The disclosure relates to methods, systems, and apparatus arranged and designed for converting non-methane hydrocarbon gases into multiple product gas streams including a predominately hydrogen gas stream and a predominately methane gas steam. Hydrocarbon gas streams are reformed, cracked, or converted into a synthesis gas stream and methane gas stream by receiving a volume of flare gas or other hydrocarbon liquid or gas feed, where the volume of hydrocarbon feed includes a volume of methane and a volume of nonmethane hydrocarbons. The hydrogen contained in the syngas may be separated into a pure hydrogen gas stream. A corresponding gas conversion system can include a super heater to provide a hydrocarbon feed/steam mixture, a heavy hydrocarbon reactor for synthesis gas formation, and a hydrogen separator to recover the hydrogen portion of the synthesis gas.

A process for reforming for producing hydrogen and generating electricity, comprises: introducing a feed comprising a hydrocarbon stream to a reformer to produce unshifted synthesis gas (syngas); introducing the unshifted syngas to a water gas shift unit to produce a shifted syngas; removing CO.sub.2 from the shifted syngas to produce a CO.sub.2 depleted syngas and a CO.sub.2 product; introducing the CO.sub.2 depleted syngas to a pressure swing adsorption unit to produce a hydrogen product and an off-gas comprising carbon monoxide, carbon dioxide, unreacted methane; splitting a portion of the hydrogen product; and providing the portion of the hydrogen product to an electricity generator for generating electricity for use within the process.

The disclosure describes a system for generating hydrogen gas from a hydrocarbon through pyrolysis with reduced soot formation and increased carbon loading. The system includes a pyrolysis reactor configured to generate the hydrogen gas from the hydrocarbon through pyrolysis. The pyrolysis reactor includes one or more fibrous substrates configured to provide a deposition surface for carbon generated from the pyrolysis of the hydrocarbon. Each fibrous substrate has an effective void fraction between 40% and 95%, and includes a plurality of fibers configured to maintain chemical and structural stability between about 850° C. and about 1300° C. The one or more fibrous substrates may have a relatively high surface area to fiber volume of the plurality of fibers.

An integrated process for the production of a useful liquid hydrocarbon product comprises: feeding a gasification zone with an oxygen-containing feed and a first carbonaceous feedstock comprising waste materials and/or biomass, gasifying the first carbonaceous feedstock in the gasification zone to produce first synthesis gas, partially oxidising the first synthesis gas in a partial oxidation zone to generate partially oxidised synthesis gas, combining at least a portion of the first synthesis gas and/or the partially oxidised synthesis gas and at least a portion of electrolysis hydrogen obtained from an electrolyser in an amount to achieve the desired hydrogen to carbon monoxide molar ratio of from about 1.5:1 to about 2.5:1, and to generate a blended synthesis gas, wherein the electrolyser operates using green electricity; and subjecting at least a portion of the blended synthesis gas to a conversion process effective to produce the liquid hydrocarbon product.

The present invention provides for a pressure swing adsorption (PSA) process for the substantial removal of H.sub.2O and CO.sub.2 from a synthesis gas to obtain a multicomponent product gas substantially free of H.sub.2O and CO.sub.2 with high recovery of the product gas. Further, the present invention provides an integrated process that achieves sufficiently high H.sub.2 and CO recoveries such that compression and recycling of the syngas purification PSA tailgas is not necessary to be economically advantageous compared to the conventional processes.

A plant and process for producing a hydrogen rich gas are provided, said process comprising the steps of: reforming a hydrocarbon feed in a reforming step using an autothermal reformer (ATR) thereby obtaining a synthesis gas comprising CH.sub.4, CO, CO.sub.2, H.sub.2 and H.sub.2O; shifting said synthesis gas in a shift configuration including a high temperature shift step; passing the shifted syngas to a first hydrogen purification unit, e.g. a PSA unit; passing a portion of the off-gas from the first hydrogen purification unit to a second hydrogen purification unit, and using off-gas from the first and second hydrogen purification unit as e.g. fuel for a preheater unit before the ATR.

A hydrogen-rich hydrocarbon fuel gas can be separated into a methane fuel stream and a hydrogen product stream. The methane fuel stream can be fed to a methane fuel fired furnace, combustion of the methane fuel stream can produce a carbon-dioxide-rich flue gas, and a carbon capture process can be performed on the carbon-dioxide-rich flue gas. The hydrogen product stream can be fed to a hydrogen fired furnace or elsewhere. Combustion of the hydrogen product stream in a hydrogen fired furnace can generate a flue gas the is low in carbon dioxide. Electrolysis of water obtained from the hydrogen fired furnace flue gas can produce hydrogen for a desired use, such as fuel for the hydrogen fired furnace, and can produce oxygen for enriching the fuel gas fed to the methane fuel fired furnace.

An environmental control system includes a carbon dioxide source; a compressor downstream of the carbon dioxide source; a Sabatier reactor downstream of the compressor, wherein the Sabatier reactor reacts carbon dioxide with hydrogen to produce methane and water; a water separator downstream of the Sabatier reactor, wherein the water separator separates hydrocarbons from water, wherein the hydrocarbons include methane; a pyrolysis assembly downstream of the water separator and upstream of the compressor, wherein the pyrolysis assembly pyrolyzes methane to produce carbon and hydrogen, wherein the pyrolysis assembly includes a pre-form that adheres carbon; and an oxygen generating assembly (OGA) downstream of the water separator and upstream of the compressor, wherein the OGA converts water to hydrogen and oxygen.

A process is described for the production of formaldehyde, comprising (a) subjecting methanol to oxidation with air in a formaldehyde production unit thereby producing a formaldehyde-containing stream; (b) separating said formaldehyde-containing stream into a formaldehyde product stream and a formaldehyde vent gas stream; wherein the vent gas stream, optionally after treatment in a vent gas treatment unit, is passed to one or more stages of: (i) synthesis gas generation, (ii) carbon dioxide removal, (iii) methanol synthesis or (iv) urea synthesis.

The invention relates to a process and a plant for the methanol synthesis, in particular for the methanol synthesis from a synthesis gas which has a hydrogen deficiency. According to the invention, a purge gas stream therefor is branched off from the synthesis gas circuit of the methanol synthesis, liberated from methanol traces in a washing device, and then treated in a hydrogen separation device which comprises a membrane separation stage and a pressure swing adsorption stage. Depending on the application and magnitude of the hydrogen deficit the membrane separation stage and the pressure swing adsorption stage can be connected in series or in parallel.