Abstract: Methods and systems for making ammonia are provided. The method can include heating a first compressed syngas to produce a heated first syngas. The heated first syngas and a second compressed syngas can be combined to produce a combined syngas. The combined syngas can be reacted within a first ammonia converter and a second ammonia converter to produce an ammonia product. Heat from the ammonia product can be transferred to a first heat transfer medium to produce a first cooled product and a second heat transfer medium. Heat from the first cooled product can be transferred to a third heat transfer medium to produce a second cooled product. Heat from the second cooled product can be transferred to the combined syngas to produce a third cooled product. The third cooled product can be separated to produce a purified ammonia product and a recycle gas.

Abstract: Methods and systems for making ammonia are provided. The method can include converting carbon monoxide in a first syngas to carbon dioxide to produce a shifted syngas. At least a portion of the carbon dioxide can be separated from the shifted syngas to produce a carbon dioxide-lean syngas. Carbon monoxide and/or carbon dioxide in the carbon dioxide-lean syngas can be converted to methane to produce a methanated first syngas. A second syngas can be separated to produce a purified second syngas and a waste gas. The methanated first syngas and the purified second syngas can be combined to produce an ammonia feedstock. The ammonia feedstock can have a hydrogen to nitrogen molar ratio of about 3.5:1 to about 2.5:1. At least a portion of the hydrogen and nitrogen in the ammonia feedstock can be reacted to produce an ammonia product.

Abstract: Systems and methods for producing syngas and ammonia are provided. The method can include reforming a hydrocarbon in a first reaction zone in the presence of one or more first catalysts and steam at conditions sufficient to produce an effluent comprising a portion of the hydrocarbon, carbon monoxide, carbon dioxide, and hydrogen. The effluent can be reformed in a second reaction zone in the presence of one or more second catalysts and nitrogen at conditions sufficient to produce a syngas comprising methane, hydrogen, nitrogen, carbon monoxide, and carbon dioxide, or any combination thereof. At least a portion of the nitrogen and hydrogen in the syngas can be converted to ammonia to produce an ammonia effluent. The ammonia effluent can be separated to produce an ammonia product and a purge gas comprising nitrogen. At least a portion of the purge gas can be recycled to the hydrocarbon, the effluent, or a combination thereof.

Abstract: Apparatus, systems, and processes for reforming hydrocarbons are provided. The process can include reforming a first hydrocarbon in the presence of steam and one or more first catalysts in a first reformer to produce a first reformed hydrocarbon. The process can also include reforming the first reformed hydrocarbon in the presence of one or more second catalysts in a second reformer to produce a second reformed hydrocarbon. The process can also include reforming a second hydrocarbon in the presence of steam and one or more third catalysts in a third reformer to produce a third reformed hydrocarbon, where heat from the second reformed hydrocarbon is transferred to the second hydrocarbon to support reforming of the second hydrocarbon.

Abstract: Methods and systems for making ammonia are provided. The method can include converting carbon monoxide in a first syngas to carbon dioxide to produce a shifted syngas. At least a portion of the carbon dioxide can be separated from the shifted syngas to produce a carbon dioxide-lean syngas. Carbon monoxide and/or carbon dioxide in the carbon dioxide-lean syngas can be converted to methane to produce a methanated first syngas. A second syngas can be separated to produce a purified second syngas and a waste gas. The methanated first syngas and the purified second syngas can be combined to produce an ammonia feedstock. The ammonia feedstock can have a hydrogen to nitrogen molar ratio of about 3.5:1 to about 2.5:1. At least a portion of the hydrogen and nitrogen in the ammonia feedstock can be reacted to produce an ammonia product.

Abstract: Methods and systems for making ammonia are provided. The method can include heating a first compressed syngas to produce a heated first syngas. The heated first syngas and a second compressed syngas can be combined to produce a combined syngas. The combined syngas can be reacted within a first ammonia converter and a second ammonia converter to produce an ammonia product. Heat from the ammonia product can be transferred to a first heat transfer medium to produce a first cooled product and a second heat transfer medium. Heat from the first cooled product can be transferred to a third heat transfer medium to produce a second cooled product. Heat from the second cooled product can be transferred to the combined syngas to produce a third cooled product. The third cooled product can be separated to produce a purified ammonia product and a recycle gas.

Abstract: Systems and methods for producing syngas and ammonia are provided. The method can include reforming a hydrocarbon in a first reaction zone in the presence of one or more first catalysts and steam at conditions sufficient to produce an effluent comprising a portion of the hydrocarbon, carbon monoxide, carbon dioxide, and hydrogen. The effluent can be reformed in a second reaction zone in the presence of one or more second catalysts and nitrogen at conditions sufficient to produce a syngas comprising methane, hydrogen, nitrogen, carbon monoxide, and carbon dioxide, or any combination thereof. At least a portion of the nitrogen and hydrogen in the syngas can be converted to ammonia to produce an ammonia effluent. The ammonia effluent can be separated to produce an ammonia product and a purge gas comprising nitrogen. At least a portion of the purge gas can be recycled to the hydrocarbon, the effluent, or a combination thereof.

Abstract: Apparatus, systems, and processes for reforming hydrocarbons are provided. The process can include reforming a first hydrocarbon in the presence of steam and one or more first catalysts in a first reformer to produce a first reformed hydrocarbon. The process can also include reforming the first reformed hydrocarbon in the presence of one or more second catalysts in a second reformer to produce a second reformed hydrocarbon. The process can also include reforming a second hydrocarbon in the presence of steam and one or more third catalysts in a third reformer to produce a third reformed hydrocarbon, where heat from the second reformed hydrocarbon is transferred to the second hydrocarbon to support reforming of the second hydrocarbon.

Abstract: Recycling a portion of autothermal reformer effluent into the steam-hydrocarbon feed stream with a thermo-compressor ejector is disclosed, using the preheated feed mixture as motive fluid. Syngas recycle-motive fluid molar ratios are 0.2-1.0, selected to optimize the overall configuration. The recycle introduces hydrogen and steam into the feed, and elevates the feed temperature, for operating the reformer in a soot-free regime. There is some pressure drop between the raw feed steam-natural gas mixture and the reformer feed, which requires the raw feed mixture to be supplied at a higher pressure, but this is offset by the lower pressure drop in the process heater and other upstream and downstream equipment due to lower quantities of steam. The feed pre-heater can have a lower duty, and the upstream and downstream equipment can be reduced in size, while the size of the autothermal reformer is about the same compared to the size needed for operation without effluent recycle.

Abstract: Recycling a portion of autothermal reformer effluent into the steam-hydrocarbon feed stream with a thermo-compressor ejector is disclosed, using the preheated feed mixture as motive fluid. Syngas recycle-motive fluid molar ratios are 0.2-1.0, selected to optimize the overall configuration. The recycle introduces hydrogen and steam into the feed, and elevates the feed temperature, for operating the reformer in a soot-free regime. There is some pressure drop between the raw feed steam-natural gas mixture and the reformer feed, which requires the raw feed mixture to be supplied at a higher pressure, but this is offset by the lower pressure drop in the process heater and other upstream and downstream equipment due to lower quantities of steam. The feed pre-heater can have a lower duty, and the upstream and downstream equipment can be reduced in size, while the size of the autothermal reformer is about the same compared to the size needed for operation without effluent recycle.