Abstract: A method for start-up and shut down of a fuel processor including an autothermal reformer employing a non-pyrophoric shift catalyst is disclosed. Also disclosed are a computer programmed to start-up or shut down a fuel processor including an autothermal reformer employing a non-pyrophoric shift catalyst or a program storage medium encoded with instruction that, when executed by a computer, start-up or shut down a fuel processor including an autothermal reformer employing a non-pyrophoric shift catalyst.

Abstract: An apparatus and method for producing a hydrogen-enriched reformate. The apparatus includes a fuel processor for converting a fuel to a reformate having fluctuations in pressure and or flow rate, means for reducing the fluctuations, a compression unit for compressing the reformate and one or more of a purification unit and a storage unit downstream of a compression unit. Means for reducing the fluctuations in the reformate can include one or more of a buffer and a conduit for providing a controlled flow of a supplemental fluid to an inlet of the compression unit. The supplemental fluid can include the compressed reformate, a hydrogen-enriched reformate, and mixtures thereof. The apparatus can include means for regulating power to the compression unit that can incrementally increase power to the compression unit particularly during start up. The purification unit can include one or more of a hydrogen selective membrane and a pressure swing adsorption unit. Methods for producing hydrogen are also disclosed.

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: A method for operating a combustor having a catalyst bed. The method includes the steps of directing a flow of air through a catalyst bed, providing heat to the catalyst bed, sensing the temperature in an upstream portion of the catalyst bed to provide an upstream temperature, directing a flow of a fuel through the catalyst bed when the upstream temperature reaches a light-off temperature to produce a combustion reaction, increasing the flow of the fuel until the flow of air and the flow of fuel have a selected air to fuel ratio, and controlling the combustion reaction within the catalyst bed by adjusting the flow of air and the flow of fuel while maintaining the selected air to fuel ratio. The method can include sensing temperatures within the catalyst bed and controlling the combustion reaction in response to the sensed temperatures. The heat provided to the catalyst bed can also be adjusted in response to the sensed temperatures.

Abstract: An apparatus and method for producing a hydrogen-enriched reformate. The apparatus includes a fuel processor for producing a reformate having fluctuations in a pressure and/or flow rate and means for reducing the fluctuations. The reformate comprises impurities that are removed by a purification unit having a plurality of adsorbent beds. A valve assembly controls the flow of reformate to the adsorbent beds based upon sensed product data generated by a product sensor. A compression unit optionally compresses the reformate prior to entering the purification unit. Means for reducing fluctuations in the pressure and/or flow rate include a buffer and/or a conduit for providing a controlled flow of a supplemental fluid to an inlet of the compression unit. A product valve can control the flow of hydrogen-enriched reformate out of the purification unit.

Abstract: An apparatus and a method for use in controlling the apparatus are disclosed. The apparatus includes a purified hydrogen generator; at least one of a compression unit, a storage unit, and a dispensing unit; and a system controller. The system controller is capable of monitoring the operation of the hydrogen generator and the compression unit, storage unit, or dispensing unit at a system level and shutting down at least one of hydrogen generator and the compression unit, storage unit, or dispensing unit upon the detection of a dangerous condition.

Abstract: A method and system are disclosed for controlling a process by establishing a control factor for a proportional-integral-derivative (PID) controller used to control a parameter of a process relative to a setpoint. A feedback signal regarding the parameter of the process is received via a sensor of the process and a first feedback loop. Automatic adjusting of the control factor of the PID controller is based on the feedback signal.

Abstract: The present invention provides a method and apparatus for controlling a level in a receptacle capable of storing a fluid. The apparatus includes a first valve governing ingress of the fluid to the receptacle, a second valve governing egress of fluid from the receptacle, wherein the second valve is positioned below the first valve. The apparatus also includes a first switch deployed between the first valve and the second valve, wherein the first switch is capable of providing a first signal indicative of fluid at the first switch and a second switch deployed between the first switch and the second valve, wherein the second switch is capable of providing a second signal indicative of an absence of fluid at the second switch. The apparatus also includes a controller capable of controlling a fluid level in the receptacle by opening and closing the first and second valves responsive to the first and second signals.

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 reaction zones arranged in a common reaction chamber. The multi-step process includes: providing a fuel to the fuel processor so that as the fuel reacts and forms the hydrogen rich gas, the intermediate gas products pass through each reaction zone as arranged in the reactor to produce the hydrogen rich gas.

Abstract: An apparatus and method for the preferential oxidation of carbon monoxide in a hydrogen-rich fluid. The apparatus utilizes one or more reactors that are dimensioned to optimize the exothermic oxidation reaction and the transfer of heat to and from the catalyst bed. A reactor of the apparatus has an elongated cylindrical catalyst bed and heat transfer means adjacent the catalyst bed. The heat transfer means is suitable for pre-heating the catalyst bed during start-up operations and for removing the heat from the catalyst bed during the oxidation reaction. One or more reactors of different dimensions may be utilized depending upon the pressure of the hydrogen-rich fluid to be directed into the apparatus and the pressure requirements for the carbon monoxide-depleted fluid exiting the apparatus. For instance, in low pressure operations where it may be desirable to minimize the pressure drop across the apparatus, two or more reactors having relatively smaller dimensions can be utilized.

Abstract: The present invention relates to an integrated gasification and hydroprocessing process. A hydrocarbonaceous fuel is first gasified to produce syngas, and then a portion of the hydrogen is removed from the syngas. The hydrogen is compressed and used as an excess reactant in a hydroprocessing unit. Hydrogen gas is recovered from the hydroprocessing unit product, purified, compressed and recycled to the hydroprocessing unit. The hydrogen-poor syngas is expanded in an expander that drives the compressor that compresses the recycled hydrogen gas. The expanded syngas is then combined with light hydrocarbons removed from the recycle hydrogen gas stream, combusted in a gas turbine and used for power generation.

Abstract: The present invention provides a method and apparatus for identifying an activation of a burst disk. A pressure data or a temperature data relating to a flow is received. A determination is made whether the flow is interrupted based upon the at least one of the pressure data and the temperature data. A burst disk activation is identified in response to determining that the flow is interrupted.

Abstract: An apparatus and method for recovering a clean liquid condensate from a synthesis gas at elevated temperatures and pressures. The apparatus includes at least one heat exchanger for reducing the temperature of the synthesis gas down to below 200° F. (93° C.) so as to form a syngas condensate at elevated pressure. The syngas condensate is flashed so that it separates into a liquid phase condensate and a gas phase. The liquid phase condensate comprises water, dissolved ammonia and particulates. The gas phase contains carbon monoxide, carbon dioxide, various sulfur containing compounds and trace amounts of other compounds that may have been dissolved in the syngas condensate. The gas phase is removed from the flash tank and sent to a sour gas treatment unit and/or flare. The liquid phase condensate is then filtered so as to remove larger sized particulates. Clean liquid condensate is reused in the gasification process.

Abstract: Apparatus and methods for converting hydrocarbon fuels to hydrogen-rich reformate that incorporate a carbon dioxide fixing mechanism into the initial hydrocarbon conversion process. The mechanism utilizes a carbon dioxide fixing material within the reforming catalyst bed to remove carbon dioxide from the reformate product. The removal of carbon dioxide from the product stream shifts the reforming reaction equilibrium toward higher hydrocarbon conversion with only small amounts of carbon oxides produced. Fixed carbon dioxide may be released by heating the catalyst bed to a calcination temperature. Heat for releasing fixed carbon dioxide from the catalyst bed is generated internally within the reactor through oxidation. A non-uniform distribution of catalysts and carbon dioxide fixing material across catalyst bed can be utilized to achieve higher conversion rates of hydrocarbon to hydrogen-rich reformate.

Abstract: Apparatus and methods for converting hydrocarbon fuels to hydrogen-rich reformate that incorporate a carbon dioxide fixing mechanism into the initial hydrocarbon conversion process. The mechanism utilizes a carbon dioxide fixing material within the reforming catalyst bed to remove carbon dioxide from the reformate product. The removal of carbon dioxide from the product stream shifts the reforming reaction equilibrium toward higher hydrocarbon conversion with only small amounts of carbon oxides produced. Fixed carbon dioxide may be released by heating the catalyst bed to a calcination temperature. A non-uniform distribution of catalysts and carbon dioxide fixing material across catalyst bed yields higher conversion rates of hydrocarbon to hydrogen-rich reformate.

Abstract: Method and apparatus for converting hydrocarbon fuels to hydrogen-rich reformate that incorporate a carbon dioxide fixing mechanism into the initial hydrocarbon conversion process and for providing a continuous supply of hydrogen-rich reformate. The apparatus includes a reforming reactor that has a catalyst bed comprising a reforming catalyst, a carbon dioxide fixing material and an optional water gas shift catalyst; a hydrogen storage device for storing reformate; and a controller for controlling the delivery of reformate from the reactor and/or storage device to an outlet. Optionally, the apparatus can include a heating device for heating the catalyst bed and a polishing unit for removing impurities from the reformate. The reforming reactor is operable in reforming and non-reforming modes. During non-reforming modes, the hydrogen storage device provides reformate to the outlet so as to maintain a continuous supply of reformate.

Abstract: Methods for converting hydrocarbon fuels to hydrogen-rich reformate that incorporate a carbon dioxide fixing mechanism into the initial hydrocarbon conversion process. The mechanism utilizes a carbon dioxide fixing material to remove carbon dioxide from the reformate product stream. The removal of carbon dioxide from the product stream shifts the reforming reaction equilibrium toward higher hydrocarbon conversion with only small amounts of carbon oxides produced. Repeated absorption/desorption of carbon dioxide by the fixing materials tends to decrease the fixing capacity of the materials. Hydration of the carbon dioxide fixing materials between one or more cycles serves to sustain their fixing capacity and to enhance the efficiencies of the reforming and shift reactions occurring in the catalyst bed. Hydration can occur during reactor start-up or shut down, periodically over a number of cycles, and/or upon a monitored change in the reformate composition.

Abstract: Apparatus and method for converting hydrocarbon fuels to hydrogen-rich reformate that incorporate a carbon dioxide fixing mechanism into the initial hydrocarbon conversion process. The mechanism utilizes a carbon dioxide fixing material within the reforming catalyst bed to remove carbon dioxide from the reformate product. The bed optionally contains a water gas shift catalyst. The removal of carbon dioxide from the product stream shifts the reforming reaction and shift reaction equilibria toward production of higher concentrations of hydrogen with only small amounts of carbon oxides produced. The carbon oxide-depleted reformate is directed to a purification bed comprising a hydrogen fixing material that removes hydrogen from the reformate stream to provide fixed hydrogen and a hydrogen-depleted reformate that flows out of the purification bed. The purification bed is heated to release fixed hydrogen from the hydrogen fixing material to provide a highly pure hydrogen gas.

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 each module being in fluid communication with adjacent modules. The modules may be arranged axially along a common axis of flow or alternatively the modules are arranged along a common axis so that they are nested one within the other. The multi-step process includes: providing a fuel processor having a plurality of modules; and feeding the hydrocarbon fuel successively through each of the modules in the reactor to produce the hydrogen rich gas.