A steam methane reformer (SMR) system includes an outer tube, wherein a first end of the outer tube is closed; an inner tube disposed in the outer tube, wherein a first end of the inner tube is open. A flow channel is defined within the inner tube and an annular space is defined between the outer tube and the inner tube, the flow channel being in fluid communication with the annular space. The SMR system includes a catalytic foam disposed in the annular space between the outer tube and the inner tube, the catalytic foam comprising a catalyst.

A method for producing hydrogen includes flowing a first gas along a bayonet flow path of a steam methane reformer (SMR) to produce a first product, including flowing the first gas through a foam disposed along the bayonet flow path; providing the first product produced in the SMR to an input of a water gas shift (WGS) reaction channel defined within a reaction tube of a WGS reactor; and flowing a second gas including the first product through the WGS reaction channel to produce a second product. Flowing the second gas includes flowing the second gas across a heat transfer material disposed in the WGS reaction channel to reduce the temperature of the flowing second gas; and flowing the second gas across a WGS catalyst disposed in the reaction channel.

The present disclosure relates generally to a methanol reforming catalyst composition comprising a ZnO phase, present in the composition in an amount of 20-75 wt. %; a zinc-aluminum spinel phase, present in the composition in an amount of 20-60 wt. %; and a Cu dopant phase, present in the composition in an amount of 0.1-20 wt. %. In various embodiments, the methanol reforming catalyst can achieve stable high methanol conversion rates and high hydrogen production rates at high temperatures (>300° C.).

Processes for converting methane and/or other hydrocarbons to synthesis gas (i.e., a gaseous mixture comprising H.sub.2 and CO) are disclosed, in which at least a portion of the hydrocarbon(s) is reacted with CO.sub.2. At least a second portion of the methane may be reacted with H.sub.2O (steam), thereby improving overall thermodynamics of the process, in terms of reducing endothermicity (AH) and the required energy input, compared to “pure” dry reforming in which no H.sub.2O is present. Catalysts for such processes advantageously possess high activity and thereby can achieve significant levels of methane conversion at temperatures below those used conventionally under comparable conditions. These catalysts also exhibit high sulfur tolerance, in addition to reduced rates of carbon (coke) formation, even in the processing (reforming) of heavier (e.g., naphtha boiling-range or jet fuel boiling-range) hydrocarbons. The robustness of the catalyst translates to high operating stability. A representative catalyst comprises 1 wt-% Pt and 1 wt-% Rh as noble metals, on a cerium oxide support.

In various aspects, the present disclosure is directed to methods and compositions for the simultaneous production of carbon nanotubes and hydrogen gas from lower hydrocarbon comprises methane, ethane, propane, butane, or a combination thereof utilizing the disclosed catalysts. In various aspects, the disclosure relates to methods for COx-free production of hydrogen with concomitant production of carbon nanotubes. Also disclosed are methods and compostions for selective base grown carbon nanotubes over a disclosed catalyst composition. In a further aspect, the disclosure relates to mono, bimetallic, and trimetallic catalysts comprising a 3d transition metal (e.g., Ni, Fe, Co, Mn, Cr, Mo, and combinations thereof) over a support material selected from a silica, an alumina, a zeolite, titatnium dioxide, and combinations thereof. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

Processes and catalysts for producing hydrogen by reforming methane are disclosed, which afford considerable flexibility in terms of the quality of the reformer feed. This can be attributed to the robustness of the noble metal-containing catalysts described herein for use in reforming, such that a number of components commonly present in methane-containing process streams can advantageously be maintained without conventional upgrading (pretreating) steps, thereby improving process economics. This also allows for the reforming of impure reformer feeds, even in relatively small quantities, which may be characterized as complex gas mixtures due to significant quantities of non-methane components. A representative reforming catalyst comprises 1 wt-% Pt and 1 wt-% Rh as noble metals, on a cerium oxide support.

A method for producing a hydrogen rich gas from a heavy hydrocarbon feed comprising the steps of introducing the hydrocarbon feed to a reactor, the reactor comprising a low temperature reforming catalyst, the low temperature reforming catalyst comprising an amount of praesodymium, 12 wt % nickel, and an aluminum oxide component, contacting the low temperature reforming catalyst with the hydrocarbon feed in the reactor, wherein the reactor operates at a temperature between 500° C. and 600° C., wherein the reactor operates at a pressure between 3 bar and 40 bar, and producing the hydrogen rich gas over the low temperature reforming catalyst, wherein the hydrogen rich gas comprises hydrogen.

A process for producing a hydrogen-rich gas stream from a liquid hydrocarbon stream, the process comprising the steps of introducing the liquid hydrocarbon stream to a dual catalytic zone, the liquid hydrocarbon stream comprises liquid hydrocarbons selected from the group consisting of liquid petroleum gas (LPG), light naphtha, heavy naphtha, gasoline, kerosene, diesel, and combinations of the same, the dual catalytic zone comprises: a combustion zone comprising a seven component catalyst, and a steam reforming zone, the steam reforming zone comprising a steam reforming catalyst; introducing steam to the dual catalytic zone, introducing an oxygen-rich gas to the dual catalytic zone; contacting the liquid hydrocarbon stream, steam, and oxygen-rich gas with the seven component catalyst to produce a combustion zone fluid; and contacting the combustion zone fluid with the steam reforming catalyst to produce the hydrogen-rich gas stream, wherein the hydrogen-rich gas stream comprises hydrogen.

A catalyst structure includes a carrier having a porous structure composed of a zeolite type compound and at least one catalytic material existing in the carrier. The carrier has channels communicating with each other, and the catalytic material is a metal fine particle and exists at least in the channel of the carrier.

The present disclosure relates to a partial oxidation catalyst that causes a light hydrocarbon partial oxidation reaction to proceed readily with high activity and high selectivity and a high-yield carbon monoxide production method using the same. The present disclosure further relates to a light hydrocarbon partial oxidation catalyst containing a zeolite supporting cobalt and rhodium.