Abstract: A system is set forth for the exothermic generation of soot depleted syngas comprising (i) reacting a hydrocarbon-containing fuel with an oxygen containing gas in a first reactor to produce the syngas and byproducts comprising CO2, H2O and soot; and (ii) introducing the syngas and byproducts into a second reactor containing a non-carbonaceous material that traps the soot for a sufficient time such that the majority of the byproduct soot is gasified via reaction with the byproduct CO2 and/or H2O to produce a syngas stream that is depleted in the soot. The system is particularly suitable for the practice of heat exchange reforming wherein a portion of the heat is recovered from the soot depleted syngas stream and used as at least a portion of the heat to facilitate the additional production of syngas via the (endothermic) catalytic reforming of natural gas and steam.

Abstract: Reactive diluent fluid (22) is introduced into a stream of synthesis gas (or “syngas”) produced in a heat-generating unit such as a partial oxidation (“POX”) reactor (12) to cool the syngas and form a mixture of cooled syngas and reactive diluent fluid. Carbon dioxide and/or carbon components and/or hydrogen in the mixture of cooled syngas and reactive diluent fluid is reacted (26) with at least a portion of the reactive diluent fluid in the mixture to produce carbon monoxide-enriched and/or solid carbon depleted syngas which is fed into a secondary reformer unit (30) such as an enhanced heat transfer reformer in a heat exchange reformer process. An advantage of the invention is that problems with the mechanical integrity of the secondary unit arising from the high temperature of the syngas from the heat-generating unit are avoided.

Abstract: A steam-hydrocarbon reforming process and apparatus wherein reformate from a prereformer is reacted in a gas heated reformer which is heated by reformed gas from a primary reformer. Reformate from the gas heated reformer is passed to the primary reformer as feed gas.

Abstract: A tubular reactor for producing a product mixture in a tubular reactor where the tubular reactor comprises an internal catalytic insert with cup-shaped structures having orifices for forming fluid jets for impinging the fluid on the tube wall. Jet impingement is used to improve heat transfer between the fluid in the tube and the tube wall in a non-adiabatic reactor. The tubular reactor and method may be used for endothermic reactions such as steam methane reforming and for exothermic reactions such as methanation.

Abstract: Reactive diluent fluid (22) is introduced into a stream of synthesis gas (or “syngas”) produced in a heat-generating unit such as a partial oxidation (“POX”) reactor (12) to cool the syngas and form a mixture of cooled syngas and reactive diluent fluid. Carbon dioxide and/or carbon components and/or hydrogen in the mixture of cooled syngas and reactive diluent fluid is reacted (26) with at least a portion of the reactive diluent fluid in the mixture to produce carbon monoxide-enriched and/or solid carbon depleted syngas which is fed into a secondary reformer unit (30) such as an enhanced heat transfer reformer in a heat exchange reformer process. An advantage of the invention is that problems with the mechanical integrity of the secondary unit arising from the high temperature of the syngas from the heat-generating unit are avoided.

Abstract: A steam-hydrocarbon reforming process and apparatus wherein reformate from a prereformer is reacted in a gas heated reformer which is heated by reformed gas from a primary reformer. Reformate from the gas heated reformer is passed to the primary reformer as feed gas.

Abstract: A process for producing a hydrogen-containing product gas by catalytic steam-hydrocarbon reforming with an overall steam-to-carbon molar ratio between 1.5 and 2.4 for the process. The process stream is reacted in at least two prereformers prior to reaction in catalyst-containing tubes in a top-fired reformer furnace. The process stream is reacted adiabatically in the first prereformer, while the process stream is heated prior to being introduced into the second prereformer and/or the second prereformer is heated. The process avoids carbon formation on the catalyst in the catalyst-containing tubes in the primary reformer.

Abstract: A steam-hydrocarbon reforming process and apparatus wherein reformate from a prereformer is reacted in a gas heated reformer which is heated by reformed gas from a primary reformer. Reformate from the gas heated reformer is passed to the primary reformer as feed gas.

Abstract: A steam-hydrocarbon reforming process and apparatus wherein reformate from a prereformer is reacted in a gas heated reformer which is heated by reformed gas from a primary reformer. Reformate from the gas heated reformer is passed to the primary reformer as feed gas.

Abstract: An ion transport membrane system comprising (a) a pressure vessel having an interior, an exterior, an inlet, and an outlet; (b) a plurality of planar ion transport membrane modules disposed in the interior of the pressure vessel and arranged in series, each membrane module comprising mixed metal oxide ceramic material and having an interior region and an exterior region, wherein any inlet and any outlet of the pressure vessel are in flow communication with exterior regions of the membrane modules; and (c) one or more gas manifolds in flow communication with interior regions of the membrane modules and with the exterior of the pressure vessel. The ion transport membrane system may be utilized in a gas separation device to recover oxygen from an oxygen-containing gas or as an oxidation reactor to oxidize compounds in a feed gas stream by oxygen permeated through the mixed metal oxide ceramic material of the membrane modules.

Abstract: An ion transport membrane system comprising (a) a pressure vessel having an interior, an exterior, an inlet, and an outlet; (b) a plurality of planar ion transport membrane modules disposed in the interior of the pressure vessel and arranged in series, each membrane module comprising mixed metal oxide ceramic material and having an interior region and an exterior region, wherein any inlet and any outlet of the pressure vessel are in flow communication with exterior regions of the membrane modules; and (c) one or more gas manifolds in flow communication with interior regions of the membrane modules and with the exterior of the pressure vessel. The ion transport membrane system may be utilized in a gas separation device to recover oxygen from an oxygen-containing gas or as an oxidation reactor to oxidize compounds in a feed gas stream by oxygen permeated through the mixed metal oxide ceramic material of the membrane modules.

Abstract: A tubular reactor for producing a product mixture in a tubular reactor where the tubular reactor comprises an internal catalytic insert with cup-shaped structures having orifices for forming fluid jets for impinging the fluid on the tube wall. Jet impingement is used to improve heat transfer between the fluid in the tube and the tube wall in a non-adiabatic reactor. The tubular reactor and method may be used for endothermic reactions such as steam methane reforming and for exothermic reactions such as methanation.

Abstract: A process for producing a hydrogen-containing product gas by catalytic steam-hydrocarbon reforming with an overall steam-to-carbon molar ratio between 1.5 and 2.4 for the process. The process stream is reacted in at least two prereformers prior to reaction in catalyst-containing tubes in a top-fired reformer furnace. The process stream is reacted adiabatically in the first prereformer, while the process stream is heated prior to being introduced into the second prereformer and/or the second prereformer is heated. The process avoids carbon formation on the catalyst in the catalyst-containing tubes in the primary reformer.

Abstract: Reactive diluent fluid (22) is introduced into a stream of synthesis gas (or “syngas”) produced in a heat-generating unit such as a partial oxidation (“POX”) reactor (12) to cool the syngas and form a mixture of cooled syngas and reactive diluent fluid. Carbon dioxide and/or carbon components and/or hydrogen in the mixture of cooled syngas and reactive diluent fluid is reacted (26) with at least a portion of the reactive diluent fluid in the mixture to produce carbon monoxide-enriched and/or solid carbon depleted syngas which is fed into a secondary reformer unit (30) such as an enhanced heat transfer reformer in a heat exchange reformer process. An advantage of the invention is that problems with the mechanical integrity of the secondary unit arising from the high temperature of the syngas from the heat-generating unit are avoided.

Abstract: Reactive diluent fluid (22) is introduced into a stream of synthesis gas (or “syngas”) produced in a heat-generating unit such as a partial oxidation (“POX”) reactor (12) to cool the syngas and form a mixture of cooled syngas and reactive diluent fluid. Carbon dioxide and/or carbon components and/or hydrogen in the mixture of cooled syngas and reactive diluent fluid is reacted (26) with at least a portion of the reactive diluent fluid in the mixture to produce carbon monoxide-enriched and/or solid carbon depleted syngas which is fed into a secondary reformer unit (30) such as an enhanced heat transfer reformer in a heat exchange reformer process. An advantage of the invention is that problems with the mechanical integrity of the secondary unit arising from the high temperature of the syngas from the heat-generating unit are avoided.

Abstract: A catalyst for adiabatically prereforming a feedstock wherein the catalyst comprises 1 to 20 wt. % nickel and 0.4 to 5 wt. % potassium on a calcium aluminate support. The overall catalyst porosity is greater than 40% with greater than 70% of the overall catalyst porosity contributed by pores having pore diameters of at least 500 ?, and having a median pore diameter greater than 2600 ?, and having a nitrogen BET area less than 6.5 m2/g.

Abstract: The present invention relates to a process for producing a hydrogen-containing gas. The process comprises introducing a regeneration gas into a hydrogen reaction vessel containing solid packing material thereby at least partially regenerating the solid packing material and forming an effluent gas from the regeneration gas. At least a portion of the effluent gas is introduced into another hydrogen reaction vessel containing solid packing material. The effluent gas may be used, for example, to purge the other hydrogen reaction vessel and/or regenerate the solid packing material in the other hydrogen reaction vessel. Solid packing materials may include at least one of a complex metal oxide, a steam hydrocarbon reforming catalyst, an oxygen ion conducting ceramic, a hydrocarbon partial oxidation catalyst, and a hydrocarbon cracking catalyst.

Abstract: A system is set forth for the exothermic generation of soot depleted syngas comprising (i) reacting a hydrocarbon-containing fuel with an oxygen containing gas in a first reactor to produce the syngas and byproducts comprising CO2, H2O and soot; and (ii) introducing the syngas and byproducts into a second reactor containing a non-carbonaceous material that traps the soot for a sufficient time such that the majority of the byproduct soot is gasified via reaction with the byproduct CO2 and/or H2O to produce a syngas stream that is depleted in the soot. The system is particularly suitable for the practice of heat exchange reforming wherein a portion of the heat is recovered from the soot depleted syngas stream and used as at least a portion of the heat to facilitate the additional production of syngas via the (endothermic) catalytic reforming of natural gas and steam.

Abstract: A process for generating synthesis gas wherein a reactant gas mixture comprising steam and a light hydrocarbon is introduced into a tubular reactor comprising a catalyzed structured packing at higher inlet mass rates than conventional tubular reactors containing random packing catalyst pellets or catalyzed structure packing.

Abstract: A catalyst for adiabatically prereforming a feedstock wherein the catalyst comprises 1 to 20 wt. % nickel and 0.4 to 5 wt. % potassium on a calcium aluminate support. The overall catalyst porosity is greater than 40% with greater than 70% of the overall catalyst porosity contributed by pores having pore diameters of at least 500 ?, and having a median pore diameter greater than 2600 ?, and having a nitrogen BET area less than 6.5 m2/g.