducts. The invention details processes that harness industrial waste liquids, like spent acid solutions, together with scrap metals such as iron or aluminum to produce hydrogen and additional useful byproducts. A key advantage of these methods is the elimination of the need for fresh or deionized water, significantly lowering the environmental footprint by transforming waste and low-cost materials into productive resources.
[0017]
The process leverages the catalyzed interaction between metal scrap and waste effluents, aided by specific catalysts and ionic species, along with an initial activation to drive a hydrogen replacement reaction from the acid waste. This also results in the production of liquid precursors for synthesizing nanoscale value-added products.
[0018]
Additional applications for clean hydrogen production, along with valuable byproducts, will become evident from the descriptions provided in this document. The examples and descriptions in this summary are meant for illustrative purposes only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0019]
The drawings provided here serve as illustrations of specific embodiments and do not represent all potential implementations, nor are they meant to
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restrict the scope of this disclosure. For the sake of simplicity, not all components are
labeled in every figure, and not every element of each embodiment is depicted.
[0020]
FIG. 1 is an exemplary schematic for the whole process of hydrogen as well as byproduct production, where 101 can be an effluent or spent acid from industry, for example spent acid from galvanizing steel industry or spent acid from chemical industries etc., which is then brought into contact with industry metal scrap 102, such as mild steel, or scrap aluminum etc. in a specially designed reactor 103 in presence of a catalyst 104 while following a proprietary process, and produce hydrogen 105 as well as a solution 106 which can be further processed to generate byproducts in a reactor 107 while combining with another reactant 108. Following this step, 109 consists of a suspension of solid slurry 110 and liquid 111 together, which are then separated by filtration process. The solid slurry 110 is then washed and dried or treated to form a compound 112. On the other hand the liquid 111 will be either recycled or thermally treated to evaporate water to form a solid compound 113 as well as distilled water.
[0021]
FIG. 2 presents experimental data illustrating the influence of catalyst 104 on hydrogen production. In this experiment, C4 represents a larger amount of catalyst compared to C3, C2, and C1. At any given time, the amount of hydrogen 105 generated is higher with the higher amount of catalyst 104. This occurs as the metal scrap 102 chemically reacts with the effluent, the source for hydrogen, or spent acid 101 in the presence of catalyst 104 through a hydrogen displacement reaction after triggering the activation process. The catalyst significantly impacts both the reaction time and kinetics.
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[0022]
FIG. 3 is an illustration showing the rate of hydrogen production as a function of time, where chemical reaction between effluent 101 and metal scrap 102 in presence of 104 displaces hydrogen from the hydrogen source liquid i.e., spent acid.
[0023]
FIG. 4 shows the rise in pressure of hydrogen 105 being produced in a sealed reactor 103 following the chemical interaction between effluent 101 and scrap 102 in presence of a catalyst 104 after a proprietary activation. This pressure increases with respect to the time initially and peaks out and then reduces as the reaction approaches toward the terminal stages. This trend reflects a Gaussian pattern following sigmoidal reaction kinetics.
[0024]
FIG. 5 shows an experimental exemplary pressure rise of hydrogen with respect to the time in the specially designed reactor 103 while it is being produced following the chemical interaction between effluent 101 and scrap 102 in presence of a catalyst 104 after a proprietary activation. A continuous reaction between 101 usually results in higher pressures and higher flow rates with respect to the time, and when the rate of hydrogen production equates with the rate of flow rate of hydrogen, the pressure inside the reaction stays at a constant value.
[0025]
FIG. 6 shows the temperature rise due to exothermic nature of the chemical interaction between 101 and 102, and the intermittent nature of fluctuations are dictated based on the operational control of chemical reactions between 101 and 102 along with accumulation of heat and pressure within the system.
[0026]
FIG. 7 shows the particle size characteristics of the solid byproduct formed 112 after letting the solution 106 to go through a series of processing steps from reactor 107 after combining with another reactant 108 to the stage of 109 with liquid
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suspension and then washing and drying up of 110. This graph clearly reflects that the
solid particles formed have multi-size distribution ranging from 10 nm to 50 microns while majority of the particles having size less than 300 nm contributing to almost 75% or above in their cumulative volume. Rest of the particles with size more than 300 nm contributes hardly to 20 to 25% or so in their cumulative volume.
[0027]
FIG. 8 shows the particle size characteristics of another solid byproduct 112 that could be synthesized after letting the solution 106 to go through a series of processing steps from reactor 107 after combining with another reactant 108 to the stage of 109 with liquid suspension and then washing and drying up of 110. This graph clearly reflects that the solid particles formed have a skewed particle size distribution where the particle size ranged from 200 nm to 30 micron with a tight size distribution, and with majority of the particles the size below 10 micron size.
[0028]
FIG. 9 shows the X-ray diffraction pattern of the solid byproduct 112 formed confirming the phase of Fe3O4 in those solid particles.
[0029]
FIG. 10 shows the scanning electron microscopy image of solid byproduct 112, which are Fe3O4 particles confirming their size mostly below 1 micron size, and majority in the range of nano to submicron range.
[0030]
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
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DETAILED DESCRIPTION
[0031]
The following examples of various embodiments of the present disclosure are provided for illustration purposes in reference to the accompanying figures. These figures are schematic representations and are not necessarily drawn to scale.
[0032]
The process begins with effluent or spent acid 101 such as that from industrial applications like steel galvanizing or various chemical processes is introduced. This spent acid 101 serves as a primary feedstock for hydrogen generation. The spent acid is then combined with industrial metal scrap 102, typically consisting of materials like mild steel or aluminum, to initiate a reaction. The mixture is placed in a specially designed reactor 103 engineered to facilitate optimal reaction conditions. A catalyst 104 is added within the reactor to accelerate the reaction, following a proprietary process. This reaction produces hydrogen gas 105 as a primary product. Additionally, it yields a solution 106 containing reaction byproducts, which are then transported for further processing in a second reactor 107. The byproduct solution from the hydrogen production stage 106 is introduced to a secondary reactor 107. Here, it is combined with another reactant 108 to create a mixture that undergoes additional reactions. The reaction output 109 consists of a suspension containing both solid slurry 110 and a liquid phase 111. This suspension is then separated through a filtration process, which divides the solid and liquid components. The solid slurry 110 is processed further by washing and drying. It can be refined into a stable compound 112, suitable for various applications or further use. The liquid 111, depending on its composition, may be recycled back into the process for reuse or directed to a thermal treatment unit. In the thermal treatment step, water is evaporated to form distilled water, and any remaining solutes are transformed into a solid compound 113.
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This sequence represents a comprehensive approach for producing hydrogen and
valuable byproducts, while integrating resource recovery and minimizing waste.
[0033]
Figure 2 provides experimental data demonstrating the effect of varying amounts of catalyst 104 on the rate and volume of hydrogen production 105. In this experiment, different catalyst levels-denoted as C1, C2, C3, and C4-were tested. Here, C4 represents the highest concentration of catalyst, while C1 represents the lowest. The data reveals that, at any point during the reaction, a higher catalyst amount C4 consistently leads to an increased volume of hydrogen produced compared to lower catalyst levels (C1, C2, and C3). This enhancement in hydrogen yield occurs as the metal scrap 102 undergoes a hydrogen displacement reaction with the effluent or spent acid 101, which acts as the hydrogen source. The reaction is initiated upon activation of the catalyst 104, which facilitates destabilizing the surface oxide layers on the scrap and thereby facilitate the displacement process by speeding up the reaction between the metal and acid. The catalyst's role is crucial, as it significantly influences both the overall reaction speed and the reaction kinetics, essentially determining how quickly and efficiently hydrogen is generated over time. This suggests that optimizing the catalyst quantity can markedly improve hydrogen production in similar processes.
[0034]
Figure 3 depicts the rate of hydrogen production over time, showcasing how the chemical reaction between the effluent 101, typically an effluent or industry acidic waste stream, and metal scrap 102 generates hydrogen in the presence of a catalyst 104. This reaction involves the displacement of hydrogen atoms from the hydrogen source, resulting in the release of hydrogen gas. The catalyst 104 is essential for accelerating the reaction between the metal and effluent. By lowering the activation energy barrier
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especially destabilizing the surface layers of the metal scrap, it enables the reaction to
proceed more readily, which is especially important given the slower kinetics that might otherwise occur with raw metal-effluent reactions. Lowering the activation barrier allows hydrogen atoms to be displaced from the spent acid or effluent source more efficiently, enhancing hydrogen production even under milder reaction conditions. The surface area of the metal scrap 102 also plays a critical role in determining the reaction rate. Larger or more fragmented pieces of metal scrap provide a greater surface area for contact with the industry effluent or spent acid, maximizing interaction sites and enabling more extensive hydrogen displacement. In Figure 3, this is reflected in the faster initial reaction rates observed when both catalyst concentration and surface area are optimized. In Figure 3, the reaction rate or hydrogen production rate is represented by Gaussian (bell-shaped) curves. These curves illustrate the dynamic changes in hydrogen generation over time. At the beginning of the reaction, the hydrogen production rate is relatively low as the catalyst activates and initial interactions between the spent acid and metal occur. During this stage, the system begins to overcome the activation energy barrier, initiating steady contact between the spent acid or effluent and metal scrap. As the reaction progresses, hydrogen production rate increases significantly. The catalyst promotes reaction kinetics, enabling rapid hydrogen displacement as more active sites are exposed on the metal surface. This phase reaches a peak hydrogen production rate, where the conditions are optimal for maximum gas generation. After reaching the peak, the reaction rate gradually decreases. This reduction is due to the depletion of available hydrogen sources in the acid and partial or full reaction of the metal scrap, leading to a slowdown in production. The reaction rate eventually stabilizes as the reaction nears completion.
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The overall efficiency and yield of hydrogen production are determined by the interplay of
factors such as catalyst concentration, metal surface area, activation energy, and reaction kinetics. By optimizing the catalyst level and maximizing the metal surface area, the reaction can achieve higher production rates, faster kinetics, and greater overall hydrogen output.
[0035]
Figure 4 illustrates the change in hydrogen pressure 105 over time within a sealed reactor 103 as hydrogen is generated from the reaction between the effluent 101 (typically a spent acid) and metal scrap 102. This process takes place in the presence of a catalyst 104, which initiates and accelerates the reaction through a proprietary activation step. At the start, the reaction proceeds gradually as the catalyst activates, reducing the activation energy barrier and initiating hydrogen production. As the reaction rate increases, hydrogen gas accumulates in the sealed reactor, causing a steady rise in pressure. This initial stage of pressure buildup corresponds to the activation and contact phase in the reaction kinetics, where the effluent begins to interact with the metal scrap under the influence of the catalyst. As the reaction intensifies, the rate of hydrogen production accelerates, reaching a peak. This peak phase is supported by the catalyst-enhanced reaction kinetics and the expanded surface area of the metal scrap, which allows more active sites to engage in the reaction. At this point, the reaction reaches its maximum hydrogen production rate, leading to a peak in pressure within the reactor. The pressure at this peak reflects the optimal conditions achieved by the interplay between the catalyst concentration, metal surface area, and the efficient displacement of hydrogen from the hydrogen source i.e., effluent or spent acid. This peak pressure is aligned with the Gaussian curve characteristics of the reaction, where the rate of hydrogen generation
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is at its highest. Following the peak, the pressure in the reactor begins to decline gradually
as the reaction progresses toward its later stages. This decline is due to the depletion of reactants-the spent acid's hydrogen sources become less available, and the metal scrap surface begins to lose reactive sites. As these resources diminish, the reaction rate decreases, and consequently, hydrogen production slows, resulting in a steady drop in pressure. This final stage is consistent with the Gaussian nature of the reaction, where the reaction rate exhibits a bell-shaped curve. After reaching maximum production, the system stabilizes and pressure slowly reduces as hydrogen production tapers off, approaching equilibrium or completion. In summary, Figure 4 shows a pressure trend that follows a Gaussian pattern in line with sigmoidal reaction kinetics. The reaction stages-initial activation, peak production, and gradual decline-are evident through the pressure variations within the reactor. The catalyst's role, metal surface area, and reaction kinetics all contribute to this behavior, allowing the reaction to reach an optimal hydrogen yield efficiently.
[0036]
Figure 5 provides data on the pressure increase of hydrogen over time within a specially designed reactor 103, illustrating how pressure evolves during hydrogen production. This process results from the chemical interaction between effluent 101, typically a spent acid, and metal scrap 102, such as mild steel or aluminum, in the presence of a catalyst 104. The reaction is initiated through a proprietary activation process, which enhances hydrogen production efficiency. In the initial phase, hydrogen production begins gradually as the catalyst activates, helping to overcome the activation energy barrier and enabling the reaction between the effluent and metal scrap. As the hydrogen starts to accumulate within the sealed reactor, a steady rise in pressure is
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observed. This pressure increase reflects the catalytic enhancement, which accelerates
the reaction kinetics, allowing hydrogen atoms to be displaced more rapidly from the effluent by the metal scrap. As the reaction progresses, the rate of hydrogen production increases, leading to a corresponding rise in both pressure and flow rate within the reactor. The continuous reaction between the effluent and metal scrap sustains a high rate of hydrogen release, driven by the catalyst and supported by the optimized surface area of the scrap material, which maximizes contact with the effluent. At this stage, the flow rate of hydrogen (the speed at which hydrogen gas moves or can be released from the reactor) rises alongside the internal pressure. The increase in flow rate and pressure continues until a dynamic balance is reached, where the reaction is at its most productive stage. As the system reaches a steady state, the rate of hydrogen production matches the rate at which hydrogen gas flows out of the reactor. This balance results in a constant pressure within the reactor. During this equilibrium phase, hydrogen production is maintained at an optimal rate, while the outflow of hydrogen prevents further pressure buildup. This indicates that the reaction conditions, catalyst activity, and metal-acid interaction are finely tuned to sustain consistent hydrogen output without excessive pressure increases. In overall, Figure 5 demonstrates that as long as the reaction conditions are ideal and the catalyst remains effective, hydrogen production will continue at a rate that maintains equilibrium pressure within the reactor. This balance highlights the importance of controlling parameters such as catalyst concentration, metal surface area, and reaction kinetics to achieve a steady hydrogen flow rate. By ensuring that hydrogen production and flow rate are aligned, the system can maintain high efficiency
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and safety, leveraging the catalyst to maximize hydrogen yield while preventing pressure
buildup.
[0037]
Figure 6 illustrates the temperature rise over time within the reactor due to the exothermic reaction between the effluent (often a spent acid) and metal scrap, such as mild steel or aluminum, catalyzed by a catalyst that enhances the reaction rate through a proprietary activation process. The exothermic nature of the reaction generates significant heat, directly correlated to the rate and extent of hydrogen production; as the reaction intensifies, the heat generated leads to a noticeable temperature rise within the sealed reactor. Additionally, intermittent fluctuations in temperature are observed, resulting from controlled adjustments made to manage the reaction's progress, including modifications to catalyst concentration, acid introduction rates, and reactor cooling mechanisms. These adjustments are crucial for maintaining a balance between reaction rate, temperature, and pressure buildup, preventing excessive temperature spikes and ensuring safe, efficient reactor operation. The exothermic reaction also causes pressure buildup as hydrogen gas accumulates alongside the generated heat, with rising temperature and pressure being interdependent in this sealed system. Proper operational control is essential to stabilize both temperature and pressure levels within safe limits, as uncontrolled accumulation could lead to instability. Overall, the temperature profile in Figure 6 emphasizes the significance of managing exothermic heat in optimizing the hydrogen production process, demonstrating that effective monitoring and control of thermal and pressure dynamics enable the system to sustain high levels of hydrogen production safely while maximizing catalyst use and enhancing reaction kinetics, thus mitigating risks associated with exothermic reactions.
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[0038]
Figure 7 illustrates the particle size distribution of the solid byproduct generated from processing the solution obtained in the reactor, following a systematic series of steps involving the reaction between the initial effluent and metal scrap, along with the introduction of an additional reactant. The analysis highlights the dynamic nature of particle formation as the process progresses from the reactor through to the washing and drying stages of the liquid suspension. The resulting solid particles display a multi-size distribution ranging from 10 nm to 50 microns, with approximately 75% or more of the cumulative volume being composed of particles smaller than 300 nm, indicating that the processing conditions favor the formation of finer particles with potentially advantageous properties for various applications. In contrast, larger particles exceeding 300 nm contribute only about 20% to 25% of the total volume, emphasizing the dominant role of smaller particles in the overall composition of the byproduct. Understanding these particle size characteristics is crucial for optimizing further processing and applications, as smaller particles generally exhibit enhanced reactivity and surface area, making them suitable for industrial uses such as catalysis and material synthesis. Overall, Figure 7 underscores the importance of particle size distribution in the solid byproduct's efficiency and application potential, guiding future enhancements in its production and use across diverse industrial contexts.
[0039]
Figure 8 presents a detailed depiction of the particle size characteristics of an alternative solid byproduct 112 synthesized from a processed solution 106 that has undergone a series of systematic processing steps. These steps begin after the initial reaction in the reactor 107 and include the introduction of an additional reactant 108, followed by the transition to a liquid suspension stage 109, and concluding with the
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washing and drying phase 110.
The formation of this solid byproduct involves a controlled chemical interaction that facilitates the precipitation of solid particles from the liquid medium. As the solution progresses through these various stages, the particles undergo significant changes in size and distribution. The addition of the second reactant plays a critical role in promoting specific interactions that lead to a more refined particle formation process, resulting in distinct characteristics that can differ markedly from those of the previous byproduct analyzed in Figure 7. The graph in Figure 8 indicates a skewed particle size distribution, with particles ranging in size from 200 nm to 30 microns. This skewness reflects the concentration of particle sizes toward one end of the spectrum, which suggests that the processing conditions favor the formation of certain particle sizes over others. Notably, the majority of particles in this distribution are below 10 microns, indicating a tight size range that enhances uniformity in the solid byproduct. The predominance of smaller particles can lead to improved surface properties, reactivity, and applicability in various industrial processes. The presence of a skewed distribution indicates that while a range of particle sizes exists, the smaller particles dominate in terms of volume, which can enhance the effectiveness of the solid byproduct in practical applications. The tight size distribution may offer advantages in processes requiring consistency and predictability, such as in catalytic applications or in the formulation of materials where particle size can significantly impact performance. Understanding the particle size characteristics of this solid byproduct is crucial for optimizing its potential applications. The tight size distribution and predominance of sub-10-micron particles may render this byproduct particularly suitable for roles in areas such as catalysis, where increased surface area and reactivity are desired, or in pharmaceuticals, where uniform
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particle sizes can affect solubility and bioavailability. Moreover, the processing conditions
leading to this skewed distribution may warrant further exploration and optimization to maximize yield and performance for specific applications. In summary, Figure 8 effectively illustrates the unique particle size characteristics of an alternative solid byproduct formed through controlled processing steps. The skewed distribution, dominated by smaller particles, underscores the importance of processing conditions in achieving desired material properties, which can inform future strategies for enhancing production and application across various industrial sectors.
[0040]
Figure 9 presents the X-ray diffraction (XRD) pattern of the solid byproduct 112, which has been synthesized through the previously discussed processing steps. This pattern is instrumental in confirming the phase composition of the solid particles, specifically identifying the presence of Fe₃O₄, commonly known as magnetite. The characterization of this phase is crucial for understanding the properties and potential applications of the solid byproduct.
[0041]
Figure 10 displays a scanning electron microscopy (SEM) image of the solid byproduct 112, specifically showcasing the Fe₃O₄ particles formed through the previously discussed synthesis process as in FIG. 1. This high-resolution imaging technique allows for detailed visualization of the particle morphology and size, confirming that the majority of these particles are predominantly below 1 micron, with a significant portion falling within the nano to submicron range, and the morphology depicts the equiaxed crystalline nature of the particles, which will be of great use in catalytical and magnetic applications in the industries.
Ramesh K. Guduru & Krishnaveni Adepu Attorney Docket No. , C , Claims:What is claimed is:
1.
A method of producing hydrogen and byproducts of high value iron or
Aluminum compounds with particles in the range of nanometers to micron by using steel or iron or aluminum scrap and industry effluent or spent acid along with a catalyst, comprising:
providing a conducting metallic steel or iron or aluminum based material as-it-is or as an anode against in contact with a conducting carbon or any other conducting natured noble or inert or stable material body while both are in contact with industry effluent or spent acid of acidic natured, and said conducting metallic steel or iron or aluminum material directly displaces hydrogen from the effluent or spent acid, and accelerated by presence of a catalyst in the spent acid solution in dissolved state and also galvanically coupling with carbon or other conducting metals of cathodic in nature, and the said catalyst consisting of free radicals that destabilize the oxide or any preventative layer that has formed or pre-existing on the anodic natured or conducting steel metal or iron or aluminum and thereby result in an exothermic reaction that enables further activation and accelerates the whole process of hydrogen generation through hydrogen displacement reaction,
2. The method as claimed in 1, wherein said effluent or spent acid comprises several contaminants in suspension, and said contaminants of non-conducting nature do not interact with the said conducting metallic steel or iron or aluminum as well as cathodic natured noble or inert or stable material that was either absent or introduced purposefully
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into the effluent or spent acid for galvanic coupling with the metallic steel material or iron or aluminum;
3. The method as claimed in 1, wherein said effluent or spent acid comprises several contaminants in suspension, and said contaminants of conducting natured interact with the said conducting metallic steel or iron or aluminum and act as an anode with respect to the metallic steel or iron or aluminum as well as cathodic natured noble or inert or stable material that was either absent or introduced purposefully into the effluent or spent acid for galvanic coupling with the metallic steel or iron or aluminum material, and said contaminants of conducting natured interact electrochemically with the said conducting metallic steel or iron or aluminum in presence of effluent, and generate hydrogen through displacement reaction with effluent; and also said contaminants of conducting natured interact electrochemically with the said conducting carbon or stable or inert material in presence of effluent, and generate hydrogen through displacement reaction with effluent;
4. The method as claimed in 1, wherein said effluent or spent acid comprises several contaminants in suspension, and said contaminants of conducting natured interact with the said conducting metallic steel or iron or aluminum and act as a cathode with respect to the metallic steel or iron or aluminum, and as an anode with respect to cathodic natured noble or inert or stable material that was either absent or introduced purposefully into the effluent or spent acid for galvanic coupling with the metallic steel or iron or aluminum material, and said contaminants of conducting natured interact electrochemically with the said conducting metallic steel or iron or aluminum in presence
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of effluent, and result in generation of hydrogen through displacement reaction between the effluent and metallic steel or iron or aluminum; and said contaminants of conducting natured interact electrochemically with the cathodic natured noble or inert or stable material and also result in generation of hydrogen through displacement reaction between the effluent and said contaminants of conducting natured;
5. The method as claimed in 1, wherein said effluent or spent acid comprises several contaminants in suspension, and said contaminants of conducting natured interact with the said conducting metallic steel or iron or aluminum and act as a cathode with respect to the metallic steel or iron or aluminum, as well as cathodic natured noble or inert or stable material that was either absent or introduced purposefully into the effluent or spent acid for galvanic coupling with the metallic steel material or iron or aluminum, and said contaminants of conducting natured interact electrochemically with the said conducting metallic steel or iron or aluminum in presence of effluent, and generate hydrogen through displacement reaction between the effluent and metallic steel or iron or aluminum, and said contaminants of conducting natured interact electrochemically with the said conducting cathodic natured noble or inert or stable material in presence of effluent, and may generate hydrogen through displacement reaction between the effluent and said cathodic natured material noble or inert or stable material;
6. The method as claimed in 1, wherein said effluent or spent acid comprises several contaminants in solution as free radicals or ions or aggressive reactants contaminants or constituents chemically interact only with the said metal of anodic nature, and generate hydrogen through displacement reaction with effluent in combination with
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or without the carbon cathode or carbon coated cathode or conductive cathodic material that was either absent or introduced purposefully into the effluent or spent acid for galvanic coupling with the metallic steel material or iron or aluminum;
7. The methods as claimed in 1 to 6, wherein said effluent or spent acid of hydrogen source comprises several contaminants in solution as free radicals or ions after either partial or complete release of hydrogen through displacement reactions between the said effluent or spent acid and the said metallic steel or iron or aluminum, and the corresponding constituents of effluent or spent liquid that resulted in hydrogen displacement from the said spent acid or effluent as claimed in 1 through 6 can be utilized for preparation of byproducts of nanometer to micron sized powders through specific chemical interactions
Wherein said chemical interactions comprise the interactions of the said effluent or spent liquid after release of hydrogen with the chemicals of opposite pH natured and result in the precipitation of neutral salts in a neutralized or pH adjusted solution, and these precipitates can be further separated and dried or treated to form the compounds of the constituents of effluent or spent acid that resulted in hydrogen displacement,
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent;
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent in different valence states;
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent along with the free radicals that were already available in the said effluent or spent liquid before the hydrogen displacement reaction, and then exceeding
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the solubility limit after the formation of the compounds during the chemical interactions and or through pH adjustments as well as through any external dissolution or temperature variations or pressure variations;
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent form the oxides through a treatment process;
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent form the oxy hydroxides through a treatment process;
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent form the hydroxides through a treatment process;
Wherein said compounds consist of constituents that displaced hydrogen from the spent acid or effluent form the compounds with the pre-existing radicals of the effluent as well as the oxygen;
8. The methods as claimed in 1 to 7, wherein said compounds formed through chemical treatment using the spent liquid formed after the release of hydrogen, comprising crystals and particles formed based on the pH of the solution treated as well as temperature of the treatment, wherein said thus formed treated compounds comprising the particles or crystals in a size range anywhere from nanometers to submicron to microns with narrow or broad or single or multi size distributions;
9. A method according to claims 7 and 8, wherein said chemical interactions comprise the interactions of the said effluent or spent liquid after release of hydrogen with the chemicals of opposite pH natured and result in the precipitation of neutral compounds or salts in a neutralized or pH adjusted solution, and these precipitates can be of porous natured and or crystallite nature and or particulate nature and or connected hierarchical
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structures and or and possibly form a new layer on the metallic steel or iron or aluminum or anodic metal itself and or dissolve or disperse as suspension particles or both or settle down in the effluent or spent acid solution, and said contaminants do not interact with the metallic steel or iron or aluminum or any other materials and thereof
10. The methods as claimed in 1 to 7, wherein said effluent or spent acid of hydrogen source comprises several contaminants in solution as free radicals or ions after complete release of hydrogen as well as preparation of byproducts of nanometer to micron sized powders through specific chemical interactions, the leftover solution can be either recycled in the whole process along with the existing catalyst in the solution or evaporated to generate the distilled water, catalyst particles, and specific compounds of contaminants that have contributed to accelerating the hydrogen displacement reaction along with the compounds of the contaminants that may not have contributed to the hydrogen displacement reaction directly,
Wherein said the chemical compounds formed of the contaminants that may not have directly resulted in the hydrogen displacement reaction but may comprise the free radicals in the spent liquid solution either before the evaporation process or in the virgin state of the liquid i.e., even before using it for hydrogen generation stage, and however the said free radicals may have accelerated the destabilization process of the oxide or any preventative layer that has formed or pre-existing on the anodic natured or conducting steel metal or iron or aluminum and thereby resulted in an exothermic reaction that enables further activation and accelerates the whole process of hydrogen generation through hydrogen displacement reaction.

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