Abstract: An apparatus and process for the activation of catalyst material utilized in ammonia cracking can include an initial use of hydrogen and heat to perform an initial stage of catalyst activation and a subsequent use of ammonia and heat to perform a subsequent state of catalyst activation. The subsequent use of ammonia can be configured so that different catalytic material at different plant elements are activated in a pre-selected sequence to provide activation of the catalytic material utilized in different plant elements. Some embodiments can be configured to avoid excess temperatures that can be detrimental to equipment that can be positioned upstream of a furnace in some embodiments while also avoiding sintering of the catalytic material.

Abstract: Residual ammonia is removed effectively from ammonia cracked gas in a hydrogen PSA system using a non-zeolitic adsorbent such as activated carbon, activated alumina or silica gel.

Abstract: Ammonia cracking process in which cracked gas is purified in a PSA system are improved by converting residual ammonia in the first cracked gas into further hydrogen and nitrogen by feeding PSA tail gas, or a gas derived therefrom, to a secondary cracking reactor and further processing the second cracked gas.

Abstract: NOx impurities in a flue gas generated in an ammonia cracking process may be removed from the flue gas by selective catalytic reduction (SCR) using an aqueous ammonia solution produced by cooling compressed tail gas from a hydrogen PSA device purifying the cracked gas.

Abstract: Recovery of a renewable hydrogen product from an ammonia cracking process, in which the cracked gas is purified in a first PSA device and at least a portion of the first PSA tail gas is recycled as fuel to reduce the carbon intensity of the renewable hydrogen product.

Abstract: Reduction of the water content of ammonia used in an ammonia cracking process allows the use of water intolerant cracking catalysts. The water removal process can also be used to recover and recycle ammonia from the cracked gas.

Abstract: The invention concerns a process and apparatus for cracking ammonia in which heated ammonia gas at super-atmospheric pressure is partially cracked in at least two adiabatic reactors in series with interstage heating in which the feed temperature to a first reactor is higher than the feed temperature to a further reactor to produce a partially cracked ammonia gas which is then fed to catalyst-containing reactor tubes in a furnace to produce a cracked gas comprising hydrogen gas, nitrogen gas and residual ammonia gas. The use of the adiabatic reactors enables more efficient heat integration within the process and the higher temperature in the first reactor enables the use of a nickel-based catalyst in that reactor as an alternative solution to the potential problem of the presence of oil in the ammonia.

Abstract: The present invention concerns a process for cracking ammonia comprising providing an ammonia-containing feed gas at a temperature of over 600° C. and a pressure in a range from about 5 bar to about 50 bar; combusting a fuel with an oxidant gas in a furnace to heat reactor tubes to achieve a maximum inner wall temperature of over 700° C. and produce a flue gas, each reactor tube comprising a catalyst bed comprising a first row transition metal-based catalyst; and feeding the ammonia-containing feed gas to the reactor tubes to produce a cracked gas at a temperature of over 600° C. on exit from the reactor tubes.

Abstract: The present invention concerns a process and apparatus for cracking ammonia gas at super-atmospheric pressure in catalyst-filled reactor tubes in a furnace. The tubes each have an upstream layer of a first catalyst and a downstream layer of a second catalyst, the first catalyst being more active than the second catalyst. Having the more active catalyst upstream reduces the temperature of the outer walls of the tubes in the region of the burner flames and the temperature of the inner walls of the tubes in the region with the highest mole fraction of ammonia. Nitriding of the metal of the tubes in this region is thereby reduced.

Abstract: Processes for cracking ammonia are improved by using heat generated in a compression unit that is used to compress PSA off gas being recycled to a PSA unit to pre-heat liquid ammonia prior to vaporization and cracking. The heat is transferred using a heat transfer fluid such as an aqueous solution comprising from about 50 wt. % to about 60 wt. % of a glycol, e.g., ethylene glycol or propylene glycol.

Abstract: The invention concerns a process and apparatus for cracking ammonia in which heated ammonia gas at super-atmospheric pressure is partially cracked catalytically in an adiabatic reaction unit to produce partially cracked ammonia gas which is heated and fed to catalyst-containing reactor tubes in a furnace to cause cracking of further ammonia and produce a cracked gas comprising hydrogen gas, nitrogen gas and residual ammonia gas. At least some, preferably all, of the duty required to heat the partially cracked ammonia gas is provided by heat exchange with the cracked gas, enabling more efficient heat integration within the process.

Abstract: Process and apparatus for producing a hydrogen-containing product by steam-hydrocarbon reforming of multiple hydrocarbon feedstocks in a production facility utilizing a prereformer in addition to the primary reformer. The temperature of the reactant mixture introduced into the prereformer is controlled depending on the composition of the reactant mixture fed to the prereformer.

Abstract: Process and apparatus for producing a hydrogen-containing product by steam-hydrocarbon reforming of multiple hydrocarbon feedstocks in a production facility utilizing a prereformer in addition to the primary reformer. The temperature of the reactant mixture introduced into the prereformer is controlled depending on the composition of the reactant mixture fed to the prereformer.

Abstract: Process and apparatus for producing a hydrogen-containing product by steam-hydrocarbon reforming of multiple hydrocarbon feedstocks in a production facility utilizing a prereformer in addition to the primary reformer. The temperature of the reactant mixture introduced into the prereformer is controlled depending on the composition of the reactant mixture fed to the prereformer.

Abstract: Process and apparatus for producing a hydrogen-containing product by steam-hydrocarbon reforming of multiple hydrocarbon feedstocks in a production facility utilizing a prereformer in addition to the primary reformer. The temperature of the reactant mixture introduced into the prereformer is controlled depending on the composition of the reactant mixture fed to the prereformer.

Abstract: Hydrogen production process and apparatus using a combined stream of gas turbine exhaust from a gas turbine and combustion air from forced draft fan as combustion oxidant in a steam reforming furnace. A valve assembly for providing draft air is included to quickly provide additional combustion air to the reformer furnace when the gas turbine unexpectedly shuts down.

Abstract: Hydrogen production process and apparatus using a combined stream of gas turbine exhaust from a gas turbine and combustion air from forced draft fan as combustion oxidant in a steam reforming furnace. A valve assembly for providing draft air is included to quickly provide additional combustion air to the reformer furnace when the gas turbine unexpectedly shuts down.