Abstract: Disclosed is a carbonaceous material which reacts rapidly with hydrogen to produce a methane-rich gas containing at least 20% by volume methane. The carbonaceous material is formed by contacting a carbon monoxide containing gas with an initiator including a ferrous group metal such as iron, cobalt, or nickel. The carbonaceous material grows from the surface of the initiator as fibers which include a ferrous metal component derived from the initiator. This ferrous metal component, which may be a metal, an alloy, a carbide, or other metallic substance, is dispersed throughout the carbon network as small nodules which are at least partially bonded to the carbon.

Abstract: Carbonaceous materials comprising major amounts of carbon, and minor amounts of hydrogen and ferrous group metal components, particularly nickel and cobalt, react with steam at low temperatures, and produce commercially attractive quantities of such gases as hydrogen, methane, carbon oxides and other light hydrocarbons.

Abstract: Substantially ash-free carbonaceous reductant for use in reduction processes is made by recovering carbon from unused carbon monoxide. The carbon monoxide contacts a catalyst which promotes formation of carbon on the catalyst. Since the off-gases from many metal ore reduction processes employing coke include a significant quantity of carbon monoxide, this carbon monoxide may be recovered and used to form the reductant which is fed to the reduction process to replace a part of the coke consumed. Provided most of the carbon monoxide in the off-gases is utilized, very favorable cost savings are achieved when the ash-free reductant is used in place of the coke. Moreover, in some instances, the ore being reduced may be used as the catalyst. Since this ore-catalyst is at least partially reduced during manufacture of the reductant, a benefit is obtained.