Abstract: Hydrogen generators and processes for operating hydrogen generators using partial oxidation/steam reforming of fuel are provided that can achieve desirable Net Hydrogen Efficiencies over a range of fuels and hydrogen product production rates and purities. Superheated steam for the reformer feed is provided through indirect heat exchange with the reformate and through indirect heat exchange with a flue gas. The relative portions of superheated steam from each heat exchange is adjusted to enhance Net Hydrogen Efficiency as a demand condition such as hydrogen product production rate or purity changes, and cooler oxygen-containing gas is used to avoid precombustion temperatures in the reformer feed.

Abstract: Partial oxidation/steam reformers (222) which use heat integrated steam cycles and steam to carbon ratios of at least about 4:1 to enable efficient operation at high pressures suitable for hydrogen purification unit operations such as membrane separation (234) and pressure swing adsorption.

Abstract: Processes and apparatus for batch annealing work pieces in a hydrogen atmosphere use pressure swing sorption to recover hydrogen from the annealing exhaust. In preferred embodiments, hydrogen for the batch annealing is generated by reforming and the recovery of hydrogen is integrated with the reforming operation.

Abstract: Apparatus and processes are provided for the generation of hydrogen which employ a reformer and water gas shift reactor. The apparatus and processes respond quickly to changes in hydrogen generation. The reformate in a region between the reformer and prior to exiting the water gas shift reactor is cooled by indirect heat exchange with water whereby substantially all the water is vaporized to steam, the steam is separated from liquid water and then introduced into the reformate.

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: An integrated reactor for producing fuel gas for a fuel cell, the integrated reactor comprises an waste gas oxidizer (WGO) assembly having an associated WGO chamber, an inlet, an outlet and a flow path for exothermic gases produced in the WGO chamber. The integrated reactor has an autothermal reactor (ATR) assembly located within the WGO chamber. The ATR assembly has an inlet means and an outlet means for process gases flowing therethrough and a catalyst bed which is intermediate the inlet and outlet means. At least a part of the inlet means of the ATR assembly is located in the flow path of the WGO chamber to facilitate the transfer of thermal energy.