The invention relates to a process for producing a converted synthesis gas from a crude synthesis gas comprising the essential synthesis gas constituents of hydrogen (H.sub.2) and carbon monoxide (CO), wherein the crude synthesis gas is initially generated in a synthesis gas generation stage and subsequently converted in a multi-stage CO conversion and thus elevated in terms of its hydrogen content. The crude synthesis gas has steam added to it as a reaction partner for the CO conversion and cooling of the converted synthesis gas affords an aqueous condensate.

The apparatus described herein comprises a first reaction chamber having an inlet for a hydrocarbon medium, particularly a gas having the composition C.sub.nH.sub.m, and an outlet. Means for decomposing the hydrocarbons into carbon particles and hydrogen by introducing heat are provided between the inlet and the outlet in the first reaction chamber. The apparatus also comprises a second reaction chamber having an elongated configuration and having a first inlet at one end and an outlet at the opposite end, wherein the first inlet of the second reaction chamber is connected with the outlet of the first reaction chamber, and wherein the second reaction chamber comprises a widening flow cross-section (measured perpendicular to the longitudinal dimension of the second reaction chamber) between the inlet and the outlet. In addition, at least one second inlet into the second reaction chamber is provided, wherein the second inlet can be connected to a source for CO.sub.2 and/or H.sub.2O. Preferably, the second inlet is connected with a source of CO.sub.2, and therefore CO.sub.2 is injected therewith during operation. A method for operating this apparatus is also described. The energy balance of a synthesis gas production can be improved with the apparatus and the method for operating compared with known methods.

A method for producing elemental carbon and hydrogen gas directly from a hydrocarbon (for example, natural gas or methane) using a chemical reaction or series of reactions. In an aspect, other materials involved such as, for example, elemental magnesium, remain unchanged and function as a catalyst.

The present invention provides a steam reforming process for heavy oil or hydrocarbons using a circulating fluidized bed reactor, the process having a reforming step and a regeneration step, wherein the reforming step and the regeneration step comprise a fluidized reactor containing a fluidizable nickel-containing reforming catalyst and produce hydrogen as a product of the reforming bed. The invention produces high purity hydrogen in the synthesis gas product stream and avoids irreversible fouling on the catalyst.

The invention relates to a process to convert hydrocarbons into hydrogen and a separate carbon phase, whereby in step a) the hydrocarbons are contacted with a molten salt, preferably comprising Zinc Chloride, at temperatures preferably above 500 C. and in step b) a solid or liquid carbon phase is separated from the molten salt at a lower temperature, preferably below 150 C. The molten salt is then preferably re-heated to the desired temperature and recycled to step a). The process avoids the emission of CO.sub.2, making the hydrogen produced in this way a zero CO.sub.2 emission fuel and which also produces a carbon product produced having a use value.

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.

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 method of co-producing a carbon dioxide containing stream and a syngas stream, including introducing a high-pressure hydrocarbon containing stream and a high-pressure oxygen containing stream into a syngas generator, thereby producing a high-pressure syngas stream, introducing a low-pressure hydrocarbon containing stream and a low-pressure oxygen containing stream into an oxy-combustion device, thereby producing a low-pressure carbon dioxide containing stream, and introducing the low-pressure carbon dioxide containing stream into a waste heat boiler, thereby producing steam, and introducing the steam into a work expander, thereby generating work and a carbon dioxide containing stream.

The invention relates to a process for producing a converted synthesis gas from a crude synthesis gas comprising the essential synthesis gas constituents of hydrogen (H.sub.2) and carbon monoxide (CO), wherein the crude synthesis gas is initially generated in a synthesis gas generation stage and subsequently converted in a multi-stage CO conversion and thus elevated in terms of its hydrogen content. The crude synthesis gas has steam added to it as a reaction partner for the CO conversion and cooling of the converted synthesis gas affords an aqueous condensate.

A method of co-producing a carbon dioxide containing stream and a syngas stream, including, introducing a first high-pressure hydrocarbon containing stream and a first high-pressure oxygen containing stream into a syngas generator, thereby producing a high-pressure syngas stream, introducing a second high-pressure hydrocarbon containing stream and a second high-pressure oxygen containing stream into an oxy-combustion device, thereby producing a high-pressure carbon dioxide containing stream, and introducing the high-pressure carbon dioxide containing stream into a work expander, thereby generating work and a carbon dioxide containing stream.