US 12370534 B1Patent grantUnited States

Copper-Oxide Catalyst for Hydrogen Release

Official patent title

g-C3N4@CuO/MgAl2O4 nanocomposite synthesis for hydrogen generation

Arabic title: تخليق مركب نانوي من g-C.SUB.3.N.SUB.4.@CuO/MgAl.SUB.2.O.SUB.4 لتوليد الهيدروجين

Invention

Problem

Sodium-borohydride hydrolysis needs an active catalyst to provide controlled hydrogen release at moderate temperature. Practical systems also need reusable catalysts and an economically and environmentally credible carrier-regeneration cycle.

Why it matters

On-demand hydrogen release could support compact fuel-cell and backup-power research where hydrogen storage cylinders are undesirable, provided lifecycle and safety constraints are addressed.

Approach

The method hydrolyzes sodium borohydride with water in the presence of a g-C3N4@CuO/MgAl2O4 catalyst containing 5–15 wt.% carbon nitride, 3–7 wt.% CuO, and 80–90 wt.% magnesium aluminate.

Who may benefit

Potential beneficiaries include hydrogen-carrier researchers, catalyst manufacturers, portable fuel-cell developers, chemical-energy-storage laboratories, and advanced-material suppliers.

Potential value

The catalyst uses nanoscale CuO and magnesium-aluminate particles dispersed on carbon-nitride sheets and reports 1,300–1,500 mL/(min·g) hydrogen generation at 30–50 °C.

Background

Sodium borohydride stores hydrogen in a chemically bound form and releases it upon hydrolysis. Without a suitable catalyst, the reaction can be too slow or difficult to control. Nanostructured oxides and carbon nitride can provide active interfaces and dispersive supports. Even when release is rapid, however, overall sustainability depends on how sodium borohydride is manufactured, how spent borate is regenerated, and whether the catalyst remains active through repeated cycles. The patent addresses the release step with a ternary composite.

Technology overview

The catalyst contains carbon-nitride nanosheets approximately 100–500 nm long, with 2–10 nm CuO and MgAl2O4 particles dispersed on them. Reported properties include 15–30 m²/g BET area, 5–10 nm slit-like pores, and several crystalline phases. A combustion-derived oxide product is calcined at 600–800 °C, mixed with urea, and reheated. In hydrolysis at 30–50 °C, the disclosure reports a six- to eight-fold ten-minute hydrogen increase versus no catalyst.

Potential applications

On-demand hydrogen-release research.
Sodium-borohydride hydrolysis catalysis.
Portable fuel-cell supply studies.
Nanocomposite catalyst development.

Evidence-supported advantages

Operates at a claimed 30–50 °C.
Uses nanoscale oxide dispersion on carbon-nitride sheets.
Reports defined composition, pore, and surface-area ranges.
Reports a six- to eight-fold increase over no catalyst.
Provides a multi-step catalyst preparation route.

Development stage

Laboratory catalyst synthesis, material characterization, and short-duration hydrolysis measurements are described; long-cycle reuse, leaching, integrated-system safety, and lifecycle performance were not established. The development stage was not independently verified.

Commercial opportunity

The catalyst could be screened for chemical hydrogen cartridges and small fuel-cell supplies. Commercial viability requires repeated-cycle activity, copper leaching and catalyst recovery studies, hydrogen purity, process heat and safety analysis, batch reproducibility, scale-up cost, and a lifecycle assessment covering sodium-borohydride production and spent-carrier regeneration.

Patent classifications

WIPO IPC

B01J27/24Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J23/00Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus

CPC

B01J23/005Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J23/02Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J27/24Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/40Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/45Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/613Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/633Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J35/647Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/04Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/088Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
C01B3/065Non-metallic elements; compounds thereof
B01J2235/15Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J2235/30Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
Y02E60/36Reduction of greenhouse gas [GHG] emissions related to energy generation, transmission or distribution

Inventors

First inventorMohamed Nady Abd El-Hameed Ibrahim
InventorMohamed Khairy Omran
InventorBabiker Yagoub Elhadi Abdulkhair

Keywords

hydrogen generation
sodium borohydride
copper oxide
magnesium aluminate
graphitic carbon nitride
hydrolysis catalyst
nanocomposite

Patent document and drawings

The patent publication is mapped to this record. Patent drawings remain within that publication; no separately cleared public media package has been supplied.