Abstract: A composite oxygen ion transport membrane having a dense layer, a porous support layer, an optional intermediate porous layer located between the porous support layer and the dense layer and an optional surface exchange layer, overlying the dense layer. The dense layer has electronic and ionic phases. The ionic phase is composed of scandia doped, yttrium or cerium stabilized zirconia. The electronic phase is composed of a metallic oxide containing lanthanum, strontium, chromium, manganese and vanadium and optionally cerium. The porous support layer is composed of zirconia partially stabilized with yttrium, scandium, aluminum or cerium or mixtures thereof. The intermediate porous layer, if used, contains the same ionic and electronic phases as the dense layer. The surface exchange layer is formed of an electronic phase of a metallic oxide of lanthanum and strontium that also contains either manganese or iron and an ionic phase of scandia doped zirconia stabilized with yttrium or cerium.

Abstract: A method of recycling process stream condensate from a steam reforming system that produces an uncontaminated superheated steam stream and one or more process condensate streams formed of condensate condensed from a water containing product stream that is also produced by the steam reforming system. The process condensate stream is collected and formed into a contaminated condensate stream. The contaminated condensate stream is then pressurized and heated with a first part of the uncontaminated superheated steam stream to form a contaminated superheated steam stream and an uncontaminated condensate stream. A second part of the uncontaminated superheated steam stream is combined with the contaminated superheated steam stream to form a combined superheated steam stream that is used as a source of steam for steam reforming. The uncontaminated condensate stream is recycled as make up for the uncontaminated superheated steam stream.

Abstract: A method of heating process streams fed to a boiler incorporating an oxygen transport membrane device that includes an oxygen-containing stream and a boiler feed water stream. The membrane device separates oxygen to support combustion of a fuel and generate heat to raise the steam. Heat is recovered and process streams are heated by separately heating portions of the oxygen-containing stream and the boiler feed water stream with a retentate stream produced from the oxygen separation and a flue gas stream generated from the combustion. The flow rate of the portion of the oxygen-containing stream heated by the retentate stream is greater than that heated by the flue gas stream to help minimize heat transfer area and thus, fabrication costs. Also, water is condensed from the flue gas stream during the heat exchange involved in the heat recovery to increase thermodynamic efficiency.

Abstract: Argon, oxygen and nitrogen contained within an incoming air feed is fractionated within an air separation system having a multiple column arrangement that includes a higher pressure column and a lower pressure column to produce oxygen and nitrogen-rich fractions and an argon column to produce an argon-rich fraction for recovery of the argon as an argon product. A two-phase stream can be formed by either expanding at least part of a liquid air stream or by a liquid oxygen column bottoms formed within a higher pressure column of the multiple column arrangement. The liquid air stream is formed by liquefying part of the air feed to be fractionated against vaporizing a pumped liquid stream composed of nitrogen and/or oxygen. The diversion of the nitrogen vapor contained in the nitrogen-rich fraction increases the liquid to vapor ratio within the lower pressure column to increase the argon recovery.

Abstract: A catalytic reactor having a mixing section connected to a downstream reaction section containing a catalyst to promote a reaction of oxygen and a hydrocarbon fed to the catalytic reactor. The mixing section is provided with a flame arrestor to prevent a stable flame from propagating should any reaction of oxygen and hydrocarbons occur during mixing. The flame arrestor permits flow in both axial and radial directions to promote mixing. Baffle elements and a downstream static mixer can also be used. The catalyst is preferably in the form of monolithic blocks enclosed by a ceramic tube that is maintained as a unitary catalyst assembly that can be removed for replacement and installation of the catalyst as a single unit.

Abstract: A system for separating air by cryogenic rectification whereby liquid production is increased by employing two separate turboexpanders, one which exhausts at a pressure no higher than that sufficient to feed the lower pressure column, the other which exhausts at a pressure no lower than that sufficient to feed the higher pressure column, and wherein one of the turboexpanders is fed with ambient temperature or modestly cooled feed air and preferably operates intermittently depending upon whether greater or lesser amounts of liquid product are desired.

Abstract: A method of forming a hydrogen transport membrane to separate hydrogen from a hydrogen containing feed in which a porous ceramic support is formed to support a dense layer of palladium or an alloy of palladium serving as a hydrogen transport material. Isolated deposits of palladium, a palladium alloy or a component of such alloy are produced on a surface of the porous ceramic support that bridge pores within the porous ceramic support without penetrating the pores and without bridging regions of the surface defined between the pores. The isolated deposits of the metal are produced by an electroless plating process.

Abstract: A catalytic reactor is provided with one or more reaction zones each formed of set(s) of reaction tubes containing a catalyst to promote chemical reaction within a feed stream. The reaction tubes are of helical configuration and are arranged in a substantially coaxial relationship to form a coil-like structure. Heat exchangers and steam generators can be formed by similar tube arrangements. In such manner, the reaction zone(s) and hence, the reactor is compact and the pressure drop through components is minimized. The resultant compact form has improved heat transfer characteristics and is far easier to thermally insulate than prior art compact reactor designs. Various chemical reactions are contemplated within such coil-like structures such that as steam methane reforming followed by water-gas shift. The coil-like structures can be housed within annular chambers of a cylindrical housing that also provide flow paths for various heat exchange fluids to heat and cool components.

Abstract: The present invention provides a filter system for treating air entering an electrochemical air separation device. The filter is provided with first and second filter sections. The first filter section is formed from a plurality of sheets of woven mesh containing surface deposits of one or more substances that are effective to interact and combine with one or more airborne contaminants to remove the same from the air. The second filter section is configured to filter particulate matter and is situated adjacent to the first filter element. The first and second filter sections are peripherally retained within a retaining structure so that the air to be treated passes through the first filter section and then the second filter section. The retaining structure can be releasably attached to a connection flange that is in turn attached to the air inlet of the electrochemical air separation device.

Abstract: A method for the cryogenic separation of air having defined temperatures for condensed feed air passed into a double column system relative to liquid oxygen and preferably to shelf vapor, and wherein kettle liquid is not subcooled from the higher pressure column to the lower pressure column.

Abstract: A cryogenic process system wherein a solids removal filter positioned in a conduit upstream of process equipment is within a filter housing having an angled bonnet which extends to the outside of insulated housing.

Abstract: A method of generating electricity in synthesis gas in which a fuel is combusted in a gas turbine to generate the electricity that at least about 60 percent by volume is derived from a source independent of the synthesis gas. The synthesis gas is produced by reacting a hydrocarbon stream, by for example, partial oxidation, autothermal reforming or steam methane reforming. After the synthesis gas stream is cooled, heat is transferred from the heated synthesis gas stream to the fuel prior to combustion in the gas turbine. All or at least a portion of the heat is transferred at a temperature no greater than about 500° F. and at a flow ratio of the fuel to the gas turbine to the synthesis gas stream from at least about 1.5. The heating of the fuel to the gas turbine lowers fuel consumption and thereby the total expenses involved in generating electricity and syngas.

Abstract: A method of separating one or more first light components from a carbon dioxide containing gaseous mixture that contains at least 30 mole percent carbon dioxide. In accordance with the method, a feed stream composed of the carbon dioxide is cooled to effect at least in part, liquefaction of the carbon dioxide containing gaseous mixture. The feed stream and a stripping gas stream are introduced into a liquid-vapor contact column to initiate counter-current vapor liquid mass transfer and the formation of a gaseous column overhead stream and a liquid column bottoms stream. The stripping gas stream contains one or more second light components having boiling point lower than that of carbon dioxide and higher than that of the first light component(s) to enrich the gaseous column overhead stream with the first light component(s).

Abstract: A method of separating one or more first light components from a carbon dioxide containing gaseous mixture that contains at least 30 mole percent carbon dioxide. In accordance with the method, a feed stream composed of the carbon dioxide is cooled to effect at least in part, liquefaction of the carbon dioxide containing gaseous mixture. The feed stream and a stripping gas stream are introduced into a liquid-vapor contact column to initiate counter-current vapor liquid mass transfer and the formation of a gaseous column overhead stream and a liquid column bottoms stream. The stripping gas stream contains one or more second light components having boiling point lower than that of carbon dioxide and higher than that of the first light component(s) to enrich the gaseous column overhead stream with the first light component(s).

Abstract: A compressor having a defined large diameter impeller having an integral shroud and having a three dimensional gas flow path defined by the impeller hub surface, blades and the shroud and having a large axially oriented inlet or inducer section with aggressive inducer blades, a defined outlet section geometry, and continuous blade geometries between the inlet and outlet sections.

Abstract: A low solidity vaned airfoil diffuser for a centrifugal compressor wherein each blade has a lean angle greater than zero and wherein the hub stagger angle may be the same as or may be different from the shroud stagger angle for each blade.

Abstract: Method for controlling the production of one or more liquid products produced by one or more plants, that can be an air separation plant, that has a liquid storage capacity and that consumes electrical power. Linguistic values related to current liquid inventory, a rate of change of liquid inventory, projected demand requirements and projected unit power costs are inputted into a expert system controller having one or more rule sets that apply such input linguistic values to produce output linguistic values that are converted back to an output numerical value of a forecasted differential production rate to be applied during a forecast period. The output numerical value of differential production is added to the current production rate of the plants to obtain a new production rate which is applied during the forecast period.

Abstract: A current collector and method of forming the same in which a slurry is prepared that contains electrically conductive particles having surface deposits of a metallic oxide on a metal or metal alloy conductor that has a lower weight percentage of the electrically conductive particles than the metal or metal alloy. The slurry is applied to a structure that contains an electrolyte and electrode layers. The resultant coated form is then fired to partly sinter the electrically conductive particles and thereby to obtain porous current collector layers affixed to the electrode layers. The current collector of the present invention is between about 5 microns and about 100 microns thick and preferably has a porosity of between about 10 percent and about 70 percent with pores having a pore size of between about 0.1 microns and about 20 microns.

Abstract: A method for carrying out cryogenic air separation wherein feed air is processed in three streams which are at different pressures, wherein one stream is turboexpanded to generate refrigeration and the other two streams are condensed to effect pressurized product vaporization.

Abstract: A method of generating a synthesis gas product stream and carbon dioxide in which a fuel is combusted in an oxygen transport membrane combustor to produce a flue gas stream containing the carbon dioxide and water. Reforming duty is divided between a combined reforming process and a gas heated reformer to produce the product stream. The flue gas stream is used to supply heat to a primary, steam methane reforming stage of the combined reforming process. Residual methane, produced in the primary stage, is reacted in a secondary stage having an oxygen transport membrane reactor. Heat produced in the secondary stage is supplied to the gas heated reactor to support its operation. The flue gas stream is cooled and water is separated therefrom to produce the carbon dioxide at a concentration of at least 85 mol percent.