A method of carrying out direct thermal decomposition of a hydrocarbon compound into carbon and hydrogen comprises: introducing a gaseous feed stream comprising at least one hydrocarbon compound into a reactor; and removing at least hydrogen gas and particulate carbon formed by thermal decomposition from the reactor. The method includes providing in the reactor a layer permeable to the particulate carbon and comprising loose particles other than the particulate carbon in a gas phase and passing the gaseous feed stream through the layer. The loose particles other than the particulate carbon comprise particles comprising a catalyst on a carrier. The method includes removing at least part of the layer from the reactor, separating constituents of the removed part, the constituents including some of the particles comprising a catalyst on a carrier, and returning the separated particles comprising a catalyst on a carrier to the layer.

High quality, catalyst-free boron nitride nanotubes (BNNTs) that are long, flexible, have few wall molecules and few defects in the crystalline structure, can be efficiently produced by a process driven primarily by Direct Induction. Secondary Direct Induction coils, Direct Current heaters, lasers, and electric arcs can provide additional heating to tailor the processes and enhance the quality of the BNNTs while reducing impurities. Heating the initial boron feed stock to temperatures causing it to act as an electrical conductor can be achieved by including refractory metals in the initial boron feed stock, and providing additional heat via lasers or electric arcs. Direct Induction processes may be energy efficient and sustainable for indefinite period of time. Careful heat and gas flow profile management may be used to enhance production of high quality BNNT at significant production rates.

A hydrogen production apparatus includes: a first furnace configured to heat a mixed gas of a raw material gas, which contains at least methane, and hydrogen to 1,000 C. or more and 2,000 C. or less; and a second furnace configured to accommodate a catalyst for accelerating a reaction of a first gas generated in the first furnace to a nanocarbon material, and to maintain the first gas at 500 C. or more and 1,200 C. or less.

The presently disclosed subject matter is generally directed to a system and method of reducing, reacting, and/or removing an oxidant or unwanted chemical species from a chemical stream. Particularly, the system and method include the use of one or more reductants that react with the undesired chemical species. The reductant and the chemical stream are added to a reactor and allowed to react for a desired amount of time. The reductant will reduce, react with, and/or remove the chemical species from the stream. The excess reductant and reaction products are then removed from the reactor, as described in more detail herein below.

Direct thermal decomposition of hydrocarbons into solid carbon and hydrogen is performed by a process and a device. The process comprises preheating a hydrocarbon gas stream to a temperature between 500 C. and 700 C. and injecting the pre-heated hydrocarbon gas stream into the reactor pool of a liquid metal reactor containing a liquid media; forming a multi-phase flow with a hydrocarbon gas comprising hydrogen and solid carbon at a temperature between 900 C. and 1200 C.; forming a carbon layer on the free surface of the liquid media made up of solid carbon particles which are then displaced into at least one carbon extraction system and at least one recipient for collecting them; and, at the same time, the gas comprising hydrogen leaves the reactor pool through a porous rigid section, being collected at a gas outlet collector from where the gas comprising hydrogen finally leaves the liquid metal reactor.

High quality, catalyst-free boron nitride nanotubes (BNNTs) that are long, flexible, have few wall molecules and few defects in the crystalline structure, can be efficiently produced by a process driven primarily by Direct Induction. Secondary Direct Induction coils, Direct Current heaters, lasers, and electric arcs can provide additional heating to tailor the processes and enhance the quality of the BNNTs while reducing impurities. Heating the initial boron feed stock to temperatures causing it to act as an electrical conductor can be achieved by including refractory metals in the initial boron feed stock, and providing additional heat via lasers or electric arcs. Direct Induction processes may be energy efficient and sustainable for indefinite period of time. Careful heat and gas flow profile management may be used to enhance production of high quality BNNT at significant production rates.

A process for decomposing a hydrocarbon-containing composition includes feeding the hydrocarbon-containing composition to a reactor containing a catalytically active molten metal or a catalytically active molten metal alloy, wherein the metal or alloy catalyzes a decomposition reaction of the hydrocarbon-containing composition into a hydrogen-rich gas phase and a solid carbon phase. The solid carbon phase is insoluble in the metal or alloy. The process may be a continuous process.

A method for making covetic metal-nanostructured carbon composites or compositions is described herein. This method is advantageous, in that it provides substantially oxygen-free covetic materials and allows precise control of the composition of the covetic material to be produced. The method comprises introducing carbon into a molten metal in a heated reactor under low oxygen partial pressure, while passing an electric current through the molten metal. The reactor is heated at a temperature sufficient to form a network of nanostructured carbon within a matrix of the metal. After heating the covetic material is recovered from the reactor.

The present invention is an apparatus and method for continuously separating, removing and purifying the solid residue, resulting from the conversion of hydrocarbons into carbon and hydrogen, from the homogeneous phase of different density contained in a cracking reactor with which said solid residue is not soluble, and where the separation of the solid carbon occur at two subsequent moments: a first separation occurs inside the reactor between the reaction products, including carbon, and the melting bath; a second separation then occurs outside the reactor between the carbon and the gas produced in a separation system (1) of the solid phase from the gas phase, where said separation system (1) also includes carbon purification.

The reaction rate of hydrocarbon pyrolysis can be increased to produce solid carbon and hydrogen by the use of molten materials which have catalytic functionality to increase the rate of reaction and physical properties that facilitate the formation and contamination-free separation of the solid carbon. Processes, materials, reactor configurations, and conditions are disclosed whereby methane and other hydrocarbons can be decomposed at high reaction rates into hydrogen gas and carbon products without any carbon oxides in a single reaction step. The process also makes use of specific properties of selected materials with unique solubilities and/or wettability of products into (and/or by) the molten phase to facilitate generation of purified products and increased conversion in more general reactions.