Methods, reactor tubes, reactors, and systems for catalysis are disclosed. A reactor tube includes an outer shell defining a catalyst bed, a catalyst within the catalyst bed, and an inner tube extending through the catalyst bed. An interior of the inner tube is isolated from the catalyst within the catalyst bed. Methods of activating a catalyst are also disclosed herein.

A process for producing methanol includes the following steps (a) reacting, via a catalytic partial oxidation (CPO) reaction, a CPO reactant mixture (hydrocarbon, oxygen, and optionally steam) in a CPO reactor to produce syngas including H.sub.2, CO, CO.sub.2, H.sub.2O, and unreacted hydrocarbons; and wherein the CPO reactor includes a CPO catalyst; (b) introducing the syngas to a methanol reactor to produce a methanol reactor effluent stream (methanol, water, hydrogen, carbon monoxide, carbon dioxide, and hydrocarbons); and (c) separating the methanol reactor effluent stream into a crude methanol stream, a hydrogen stream, a CO.sub.2 stream, and a purge gas stream. The crude methanol stream comprises includes methanol and water; wherein the purge gas stream includes carbon monoxide and hydrocarbons; and the CO2 stream includes at least a portion of the CO2 of the methanol reactor effluent stream; and (d) recycling at least a portion of the CO2 stream to the CPO reactor.

A plant for the co-production of methanol and ammonia from a hydrocarbon feed without venting to the atmosphere carbon dioxide captured from the methanol or ammonia synthesis gas and without using expensive air separation units and water gas shift.

A process and plant for the co-production of methanol and ammonia together with urea production from a hydrocarbon feed without venting to the atmosphere carbon dioxide captured from the methanol or ammonia synthesis gas and without using expensive air separation units and water gas shift. Carbon dioxide is removed from flue gas from reforming section and used to convert partially or fully all ammonia into urea.

A method for producing methanol is disclosed. The method includes supplying a high oxygen content oxidant to combust hydrocarbons, in particular methane, and then using the resulting hot gases to heat natural gas so as to convert the natural gas to synthesis gas. The synthesis gas is used to produce methanol in a methanol synthesis reactor. At least some of the carbon dioxide from the hot gases is fed to the methanol synthesis reactor to make methanol.

A feedstock delivery system transfers a carbonaceous material, such as municipal solid waste, into a product gas generation system. The feedstock delivery system includes a splitter for splitting bulk carbonaceous material into a plurality of carbonaceous material streams. Each stream is processed using a weighing system for gauging the quantity of carbonaceous material, a densification system for forming plugs of carbonaceous material, a de-densification system for breaking up the plugs of carbonaceous material, and a gas and carbonaceous material mixing system for forming a carbonaceous material and gas mixture. A pressure of the mixing gas is reduced prior to mixing with the carbonaceous material, and the carbonaceous material to gas weight ratio is monitored. A transport assembly conveys the carbonaceous material and gas mixture to a first reactor where at least the carbonaceous material within the mixture is subject to thermochemical reactions to form the product gas.

Method for the preparation of synthesis gas based on a combination of the ATR process or partial oxidation of hydrocarbon fee stock using oxygen from the electrolysis of water and an air separation unit to produce the synthesis gas.

A system having a catalytic partial oxidation (CPO) reactor operable to produce a CPO reactor effluent characterized by a hydrogen to carbon monoxide (H.sub.2/CO) molar ratio and an M ratio (H.sub.2—CO.sub.2)/(CO+CO.sub.2); a steam methane reforming (SMR) reactor operable to produce an SMR reactor effluent characterized by a H.sub.2/CO molar ratio greater than that of the CPO reactor effluent, and an M ratio greater than that of the CPO reactor effluent. The system includes a flow line(s) configured to combine at least a portion of the CPO reactor effluent with at least a portion of the SMR reactor effluent to provide a combined syngas stream upstream or downstream of a heat exchanger operable to transfer heat from at least a portion of the CPO reactor effluent, at least a portion of the SMR reactor effluent, or the combined syngas stream to the first portion and/or the second portion of hydrocarbons.

A reformer for production of synthesis gas may include a reformer firing space having a reformer base, reformer walls, and a reformer roof. The reformer may include a first reformer tube and a second reformer tube, with at least sections of the first reformer tube and the second reformer tube being arranged within the reformer firing space. At least one reformer burner is disposed outside the reformer firing space. A cooling duct on or beneath the reformer base is disposed between the first reformer tube and the second reformer tube. The first reformer tube and the second reformer tube can be connected to a collecting system outside the reformer firing space, with the collecting system being disposed beneath the reformer base.

It is provided a method of converting a carbonaceous material into syngas at a carbon conversion rate of at least 78% comprising gasifying the carbonaceous material in a fluidized bed reactor producing a crude syngas, classifying the crude syngas by particle size and density into a cut sizing device, introducing the classified particle crude syngas into a thermal reformer and reforming the classified crude syngas at a temperature above mineral melting point, producing the syngas.