A segregated steam system and process in a hydrogen production facility wherein boiler feed water is heated by indirect heat exchange with a reformate, the heated boiler feed water is used to heat water condensate formed from the reformate, the heated water condensate is passed to a first steam drum for producing steam for a reformer feed gas mixture, and a second portion of the heated boiler feed water is passed to a second steam drum for producing steam for export.

Steam reforming processes can include treatment of syngas by water gas shift, water separation, and hydrogen separation by pressure swing adsorption (PSA). Additionally, CO.sub.2 can be scrubbed from the syngas prior to the PSA. PSA tail gas, including CH.sub.4, CO, and H.sub.2, can be recompressed and recycled to the PSA for further hydrogen separation and to the steam reformer feed to convert eventually all carbon in the feedstock into CO.sub.2 for the scrubber to separate. Fuel requirements can be fulfilled by part of the hydrogen product to eliminate stack CO.sub.2 emissions. The hydrogen used as fuel is heated and turbo-expanded to provide power before being combusted as fuel. A nitrogen purge may be added.

A steam reforming catalyst that includes treated black powder (primarily hematite), and a method of treating black powder (e.g., from a natural gas pipeline) to give the treated black powder. A steam reformer having the treated black powder as reforming catalyst, and a method of producing syngas with the steam reformer.

A process for reforming for producing hydrogen and generating electricity, comprises: introducing a feed comprising a hydrocarbon stream to a reformer to produce unshifted synthesis gas (syngas); introducing the unshifted syngas to a water gas shift unit to produce a shifted syngas; removing CO.sub.2 from the shifted syngas to produce a CO.sub.2 depleted syngas and a CO.sub.2 product; introducing the CO.sub.2 depleted syngas to a pressure swing adsorption unit to produce a hydrogen product and an off-gas comprising carbon monoxide, carbon dioxide, unreacted methane; splitting a portion of the hydrogen product; and providing the portion of the hydrogen product to an electricity generator for generating electricity for use within the process.

In a hydrocarbon-fed steam methane reformer hydrogen-production process and system, carbon dioxide is recovered in a pre-combustion context, and optionally additional amounts of carbon dioxide are recovered in a post-combustion carbon dioxide removal, to provide the improved carbon dioxide recovery or capture disclosed herein.

A hybrid fuel cell system includes a fuel supply system including a fuel tank, a start-up subsystem, a reforming subsystem and a depressurization system. The reforming subsystem is to receive fuel and to reform fuel to generate a hydrogen enriched gases and steam mixture. The hybrid fuel cell system includes a water supply system that provides water for the steam generator. The water supply system includes a water condenser directly downstream from the reforming subsystem that is in fluid communication with the hydrogen enriched gases and steam mixture to condense the hydrogen enriched gases and steam mixture into water and hydrogen enriched gases. The depressurization system is to reduce a pressure of the hydrogen enriched gases. The hybrid fuel cell system includes a fuel cell stack downstream from the depressurization system and having an anode inlet in fluid communication with the depressurization system to receive the hydrogen enriched gases.

A process is proposed for producing pure hydrogen by steam reforming of a feed gas comprising hydrocarbons, preferably natural gas or naphtha, with a simultaneously low and preferably adjustable export steam flow rate. The process includes the steam reforming of the feed gas, for which the heat of reaction required is provided by combustion of one or more fuel gases with combustion air in a multitude of burners arranged within the reformer furnace. According to the invention, the combustion air, before being introduced into the burners, is heated by means of at least one heat exchanger in indirect heat exchange with the hot flue gas to temperatures of at least 530° C.

Catalyst systems are provided for reforming of hydrocarbons, along with methods for using such catalyst systems. The catalyst systems can be deposited or otherwise coated on a surface or structure, such as a monolith, to achieve improved activity and/or structural stability. The metal oxide support layer can correspond to a thermally stable metal oxide support layer, such as a metal oxide support layer that is thermally phase stable at temperatures of 800° C. to 1600° C. The catalyst systems can be beneficial for use in cyclical reaction environments, such as reverse flow reactors or other types of reactors that are operated using flows in opposing directions and different times within a reaction cycle.

Systems and methods are provided for using size-reversing materials in vessels where direct heating is used to at least partially provide heat for reforming reactions under cyclic reforming conditions. An example of a size-reversing material is the combination of NiO and Al.sub.2O.sub.3. It has been discovered that size-reversing materials can undergo a phase transition that can assist with re-dispersion of metal at elevated temperatures. This can assist with maintaining catalytic activity for reforming over longer time periods in the presence of cyclic reforming conditions.

A process to optimize carbon from carbon dioxide in synthesis gas used to produce synthetic chemicals and fuels. The process involves using captured carbon dioxide from any source and controlling its reformation with gaseous hydrocarbons to produce a synthesis gas with a specific carbon monoxide to hydrogen ratio suitable for selected intermediate and end products. The carbon from carbon dioxide displaces fossil carbon and lowers the carbon intensity of the products. The process uses any hydrocarbon gas, fossil or renewable, and may utilize steam to optimize the synthesis gas composition. The invention also includes recycling gases and the generation of heat, steam and electrical power for the reformer and other equipment, significantly reducing the carbon footprint of the plant.