Apparatus for converting Spent Pot Lining (SPL) into inert slag, aluminum fluoride and energy includes a plasma arc furnace such that the destruction of SPL occurs therein. The furnace generates an electric arc within the waste, which arc travels from an anode to a cathode and destroys the waste due to the arc's extreme temperature, thereby converting a mineral fraction of SPL into vitrified inert slag lying within a crucible of the furnace. The furnace gasifies the carbon content of the SPL and produces a well-balanced syngas. The gasification takes place due to the controlled intake of air and steam into the furnace. The gasification reaction liberates significant amount of energy. Steam captures this excess energy, to provide part of the oxygen requirement for gasification and to contribute to raise the syngas H2 content. Steam also contributes to converting some SPL fluorides (NaF and Al2F3) into hydrogen fluoride. The plasma SPL processing system is compact (occupying less area than some competitive methods of SPL treatment), can be installed in close proximity to the aluminium plant (minimizing transportation of SPL and AlF3), and requires only electricity as its energy source and thus no fossil fuels.

Provided are methods for preparing hydrogen and solid carbon. Illustrative methods comprise providing a feedstock comprising gaseous hydrocarbons to a microwave-inert reaction vessel and/or a radio wave-inert reaction vessel. The reaction vessel has solid carbon, about 0% water and about 0% molecular oxygen inside the reaction vessel and the carbon inside the reaction vessel is operable to heat the feedstock comprising gaseous hydrocarbons. The carbon is then exposed to microwaves and/or radio waves until the solid carbon is at a temperature of at least 1200 Kelvin, thereby forming hydrogen and solid carbon. Once formed, the hydrogen and solid carbon are separated.

Hydrogen-producing fuel processing systems and related methods. The systems include a hydrogen-producing region configured to produce a mixed gas stream from a feedstock stream, a hydrogen-separation membrane module having at least one hydrogen-selective membrane and configured to separate the mixed gas stream into a product hydrogen stream and a byproduct stream, and an oxidant delivery system configured to deliver an oxidant-containing stream to the hydrogen-separation membrane module in situ to increase hydrogen permeance of the hydrogen-selective membrane. The methods include operating a hydrogen-producing fuel processing system in a hydrogen-producing regime, and subsequently operating the hydrogen-producing fuel processing system in a restoration regime, in which an oxidant-containing stream is delivered to the hydrogen-separation membrane module in situ to expose the at least one hydrogen-selective membrane to the oxidant-containing stream to increase the hydrogen permeance of the at least one hydrogen-selective membrane.

A method for producing a homogenous molten composition and a fluid product is disclosed. For example, the method includes producing a first molten metal composition in an enclosed volume, contacting a hydrocarbon reactant with the first molten metal composition, decomposing the hydrocarbon reactant into at least one fluid product and carbon, forming a metal alloy from a mixture of the carbon and the first molten metal composition, and separating a homogenous second molten composition from the metal alloy.

A process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, comprising the steps of: continuously providing the carbonaceous feedstock of fluctuating compositional characteristics to a gasification zone; gasifying the carbonaceous feedstock in the gasification zone to obtain raw synthesis gas; recovering at least part of the raw synthesis gas from the gasification zone and supplying at least part of the recovered raw synthesis gas to a partial oxidation zone; equilibrating the H.sub.2:CO ratio of the raw synthesis gas in the partial oxidation zone to obtain equilibrated synthesis gas; recovering at least part of the equilibrated synthesis gas from the partial oxidation zone and treating the gas to remove impurities and generate a fine synthesis gas; and converting the optionally adjusted fine synthesis gas into the useful product in a further chemical reaction requiring a usage ratio.

Generation of bubbles in an organic-substance production apparatus is suppressed. A gas treatment method including: an adsorption step of passing a source gas containing at least carbon dioxide and nitrogen through an adsorption unit housing an adsorbent for adsorbing carbon dioxide to reduce a carbon dioxide concentration in the source gas; a supply step of supplying the source gas whose carbon dioxide concentration has been reduced by the adsorption step to an organic-substance production apparatus that produces an organic substance; and a monitoring step of monitoring a carbon dioxide concentration and a nitrogen concentration in the source gas before passing through the adsorption unit, a carbon dioxide concentration and a nitrogen concentration in the source gas after having passed through the adsorption unit, or a carbon dioxide concentration and a nitrogen concentration in the source gas having been supplied to the organic-substance production apparatus; wherein the adsorption step has an ability regulation step of enhancing an ability of the adsorption unit to reduce a carbon dioxide concentration in the source gas, when a total concentration of the carbon dioxide concentration and the nitrogen concentration monitored in the monitoring step exceeds a threshold value.

A process for producing acrylic acid from carbonaceous materials such as biomass. The carbonaceous material, such as biomass, is gasified to produce synthesis gas. The synthesis gas then is subjected to a plurality of reactions to produce acrylic acid.

Combining multiple subsystems involving biomass processing, biomass gasification of the processed biomass where a synthesis gas is produced then converted to hydrogen fuels or other transportation fuels for use in coupled transportation systems sized to consume all the transportation fuel produced. Carbon in the biomass is converted to CO.sub.2 in the conversion process and a portion of that CO.sub.2 is captured and sequestrated for long term storage.

The invention provides a calcined Fe.sub.x—Al.sub.y—O.sub.z based catalyst for the decomposition of hydrocarbons such as methane to produce hydrogen and carbon. The catalyst comprises iron oxide mixed with aluminum oxide and calcined at temperatures above 1100° C., where Fe.sub.x—Al.sub.y—O.sub.z is a chemical composition with x>0.1, y>0.1, z≥0 and 0<x/y<200. Reaction of the calcined Fe.sub.x—Al.sub.y—O.sub.z catalyst with methane generates a product stream comprising at least 40 vol. % H.sub.2 and carbon. In an embodiment, carbon is separated from the catalyst and the catalyst is reused for continuous methane decomposition to produce H.sub.2.

A system and method for producing Syngas from the CO.sub.2 in a gaseous stream, such as an exhaust stream, from a power plant or industrial plant, like a cement kiln, is disclosed. A preferred embodiment includes providing the gaseous stream to pyrolysis reactor along with a carbon source such as coke. The CO.sub.2 and carbon are heated to about 1330° C. and at about one atmosphere with reactants such as steam such that a reaction takes place that produces Syngas, carbon dioxide (CO.sub.2) and hydrogen (H.sub.2). The Syngas is then cleaned and provided to a Fischer-Tropsch synthesis reactor to produce Ethanol or Bio-catalytic synthesis reactor.