The present invention describes a processes, systems, and catalysts for the utilization of carbon dioxide into high quality synthesis gas that can then be used to produce fuels (e.g., diesel fuel) and chemicals. In one aspect, the present invention provides a process for the conversion of a feed gas comprising carbon dioxide and hydrogen to a product gas comprising carbon monoxide and water.

The invention concerns a process and apparatus for cracking ammonia in which heated ammonia at super-atmospheric pressure is partially cracked over a first catalyst in a reaction zone of an electrically heated reactor to produce partially cracked ammonia gas which is then cracked in reactor tubes containing a second catalyst in a fired reactor to produce cracked gas comprising hydrogen gas, nitrogen gas and residual ammonia. The cracked gas is cooled and hydrogen is recovered from the cooled cracked gas in a hydrogen recovery unit. Offgas from the hydrogen recovery unit, or a cracked offgas derived therefrom, provides at least some, preferably all, of the fuel requirement in the fired reactor. Varying the power input to the first part of the cracking reaction enables direct control of the heat flux profile and hence accommodate any excess or shortfall in the heat input from the fired reactor.

The invention concerns a process and apparatus for cracking ammonia in which heated ammonia at super-atmospheric pressure is partially cracked in reactor tubes containing a first catalyst in a fired reactor to produce partially cracked ammonia gas which is then cracked over a second catalyst in a reaction zone of an electrically heated reactor to produce cracked gas comprising hydrogen gas, nitrogen gas and residual ammonia. The cracked gas is cooled and hydrogen is recovered from the cooled cracked gas in a hydrogen recovery unit. Offgas from the hydrogen recovery unit, or a cracked offgas derived therefrom, provides at least some, preferably all, of the fuel requirement in the fired reactor. Varying the power input to the second part of the cracking reaction enables direct control of the heat flux profile and hence optimization of the conversion.

A thermochemical treatment installation includes a reaction chamber, at least one gas inlet, and a gas preheater chamber situated between the gas inlet and the reaction chamber. The preheater chamber has a plurality of perforated distribution trays held spaced apart one above another. The preheater chamber also includes, between at least the facing distribution trays, a plurality of walls defining flow paths for a gas stream between said trays.

The present disclosure is directed to steam reformers for the production of a hydrogen rich reformate, comprising a shell having a first end, a second end, and a passage extending generally between the first end and the second end of the shell, and at least one heat source disposed about the second end of the shell. The shell comprises at least one conduit member comprising at least one thermally emissive and high radiant emissivity material, at least partially disposed within the shell cavity. The shell further comprises at least one reactor module at least a portion of which is disposed within the shell cavity and about the at least one conduit member and comprises at least one reforming catalyst. The disclosure is also directed to methods of producing a hydrogen reformate utilizing the steam reformers, comprising the steps of combusting a combustible mixture in a burner to produce a combustion exhaust that interacts with the steam reactor module(s) through surface to surface radiation and convection heat transfer, and reforming a hydrocarbon fuel mixed with steam in the steam reformers to produce a hydrogen-containing reformate. The present disclosure is further directed to reactor modules for use with the above steam reformers and methods of producing a hydrogen reformate.

A hydrogen generator includes a hydro-desulfurizer, a reformer, a reactor and an electric heater. The hydro-desulfurizer is operative to remove a sulfur compound in a raw material and including a tubular first wall. The reformer is operative to generate a hydrogen-containing gas by using the raw material supplied from the hydro-desulfurizer. The reactor includes a tubular second wall provided coaxially with the first wall so as to be opposed to the first wall. The electric heater is annularly provided in a gap between the first wall and the second wall so as to extend in an axial direction of the first wall and turn back in the axial direction of the first wall. The electric heater includes a first portion contacting the first wall and a second portion contacting the second wall. A connecting portion, which connects the first portion and the second portion, has elasticity.

A reactor uses catalyst blocks for conversion of light hydrocarbons to hydrogen and to liquid hydrocarbons. The catalyst blocks stacked on top of one another within the reactor facilitate conversion of the light hydrocarbons. Electric heaters can be arranged in a variety of orientations within the reactor to supply heat for the conversion reaction. Alternatively, the catalyst blocks can be located within reaction tubes within the reactor and heated by combustion of a fuel adjacent to the reaction tubes. When operated in a regeneration mode, coke that accumulates within the reactor is removed by oxidation.

A system for continuously treating recycled polymeric material includes a hopper configured to feed the recycled polymeric material into the system. An extruder can turn the recycled polymeric material in a molten material. In some embodiments, the extruder uses thermal fluids, electric heaters, and/or a separate heater. The molten material is depolymerized in a reactor. In some embodiments, a catalyst is used to aid in depolymerizing the material. In certain embodiments, the catalyst is contained in a permeable container. The depolymerized molten material can then be cooled via a heat exchanger. In some embodiments, multiple reactors are used. In certain embodiments, these reactors are connected in series. In some embodiments, the reactor(s) contain removable static mixer(s) and/or removable annular inserts.

A system for continuously treating recycled polymeric material includes a hopper configured to feed the recycled polymeric material into the system. An extruder can turn the recycled polymeric material in a molten material. In some embodiments, the extruder uses thermal fluids, electric heaters, and/or a separate heater. The molten material is depolymerized in a reactor. In some embodiments, a catalyst is used to aid in depolymerizing the material. In certain embodiments, the catalyst is contained in a permeable container. The depolymerized molten material can then be cooled via a heat exchanger. In some embodiments, multiple reactors are used. In certain embodiments, these reactors are connected in series. In some embodiments, the reactor(s) contain removable static mixer(s) and/or removable annular inserts.

In accordance with one or more embodiments, a tubular catalyst-containing reactor system is provided. The system includes a housing and a vaporizer unit in the housing comprising a helically wound tubular assembly for receiving and at least partially vaporizing a liquid chemical reactant stream. A reformer unit in the housing receives a vaporized chemical reactant stream from the vaporizer unit. The reformer unit comprises a helically wound tubular assembly connected to and positioned coaxially relative to the helically wound tubular assembly of the vaporizer unit. The helically wound tubular assembly of the reformer unit contains a catalyst for catalyzing formation of gas product stream from the vaporized chemical reactant stream. A burner unit heats the vaporizer unit and the reformer unit. The burner unit receives a fuel stream and an air stream and produces a flame generally inside the helically wound tubular assemblies of the vaporizer unit and the reformer unit.