Abstract: Systems and methods are provided for conversion of methane and/or other hydrocarbons to hydrogen by pyrolysis while reducing or minimizing production of carbon oxides. The conversion of hydrocarbons to hydrogen is performed in one or more pyrolysis or conversion reactors that contain a plurality of sequential fluidized beds. The fluidized beds are arranged so that the coke particles forming the fluidized bed move in a counter-current direction relative to the gas phase flow of feed (e.g., methane) and/or product (H2) in the fluidized beds. By using a plurality of sequential fluidized beds, the heat transfer and management benefits of fluidized beds can be realized while also at least partially achieving the improved reaction rates that are associated with a plug flow or moving bed reactor.

Abstract: Methods are provided for upgrading of pyrolysis carbon in order to allow for conversion of the pyrolysis carbon into higher value products. Instead of attempting to convert methane into a high value carbon product (such as carbon nanotubes) and H2 in a single reaction step, pyrolysis conditions can be used to form H2 and pyrolysis carbon. The pyrolysis carbon can then be treated in order to convert the pyrolysis carbon (H to C atomic ratio of less than 0.20) into a product with a higher hydrogen content (H to C atomic ratio of 0.25-0.9 or 2.0-7.0 wt % H). The treatment can correspond to exposing the pyrolysis carbon with hydrogen in the presence of a catalyst, exposing the pyrolysis carbon to conditions for alkylation, or a sequential combination thereof. This can convert the pyrolysis carbon into heavy hydrocarbon products that are resin-like solids at room temperature.

Abstract: Systems and methods are provided for performing ammonia cracking as the endothermic reaction step of a reaction cycle in a cyclic reaction environment, such as a reverse flow reaction environment. In such aspects, heat for the endothermic reaction can be provided by direct heating during a regeneration step. Optionally, the fuel for the regeneration step can correspond to additional ammonia and/or can include hydrogen generated during the ammonia cracking reaction step. Optionally, a selective catalytic reduction (SCR) zone can be included as part of the reactor, to reduce or minimize the amount of nitrogen oxides in the regeneration effluent from the reactor.

Abstract: Systems and methods are provided for performing both reforming and partial oxidation as part of the reaction step of a reaction cycle in a cyclic reaction environment such as a reverse flow reaction environment, where heat is provided by direct heating during a regeneration step. In some aspects, performing a combination of reforming and partial oxidation can allow for higher conversion of hydrocarbons than reforming alone while reducing or minimizing the peak temperatures within the cyclic reaction environment. In some aspects, performing both reforming and partial oxidation can also allow for an improved molar ratio of H2 to CO in the resulting effluent from the conversion reaction (relative to partial oxidation) while still maintaining high total conversion.

Abstract: Systems and methods are provided for performing reforming in a manner where the flows for providing heat for the endothermic reforming reaction are counter-current to the flows for the reforming reaction. Although the flows are counter-current, the systems and methods also allow the heating profile of the reactor to have a temperature peak toward the middle of the reactor, as opposed to at the end of the reactor. This shift of the temperature peak toward the middle allows for improved heat utilization and recovery during operation of the reactor.

Abstract: Systems and methods are provided for conversion of methane and/or other hydrocarbons to hydrogen by pyrolysis while reducing or minimizing production of carbon oxides. The heating of the pyrolysis environment can be performed at least in part by using electrical heating within a first stage to heat the coke particles to a desired pyrolysis temperature. This electrical heating can be performed in a hydrogen-rich environment in order to reduce, minimize, or eliminate formation of coke on the surfaces of the electrical heater. The heated coke particles can then be transferred to a second stage for contact with a methane-containing feed, such as a natural gas feed. Depending on the configuration, pyrolysis of methane can potentially occur in both the first stage and second stage. In some aspects, the hydrogen-rich environment in the first stage is formed by passing the partially converted effluent from the second stage into the first stage.

Abstract: Systems and methods are provided for production of carbon nanotubes and H2 using a reaction system configuration that is suitable for large scale production. In the reaction system, a substantial portion of the heat for the reaction can be provided by using a heated gas stream. Optionally, the heated gas stream can correspond to a heated H2 gas stream. By using a heated gas stream, when the catalyst precursors for the floating catalyst-chemical vapor deposition (FC-CVD) type catalyst are added to the gas stream, the gas stream can be at a temperature of 1000° C. or more. This can reduce or minimize loss of catalyst precursor material and/or deposition of coke on sidewalls of the reactor. Additionally, a downstream portion of the reactor can include a plurality of flow channels of reduced size that are passed through a heat exchanger environment, such as a shell and tube heat exchanger.

Abstract: Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

Abstract: Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

Abstract: Systems and methods are provided for production of carbon nanotubes and H2 using a reaction system configuration that is suitable for large scale production. In the reaction system, a substantial portion of the heat for the reaction can be provided by using a heated gas stream. Optionally, the heated gas stream can correspond to a heated H2 gas stream. By using a heated gas stream, when the catalyst precursors for the floating catalyst—chemical vapor deposition (FC-CVD) type catalyst are added to the gas stream, the gas stream can be at a temperature of 1000° C. or more. This can reduce or minimize loss of catalyst precursor material and/or deposition of coke on sidewalls of the reactor. Additionally, a downstream portion of the reactor can include a plurality of flow channels of reduced size that are passed through a heat exchanger environment, such as a shell and tube heat exchanger.

Abstract: Systems and methods are provided for conversion of methane and/or other hydrocarbons to hydrogen by pyrolysis while reducing or minimizing production of carbon oxides. The conversion of hydrocarbons to hydrogen is performed in one or more pyrolysis or conversion reactors that contain a plurality of sequential fluidized beds. The fluidized beds are arranged so that the coke particles forming the fluidized bed move in a counter-current direction relative to the gas phase flow of feed (e.g., methane) and/or product (H2) in the fluidized beds. By using a plurality of sequential fluidized beds, the heat transfer and management benefits of fluidized beds can be realized while also at least partially achieving the improved reaction rates that are associated with a plug flow or moving bed reactor.

Abstract: Apparatuses and methods are provided for generating elemental hydrogen and carbon from a hydrocarbon feed. In some examples, the apparatus can include a first tube and a second tube. The first tube can be configured to carry a hydrocarbon feed along a first flow path. The second tube can be configured to carry a fuel and an oxygen-containing gas along a second flow path, where the first flow path and second flow path are countercurrent. A porous wall can sperate the first tube from the second tube where the porous wall can be configured to allow heat and gas to pass from the second tube to the first tube.

Abstract: Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

Abstract: Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Abstract: In various aspects, methods and systems are provided for monitoring catalyst bed levels using multiple sensors that are temporarily installed in a reactor during catalyst loading. The multiple sensors are able to take distance measurements at substantially the same time and at predetermined time intervals so as to provide a catalyst time profile. The catalyst time profile allows an operator monitor catalyst levels during and after catalyst loading. Once catalyst loading is completed, the multiple sensors are removed from the reactor.

Abstract: A process for upgrading a liquid petroleum or chemical stream wherein said stream flows countercurrent to the flow of a treat gas, such as a hydrogen-containing gas, in at least one reaction zone. The temperature of at least a portion of the liquid stream in the reactor is used to control the flooding characteristics of the reactor.