Systems and methods for integrated production of aromatics and other chemicals are described. Systems and methods may include a process for producing benzene, methanol, butanals, dimethyl ethers, olefins and other chemicals that includes providing methane to a first reactor to produce a first product stream comprising benzene and hydrogen; recovering benzene and mixing the first product stream with a carbon dioxide and/or steam feed stream; providing the combined benzene depleted first product stream and carbon dioxide and/or steam feed stream to a second reactor to produce a second product stream comprising synthesis gas, water and unconverted methane and carbon dioxide; and providing the synthesis gas to a third reactor to produce a third product stream comprising methanol, butanals, and other chemicals.

The present technology is directed to processes involving formation of hydrocarbons and oxygenated hydrocarbons through use of oxygen supplied by ion transport membranes. More particularly, the present technology relates in part to a process involving steam reforming and subsequent production of a synthetic product where carbon dioxide and/or hydrogen downstream of the process is reclaimed to generate the synthetic product. The present technology also relates in part to an ethylene formation process involving a viral-templated coupling catalyst in the presence of an ion transport membrane.

The present disclosure relates to a reactor and a method of operation for an exothermal process being catalyzed by a catalytically active material receiving a reactant gas and providing a product gas, in which said exothermal process has a heat development having a potential for thermally degrading said catalytically active material, and which exothermal process operates at a temperature at which the reactants and at least 80% or all of the products are present as gases, said method comprising the steps of a) directing the reactant gas to a first zone of a material catalytically active in the exothermal process producing an first product gas, and b) directing the first product gas to a second zone of a material catalytically active in the exothermal process producing a product gas, with the option of fully or partially by-passing either said first zone or said second zone, while directing a non-condensing gas stream having a temperature at least 50° C. lower than the product gas to said by-passed zone, wherein the choice of by-passing said zone is made based on the time of operation or a process parameter reflecting the catalytic activity of the zone of catalytically active material which is not by-passed with the associated benefit of reducing the extent of thermal deactivation of the catalytically active material, and thus increasing the overall lifetime of the catalytically active material.

Systems and methods are provided for incorporating molten carbonate fuel cells into a heat recovery steam generation system (HRSG) for production of electrical power while also reducing or minimizing the amount of CO.sub.2 present in the flue gas exiting the HRSG. An optionally multi-layer screen or wall of molten carbonate fuel cells can be inserted into the HRSG so that the screen of molten carbonate fuel cells substantially fills the cross-sectional area. By using the walls of the HRSG and the screen of molten carbonate fuel cells to form a cathode input manifold, the overall amount of duct or flow passages associated with the MCFCs can be reduced.

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.

Processes for converting methane into an olefin and methanol are provided. The olefin can be ethylene. Certain exemplary processes can involve parallel use of both steam reforming of methane and oxidative dry reforming of methane to prepare syngas. The processes can further involve conversion of syngas to ethylene and to methanol.

A CO shift catalyst according to the present invention reforms carbon monoxide (CO) in gas. The CO shift catalyst has one of molybdenum (Mo) or iron (Fe) as a main component and has an active ingredient having one of nickel (Ni) or ruthenium (Ru) as an accessory component and one or two or more kinds of oxides from among titanium (Ti), zirconium (Zr), and cerium (Ce) for supporting the active ingredient as a support. The temperature at the time of manufacturing and firing the catalyst is equal to or higher than 550° C.

Method for the preparation of synthesis gas combining electrolysis of carbon dioxide, autothermal reforming and 5 optionally tubular steam reforming of a hydrocarbon feed stock.

Some variations provide a process for producing mixed alcohols, comprising: purifying a biogas feedstock to generate a renewable natural gas stream comprising methane; introducing the renewable natural gas stream into a methane-to-syngas unit operated at effective conditions to convert the methane to a first syngas stream containing at least H.sub.2, CO, and CO.sub.2; purifying the first syngas stream, including separating the CO.sub.2 from the first syngas stream, and optionally separating some of the H.sub.2 from the first syngas stream, thereby generating a clean syngas stream; introducing the clean syngas stream into a mixed-alcohol reactor operated at effective alcohol synthesis conditions with an alcohol-synthesis catalyst, thereby generating mixed alcohols; and purifying the mixed alcohols to generate a mixed-alcohol product. The mixed-alcohol product may be blended with a hydrocarbon fuel, such as gasoline, to produce a blended fuel. The blended fuel has significantly lower carbon intensity than the base hydrocarbon fuel.

Sulfur-tolerant reforming catalysts that include bulk alumina in the catalyst support are provided. The sulfur-tolerant reforming catalysts can include a sulfur-tolerant catalytic metal to facilitate reforming. The catalyst can further include a support material that includes at least some alumina as bulk alumina and/or octahedrally coordinated alumina. The sulfur-tolerant reforming catalysts can be regenerated, such as periodically regenerated, under relatively mild conditions that allow the catalysts to maintain reforming activity in the presence of 1 vppm to 1000 vppm of sulfur in the feed for reforming.