A method and system for producing a synthesis gas in an oxygen transport membrane based reforming system is disclosed that carries out a primary reforming process within a reforming reactor, and a secondary reforming process within an oxygen transport membrane reactor and in the presence of heat generated from a oxygen transport membrane reactor and an auxiliary source of heat. The auxiliary source of heat is disposed within the reactor housing proximate the reforming reactors and may include an auxiliary reactively driven oxygen transport membrane reactor or a ceramic burner.

Reactor-exchanger comprising at least 3 stages with, on each stage, at least one area promoting the heat exchanges and at least one distribution area upstream and/or downstream of the area promoting the heat exchanges, characterized in that the area promoting the heat exchanges comprises cylindrical millimetric channels, there being 1 to 1000 of said channels with a length of between 10 mm and 500 mm.

The present disclosure provides a Fischer-Tropsch tail gas recycling system, including: a Fischer-Tropsch reactor providing a source of tail gas; a first preheater for preheating the tail gas to between about 200 and 300 degrees C.; a hydrogenator for hydrogenating the tail gas; an expansion device for reducing the pressure of the tail gas to between about 2.5 and 5 bar; a second preheater for preheating a feed gas comprising the tail gas and steam to between about 500 and 600 degrees C.; and a catalytic reformer for reforming the feed gas in the presence of a catalyst, wherein the catalytic reformer operates at about 2 bar and about 1000 degrees C., for example. Optionally, CO2 and/or natural gas are also added to the tail gas and/or steam to form the feed gas.

A method for producing hydrogen in a steam methane reformer is disclosed. The method provides for the steps of feeding a mixture of fuel and air to a steam methane reformer; feeding a mixture of steam and hydrocarbons to the steam methane reformer; contacting the steam and hydrocarbons with a metal monolith supported catalyst; providing an electric current to the metal monolith supported catalyst; and recovering the hydrogen. The electric current applied to the metal monolith supported catalyst will encounter electrical resistance which will create heat. This heat can supplement that provided for by the reaction of the fuel and air allowing for a reduction in fueling costs as well as treatment costs of the resultant flue gas.

A reactor containing a heat exchanger is disclosed, which can be operated with co-current or counter-current flow. Also disclosed is a system that includes a reactor having a reformer and a vaporizer, a fuel supply, and a water supply. The reactor includes a source of combustion gas, a reformer operative to receive reformate, and a vaporizer operative to receive water. The reformer and vaporizer each include a stack assembly formed by a combination of separator shims and channel shims. The separator shims and channel shims are stacked in a regular pattern to form two sets of channels within the stack assembly. One set of channels will have vertical passageways at either end and a horizontal flowpath between them, while the other set of channels has only a horizontal flowpath.

An input stream of gaseous nitrogen and carbon dioxide is introduced into a first interior volume of a separation vessel that is divided into first and second interior volumes by a separation membrane that includes a metal layer. The metal layer selectively permits movement of nitrogen through the metal layer. An output stream of gaseous nitrogen and carbon dioxide is conveyed out of the first interior volume and into a reaction vessel. The volume fraction of carbon dioxide is greater in the output stream than in the input stream; the volume fraction of nitrogen is reduced in the output stream relative to the input stream. Nitrogen is removed from the second interior volume to maintain a gradient of nitrogen partial pressure across the separation membrane that causes net transport of nitrogen from the first interior volume through the separation membrane into the second interior volume.

Disclosed is a technology based upon the nesting of tubes to provide chemical reactors or chemical reactors with built in heat exchanger. As a chemical reactor, the technology provides the ability to manage the temperature within a process flow for improved performance, control the location of reactions for corrosion control, or implement multiple process steps within the same piece of equipment. As a chemical reactor with built in heat exchanger, the technology can provide large surface areas per unit volume and large heat transfer coefficients. The technology can recover the thermal energy from the product flow to heat the reactant flow to the reactant temperature, significantly reducing the energy needs for accomplishment of a process.

A reformer unit and high temperature, pressure, or both variable orifice flow controller is provided. The reformer unit may have a reforming section, a heat exchanging section, and a bypass section. The bypass section provides a flow path for the hydrocarbon-containing fuel around the reforming section and has a variable orifice flow controller positioned in the bypassing flow path.

A fuel cell system having a fuel cell stack, comprising an anode portion and a cathode portion, a source of hydrocarbon fuel, and a reformer unit having one or more cold-side, reforming passages, a fuel supply conduit, a reformate exhaust conduit, one or more hot-side channels, a cathode exhaust conduit, a cathode inlet conduit, one or more bypass channels having non-reforming passages for fuel to bypass the cold-side channels, and a flow controller for controlling the flowrate in the bypass channels, and methods for operating the same, is provided.

A reforming unit for a fuel cell system is provided. The reforming unit may comprise a reforming section, a heat exchanging section and a bypass plenum. The reforming section reforms a hydrocarbon containing fuel. The heat exchanging section effects a heat transfer between a fluid flowing therethrough and the fluid flowing through the reforming section, the bypass plenum, or both. The bypass plenum provides a flowpath for the hydrocarbon-containing fuel to bypass the reforming section. The bypass plenum may comprise a flow restrictor in the outlet of the bypass plenum to control the amount of fluid communication between the outlet of the bypass plenum and the outlet of the reforming section.