A process for producing hydrogen comprising the steps of reforming a hydrocarbon feedstock to form a synthesis gas; subjecting the synthesis gas to one or more stages of water gas shift to convert carbon monoxide to carbon dioxide and form a hydrogen-enriched synthesis gas; and treating the hydrogen-enriched synthesis gas to form a purified hydrogen product and tail gas stream containing methane, wherein at least a portion of the tail gas stream is treated by subjecting it to partial oxidation or autothermal reforming to form a partially-oxidised or reformed tail gas, followed by of water gas shift of the partially-oxidised or reformed tail gas to form a hydrogen-enriched tail gas, and a step of carbon dioxide removal from the hydrogen-enriched tail gas to form a hydrogen stream and a carbon dioxide stream, wherein the carbon dioxide stream is recovered and a portion of the hydrogen stream is a fuel.

A synthesis gas plant for producing a synthesis gas, where the synthesis gas plant includes a reforming section arranged to receive said feed gas and provide a combined synthesis gas, wherein said reforming section includes an electrically heated reforming reactor, a fired reforming reactor and an optional third reforming reactor. The reforming section is arranged to output a combined synthesis gas. An optional post processing unit downstream the reforming section is arranged to receive said combined synthesis gas stream and provide a post processed synthesis gas stream. A gas separation unit arranged to separate the combined synthesis gas stream or the post processed synthesis gas stream into a condensate, a product synthesis gas and an off-gas. At least a part of the off-gas is recycled from said gas separation unit to said one or more burners. Also, a process for producing synthesis gas from a feed gas comprising hydrocarbons.

Method for the preparation of synthesis gas combining electrolysis of water, tubular steam reforming and autothermal reforming of a hydrocarbon feed stock in parallel.

Syngas production and separation plant comprising: -At least one reformer for converting a hydrocarbon feedstock into a gas stream comprising hydrogen, carbon monoxide and at least one hydrocarbon as impurity, said reformer comprising a fired tubular reformer, a radiant section, a convection section and a heat recovery section, -a carbon monoxide cold box downstream of the reformer configured to produce a carbon monoxide-enriched gas stream and a waste gas stream comprising hydrogen and at least one hydrocarbon, -a passageway for feeding the radiant section of the reformer with a first part of the waste gas stream from cold box, -a compressor for compressing a second part of the waste gas stream from cold box, -a hydrogen-permeating membrane separation system configured to be fed by the compressed second part of the waste gas stream and to produce a hydrogen-enriched permeate and a hydrocarbon-enriched retentate.

A process is described for steam reforming a hydrocarbon feedstock, comprising passing a mixture of the hydrocarbon feedstock and steam through a catalyst bed comprising a particulate nickel steam reforming catalyst and a structured nickel steam reforming catalyst disposed within a plurality of externally heated tubes in a tubular steam reformer, wherein each tube has an inlet to which the mixture of hydrocarbon and steam is fed, an outlet from which a reformed gas containing hydrogen, carbon monoxide, carbon dioxide, steam and methane is recovered, and the steam reforming catalyst at the outlet of the tubes is the structured steam reforming catalyst, wherein the particulate steam reforming catalyst comprises 5 to 30% by weight nickel, and the structured steam reforming catalyst comprises nickel dispersed over the surface of a porous metal oxide present as a coating on a non-porous metal or ceramic structure.

A plant and process for producing a hydrogen rich gas are provided, said process including the steps of: steam reforming a hydrocarbon feed into a synthesis gas; shifting the synthesis gas and conducting the shifted gas to a hydrogen purification unit, subjecting CO.sub.2-rich off-gas from the hydrogen purification unit to a carbon dioxide removal in a low temperature CO.sub.2-removal section and recycling CO.sub.2-depleted off-gas rich in hydrogen to the process. A drying unit upstream the CO.sub.2-removal section is provided, under the addition of regeneration gas produced in the plant and process.

A process includes feeding atmospheric air to an air separation unit to produce a flow of nitrogen and a flow of oxygen; combining the oxygen with a hydrocarbon flow and water in an auto-thermal reformer to produce a retentate stream to a membrane water gas shift reactor (M-WGSR); generating, from the retentate stream to the M-WGSR, a permeate stream from the M-WGSR that includes a first flow of carbon dioxide and a first combined flow of hydrogen and nitrogen; feeding a retentate stream to a membrane steam methane reformer (M-SMR) to produce a permeate stream from the M-SMR that includes a second flow of carbon dioxide and a second combined flow of hydrogen and nitrogen; feeding the first and second combined flows to an ammonia synthesis unit to produce ammonia; and feeding the first and second flows of carbon dioxide and the ammonia to a urea synthesis unit to produce a flow of urea by fully utilizing the carbon dioxide.

A method of producing hydrogen from a hydrocarbon feedstock is provided. Wherein, at least a portion of a fuel stream comprises a superheated ammonia stream. And, at least: a first portion of a hydrogen-rich stream is combined with a shifted syngas stream prior to introduction into a pressure swing adsorber, a second portion of the hydrogen-rich stream is combined with the fuel stream prior to introduction into a steam methane reformer, and/or a third portion of the hydrogen-rich stream is combined with a hydrocarbon containing feedstock stream and a steam stream prior to introduction into a feed pre-heater. Heat integration between the ammonia vaporization and superheating steps is employed to cool process streams to minimize and even eliminate a dedicated cryogenic refrigeration system.