Abstract: A method for causing chemical reactions between fluids, comprising the steps of arranging a plurality of metal sheets for providing first fluid flow channels adjacent to and in heat transfer contact with second fluid flow channels between adjacent ones of the metal sheets, placing catalyst material within at least some of the flow channels, passing a first fluid mixture through the first fluid flow channels and a second fluid mixture through the second fluid flow channels, wherein the first fluid mixture is different from the second fluid mixture, each fluid mixture undergoing separate reactions, one of the reactions being endothermic while the other reaction is exothermic, and causing heat to transfer between the adjacent fluid flow channels.

Abstract: A hydrogen generator of the invention includes: a reformer for generating a hydrogen-rich gas from a feed gas and water by a reaction using a reforming catalyst body and sending it out from an outlet port; a material feed system for feeding the feed gas to the reformer; a burner for supplying, to the reforming catalyst body, heat generated by mixing a fuel gas with air and burning it; and an air supply system for supplying air to the burner; wherein, when purging an interior of the reformer using the feed gas in shutting down the hydrogen generator, an amount of the air supplied is increased to put out a flame of the burner, and a purge gas sent out from the outlet port by the purging is mixed and diluted with the air in the burner and is discharged outside.

Abstract: This invention relates to the use of a copper oxide adsorbent to remove mercury from a feed stream. When the feed stream is low in sulfur content, a sulfidation agent such as hydrogen sulfide should be added to the feed stream.

Abstract: A method and apparatus for use in controlling the reaction temperature of a fuel processor are disclosed. The apparatus includes a fuel processor reactor, the reactor including a water gas shift reaction section; a temperature sensor disposed within the reaction section; a coolant flow line through the reaction section; and an automated control system. The automated control system controls the reaction temperature by determining a first component for a setting adjustment for the actuator from the measured temperature and a setpoint for the measured temperature; determining a second component for the setting adjustment from a hydrogen production rate for the fuel processor; and determining the setting adjustment from the first and second components.

Abstract: The present invention is a chemical reactor and method for catalytic chemical reactions having gas phase reactants. The chemical reactor has reactor microchannels for flow of at least one reactant and at least one product, and a catalyst material wherein the at least one reactant contacts the catalyst material and reacts to form the at least one product. The improvement, according to the present invention is: the catalyst material is on a porous material having a porosity that resists bulk flow therethrough and permits molecular diffusion therein. The porous material further has a length, a width and a thickness, the porous material defining at least a portion of one wall of a bulk flow path through which the at least one reactant passes.

Abstract: Improved feedstocks for hydrogen-producing fuel processing and fuel cell systems, and fuel processing and fuel cell systems incorporating the same. The fuel processing systems include a fuel processor adapted to produce a product hydrogen stream from at least one feed stream containing at least a carbon-containing feedstock and an aversive agent. The fuel processing systems may also include a fuel cell stack adapted to produce an electric current from the product hydrogen stream. The feedstock is at least substantially formed of a hydrocarbon or alcohol. In some instances the feedstock includes methanol and the aversive agent is delivered to a hydrogen-producing region of the fuel processor with the carbon containing feedstock. The aversive agent can include at least one odorant, flavorants regurgitant, and/or dye. In other instances, the feed stream includes water or the feed stream is delivered to a fuel stack that produces and electric current therefrom.

Abstract: This invention relates to a process for converting a carbonaceous material to a desired product comprising one or more hydrocarbons or one or more alcohols, the process comprising: (A) gasifying the carbonaceous material at a temperature in excess of about 700° C. to form synthesis gas; and (B) flowing the synthesis gas in a microchannel reactor in contact with a catalyst to convert the synthesis gas to the desired product.

Abstract: Processes for conversion of a carbonaceous composition into a gas stream comprising methane are provided, where an energy-efficient process and/or apparatus is used to separate methane out of a gas stream comprising methane, carbon monoxide, and hydrogen. Particularly, methane can be separated from hydrogen and carbon monoxide using novel processes and/or apparatuses that generate methane hydrates. Because hydrogen and carbon monoxide do not readily form hydrates, the methane is separated from a gas stream. The methane can be captured as a substantially pure stream of methane gas by dissociating the methane from the hydrate and separating out any residual water vapor.

Abstract: Particulate compositions are described comprising a carbonaceous material, such as petroleum coke and/or coal, treated or otherwise associated with a gasification catalyst, where the catalyst is at least in part derived from a leachate from a biomass char, for gasification in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, and other higher hydrocarbons are formed. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Abstract: Particulate compositions are described comprising an intimate mixture of a coal and a gasification catalyst. The particulate compositions are gasified in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Abstract: Particulate compositions are described comprising an intimate mixture of a biomass, such as switchgrass or hybrid poplar, a non-biomass carbonaceous material, such as petroleum coke or coal, and a gasification catalyst, where the gasification catalyst is loaded onto at least one of the biomass or non-biomass for gasification in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, and other higher hydrocarbons are formed. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Abstract: Processes for the generation of steam are provided for use in an integrated catalytic gasification process for converting carbonaceous materials to combustible gases, such as methane. Generally, the exhaust gas from a steam generating reactor is provided along with steam, a carbonaceous feedstock, and a gasification catalyst, to a catalytic gasifier, wherein under appropriate temperature and pressure conditions, the carbonaceous feedstock is converted into a plurality of product gases, including, but not limited to, methane, carbon monoxide, hydrogen, and carbon dioxide. As substantially all the carbon dioxide produced from the steam generation process and the gasification process are subsequently directed though gas purification and separation processes, substantially all the carbon dioxide may be recovered, yielding a process having a near zero carbon footprint.

Abstract: Integrated catalytic gasification processes are provided involving generating steam for converting carbonaceous materials to combustible gases, such as methane. Generally, steam generated from the combustion of a biomass is provided to a catalytic gasifier, wherein under appropriate temperature and pressure conditions, a carbonaceous feedstock is converted into a plurality of product gases, including, but not limited to, methane, carbon monoxide, hydrogen, and carbon dioxide.

Abstract: The present invention discloses a hybrid combustor, such as an anode tailgas oxidizer (ATO), for fuel processing applications which combines both flame and catalytic type burners. The hybrid combustor of the present invention combines the advantages of both flame and catalytic type burners. The flame burner component of the hybrid combustor is used during start-up for the preheating of the catalytic burner component. As soon as the catalytic burner bed is preheated or lit off, the flame burner will be shut off. Optionally, the hybrid combustor may also include an integrated heat recovery unit located downstream of the catalytic burner for steam generation and for the preheating of the feed for a reformer, such as an autothermal reformer.

Abstract: A method for converting a methane gas to liquid fuel forms a non-thermal plasma with radicals and directs the plasma over a catalyst to convert the radicals to higher hydrocarbons in liquid form. The method can be performed in a reactor such as a microwave plasma reactor, or a pulsed corona discharge plasma reactor. A system for performing the method includes a methane gas source, a reactant gas source, a reactor and a catalyst.

Abstract: High surface area iron oxides that can be ferroxane-derived iron oxides are described, as well as methods of using the same to remove at least a portion of one or more sulfur-containing species from a gas stream or liquid stream.

Abstract: A system for production of hydrogen comprises at least one steam reforming zone configured to receive a first fuel and steam to produce a first reformate gas stream comprising hydrogen using a steam reforming process. The system further comprises a mixed reforming zone configured to receive an oxidant to produce a second reformate gas stream comprising hydrogen, wherein the first reformate gas stream is sent to the mixed reforming zone to complete the reforming process.

Abstract: A method and system for hydrogen sulfide removal from a sour gas mixture including hydrogen sulfide includes providing an aqueous solution comprising a transition metal oxide, sulfide or carbonate compound, wherein a transition metal of the transition metal oxide is at a first valence and has at least one reduction state from the first valence. The sour gas mixture is reacted with the transition metal compound and the aqueous solution in a reactor, wherein sulfide from the hydrogen sulfide is oxidized to form elemental sulfur and the transition metal is reduced to form a reduced state transition metal compound. An electrochemical redox reaction is performed including the reduced state transition metal compound to regenerate the transition metal compound in an electrolyzer comprising an anode, a cathode, and an electrolyte membrane between the anode and cathode, wherein an oxygen including gas is added to the cathode during the electrochemical redox reaction.

Abstract: Particulate compositions are described comprising an intimate mixture of a coal and a gasification catalyst in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, carbon dioxide, hydrogen sulfide, ammonia and other higher hydrocarbons are formed. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Abstract: Particulate compositions are described comprising an intimate mixture of a petroleum coke and an alkali metal gasification catalyst, where the alkali metal gasification catalyst comprises a combination of an alkali metal hydroxide and one or more other alkali metal compounds are loaded onto coke for gasification in the presence of steam to yield a plurality of gases including methane and at least one or more of hydrogen, carbon monoxide, and other higher hydrocarbons are formed. Processes are also provided for the preparation of the particulate compositions and converting the particulate composition into a plurality of gaseous products.

Abstract: A process for preparation of synthesis gas and/or hydrogen by counter-currently providing an oxidation reactant stream through an oxidation chamber and a reforming reactant stream through a steam reforming chamber is described. Also provided is a reactor for conducting the reaction.

Abstract: Methods for fractional catalytic pyrolysis which allow for conversion of biomass into a slate of desired products without the need for post-pyrolysis separation are described. The methods involve use of a fluid catalytic bed which is maintained at a suitable pyrolysis temperature. Biomass is added to the catalytic bed, preferably while entrained in a non-reactive gas such as nitrogen, causing the biomass to become pyrolyzed and forming the desired products in vapor and gas forms, allowing the desired products to be easily separated.

Abstract: Processes for extracting and recycling alkali metal compounds present in the char produced from the catalytic gasification of carbonaceous materials are provided involving at least contacting the char with and alkali metal hydroxide followed by carbon dioxide. Both the alkali metal hydroxide and carbon dioxide treatments serve to convert at least a portion of the insoluble alkali metal compounds in the char into soluble species which can be recovered and recycled.

Abstract: The present invention provides processes for making syngas-derived products. For example, one aspect of the present invention provides a process for making a syngas-derived product, the process comprising (a) providing a carbonaceous feedstock; (b) converting the carbonaceous feedstock in a syngas formation zone at least in part to a synthesis gas stream comprising hydrogen and carbon monoxide; (c) conveying the synthesis gas stream to a syngas reaction zone; (d) reacting the synthesis gas stream in the syngas reaction zone to form the syngas-derived product and heat energy, a combustible tail gas mixture, or both; (e) recovering the syngas-derived product; and (f) recovering the heat energy formed from the reaction of the synthesis gas stream, burning the combustible tail gas mixture to form heat energy, or both.

Abstract: Hydrogen sulfide is oxidized to sulfur by means of treatment with an aqueous acid solution containing trivalent iron and a hetero polyacid having formula (I): HnXVyM(12-y)O40; or a sole hetero polyacid having formula (II): HnMeM12O40; wherein the symbols X, M Me n and y are specified in the text. At the end of the oxidation, the solution is treated with gas containing oxygen to re-oxidize the reduced metal.

Abstract: The present invention relates to a hydrogenolysis process and catalyst for conversion of ethane to methane in a natural gas stream when such streams contain large quantities of ethane. Such natural gas streams include the product of the in situ treatment of oil shale to produce oil and gas. Hydrogenolysis catalysts have been identified that produce high yields of ethane at low light-off temperatures.

Abstract: Process for the production of sulfur, obtained in pure form, and possibly easily disposable even at ambient temperature, starting from hydrogen sulphide contained in natural gas, which includes: a) oxidizing a portion of hydrogen sulphide to sulfur dioxide; b) dissolving in water the sulfur dioxide obtained in step (a); c) carrying out the reaction (I): 2H2S+SO2?3S+2H2O (I) making the remaining hydrogen sulphide to react with the solution prepared in step (b); and d) using the thus obtained sulfur suspension for the production sulfur or, alternatively, to use it for the disposal of the sulfur itself in a site reserved for such purpose.

Abstract: An impurity removing unit removes an impurity gas from a target gas while the target gas is in a gaseous state. A compressing unit compresses the impurity gas to produce compressed impurity gas. A drying unit removes water from the compressed impurity gas to produce a dried compressed impurity gas. A disposing unit disposes the dried compressed impurity gas into an underground aquifer.

Abstract: To generate methane from biomass, a biomass pulp is produced from the biomass with a desired dry mass content being set, and the biomass pulp is placed under pressure. The biomass pulp is heated under pressure in order to liquefy the solid organic components of the biomass pulp. The pressurized and heated biomass pulp is heated further to at least the critical temperature of the biomass pulp. Solids precipitated under pressure and increased temperature are separated from the fluid phase. At least a part of the remaining fluid phase is gasified under pressure and increased temperature by means of a reactor to form a methane-rich gas.

Abstract: This invention teaches a process that includes extraction of gas in which the presence of foam results in the carry over in the outlet gas stream of excessive liquids and/or solids, including the steps of injecting the foam laden gas stream tangentially into a cyclonic separator having an axial gas outlet and a liquid outlet, under conditions in which the inlet stream is subjected to at least about 150 G's, the outlet gas being substantially liquids/solids free and the outlet liquid stream being conveyed for disposal or further processing.

Abstract: The present invention provides a method for storing thermal energy, such as solar energy, as a fuel, by heating a reactive oxide substrate to a first temperature, such that the reactive oxide substrate is reduced, wherein the reactive oxide substrate includes a cerium oxide. The method also includes contacting the reduced reactive oxide substrate at a second temperature with a gas mixture including carbon dioxide, wherein the first temperature is greater than the second temperature, thereby preparing the fuel. The present invention also provides a method for preparing the reactive oxide substrates by heating a mixture including a doped cerium oxide and a pore-forming agent, such that pores are formed in the doped cerium oxide, thereby forming the reactive oxide substrate.

Abstract: The present invention relates to particulate compositions of a lower ash type petroleum coke containing at least two preselected components (alkali metal and calcium) that exhibit an efficient, enhanced-yielding gasification to value added gaseous products, particularly when used in a steady-state integrated gasification process. The compositions of the present invention are particularly useful for catalytic gasification of petroleum coke at moderate temperatures ranging from about 450° C. to about 900° C. Advantageously, the compositions can be readily incorporated into fluidized bed gasification units, and can result in a cost-effective, high-yielding production of methane gas from petroleum coke.

Abstract: The present invention relates to particulate compositions of a lower ash type petroleum coke containing at least two preselected components (alkali metal and iron) that exhibit an efficient, enhanced-yielding gasification to value added gaseous products, particularly when used in a steady-state integrated gasification process. The compositions of the present invention are particularly useful for catalytic gasification of petroleum coke at moderate temperatures ranging from about 450° C. to about 900° C. Advantageously, the compositions can be readily incorporated into fluidized bed gasification units, and can result in a cost-effective, high-yielding production of methane gas from petroleum coke.

Abstract: Systems and processes for producing syngas are provided. A first hydrocarbon can be partially oxidized in the presence of an oxidant and one or more first catalysts at conditions sufficient to partially combust a portion of the first hydrocarbon to provide carbon dioxide, non-combusted first hydrocarbon, and heat. At least a portion of the non-combusted first hydrocarbon can be reformed in the presence of at least a portion of the heat generated in the partial oxidation step and the one or more first catalysts to provide a first syngas. The first syngas can comprise hydrogen, carbon monoxide, and carbon dioxide. Heat can be indirectly exchanged from the first syngas to a second hydrocarbon to reform at least a portion of the second hydrocarbon in the presence of steam and one or more second catalysts to provide a second syngas. The second syngas can comprise hydrogen, carbon monoxide, and carbon dioxide.

Abstract: A process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. In one embodiment, a slurry of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor to generate methane rich producer gases which are fed into a steam pyrolytic reformer to generate synthesis gas comprising hydrogen and carbon monoxide. A portion of the hydrogen is used as the internal hydrogen source. The remaining synthesis gas is either used as fuel to produce electricity and/or process heat or is fed into a Fischer-Tropsch reactor to produce liquid fuel. In another embodiment of the invention, carbonaceous material can be heated simultaneously in the presence of both hydrogen and steam to undergo steam pyrolysis and hydro-gasification in a single step.

Abstract: A catalytic element useful for promoting catalytic gas phase reactions is provided, comprising a porous ceramic body comprising a multiplicity of open pores having a coating comprising a basic oxide material and a catalyst material selected from transition metal and noble metal compounds

Abstract: The present invention relates to systems and processes for producing syngas in steam methane reformer (SMR)-based plants, particularly to the use of a high space velocity, dual mode catalytic reactor to pre-reform plant feedstock. The dual mode reactor has the capability to operate in two modes: either without oxygen addition in a reforming mode or with oxygen addition in a partial oxidation-reforming mode. The dual mode reactor allows the syngas production rate of the plant to be manipulated without the added capital expense of a reheat coil and with reduced impact on export steam production.

Abstract: A method of producing natural gas from a heavy hydrocarbon-containing subterranean formation includes: placing a catalyst having at least one transition metal into the formation, injecting an anoxic stimulation gas into the formation, and collecting the natural gas generated in the formation. The method may be performed outside the context of a subterranean formation under controlled conditions. Thus, a method of producing natural gas from bitumen includes: providing an anoxic mixture of heavy hydrocarbons and a catalyst having at least one transition metal, adding an anoxic stimulation gas to the mixture, and heating the mixture in the presence of the stimulation gas.

Abstract: A fuel reforming system generates burnt gas by burning fuel and air in a burner (6) during system startup, and the temperatures of a reforming reactor (7) and carbon monoxide oxidizer (40) are raised by supplying the burnt gas to the reforming reactor (7) and carbon monoxide oxidizer (40). The temperature of the burnt gas produced by the burner (6) is increased according to the elapsed time from the beginning of the startup processing.

Abstract: A method and apparatus are disclosed for regenerating calcium oxide used in the production of hydrogen gas. The method includes steps of: (a) streaming a solid reactant into an inlet port of a contactor vessel; (b) streaming a purge oxidant into an oxidant port of the contactor vessel to reduce a partial pressure of a gas over the solid reactant; (c) venting the gas from a gas port of the contactor vessel; and (d) removing the solid reactant from a discharge port of the contactor vessel.

Abstract: An apparatus for carrying out a multi-step process of converting hydrocarbon fuel to a substantially pure hydrogen gas feed includes a plurality of modules stacked end-to-end along a common axis. Each module includes a shell having an interior space defining a passageway for the flow of gas from a first end of the shell to a second end of the shell opposite the first end, and a processing core being contained within the interior space for effecting a chemical, thermal, or physical change to a gas stream passing axially through the module. the multi-step process includes: providing a fuel processor having a plurality of modules stacked end-to-end along a common axis; and feeding the hydrocarbon fuel successively through each of the modules in an axial direction through the tubular reactor to produce the hydrogen rich gas.

Abstract: The invention is directed to processes and apparatuses for gas treatment, in particular for the purification of methane rich gas streams, such as gas obtained from the conversion from organic matter (“biogas”). In accordance with the present invention there is provided an apparatus and a process for producing a purified methane comprising gas stream (P) from a methane containing gas stream (A), comprising the steps of: (a) pressurising said methane containing gas stream (A) and subsequently cooling it, whereby a stream comprising condensed contaminants (C) and a methane comprising stream (B) are obtained; (b) optionally feeding said methane comprising stream (B) to an adsorption unit and/or a catalytic conversion unit, whereby the concentration of contaminants in stream (B) is further decreased; and (c) cooling the methane comprising stream (B) to a temperature which is sufficient to condensate CO2 from said stream (B), whereby said purified methane comprising gas stream (P) is obtained.

Abstract: Hydrogen generators and integrated hydrogen generator/fuel cells systems are operated by determining the condition of the hydrogen generator and the condition of the fuel to the hydrogen generator for selection of predetermined flow rates for each of the externally-provided raw materials. The processes of the invention can provide rapid transitions between hydrogen production rates while enabling enhanced efficiency and stability during transient operations.

Abstract: A synthesis plant includes a separation system upstream of a synthesis loop that removes excess nitrogen and other gaseous compounds from a feed gas having a ratio of hydrogen to nitrogen of less than 3:1, thereby producing a syngas with a ratio of hydrogen to nitrogen at about 3:1. Particularly preferred separation systems include a coldbox with a refrigerant other than air, or a pressure swing absorption system.

Abstract: A device is described for mixing two fluids, inserted in or combined with a reactor, which can also be used for catalytic partial oxidation, substantially consisting of the following zones:—a first feeding zone equipped with means for allowing a first fluid, possibly gaseous under the operating conditions, to enter in an axial direction;—an underlying distribution zone containing a bundle of pipes preferably parallel to the axis inside which said fluid is uniformly distributed;—a second feeding zone equipped with means for allowing a second fluid to enter the distribution zone containing the bundle of preferably parallel pipes and to be uniformly distributed outside said parallel pipes;—a mixing zone separated from the distribution zone by a pipe-plate supporting said parallel pipes, said pipe-plate having slits or openings in order to uniformly discharge the second fluid in an axial direction into the mixing area, and said parallel pipes extending beyond said pipe-plate into the mixing zone.

Abstract: A chemical reaction apparatus includes a solid body in which a reaction flow path is formed, and a heater having a thin-film heater formed on the body to oppose the reaction flow path and at least partially exposed to the reaction flow path, and which supplies a predetermined heat amount to the reaction flow path by the thin-film heater.

Abstract: A process for producing synthetic hydrocarbons that reacts carbon dioxide, obtained from seawater of air, and hydrogen obtained from water, with a catalyst in a chemical process such as reverse water gas shift combined with Fischer Tropsch synthesis. The hydrogen is produced by nuclear reactor electricity, nuclear waste heat conversion, ocean thermal energy conversion, or any other source that is fossil fuel-free, such as wind or wave energy. The process can be either land based or sea based.

Abstract: An apparatus and method for producing hydrogen. The apparatus includes a fuel processor, a purification unit and a system controller. The controller determines a calculated flow of reformate from the fuel processor and operates the purification unit based on the calculated flow. The calculated flow is derived from a process model of the fuel processor and known feed(s) to the fuel processor. The calculated flow of reformate is used to control the flow of reformate to adsorbent beds within the purification unit and can be used to control other materials flows within the apparatus. Means for reducing fluctuations in the pressure and/or flow rate of reformate flowing from the fuel processor to the purification unit are also disclosed. The purity of the hydrogen produced can be maintained by adjusting the operation of the purification unit in response to changes in reformate composition, pressure and/or flow rate.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying first and second fluids, respectively, wherein at least the first fluids undergo a chemical reaction. Each first flow channel containing a removable gas-permeable catalyst structure (20) incorporating a metal substrate, the catalyst structure defining flow paths therethrough, with catalytic material on at least some surfaces of each such path. The catalyst structure also incorporates a multiplicity of projecting resilient lugs (22) which support the catalyst structure (20) spaced away from at least one adjacent wall of the channel (17).

Abstract: An apparatus and method for enhancing the yield and purity of hydrogen when reforming hydrocarbons is disclosed in one embodiment of the invention as including receiving a hydrocarbon feedstock fuel (e.g., methane, vaporized methanol, natural gas, vaporized diesel, etc.) and steam at a reaction zone and reacting the hydrocarbon feedstock fuel and steam in the presence of a catalyst to produce hydrogen gas. The hydrogen gas is selectively removed from the reaction zone while the reaction is occurring by selectively diffusing the hydrogen gas through a porous ceramic membrane. The selective removal of hydrogen changes the equilibrium of the reaction and increases the amount of hydrogen that is extracted from the hydrocarbon feedstock fuel.