Abstract: The present invention relates to a method and furnace for generating straightened flames in a steam methane reformer or ethylene cracking furnace where fuel-staged burners are used. Fuel staging may be used for reducing NOx emissions. Criteria for generating straightened flames are provided. These criteria relate to oxidant conduit geometry and furnace geometry. Techniques for modifying the furnace and/or burners to achieve these criteria are also provided.

Abstract: A steam/hydrocarbon reformer employing a conventional radiantly heated first reformer section and a flue-gas heated second reformer section is disclosed. The second reformer section comprises catalyst-containing tubes for partially reforming a hydrocarbon stream. The catalyst-containing tubes in the second reformer section are disposed in a conduit for conveying flue gas from the first reformer section, thereby receiving heat from the flue gases. The flue gases flow either cocurrent or countercurrent to the process gas in the catalyst-containing tubes in the second reformer section. The partially reformed hydrocarbon stream from the second reformer section is fed to the catalyst-containing tubes in the first reformer section thereby producing a hydrogen-rich synthesis gas.

Abstract: A process for adiabatically prereforming a feedstock, includes: providing an adiabatic reactor; providing a catalyst containing 1-20 wt. % nickel and 0.4-5 wt. % potassium, wherein the catalyst has an overall catalyst porosity of 25-50% with 20-80% of the overall catalyst porosity contributed by pores having pore diameters of at least 500 ?; providing the feedstock containing natural gas and steam, wherein the natural gas contains an initial concentration of higher hydrocarbons, and a ratio of steam to natural gas in the feedstock is from 1.5:1 to 5:1; preheating the feedstock to a temperature of 300-700° C. to provide a heated feedstock; providing the heated feedstock to the reactor; and producing a product containing hydrogen, carbon monoxide, carbon dioxide, unreacted methane, and steam, wherein said product contains a reduced concentration of higher hydrocarbons less than the initial concentration of higher hydrocarbons, to prereform the feedstock.

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.