US 12453964 B1Patent grantUnited States

Copper-Based Catalyst for Hydrogen Release

Official patent title

Method for hydrogen generation using nanocomposite

Arabic title: طريقة لتوليد الهيدروجين باستخدام مركب نانوي

Invention

Problem

Hydrogen release from sodium borohydride is slow without a catalyst, while noble-metal catalysts can be constrained by scarcity and cost and chemical-hydride systems must manage reaction residues and regeneration.

Why it matters

A transition-metal nanocomposite for borohydride hydrolysis could support on-demand hydrogen research, but gas yield, catalyst reuse, copper leaching, process safety, carrier regeneration, and system economics require independent verification.

Approach

The method reacts NaBH4 with water in the presence of a microwave-fabricated Cu2(OH)3NO3/CaSiO3/g-C3N4 nanocomposite to catalyze hydrolysis and generate hydrogen.

Who may benefit

Potential beneficiaries include hydrogen-generation researchers, chemical-hydride reactor developers, catalyst manufacturers, portable-energy laboratories, and materials groups studying copper/calcium-silicate/carbon-nitride hybrids.

Potential value

The disclosure combines a three-component mesoporous catalyst, stated hydrolysis-rate ranges, room-near and elevated temperature conditions, and a defined microwave synthesis route in one hydrogen-generation method.

Background

Sodium borohydride stores hydrogen chemically and can release it through hydrolysis, but its uncatalyzed reaction is too slow for many on-demand concepts. Noble-metal catalysts can accelerate the reaction, yet their scarcity and cost motivate transition-metal alternatives. Any practical chemical-hydride system must also address reactant storage, heat release, hydrogen purification, catalyst separation, spent sodium-metaborate management, and regeneration of the carrier. The patent specifically evaluates a copper-hydroxide-nitrate/calcium-silicate/carbon-nitride composite for this catalytic role.

Technology overview

The catalyst contains 20–40 wt.% each of g-C3N4, Cu2(OH)3NO3, and CaSiO3. Claims state hydrogen rates of 2400–2600 mL/min at 35–40 °C and 250–300 mL/min at 25–30 °C when hydrolyzing 0.5–1 g NaBH4. CaSiO3 and g-C3N4 are prepared separately, then mixed with a copper salt in glycol and microwaved at 160–200 °C and 4–6 bar for 30–90 minutes. The product includes nanorods, nanowires, nanosheets, and mesopores.

Potential applications

Potential laboratory hydrogen generation from sodium borohydride.
Potential chemical-hydride reactor kinetics studies.
Potential catalyst-reuse and deactivation research.
Potential on-demand hydrogen-source development after safety validation.

Evidence-supported advantages

Uses a non-noble-metal, three-component catalyst.
Defines hydrolysis rates at two temperature ranges.
Specifies mesopore, nanorod, nanowire, and nanosheet features.
Provides a corresponding microwave fabrication process.

Development stage

Patent publication describing catalyst fabrication, characterization, and hydrogen-generation testing; independent validation and commercialization were not established.

Commercial opportunity

The method may interest chemical-hydride and portable hydrogen-system developers. Commercial assessment should independently verify gas-rate measurements, total yield, catalyst dosage and reuse, copper leaching, hydrogen purity, heat and pressure control, NaBH4 handling, sodium-metaborate recovery and regeneration, reactor scale-up, catalyst manufacture, lifecycle energy, and delivered-hydrogen cost.

Patent classifications

WIPO IPC

B01J27/25Chemical 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

CPC

B01J23/02Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J27/25Chemical 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
B01J35/615Chemical 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
B01J37/08Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
B01J37/342Chemical or physical processes, e.g. catalysis or colloid chemistry; their relevant apparatus
C01B21/0605Non-metallic elements; compounds thereof
C01B3/06Non-metallic elements; compounds thereof
C01B3/065Non-metallic elements; compounds thereof
C01B33/24Non-metallic elements; compounds thereof
Y02E60/36Reduction of greenhouse gas [GHG] emissions related to energy generation, transmission or distribution

Inventors

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

Keywords

hydrogen generation
sodium borohydride
hydrolysis
Cu2(OH)3NO3
CaSiO3
g-C3N4
microwave synthesis
nanocomposite catalyst

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.