Abstract: High purity hydrogen is produced by a steam reforming hydrogen production unit with at least one of a bayonet reactor for reforming steam and a hydrocarbon, a recuperative burner, and a regenerative burner such that the steam reforming unit produces little or no steam in excess of the steam reforming process requirements. High purity hydrogen is separated from the syngas exiting the reformer via a pressure swing adsorption unit and combined with high purity nitrogen from an air separation unit as feedstock to a Haber process ammonia synthesis unit. Compressors for the ammonia synthesis unit are driven by higher efficiency drivers than are possible using the low temperature steam conventionally exported from a steam reforming unit. Compression power requirements are reduced.

Abstract: A support structure for a structured catalytic packing is disclosed. The support structure is in a fixed position relative to the reactor tube containing it. It supports catalyzed casings that are free to move relative to the support structure. The support structure and casings are inserted in the reactor tube such that the support structure is located proximate the longitudinal axis of the tube and the casings are located between the support structure and the reactor tube wall. The support structure comprises a central support tube or rod proximate to, and impervious or perforated discs perpendicular to, the longitudinal axis of the reactor tube, and may comprise spacers separating the discs.

Abstract: A bayonet reactor including a catalytic reactor in the form of an annular structured packing is provided with increased surface area for the transfer of heat between annulus gas and return gas, an increased coefficient of heat transfer between the annulus and return gases, and a reduced overall pressure drop relative to conventional reactors. The reactors of the present technology can enable intensified catalytic processing.

Abstract: An apparatus includes a furnace having at least one bayonet reforming tube. The furnace is adapted to receive a gas including a hydrocarbon and at least one of steam and carbon dioxide via the bayonet reforming tube, heat and catalytically react the gas to form syngas at a first temperature, cool the syngas to a second temperature lower than the first temperature, and eject the syngas from the tube. The furnace has a first effluent stream including flue gas and a second effluent stream including syngas. The apparatus also includes a first heat recovery section adapted to transfer heat from the first effluent stream to a first heat load including one of air, water, and steam, and a second heat recovery section adapted to transfer heat from the second effluent stream to a second heat load.

Abstract: An apparatus includes an inlet, an outlet, and a sheet disposed proximate a heat transfer surface, wherein the sheet is oriented in a sheet plane that is displaced from a plane of the heat transfer surface by an angle of at least 10 degrees. The apparatus also includes a plurality of tabs attached to the sheet, the tabs lying in respective tab planes, wherein the tab planes and the sheet plane intersect forming respective intersections. The intersections of the tab planes and the sheet plane are substantially parallel. The intersections of the tab planes and the sheet plane are at an angle of less than 88° to the heat transfer surface, and the plurality of tabs collectively form channels directing a fluid passing from the inlet to the outlet to impinge the heat transfer surface.

Abstract: A structured packing for insertion in a reactor having an inlet, an outlet, a wall and an axis. The packing comprises a first part, i.e., a reactor core and a second part, i.e., a reactor casing. The second part is free to move relative to the first part. The first part and the second part are inserted in the reactor such that the first part is located proximate the axis and the second part is located between the first part and the reactor wall. In general, the second part will be in contact with the reactor wall.

Abstract: A structured packing for insertion in a reactor having an inlet, an outlet, a wall and an axis. The packing comprises a first part, i.e., a reactor core and a second part, i.e., a reactor casing. The second part is free to move relative to the first part. The first part and the second part are inserted in the reactor such that the first part is located proximate the axis and the second part is located between the first part and the reactor wall. In general, the second part will be in contact with the reactor wall.