Embodiments of the invention relate to systems and methods for cracking hydrocarbons into hydrogen gas and carbon using heating of a fluidized bed. The systems and methods utilize electrically conductive carbon or graphite particles as a fluidized bed material for heating hydrocarbon feedstock to at least a pyrolysis temperature. The electrically conductive carbon, graphite, or other particles may be heated by electrically powered sources that include induction heating, microwave heating, millimeter wave heating, joule heating and/or plasma heating. Combustion heating may also be employed in varying amounts with varying combinations of electrically powered heating sources.

Embodiments of the invention relate to systems and methods for cracking hydrocarbons into hydrogen gas and carbon using heating of a fluidized bed. The systems and methods utilize electrically conductive carbon or graphite particles as a fluidized bed material for heating hydrocarbon feedstock to at least a pyrolysis temperature. The electrically conductive carbon, graphite, or other particles may be heated by electrically powered sources that include induction heating, microwave heating, millimeter wave heating, joule heating and/or plasma heating. Combustion heating may also be employed in varying amounts with varying combinations of electrically powered heating sources.

A system includes a pyrolysis reactor containing a bed of particulates, a solids heating section, and a separator in fluid communication with the pyrolysis reactor through the product gas outlet. The pyrolysis reactor comprises a feed gas inlet at a lower portion of the bed, a product gas outlet above the bed, a particulate outlet above the feed gas inlet, a particulate inlet near the top of the bed, and a solids product outlet in a lower portion of the pyrolysis reactor. The solids heating section is configured to accept a portion of the particulates from the pyrolysis reactor through the particulate outlet, heat the portion of the particulates to form heated particulates, and return the heated particulates to the pyrolysis reactor through the particulate inlet, and the separator is configured to separate any particulates in a product gas produced, and return the particulates to the pyrolysis reactor.

A system includes a pyrolysis reactor containing a bed of particulates, a solids heating section, and a separator in fluid communication with the pyrolysis reactor through the product gas outlet. The pyrolysis reactor comprises a feed gas inlet at a lower portion of the bed, a product gas outlet above the bed, a particulate outlet above the feed gas inlet, a particulate inlet near the top of the bed, and a solids product outlet in a lower portion of the pyrolysis reactor. The solids heating section is configured to accept a portion of the particulates from the pyrolysis reactor through the particulate outlet, heat the portion of the particulates to form heated particulates, and return the heated particulates to the pyrolysis reactor through the particulate inlet, and the separator is configured to separate any particulates in a product gas produced, and return the particulates to the pyrolysis reactor.

Systems and methods of pyrolyzing gaseous hydrocarbons include a reaction chamber and a plenum in fluid communication therewith. A light source directs electromagnetic radiation through a window into the reaction chamber. A first recirculation conduit connected between an offtake and an intake of the reaction chamber recirculates to the intake of the reaction chamber a portion of an aerosol product from the offtake of the reaction chamber. A filter operatively associated with the offtake of the reaction chamber receives un-recirculated amounts of the aerosol product and produces a retentate that includes particulate matter removed from the aerosol product. First and second gas separators operatively associated with the filter separate hydrogen and unreacted hydrocarbons from a filtrate of the filter. A second recirculation conduit connected between the second gas separator and the intake of the plenum recirculates unreacted hydrocarbons from the filtrate to the plenum.

Systems and methods of pyrolyzing gaseous hydrocarbons include a reaction chamber and a plenum in fluid communication therewith. A light source directs electromagnetic radiation through a window into the reaction chamber. A first recirculation conduit connected between an offtake and an intake of the reaction chamber recirculates to the intake of the reaction chamber a portion of an aerosol product from the offtake of the reaction chamber. A filter operatively associated with the offtake of the reaction chamber receives un-recirculated amounts of the aerosol product and produces a retentate that includes particulate matter removed from the aerosol product. First and second gas separators operatively associated with the filter separate hydrogen and unreacted hydrocarbons from a filtrate of the filter. A second recirculation conduit connected between the second gas separator and the intake of the plenum recirculates unreacted hydrocarbons from the filtrate to the plenum.