Systems and methods for producing a decarbonized blue hydrogen gas for cracking operations utilizing a standard separation process, such as Pressure Swing Absorption (PSA), to separate a tail gas mixture of hydrogen and hydrocarbons into hydrogen gas and a PSA effluent that is used in a hydrogen generation unit to produce the decarbonized blue hydrogen gas for cracking operations

A process for hydrogen recovery from refinery gas system comprising supplying the refinery gas to an inlet manifold fluidly coupled to a conditioning stage, the conditioning stage comprising a reactor having a reforming catalyst deposited on an ultra-short-channel-length metal substrate; supplying oxidant to the conditioning stage via the inlet manifold; supplying steam from a steam generator to the conditioning stage via the inlet , manifold; reacting the refinery gas in the conditioning stage; and discharging a product through a discharge outlet fluidly coupled to the conditioning stage, the discharge outlet configured to flow the product for use by a downstream reformer. The process allows to either increase the H2 production rate or lower the firing rate while maintaining a constant H2 production rate for the downstream steam reformer, independent of the feed compositional variability of the refinery or still gas.

Embodiments of the present disclosure are directed to a diesel reformer system comprising: a diesel autothermal reforming unit; a post-reforming unit disposed downstream of the autothermal reforming unit; a heat exchanger disposed downstream of the post-reforming unit; and a desulfurization unit disposed downstream of the heat exchanger.

As part of an integrated oxidative alkane dehydrogenation and hydrogen generation process, carbon dioxide from Pressure Swing Adsorption (PSA) off gas stream of Hydrogen Generation Unit (HGU), and alkane from any known source are sent to oxidative dehydrogenation (ODH) unit for producing high value olefins, such as ethylene, propylene and butenes. Products formed from ODH reactor are separated and the stream comprising of hydrogen, carbon monoxide and methane are recycled to Shift reactor of HGU unit for enhanced production of hydrogen at PSA.

As part of an integrated oxidative alkane dehydrogenation and hydrogen generation process, carbon dioxide from Pressure Swing Adsorption (PSA) off gas stream of Hydrogen Generation Unit (HGU), and alkane from any known source are sent to oxidative dehydrogenation (ODH) unit for producing high value olefins, such as ethylene, propylene and butenes. Products formed from ODH reactor are separated and the stream comprising of hydrogen, carbon monoxide and methane are recycled to Shift reactor of HGU unit for enhanced production of hydrogen at PSA.

A disulfide oil hydrocarbon stream or a mixture of a disulfide oil hydrocarbon stream and a residual oil is partially oxidized in a gasifier to produce a hot raw synthesis gas containing hydrogen and carbon monoxide which can be passed to a steam generating heat exchanger to cool the hot raw synthesis gas and to produce steam which can be used to generate electricity via a turbine and, optionally, subjecting the cooled synthesis gas to the water/gas shift reaction to produce additional hydrogen and carbon dioxide.

An integrated refinery process for the disposal of metal-containing spent coked catalyst from hydrotreating and/or hydrocracking unit operations includes introducing the spent coked catalyst into a membrane wall gasification reactor in the form of flowable particles along with predetermined amounts of oxygen and steam based upon an analysis of the hydrocarbon content of the coke, and optionally, a liquid hydrocarbon; gasifying the feed to produce synthesis gas and a slag material; recovering and subjecting the slag material to further processes in preparation for a leaching step to solubilize and form one or more active phase metal compounds that are recovered from the leaching solution, either separately by sequential processing, or together. The recovered active metal compounds can be used, e.g., in preparing fresh catalyst for use in the refinery's hydroprocessing units.

Reactors are provided that can include a first set of fluid channels and a second set of fluid channels oriented in thermal contact with the first set of fluid channels. The reactor assemblies can also provide where the channels of either one or both of the first of the set of fluid channels are non-linear. Other implementations provide for at least one of the first set of fluid channels being in thermal contact with a plurality of other channels of the second set of fluid channels. Reactor assemblies are also provided that can include a first set of fluid channels defining at least one non-linear channel having a positive function, and a second set of fluid channels defining at least another non-linear channel having a negative function in relation to the positive function of the one non-linear channel of the first set of fluid channels. Processes for distributing energy across a reactor are provided. The processes can include transporting reactants via a first set of fluid channels to a second set of fluid channels, and thermally engaging at least one of the first set of fluid channels with at least two of the second set of fluid channels.

A disulfide oil hydrocarbon stream or a mixture of a disulfide oil hydrocarbon stream and a residual oil is partially oxidized in a gasifier to produce a hot raw synthesis gas containing hydrogen and carbon monoxide which can be passed to a steam generating heat exchanger to cool the hot raw synthesis gas and to produce steam which can be used to generate electricity via a turbine and, optionally, subjecting the cooled synthesis gas to the water/gas shift reaction to produce additional hydrogen and carbon dioxide.

A method for reducing a carbon emissions intensity of a fuel includes producing a first hydrocarbon fluid; capturing a carbon dioxide (CO.sub.2) fluid from the first hydrocarbon fluid production; and injecting the captured carbon dioxide into a subterranean zone from one or more wellbores to enhance a production of a second hydrocarbon fluid from the zone, at least one of the first or the second hydrocarbon fluids processable into a hydrocarbon fuel that includes a low carbon intensity fuel based, at least in part, on the captured and injected CO.sub.2 fluid.