Abstract: A method and apparatus for producing a synthesis gas product having one or more oxygen transport membrane elements thermally coupled to one or more catalytic reactors such that heat generated from the oxygen transport membrane element supplies endothermic heating requirements for steam methane reforming reactions occurring within the catalytic reactor through radiation and convention heat transfer. A hydrogen containing stream containing no more than 20 percent methane is combusted within the oxygen transport membrane element to produce the heat and a heated combustion product stream. The heated combustion product stream is combined with a reactant stream to form a combined stream that is subjected to the reforming within the catalytic reactor. The apparatus may include modules in which tubular membrane elements surround a central reactor tube.

Abstract: A method and apparatus for supplying oxygen to meet a user demand in which oxygen is separated from air by an electrically driven oxygen separation device to supply oxygen to meet the user demand and to charge an adsorbent bed with all or part of the separated oxygen. When a user demand exists, oxygen can be supplied from both the electrically driven oxygen separation device and from oxygen desorbed from the adsorbent bed.

Abstract: A composite oxygen transport membrane having a dense layer, a porous support layer and an intermediate porous layer located between the dense layer and the porous support layer. Both the dense layer and the intermediate porous layer are formed from an ionic conductive material to conduct oxygen ions and an electrically conductive material to conduct electrons. The porous support layer has a high permeability, high porosity, and a high average pore diameter and the intermediate porous layer has a lower permeability and lower pore diameter than the porous support layer. Catalyst particles selected to promote oxidation of a combustible substance are located in the intermediate porous layer and in the porous support adjacent to the intermediate porous layer. The catalyst particles can be formed by wicking a solution of catalyst precursors through the porous support toward the intermediate porous layer.

Abstract: A method and apparatus for producing a treated hydrocarbon containing stream for use as a feed to a hydrogen plant having a steam methane reformer in which an untreated hydrocarbon containing stream is introduced into two reaction stages connected in series to hydrogenate olefins and to convert organic sulfur species to hydrogen sulfide. The second of the two stages can also be operated in a pre-reforming mode to generate additional hydrogen through introduction of the oxygen and steam into such stage. A sulfur tolerant catalyst is used in both stages to promote hydrogenation and oxidation reactions. Sulfur is removed between stages by adsorption of the hydrogen sulfide to prevent deactivation of the catalyst in the second of the stages that would otherwise occur during operation of the second reaction stage in a pre-reforming mode of operation.

Abstract: Method and apparatus of separating an oxygen and nitrogen containing feed stream, for example, air, in higher and lower pressure columns. A crude liquid oxygen stream condenses nitrogen vapor in the higher pressure column for reflux purposes and results in the partial vaporization of the crude liquid oxygen stream to produce vapor and liquid fractions thereof. The liquid fraction condenses a lower pressure part of the feed stream and results in the liquid fraction being at least partially vaporized. Both the vapor fraction of the crude liquid oxygen stream and the liquid fraction after having been at least partially vaporized are introduced into the lower pressure column. Boil-up is produced within a bottom region of the lower pressure column by partially vaporizing an oxygen-rich liquid column bottoms against condensing a higher pressure part of the feed stream and then utilizing vapor or residual liquid as an oxygen product.

Abstract: A separation method and apparatus that separates a component from a feed stream by use of a membrane in which separation is driven, at least in part, by a sweep stream. The sweep stream may be pumped to a supercritical pressure and then heated to at least near supercritical temperature, at least in part, through heat exchange with a component laden sweep stream being discharged from the membrane. A multi-component mixture can also be used that will produce the sweep stream as a vapor as a result of the heat exchange. The component laden sweep stream, due to cooling through the indirect heat exchange, will form a two-phase fluid that can be phase separated into a vapor phase enriched in the component that can be taken as a product and a residual liquid that can be recirculated in the formation of the sweep stream in the liquid state.

Abstract: An Apparatus for purifying a feed stream containing carbon dioxide in which the feed stream, after having been compressed and dried, is partly cooled and then used to reboil a stripping column. Thereafter, the feed stream is further cooled and expanded to a lower operational temperature of the stripping column. A carbon dioxide product stream composed of the liquid column bottoms of the stripping column is expanded at one or more pressures to generate refrigeration, then fully vaporized within the main heat exchanger and compressed by a compressor to produce a compressed carbon dioxide product. Refrigeration is recovered in the main heat exchanger from a column overhead stream extracted from the stripping column within the main heat exchanger either directly or indirectly by auxiliary processing in which carbon dioxide is further separated and optionally recycled back to the main compressor used in compressing the feed stream.

Abstract: An apparatus for generating electrical power in which a synthesis gas stream generated in a gasifier is partially oxidized, expanded and thereafter, is combusted in an oxygen transport membrane system of a boiler. The combustion generates heat to raise steam to in turn generate electricity by a generator coupled to a steam turbine. The resultant flue gas can be purified to produce a carbon dioxide product.

Abstract: A distillation apparatus and method in which first and second compressed streams are formed from a compressed feed stream, for example, compressed air. The first compressed stream is fully cooled within a main heat exchanger so that it is substantially condensed. The second compressed stream is partly cooled within the main heat exchanger and then introduced into a turboexpander at a temperature such that the turboexpander exhaust stream is superheated. Part of the first compressed stream is mixed with the exhaust stream to produce a combined stream that is no more than 10° C. above saturation temperature at the pressure of the exhaust stream. The combined stream is introduced into a distillation column unit to produce one or more products that are enriched in components of the feed to be separated. In such manner the turboexpansion can occur at a higher temperature and with increased refrigerating effect.

Abstract: Method and apparatus of separating a nitrogen from a compressed and purified feed stream in a cryogenic rectification plant that employs a distillation column to produce a nitrogen-rich vapor as a column overhead and an oxygen-rich liquid column bottoms. Reflux is generated for the column by condensing part of the nitrogen-rich vapor within a down-flow heat exchanger. A stream of the oxygen-rich liquid column bottoms is introduced into an ejector which draws a stream of an oxygen-rich liquid phase produced from the outlet of a down-flow heat exchanger. The combined oxygen-rich liquid exiting the ejector is fed to the down-flow heat exchanger to condense the nitrogen-rich vapor. In such manner, part of the oxygen-rich liquid phase is recirculated to prevent dry-out of the down-flow heat exchanger outlet and to maintain effective condensation of the nitrogen-rich vapor.

Abstract: The present invention provides a method of liquefying a hydrogen feed stream and a liquefier for carrying out such a method in which ortho-species of hydrogen contained in a hydrogen feed stream is converted to the para-species in higher and lower temperature catalytic converters. An adsorption unit, located between the higher and lower temperature catalytic converters, adsorbs a portion of the ortho content of the feed stream. The adsorbed portion is desorbed during regeneration of an adsorbent bed of the adsorption unit and is recirculated back for treatment in the higher temperature catalytic converter to reduce the degree to which the ortho-species are converted to the para-species in the lower temperature catalytic converter and at lower temperatures.

Abstract: Separation method and apparatus for separating a gaseous mixture, for example, air, in a cryogenic rectification plant in which a compressed stream is divided into subsidiary streams that are extracted from a main heat exchanger of the plant at higher and lower temperatures. The two streams are then combined and expanded in a turboexpander to generate refrigeration for the plant. The flow rates of the two streams are adjusted to control inlet temperature of a turboexpander supplying plant refrigeration and to minimize potential deviation of the turboexpander exhaust from a saturated vapor state. Control of the expansion ratio can advantageously be applied to allow variable liquid production from the rectification plant.

Abstract: The present invention provides a method and a control system for controlling an adsorbent bed unit in which an adsorbent bed concentration of an impurity within an adsorbent bed of the adsorbent bed unit is measured. The adsorbent bed concentration is controlled by manipulating the feed cycle time during which an adsorbent bed is adsorbing the impurities to maintain the adsorbent bed concentration at a targeted adsorption bed concentration. The targeted adsorption bed concentration is determined such that the product impurity concentration is maintained at product impurity concentration targets. The method and control system can incorporate a supervisory level of control reactive to product impurity concentration levels and related targets to determine the targeted adsorption bed concentration and a primary level of control that calculates the feed cycle time based upon an error between the measured and targeted adsorption bed concentrations. Proportional integral control can be used for such purposes.

Abstract: An airfoil diffuser for a centrifugal compressor formed by a diffuser passage area and a plurality of diffuser blades located within the diffuser passage area. The diffuser passage area is defined between a hub plate and a shroud of the centrifugal compressor. Each of the diffuser blades has a twisted configuration in a stacking direction as taken between the hub plate and an outer portion of the shroud located opposite to the hub plate. As a result of the twisted configuration, the diffuser blade inlet blade angle decreases from the hub plate to the outer portion of the shroud and solidity measurements at leading edges of the diffuser plates vary between a lower solidity value measured at the hub plate of less than 1.0 and a high solidity value measured at the outer portion of the shroud of no less than 1.0.

Abstract: Carbon dioxide emissions within a refinery are reduced by reforming a hydrocarbon containing feed at low pressure to enhance the conversion of methane to hydrogen and carbon monoxide and thereby reduce methane slip. The hydrocarbon containing feed is composed entirely or at least in part of a refinery off gas. The resulting reformed stream is then subjected to water-gas shift conversion to form a shifted stream from which carbon dioxide is separated. As a result of the separation and the low pressure reforming, hydrogen containing fuel gas streams, that are thereby necessary lean in carbon dioxide and methane, are used in firing the steam methane reformer and other fuel uses within the refinery to reduce carbon dioxide emissions. The carbon dioxide that is separated can be sequestered or used in other processes such as enhanced oil recovery.

Abstract: The present invention provides a method and apparatus for generating refrigeration in a process operating at sub-ambient temperatures in which the refrigeration is generated by a turboexpander. The turboexpander is coupled to a generator controlled so that its speed is maintained at a setpoint through electromagnetic braking and its power output is maintained at line matching voltage and frequency. The speed control of the generator therefore, also controls the speed of the turboexpander. The setpoint is calculated to be equal to a product of an operational efficiency parameter, U/Co, and a square root of twice the enthalpy drop in the flow passing through the turboexpander divided by a product of pi and a diameter of an impeller employed within the turboexpander.

Abstract: A hydrogen production method and facility in which a synthesis gas stream produced by the gasification of a carbonaceous substance is processed within a synthesis gas processing unit in which the carbon monoxide content is reacted with steam to produce additional hydrogen that is removed by a pressure swing adsorption unit. The tail gas from the pressure swing adsorption unit is further reformed with the addition of a hydrocarbon containing stream in a steam methane reforming system, further shifted to produce further additional hydrogen. The further hydrogen is then separated in another pressure swing adsorption unit.

Abstract: A method of producing a hydrogen product stream in which a steam stream is reacted with a hydrocarbon containing stream within a steam methane reformer. The resulting product stream is subjected to a water gas shift reaction and then to pressure swing adsorption to produce the hydrogen product stream. The hydrocarbon stream is alternatively formed from a first type of feed stream made up of natural gas, refinery off-gas, naphtha or synthetic natural gas or combinations thereof and a second type that is additionally made up of a hydrogen and carbon monoxide containing gas. During use of both of the types of feed streams, the flow rate of the steam stream is not substantially changed and reformer exit temperatures of both the reactant and the flue gas side are held essentially constant.

Abstract: Purification method and apparatus for purifying a gas stream by oxygen removal. The apparatus includes primary and secondary oxygen separation zones and tubular electrically driven oxygen separation elements. There are more elements in the primary zone than the secondary zone so that low concentrations of oxygen can be obtained in a purified stream and turbulent flow conditions can also be obtained that will permit purification to very low levels. In addition, a junction is provided to connect the tubular separation elements to metallic elements such as manifolds.

Abstract: Method of controlling production of a plant incorporating one or more chemical processes in which products are produced through consumption of raw materials. In accordance with the method, current production rates of the products are computed by semi-empirical process models that are corrected through error corrections of actual production rates to produce corrected models. The production is then optimized using the corrected models to maximize the variable margin gained upon the sale of the products. The optimization yields targets that either directly or at least influence consumption of the raw materials. The raw materials are then introduced into the process or processes in accordance with the targets.