Abstract: A method for determining a carbon content value of a hydrocarbon-containing mixture. At least one composition-dependent bulk property of the hydrocarbon-containing mixture is measured and optionally at least one non-hydrocarbon component concentration is measured with the resulting measurements used in a carbon content correlation for calculating the carbon content of the hydrocarbon-containing mixture. The carbon content may be used in a hydrogen and/or synthesis gas production process for calculating a target flow rate of steam to be combined with the hydrocarbon-containing mixture to form a mixed feed having a target steam-to-carbon ratio.

Abstract: In a process for producing a hydrogen-containing gas, a hydrocarbon feed gas and steam are introduced into a reaction vessel containing a complex metal oxide and steam-hydrocarbon reforming catalyst thereby forming a combustible gas mixture comprising hydrogen. A regeneration gas comprising greater than 0.1 volume % oxygen up to and including 2 volume % oxygen is introduced into the reaction vessel to displace at least a portion of the combustible gas mixture from the reaction vessel. Subsequently, additional regeneration gases may be introduced into the reaction vessel. Numerous means for providing various regeneration gases are presented.

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 method for determining a carbon content value of a hydrocarbon-containing mixture. At least one composition-dependent bulk property of the hydrocarbon-containing mixture is measured and optionally at least one non-hydrocarbon component concentration is measured with the resulting measurements used in a carbon content correlation for calculating the carbon content of the hydrocarbon-containing mixture. The carbon content may be used in a hydrogen and/or synthesis gas production process for calculating a target flow rate of steam to be combined with the hydrocarbon-containing mixture to form a mixed feed having a target steam-to-carbon ratio.

Abstract: A staged steam hydrocarbon reformer is disclosed having a chamber within which convectively heated reformer stages are enclosed. The reformer stages are tubes containing steam reforming catalyst. The stages are in serial fluid communication with one another through mixing vessels positioned between each stage. The first reforming stage is fed a mixture of steam and a gaseous hydrocarbon. Partially reformed gases having increased hydrogen concentration are produced at each stage and are mixed with additional gaseous hydrocarbon and optionally steam in the mixing vessels. Collection and distribution manifolds provide fluid communication between the reformer stages and the mixing vessels. A method is also disclosed in which partially reformed gases from a preceding stage are mixed with gaseous hydrocarbon and steam having a lower steam to carbon ratio than the fresh feed to the previous stage.

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 method for generating hydrogen in a production facility having a catalytic steam reformer, a boiler downstream of the catalytic steam reformer, optionally having a prereformer, and optionally having a shift reactor, wherein the reformer feed gas mixture is formed using a steam-containing recycle gas mixture which was formed from boiler effluent. The boiler generates steam which may be used to form the reformer feed gas mixture, used elsewhere in the production facility, and/or used for export 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: 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 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 staged steam hydrocarbon reformer is disclosed having a chamber within which convectively heated reformer stages are enclosed. The reformer stages are tubes containing steam reforming catalyst. The stages are in serial fluid communication with one another through mixing vessels positioned between each stage. The first reforming stage is fed a mixture of steam and a gaseous hydrocarbon. Partially reformed gases having increased hydrogen concentration are produced at each stage and are mixed with additional gaseous hydrocarbon and optionally steam in the mixing vessels. Collection and distribution manifolds provide fluid communication between the reformer stages and the mixing vessels. A method is also disclosed in which partially reformed gases from a preceding stage are mixed with gaseous hydrocarbon and steam having a lower steam to carbon ratio than the fresh feed to the previous stage.

Abstract: A method and apparatus for the production of hydrogen-rich gas are provided. The method and apparatus prevent over-reduction of iron oxide-based shift catalyst by introducing an oxidative stream along with a carbon monoxide containing gaseous feed stream from a catalytic steam reformer to the catalyst bed region and thereby limits structural deterioration of the catalyst. Various sources may provide the oxidative stream including a shift catalyst bed region and a selective oxidation catalyst region.

Abstract: A method for determining a carbon content value of a hydrocarbon-containing mixture. At least one composition-dependent bulk property of the hydrocarbon-containing mixture is measured and optionally at least one non-hydrocarbon component concentration is measured with the resulting measurements used in a carbon content correlation for calculating the carbon content of the hydrocarbon-containing mixture. The carbon content may be used in a hydrogen and/or synthesis gas production process for calculating a target flow rate of steam to be combined with the hydrocarbon-containing mixture to form a mixed feed having a target steam-to-carbon ratio.

Abstract: A method for generating hydrogen in a production facility having a catalytic steam reformer, a boiler downstream of the catalytic steam reformer, optionally having a prereformer, and optionally having a shift reactor, wherein the reformer feed gas mixture is formed using a steam-containing recycle gas mixture which was formed from boiler effluent. The boiler generates steam which may be used to form the reformer feed gas mixture, used elsewhere in the production facility, and/or used for export steam.

Abstract: In a process for producing a hydrogen-containing gas, a hydrocarbon feed gas and steam are introduced into a reaction vessel containing a complex metal oxide and steam-hydrocarbon reforming catalyst thereby forming a combustible gas mixture comprising hydrogen. A regeneration gas comprising greater than 0.1 volume % oxygen up to and including 2 volume % oxygen is introduced into the reaction vessel to displace at least a portion of the combustible gas mixture from the reaction vessel. Subsequently, additional regeneration gases may be introduced into the reaction vessel. Numerous means for providing various regeneration gases are presented.

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 method and apparatus for the production of hydrogen-rich gas are provided. The method and apparatus prevent over-reduction of iron oxide-based shift catalyst by introducing an oxidative stream along with a carbon monoxide containing gaseous feed stream from a catalytic steam reformer to the catalyst bed region and thereby limits structural deterioration of the catalyst. Various sources may provide the oxidative stream including a shift catalyst bed region and a selective oxidation catalyst region.

Abstract: Method of making a product gas mixture comprising providing a first gas mixture, contacting the first gas mixture with a lean absorber liquid at a first pressure and absorbing a portion of the first gas mixture in the lean absorber liquid to provide a rich absorber liquid and a non-absorbed residual gas, pressurizing the rich absorber liquid provide a pressurized rich absorber liquid, stripping the pressurized rich absorber liquid with a stripping gas at a second pressure greater than the first pressure to provide a pressurized lean absorber liquid and the product gas mixture, and reducing the pressure of the pressurized lean absorber liquid to provide the lean absorber liquid at the first pressure.

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.