Abstract: A tube seal device suitable for use in a heat exchange reactor comprising one or more tubes is described, said tube seal device comprising a seal tube and an inner tube disposed within the seal tube to provide an overlapping region, said inner tube having within said overlapping region, (i) an interior constriction of reduced cross sectional area forming a low-pressure region, (ii) an expansion region adjacent the constriction of cross sectional area greater than that of the constriction, and (iii) one or more passages through the wall of the inner tube connecting said low-pressure region to the exterior of the inner tube, wherein the tube seal device further comprises one or more grooves formed around an inner face of the seal tube in the overlapping region corresponding to the low-pressure region of the inner tube.

Abstract: An apparatus for steam reforming of hydrocarbons is described including a steam reformer containing a plurality of externally-heated vertical tubes each tube having an inlet for a feed gas mixture including hydrocarbon and steam, and an outlet for a reformed gas mixture, wherein the tubes contain a particulate steam reforming catalyst adjacent the outlet and a structured steam reforming catalyst adjacent the inlet. A process for steam reforming of hydrocarbons using the apparatus is also described.

Abstract: A process for the steam reforming of hydrocarbons comprises partially oxidizing a feedgas comprising a hydrocarbon feedstock with an oxygen-containing gas in the presence of steam to form a partially oxidized hydrocarbon gas mixture at a temperature >1200° C. and passing the resultant partially oxidized hydrocarbon gas mixture through a bed of steam reforming catalyst, wherein the bed comprises a first layer and a second layer, each layer comprising a catalytically active metal on an oxidic support wherein the oxidic support for the first layer is a zirconia.

Abstract: A catalyst arrangement disposed within a vertical reaction tube includes a structured catalyst within an upper part of the reaction tube, a particulate catalyst beneath the structured catalyst in a lower part of the reaction tube, and a catalyst support device located between the structured catalyst and the particulate catalyst, wherein the catalyst support device includes a cylindrical body having a first end adapted for connection to the structured catalyst, and a second end, and the cylindrical body has a diameter 70-90% of the internal diameter of the tube and a length/diameter in the range 0.5-2.5.

Abstract: A process for the steam reforming of hydrocarbons comprises partially oxidising a feedgas comprising a hydrocarbon feedstock with an oxygen-containing gas in the presence of steam to form a partially oxidised hydrocarbon gas mixture at a temperature >1200° C. and passing the resultant partially oxidised hydrocarbon gas mixture through a bed of steam reforming catalyst, wherein the bed comprises a first layer and a second layer, each layer comprising a catalytically active metal on an oxidic support wherein the oxidic support for the first layer is a zirconia.

Abstract: A process for the steam reforming of hydrocarbons comprises partially oxidizing a feedgas comprising a hydrocarbon feedstock with an oxygen-containing gas in the presence of steam to form a partially oxidized hydrocarbon gas mixture at a temperature >1200° C. and passing the resultant partially oxidized hydrocarbon gas mixture through a bed of steam reforming catalyst, wherein the bed comprises a first layer and a second layer, each layer comprising a catalytically active metal on an oxidic support wherein the oxidic support for the first layer is a zirconia.

Abstract: A catalyst arrangement disposed within a vertical reaction tube includes a structured catalyst within an upper part of the reaction tube, a particulate catalyst beneath the structured catalyst in a lower part of the reaction tube, and a catalyst support device located between the structured catalyst and the particulate catalyst, wherein the catalyst support device includes a cylindrical body having a first end adapted for connection to the structured catalyst, and a second end, and the cylindrical body has a diameter 70-90% of the internal diameter of the tube and a length/diameter in the range 0.5-2.5.

Abstract: An apparatus for steam reforming of hydrocarbons is described including a steam reformer containing a plurality of externally-heated vertical tubes each tube having an inlet for a feed gas mixture including hydrocarbon and steam, and an outlet for a reformed gas mixture, wherein the tubes contain a particulate steam reforming catalyst adjacent the outlet and a structured steam reforming catalyst adjacent the inlet. A process for steam reforming of hydrocarbons using the apparatus is also described.

Abstract: A process for converting a hydrocarbon feedstock into a synthesis gas includes: (i) passing a first stream including a hydrocarbon and steam to externally-heated catalyst-filled tubes in a heat exchange reformer where steam reforming reactions take place to generate a first reformed gas mixture, (ii) passing a second stream including a hydrocarbon and steam, after a heating step, to an autothermal reformer, where it is combined with an oxidant gas containing free oxygen and autothermally reformed to generate a second reformed gas mixture, (iii) mixing the second reformed gas mixture and the first reformed gas mixture to form a combined reformed gas mixture, and (iv) using the combined reformed gas mixture to heat the catalyst filled tubes in the heat exchange reformer to form a partially-cooled combined reformed gas mixture, wherein the partially-cooled combined reformed gas mixture is used to pre-heat the second stream fed to the autothermal reformer.

Abstract: A process for the conversion of a hydrocarbon to CO2 and electrical power is described which includes subjecting a gas mixture of a hydrocarbon feed stream and steam to an integrated reforming process including stages of steam reforming in a gas-heated reformer and secondary reforming to generate a reformed gas mixture, increasing the hydrogen content of the reformed gas mixture by subjecting it to one or more water-gas-shift stages, cooling the resulting hydrogen-enriched reformed gas and separating condensed water therefrom, passing the resulting de-watered hydrogen-enriched reformed gas to one or more stages of carbon dioxide separation to recover carbon dioxide, combusting the remaining hydrogen-containing fuel stream with an oxygen containing gas in a gas turbine to generate electrical power and passing the exhaust gas mixture from the gas turbine to a heat recovery steam generation system that feeds one or more steam turbines to generate additional electrical power.

Abstract: A process for converting a hydrocarbon feedstock into a synthesis gas includes: (i) passing a first stream including a hydrocarbon and steam to externally-heated catalyst-filled tubes in a heat exchange reformer where steam reforming reactions take place to generate a first reformed gas mixture, (ii) passing a second stream including a hydrocarbon and steam, after a heating step, to an autothermal reformer, where it is combined with an oxidant gas containing free oxygen and autothermally reformed to generate a second reformed gas mixture, (iii) mixing the second reformed gas mixture and the first reformed gas mixture to form a combined reformed gas mixture, and (iv) using the combined reformed gas mixture to heat the catalyst filled tubes in the heat exchange reformer to form a partially-cooled combined reformed gas mixture, wherein the partially-cooled combined reformed gas mixture is used to pre-heat the second stream fed to the autothermal reformer.

Abstract: A process for the steam reforming of hydrocarbons comprises partially oxidising a feedgas comprising a hydrocarbon feedstock with an oxygen-containing gas in the presence of steam to form a partially oxidised hydrocarbon gas mixture at a temperature >1200° C. and passing the resultant partially oxidised hydrocarbon gas mixture through a bed of steam reforming catalyst, wherein the bed comprises a first layer and a second layer, each layer comprising a catalytically active metal on an oxidic support wherein the oxidic support for the first layer is a zirconia.

Abstract: A process for the steam reforming of hydrocarbons comprises partially oxidising a feedgas comprising a hydrocarbon feedstock with an oxygen-containing gas in the presence of steam to form a partially oxidised hydrocarbon gas mixture at a temperature >1200° C. and passing the resultant partially oxidised hydrocarbon gas mixture through a bed of steam reforming catalyst, wherein the bed comprises a first layer and a second layer, each layer comprising a catalytically active metal on an oxidic support wherein the oxidic support for the first layer is a zirconia.

Abstract: A process for the conversion of a hydrocarbon to CO2 and electrical power is described which includes subjecting a gas mixture of a hydrocarbon feed stream and steam to an integrated reforming process including stages of steam reforming in a gas-heated reformer and secondary reforming to generate a reformed gas mixture, increasing the hydrogen content of the reformed gas mixture by subjecting it to one or more water-gas-shift stages, cooling the resulting hydrogen-enriched reformed gas and separating condensed water therefrom, passing the resulting de-watered hydrogen-enriched reformed gas to one or more stages of carbon dioxide separation to recover carbon dioxide, combusting the remaining hydrogen-containing fuel stream with an oxygen containing gas in a gas turbine to generate electrical power and passing the exhaust gas mixture from the gas turbine to a heat recovery steam generation system that feeds one or more steam turbines to generate additional electrical power.

Abstract: An apparatus for steam reforming of hydrocarbons comprises a heat exchange reformer having disposed within a plurality of vertical catalyst-filled tubes, through which a gas mixture comprising hydrocarbon and steam may be passed, and to which heat may be transferred by means of a heat exchange medium flowing around the external tube surfaces, wherein heat exchange adapting means are provided within the reformer so that the tubes have a zone of lower heat exchange extending from the bottom of the catalyst up to 25% of the catalyst depth with no heat exchange enhancement means provided in that zone. A process for steam reforming of hydrocarbons employs this apparatus.

Abstract: An apparatus for steam reforming of hydrocarbons comprises a heat exchange reformer having disposed within a plurality of vertical catalyst-filled tubes, through which a gas mixture comprising hydrocarbon and steam may be passed, and to which heat may be transferred by means of a heat exchange medium flowing around the external tube surfaces, wherein heat exchange adapting means are provided within the reformer so that the tubes have a zone of lower heat exchange extending from the bottom of the catalyst up to 25% of the catalyst depth with no heat exchange enhancement means provided in that zone. A process for steam reforming of hydrocarbons employs this apparatus.

Abstract: A process for the steam reforming of hydrocarbons comprises partially oxidising a feedgas comprising a hydrocarbon feedstock with an oxygen-containing gas in the presence of steam to form a partially oxidised hydrocarbon gas mixture at a temperature >1200° C. and passing the resultant partially oxidised hydrocarbon gas mixture through a bed of steam reforming catalyst, wherein the bed comprises a first layer and a second layer, each layer comprising a catalytically active metal on an oxidic support wherein the oxidic support for the first layer is a zirconia.

Abstract: Heat exchange apparatus and process, particularly heat exchange primary reforming with the primary reformed gas being subjected to partial combustion (and optionally secondary reforming) and the resultant partially combusted gas being used as the heat exchange medium to supply heat required for the primary reforming. The apparatus includes process fluid inlet and outlet zones separated from the heat exchange zone by boundary means such as tube sheets or header pipes. A plurality of heat exchange tubes for a process fluid extending through a heat exchange zone from one of the boundary means and slideably engage at the other boundary means with seal tubes fastened to said other boundary means.