Abstract: An exothermic reaction and an endothermic reaction are thermally combined in a reactor having at least one oxygen selective ion transport membrane that provides the exothermic reaction with oxygen from an oxygen-containing gas such as air. The thermal requirements of the endothermic reaction are satisfied by the exothermic reaction. Dependent on the reactor design employed, the exothermic and endothermic reactions may be gaseously combined.

Abstract: Partial oxidation of hydrocarbons to produce hydrogen and carbon monoxide is carried out by a fixed bed or a fluidized bed process which includes the steps of passing steam and/or carbon dioxide through a perovskite-type ceramic mixed conductor in an adsorption zone at an elevated temperature, thereby at least partially saturating the mixed conductor with oxygen and producing hydrogen and/or carbon monoxide, and subsequently contacting the hot, at least partially oxygen-saturated mixed conductor with a hydrocarbon in a partial oxidation reaction zone. During the partial oxidation reaction phase of the process, the sorbed oxygen reacts with the hydrocarbon, thereby producing hydrogen and carbon monoxide.

Abstract: Diatomic hydrogen and unsaturated hydrocarbons are produced as reactor gases in a fast quench reactor. During the fast quench, the unsaturated hydrocarbons are further decomposed by reheating the reactor gases. More diatomic hydrogen is produced, along with elemental carbon. Other gas may be added at different stages in the process to form a desired end product and prevent back reactions. The product is a substantially clean-burning hydrogen fuel that leaves no greenhouse gas emissions, and elemental carbon that may be used in powder form as a commodity for several processes.

Abstract: A process for the preparation of a synthesis gas containing hydrogen and carbon monoxide by a combination of catalytic partial oxidation and further an autothermal reforming process, comprising

Abstract: A method of preparing a catalyst, including molding a mixture of magnesium oxide with a binder selected from carbon, fatty acids having 12-22 carbon atoms, magnesium salts of fatty acids having 12-22 carbon atoms, carboxymethyl cellulose, a magnesium salt of carboxymethyl cellulose and polyvinyl alcohol and calcining the molded mixture to obtain a carrier having a specific surface area of 5 m2/g of less. The carrier is impregnated with an aqueous solution containing Rh and/or Ru compounds for loading a catalytic metal component and then dried and calcined. The catalyst is used for reforming a lower hydrocarbon gas with steam and carbon dioxide or with carbon dioxide to produce a synthesis gas.

Abstract: Partial oxidation of hydrocarbons to produce hydrogen and carbon monoxide is carried out by a cyclical process which includes passing air through a perovskite ceramic substance at elevated temperature, thereby adsorbing oxygen from the air, and subsequently contacting the hot oxygen-containing ceramic substance with a hydrocarbon. During the partial oxidation reaction phase of the process, the sorbed oxygen reacts with the hydrocarbon, thereby producing the desired gas products and regenerating the adsorbent for the next cycle of the process.

Abstract: A process and apparatus for producing and burning synthesis gas. Carbonaceous waste material is pyrolytically decomposed in a primary reactor in the presence of steam to produce raw product gas containing H2 and CO. The raw product gas and CO2 is then introduced into a coke containing secondary reactor under pyrolyzing conditions, so that the CO2 and coke react to produce combustible gas having an increased CO content. The combustible gas is mixed with oxygen and CO2 to produce a combustible mixture which is burned as a fuel to produce heat, CO2 and H2O. A portion of the produced CO2 is recovered and used as the source of CO2 gas in the combustible mixture and as a source of CO2 gas for the secondary reactor. Preferably filters and scrubbers are used in a closed loop system to avoid undesirable emissions into the environment.

Abstract: Disclosed are a catalyst for producing a synthesis gas using a carbon-containing organic compound as a raw material and a process for producing carbon monoxide. The catalyst for producing a synthesis gas is composed of a carrier formed of a metal oxide and at least one catalytic metal selected from rhodium, ruthenium, iridium, palladium and platinum and supported on the carrier and is characterized in that the catalyst has a specific surface area of 25 m2/g or less, in that the electronegativity of the metal ion of the carrier metal oxide is 13.0 or less and in that the amount of the supported catalytic metal is 0.0005-0.1 mole %, in terms of a metal, based on the carrier metal oxide.

Abstract: Process for preparation of a hydrogen and/or carbon monoxide rich gas by catalytic autothermal reforming of a hydrocarbon feedstock containing higher hydrocarbons in an autothermal reformer comprising the further steps of (a) passing the hydrocarbon feedstock through a reactor containing steam reforming catalyst to remove or reduce the contents of higher hydrocarbons in the hydrocarbon feedstock; (b) passing the effluent from the first reactor to an autothermal reformer; and (c) withdrawing from the autothermal reformer a product gas rich in hydrogen and carbon monoxide.

Abstract: Process for producing a CO/H2/N2 atmosphere through the oxidation of a gaseous hydrocarbon by an oxygen-containing medium in a catalytic bed reactor. The oxygen-containing medium is an O2N2 residual coming from a liquid removed from the bottom of a fractionating column for the production of gaseous nitrogen or the residual including nitrogen and oxygen, coming from the waste of an apparatus for separating air by a membrane technique. The invention includes a plant for carrying out the process.

Abstract: Catalysts comprising a catalytically active metal on a NiO—MgO coated porous metal alloy support that are active for catalyzing the oxidative conversion of methane to CO and H2 are disclosed. The preferred catalytically active metal is rhodium and the porous metal alloy support is preferably a perforated fecralloy foil. A method of making the catalysts and coated supports, and processes for using the new catalysts for converting light hydrocarbons, such as methane, to synthesis gas, are disclosed.

Abstract: The present invention relates to a method of containing nickel into the alumina aerogel prepared by sol-gel method and supercritical drying and of preparing the nickel-alumina hybrid aerogel catalyst. The nickel-alumina catalyst prepared in the present invention has an excellent reactivity with a prolonged lifetime.

Abstract: Thermally integrated monolith catalysts active for catalyzing the oxidative conversion of methane to CO and H2 are disclosed. The composition and multi-layer configuration facilitates heat balancing between exothermic and endothermic reactions that take place in different sections of the monolith in a short contact time syngas reactor. The monolith comprises an active catalyst material supported by a multi-layer structure made of thin, porous metal pieces, the opposing faces of which are joined together at their perimeters. The metal pieces may be perforated disks made of at least two metals or metal oxides, and may also include a metal oxide coating.

Abstract: A method is disclosed for converting light hydrocarbons to synthesis gas employing a reduced nickel alloy monolith catalyst which catalyzes a net partial oxidation reaction. Certain preferred catalysts comprise bulk Ni—Cr, Ni—Co—Cr or Ni—Rh alloy materials. A method of making a bulk nickel alloy catalyst includes depositing a combination of chromium and cobalt metals, or rhodium metal, onto a nickel metal substrate and then thermally diffusing the Cr and Co coating, or the Rh coating, into the atomic lattice of the nickel substrate to produce a bulk Ni—Co—Cr or Ni—Rh alloy monolith catalyst. Preferred 3—D catalyst configurations include perforated foil, metal gauze, metal foam and expanded metal. The catalysts are mechanically strong and self-supporting, and retain high activity and selectivity to carbon monoxide and hydrogen products under syngas production conditions of high flow rate, superatmospheric pressure and high temperature.

Abstract: This invention provides a process for the catalytic partial oxidation of a hydrocarbon feedstock by contacting a feed stream including a hydrocarbon feedstock and an oxygen-containing gas with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream including carbon monoxide and hydrogen. The process of this invention is characterized by using an unsupported porous catalyst containing rhodium, such as rhodium foam.

Abstract: Reticulated ceramic monolithic catalysts and non-poisoning catalyst supports comprising one or more metal oxides of chromium, cobalt, nickel, an alkaline earth, a rare earth, or another sinterable metal oxide that are active in any of various chemical oxidation reactions are disclosed. Methods of making the new reticulated ceramic structures comprising impregnating an organic foam or other pore-templating material are also disclosed. Processes for the catalytic conversion of light hydrocarbons to products comprising carbon monoxide and hydrogen employing reticulated ceramic catalysts are described.

Abstract: A process for autothermal catalytic steam reforming of hydrocarbons by passing a reactant mixture of hydrocarbons, oxygen and water or water vapor, heated to a preheating temperature, over a catalyst. The process is operated adiabatically and the catalyst has a coating of a catalyst material on a support structure, the catalyst material containing at least one platinum group metal on an oxidic support material which can be aluminum oxide, silicon dioxide, titanium dioxide or mixed oxides thereof and zeolites.

Abstract: Catalysts and processes for the catalytic conversion of hydrocarbons to carbon monoxide and hydrogen employing new families of chromium-rare earth based catalysts are disclosed. One highly active and selective catalyst system, providing greater than 95% CH4 conversion, and 97-98% selectivity to CO and H2 by a net catalytic partial oxidation reaction, is a Ce—Cr—Ni containing compound. A preferred process for the catalytic conversion of a hydrocarbon comprises contacting a feed stream comprising a methane-containing hydrocarbon feedstock and an oxygen-containing gas with a chromium-rare earth containing catalyst in a short contact time reactor maintained at partial oxidation promoting conditions effective to produce synthesis gas.

Abstract: Disclosed is a process for producing a synthesis gas by an autothermal reforming method including a step of partially oxidizing a carbon-containing organic compound to produce a high temperature mixed gas, and a synthesis producing step of reacting the unreacted carbon-containing organic compound contained in the high temperature mixed gas with carbon dioxide and/or steam, wherein a catalyst having a considerably suppressed carbon deposition activity is used as a catalyst for the synthesis gas producing step. The catalyst is characterized in that the catalyst comprises a carrier formed of a metal oxide, and at least one catalytic metal selected from rhodium, ruthenium, iridium, palladium and platinum and supported on the carrier, in that the catalyst has a specific surface area of 25 m2/g or less, in that metal ion of the carrier metal oxide has electronegativity of 13.0 or less, and in that the amount of the catalytic metal supported is 0.0005-0.

Abstract: Processes for the catalytic conversion of hydrocarbons to carbon monoxide and hydrogen employing new chromium-based catalysts are disclosed. One highly active and selective catalyst system, providing greater than 95% CH4 conversion, and 97-98 % selectivity to CO and H2, is a chromium-containing catalyst consisting of a CoCr2O4 cubic spinel precursor dispersed in a chromium oxide matrix. Some other preferred catalysts compositions comprise nickel-chromium containing and rare earth-chromium containing compounds.

Abstract: Process for the preparation of a hydrogen and/or carbon monoxide rich gas from a hydrocarbon feedstock comprising partial oxidation of the feedstock with an oxidant supplied by permeation through a membrane and steam reforming of the feedstock in presence of a steam reforming catalyst being arranged on permeation side of the membrane, wherein steam reforming activity of catalyst is reduced at inlet region of the catalyst bed.

Abstract: Syngas catalyst compositions supported on refractory ceramic textiles and fibrous ceramic composite catalysts are disclosed, together with their methods of making and use for catalyzing syngas production from methane by a net partial oxidation reaction. In certain preferred embodiments the active catalyst material is Rh, Ni, Cr, or combinations thereof. The ceramic textiles may be arranged in a variety of 3-D forms, such as Nextel™ or various woven or braided meshes and layers. The ceramic textile is easier to scale up to commercial reactor dimensions than the conventional foams and monoliths comprising ceramics and metals. Tolerance to thermal expansion and thermal heat integration are also improved by the new catalysts. A synthesis gas production process employs a new ceramic composite catalyst in a fixed reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream comprising carbon monoxide and hydrogen in a molar ratio of about 2:1 H2/CO.

Abstract: A method is disclosed for the catalytic conversion of light hydrocarbons to synthesis gas. The method involves the contacting of a feed stream comprising the hydrocarbon feedstock and an O2-containing gas with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream comprising carbon monoxide and hydrogen. The preferred catalysts of the invention comprise bulk nickel monoliths that have been activated by heating in a reducing environment. The preferred catalysts convert hydrocarbons to syngas primarily by a predominantly partial oxidation reaction and retain a high level of activity and selectivity to carbon monoxide and hydrogen under conditions of elevated pressure, high gas space velocity and high temperature in a short contact time reactor.

Abstract: A process and apparatus for producing and burning synthesis gas. Carbonaceous waste material is pyrolytically decomposed in a primary reactor in the presence of steam to produce raw product gas containing H2 and CO. The raw product gas and CO2 is then introduced into a coke containing secondary reactor under pyrolyzing conditions, so that the CO2 and coke react to produce combustible gas having an increased CO content. The combustible gas is mixed with oxygen and CO2 to produce a combustible mixture which is burned as a fuel to produce heat, CO2 and H2O. A portion of the produced CO2 is recovered and used as the source of CO2 gas in the combustible mixture and as a source of CO2 gas for the secondary reactor. Preferably filters and scrubbers are used in a closed loop system to avoid undesirable emissions into the environment.

Abstract: A process for producing carbon monoxide (CO) by reforming methane and steam in the presence of a reforming catalyst to produce a reformate product enriched in CO, carbon dioxide (CO2) and hydrogen. CO2 in the enriched reformate is shifted to CO in an integrated sorption enhanced reaction (SER) cycle which employs a series of cyclic steps to facilitate reaction of CO2 and hydrogen at high conversion and to produce a CO-enriched product obtained at reactor feed pressure and at essentially constant flow rate. A series of adsorbent regeneration step including depressurization, purging and product pressurization are used to desorb water which is selectively adsorbed by the adsorbent during the shift reaction and to prepare the reactor for a subsequent process cycle.

Abstract: Process for suppression of soot formation in the preparation of hydrogen and/or carbon monoxide rich gas by partial oxidation of a hydrocarbon feedstock, comprising the steps of

Abstract: A process and a metal catalyst are provided for the partial oxidation of hydrocarbons to produce hydrogen and carbon monoxide. The process is conducted by contacting a mixture of a hydrocarbon-containing gas and an oxygen-containing gas in the presence of a metal catalyst. The metal catalyst is a transition or noble metal supported on a ceria monolith substrate. Partial oxidation of hydrocarbons can be carried out at low initiation temperatures with high product yields.

Abstract: A cyclic process for operating an equilibrium controlled reaction in a plurality of reactors containing an admixture of an adsorbent and a reaction catalyst suitable for performing the desired reaction which is operated in a predetermined timed sequence wherein the heating and cooling requirements in a moving reaction mass transfer zone within each reactor are provided by indirect heat exchange with a fluid capable of phase change at temperatures maintained in each reactor during sorpreaction, depressurization, purging and pressurization steps during each process cycle.

Abstract: A gas generator for generating a hydrogen-rich carbon-monoxide-lean gas from a water-fuel mixture by catalytic steam reforming and/or from an oxygen-fuel mixture by partial oxidation includes at least one fuel reservoir vessel; a reforming reactor; a CO shift reactor; a gas purifying unit; and a line to feed water from a water reservoir vessel into the reformate gas stream fed to the CO shift reactor. The water reservoir vessel contains a water-methanol mixture having a mixing ratio effective to ensure adequate frost protection.

Abstract: Disclosed is a process for producing a synthesis gas by reacting a carbon-containing organic compound with steam and/or carbon dioxide using a catalyst whose carbon deposition activity is considerably suppressed. The catalyst is characterized in that it comprises a carrier formed of a metal oxide, and at least one catalytic metal selected from rhodium, ruthenium, iridium, palladium and platinum and supported on the carrier, in that the catalyst has a specific surface area of 25 m2/g or less, in that the electronegativity of the metal ion of the carrier metal oxide is 13.0 or less and in that the amount of the catalytic metal is 0.0005-0.1 mole %, in terms of metal, based on the carrier metal oxide.

Abstract: The present invention is a process for producing an essentially pure carbon monoxide (CO) product and an essentially pure hydrogen product by reforming a hydrocarbon such as methane and steam in the presence of a reforming catalyst to produce a reformate product enriched in CO, carbon dioxide and hydrogen. The reformate is subjected to an integrated series of separation steps and carbon dioxide present in a portion of the waste effluent recovered from such series of spearation steps is shifted to CO in an integrated sorption enhanced reaction (SER) process.

Abstract: The invention relates to a process for production of a mixture comprising hydrogen and CO by partial oxidation of a hydrocarbon by an oxygenated medium, according to which the processing is carried out under autothermal conditions with the heat given off by said oxidation being recovered to maintain the endo-thermic reactions which take place between the non-oxidized fraction of said hydrocarbon and the CO2 and the steam produced by said oxidation, being characterized in that the reaction gas mixture comprising the hydrocarbon and the oxygenated medium is passed through a porous medium (4) which has been preheated beforehand, thus making it possible to heat the reaction gas mixture by heat exchange with the porous medium to a temperature threshold sufficient to initiate combustion reactions, rendering unnecessary an external heat supply when operating continuously.

Abstract: The present invention provides a method of steam reforming a hydrocarbon over a spinel-containing catalyst at short residence times or short contact times. The present invention also provides spinel-containing catalysts. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described.

Abstract: A plasma reactor including a first dielectric having at least one capillary defined therethrough, and a segmented electrode including a plurality of electrode segments, each electrode segment is disposed proximate an associated capillary. Each electrode segment may be formed in different shapes, for example, a pin, stud, washer, ring, or disk. The electrode segment may be hollow, solid, or made from a porous material. The reactor may include a second electrode and dielectric with the first and second dielectrics separated by a predetermined distance to form a channel therebetween into which the plasma exiting from the capillaries in the first dielectric is discharged. The fluid to be treated is passed through the channel and exposed to the plasma discharge. If the electrode segment is hollow or made of a porous material, then the fluid to be treated may be fed into the capillaries in the first dielectric and exposed therein to the maximum plasma density.

Abstract: The present invention is a process for operating equilibrium controlled reactions in continuous mode wherein a feedstock is reacted in a plurality of reactors containing an admixture of a desired process catalyst and an adsorbent to form a product which is selectively adsorbed by the adsorbent and an admixture containing a product which is withdrawn from the reactor. A series of separation steps is used to desorb the product which is selectively adsorbed by the adsorbent and to prepare the reactor for a subsequent process cycle. The process utilizes a novel series of adsorption and desorption steps to collect the less selectively adsorbed product in substantially pure form under relatively constant flow rate at feedstock pressure.

Abstract: A system for generating hydrogen-rich gas has a reformer for catalytic water vapor reforming of a water vapor/fuel mixture by an input supply of thermal energy, and a CO oxidation stage for removing carbon monoxide from the hydrogen-rich gas while emitting heat, with the reformer and the CO oxidation stage being thermally coupled. An oxygen quantity fed to the CO oxidation stage is adjusted as a function of the gas temperature in or at the output of the reformer/oxidation stage. This can take place by an automatic (feedback) control, a combination of open loop control and automatic control or by an adaptive characteristic diagram.

Abstract: The present invention includes an improvement to the existing method of steam reforming of hydrocarbon, wherein the improvement comprises: the flowing is at a rate providing a residence time less than about 0.1 sec resulting in obtaining product formation yield or amount that is the same or greater compared to product formation at a longer residence time. Another improvement of the present invention is operation at a steam to carbon ratio that is substantially stoichiometric and maintaining activity of the supported catalyst. The present invention also includes a catalyst structure for steam reforming of a hydrocarbon.

Abstract: A improved hydrocarbon conversion process, comprising applying a plating, cladding, paint or other coating to at least a portion of a hydrocarbon conversion reactor system which is used to convert hydrocarbons to products in the presence of steam, said coating being effective to reduce the amount of undesirable by-products in said process; and operating the hydrocarbon conversion process at a steam to hydrocarbon ratio that is lower than the steam to hydrocarbon ratio at which said process was operated prior to applying said coating. Preferred hydrocarbon conversion process includes steam cracking of hydrocarbons to produce ethylene and dehydrogenation of ethylbenzene to styrene.

Abstract: Disclosed are a catalyst for producing a synthesis gas using a carbon-containing organic compound as a raw material and a process for producing carbon monoxide. The catalyst for producing a synthesis gas is composed of a carrier formed of a metal oxide and at least one catalytic metal selected from rhodium, ruthenium, iridium, palladium and platinum and supported on the carrier and is characterized in that the catalyst has a specific surface area of 25 m2/g or less, in that the electronegativity of the metal ion of the carrier metal oxide is 13.0 or less and in that the amount of the supported catalytic metal is 0.0005-0.1 mole %, in terms of a metal, based on the carrier metal oxide.

Abstract: A novel injector/reactor apparatus and an efficient process for the partial oxidation of light hydrocarbon gases, such as methane, to convert such gases to useful synthesis gas for recovery and/or subsequent hydrocarbon synthesis. Sources of a light hydrocarbon gas, such as methane, and oxygen or an oxygen-containing gas are preheated and pressurized and injected through an injector means at high velocity into admixture with each other in the desired relative proportions, at a plurality of mixing nozzles which are open to the catalytic partial oxidation reaction zone and are uniformly-spaced over the face of the injector means, to form a reactant gaseous premix having a pressure drop equal to at least about 3% of the lowest upstream pressure of either of said gases.

Abstract: Process for preparation of a hydrogen and/or carbon monoxide rich gas by catalytic autothermal reforming of a hydrocarbon feedstock containing higher hydrocarbons in an autothermal reformer comprising the further steps of

Abstract: Process for the preparation of hydrogen and/or carbon monoxide rich gas by catalytic steam reforming of a hydrocarbon feedstock, wherein a first stream of the feedstock is autothermally steam reformed in parallel with a second stream of the feedstock being steam reformed in presense of a steam reforming catalyst in heat conducting relationship with hot effluent from the autothermal steam reforming and with steam reformed hot effluent withdrawn from steam reforming catalyst, and the effluent from the autothermal steam reforming step and the heat exchange steam reforming step are combined after having supplied heat to steam reforming reactions proceeding in the second stream of the feedstock.

Abstract: Synthesis gas is produced from a methane-containing reactant gas in a mixed conducting membrane reactor in which the reactor is operated to maintain the product gas outlet temperature above the reactant gas feed temperature wherein the total gas pressure on the oxidant side of the membrane is less than the total gas pressure on the reactant side of the membrane. Preferably, the reactant gas feed temperature is below a maximum threshold temperature of about 1400° F. (760° C.), and typically is between about 950° F. (510° C.) and about 1400° F. (760° C.). The maximum temperature on the reactant side of the membrane reactor is greater than about 1500° F. (815° C.).

Abstract: A hydrocarbon fuel reforming method is disclosed suitable for producing synthesis hydrogen gas from reactions with hydrocarbons fuels, oxygen, and steam. A first mixture of an oxygen-containing gas and a first fuel is directed into a first tube 108 to produce a first reaction reformate. A second mixture of steam and a second fuel is directed into a second tube 116 annularly disposed about the first tube 108 to produce a second reaction reformate. The first and second reaction reformates are then directed into a reforming zone 144 and subject to a catalytic reforming reaction. In another aspect of the method, a first fuel is combusted with an oxygen-containing gas in a first zone 108 to produce a reformate stream, while a second fuel under steam reforming in a second zone 116. Heat energy from the first zone 108 is transferred to the second zone 116.

Abstract: Carbon monoxide is produced in a fast quench reactor. The production of carbon monoxide includes injecting carbon dioxide and some air into a reactor chamber having a high temperature at its inlet and a rapidly expanding a reactant stream, such as a restrictive convergent-divergent nozzle at its outlet end. Carbon dioxide and other reactants such as methane and other low molecular weight hydrocarbons are injected into the reactor chamber. Other gas may be added at different stages in the process to form a desired end product and prevent back reactions. The resulting heated gaseous stream is then rapidly cooled by expansion of the gaseous stream.