Abstract: Processes and apparatus for low-CO2 emissions methanol production using a high efficiency (>90%) reformer fired with a low-carbon fuel (C:H<0.03) to produce syngas. CO2 is removed from the syngas, and the CO2-lean syngas is fed to a methanol synthesis loop. A purge stream from the methanol synthesis loop is processed to recover a hydrogen-rich stream and a tail gas stream. The hydrogen-rich stream is supplied as fuel to fire the reformer, along with a portion (<10%) of the tail gas, to produce a CO2-lean flue gas (<3 vol %, dry basis). The flue gas is optionally cooled below a dew point to form condensate, which can be collected and removed. The methanol production can have a carbon efficiency of 97% or more, and a CO2 emissions reduction (compared to natural gas firing) of 88% or more.

Abstract: Methods and apparatus for improved efficiency and flue gas scrubbing in a fired heater using a condensing convection section. The method preheats a hydrocarbon or hydrocarbon/water process feed stream in a coil in the convection section of a fired heater, collects condensate from the flue gas, and scrubs the flue gas with the recirculated condensate. The apparatus has a heat transfer coil disposed in the convection section, to preheat a process stream and form condensate from the flue gas, and a condensate recirculation loop to collect the condensate from the convection section and scrub the flue gas with the condensate.

Abstract: A reformer suitable for micro-scale design has horizontal catalyst tube(s) passing through a baffled radiant section for convective and radiant heat transfer to the tube(s). To reduce the footprint and/or to facilitate field assembly a combustion chamber and convection section can be oriented transversely with respect to the radiant section; the tube(s) can be horizontal and/or include structured catalyst; and/or the combustion chamber provides flameless combustion or produces a flame without impinging on the tubes. Also, a skid frame-mountable version of the reformer; and a process for transporting, assembling, and/or operating the steam methane reformer.

Abstract: A reformer suitable for micro-scale design has horizontal catalyst tube(s) passing through a baffled radiant section for convective and radiant heat transfer to the tube(s). To reduce the footprint and/or to facilitate field assembly a combustion chamber and convection section can be oriented transversely with respect to the radiant section; the tube(s) can be horizontal and/or include structured catalyst; and/or the combustion chamber provides flameless combustion or produces a flame without impinging on the tubes. Also, a skid frame-mountable version of the reformer; and a process for transporting, assembling, and/or operating the steam methane reformer.

Abstract: Flue gas entry into the tunnel(s) of a furnace is controlled by openings through the entry ports. A furnace tunnel assembly system uses interlocking refractory blocks to form a longitudinal wall of a flue gas flow channel in a firebox. Plugs in some of the ports inhibit flue gas entry from the firebox to the flow channel, and flow passages in some of the ports allow the flue gas to enter the flow channel from the firebox. The flow passages can be provided as inserts having orifices of varying diameter and a profile matching the ports in which they are placed. Matching the flow conductivity (or cross-sectional flow area) and pressure drop through the individual ports to the desired mass flow, the flue gas flow can be distributed evenly, or as otherwise desired, into different ports, intervals, and/or regions of the tunnel.

Abstract: Flue gas entry into the tunnel(s) of a furnace is controlled by varying the flow conductivity or size of the individual or groups of openings through the entry ports. The openings can be provided either as gaps between adjacent blocks, or through bores of varying diameter, or as inserts having orifices of varying diameter and a profile matching the ports in which they are placed. Matching the flow conductivity (or cross-sectional flow area) and pressure drop through the individual ports to the desired mass flow, the flue gas flow can be distributed evenly, or as otherwise desired, into different ports, intervals, and/or regions of the tunnel.

Abstract: Flue gas entry into the tunnel(s) of a furnace is controlled by varying the flow conductivity or size of the individual or groups of openings through the entry ports. The openings can be provided either as gaps between adjacent blocks, or through bores of varying diameter, or as inserts having orifices of varying diameter and a profile matching the ports in which they are placed. Matching the flow conductivity (or cross-sectional flow area) and pressure drop through the individual ports to the desired mass flow, the flue gas flow can be distributed evenly, or as otherwise desired, into different ports, intervals, and/or regions of the tunnel.

Abstract: Ammonia is produced in a reactor in which pseudoisothermal conditions can be approached by convective cooling of a reaction zone of the reactor by positioning at least a portion of the reaction zone in indirect contact with a flow of hot gas such as exhaust gas or preheated air. The hot gas may be supplied from a fired heater, a boiler, a reformer, a process air preheat furnace, a gas turbine, or the like. The reactor converts a feed stream of a purge gas or syngas to ammonia. The method may be implemented in a primary synthesis loop or in a purge gas loop of a new ammonia plant, or by retrofitting an existing ammonia plant. Cooperatively installed with a primary ammonia synthesis loop, the reactor increases total ammonia production.

Abstract: Ammonia is produced in a reactor 22, 24, 246, 248, 250 or 252, in which pseudoisothermal conditions can be approached by convective cooling of a reaction zone of the reactor by positioning at least a portion of the reaction zone in indirect contact with a flow of hot gas such as exhaust gas 18 or preheated air. The hot gas 18 may be supplied from a fired heater, a boiler 10, a reformer 202, a process air preheat furnace, a gas turbine, or the like. The reactor converts a feed stream of a purge gas 12 or syngas to ammonia. The method may be implemented in a primary synthesis loop (as at 246, 248, 250, 252) or in a purge gas loop 12 of a new ammonia plant, or by retrofitting an existing ammonia plant. Cooperatively installed with a primary ammonia synthesis loop, the reactor increases total ammonia production.