Abstract: This disclosure provides a method to produce highly attrition resistant pellets by encapsulating reactive components in a vitrified clay outer layer. The reactive component mixture is present relative to the clay substrate in a weight ratio of part per 60-100 part to about 60 parts of the clay substrate. The reactive components are agglomerated first, and clay substrate is added to form the outer layer of the pellet. The pellets are calcined at temperatures above 1200 C to form a vitrified clay semi porous outer layer providing high strength to the pellet while facilitating the gas transfer for the reaction with the encapsulated reactive components. Pellets containing CuO—Fe2O3-alumina oxygen carrier for chemical looping combustion of fuel demonstrated high attrition resistance and high reactivity with methane.

Abstract: The invention provides a calcined Fex—Aly—Oz based catalyst for the decomposition of hydrocarbons such as methane to produce hydrogen and carbon. The catalyst comprises iron oxide mixed with aluminum oxide and calcined at temperatures above 1100° C., where Fex—Aly—Oz is a chemical composition with x>0.1, y>0.1, z?0 and 0<x/y<200. Reaction of the calcined Fex—Aly—Oz catalyst with methane generates a product stream comprising at least 40 vol. % H2 and carbon. In an embodiment, carbon is separated from the catalyst and the catalyst is reused for continuous methane decomposition to produce H2.

Abstract: The invention provides a process for producing hydrogen having the steps of reacting a fuel with a combination of two oxygen carriers to produce gaseous products and reduced oxygen carriers; reacting a portion of the reduced oxygen carriers with steam to generate hydrogen and partially oxidized oxygen carriers; and reacting the partially oxidized oxygen carriers and remaining reduced oxygen carriers with air to generate heat and regenerate the two oxygen carriers in their original oxidation state, wherein the heat and regenerated oxygen carriers are reused.