Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

A method of preheating a feed to a molten material reactor comprises heating a hydrocarbon feed in a first heat exchanger using a cooled product gas to produce a heated hydrocarbon feed stream, pyrolyzing at least a portion of the C.sub.2+ hydrocarbons in the heated feed stream in a pyrolysis reactor to produce a pyrolyzed hydrocarbon stream, and heating the pyrolyzed hydrocarbon stream in a second heat exchanger using a product gas to produce a pre-heated feed gas. The heated hydrocarbon feed stream comprises methane and one or more C.sub.2+ hydrocarbons.

A feedstock gas, such as natural gas, is introduced into a mixing chamber. A combustible gas is introduced into a combustion chamber, for example simultaneously to the introduction of the feedstock gas. Thereafter, the combustible gas is ignited so as to cause the combustible gas to flow into the mixing chamber via one or more fluid flow paths between the combustion chamber and the mixing chamber, and to mix with the feedstock gas. The mixing of the combustible gas with the feedstock gas causes one or more products to be produced.

A system for hydrogen recovery includes a dryer having an inlet that may be fluidly connected to a hydrogen outlet of a hydrogen generator, a hydrogen using device having an inlet fluidly connected to a dry hydrogen outlet of the dryer, and one or more conduits fluidly connecting a wet hydrogen outlet from the dryer and an impure hydrogen exhaust outlet of the hydrogen using device to the inlet of the dryer.

A cooler installed to cool NG supplied from a compressor to a pyrolysis reactor and configured to independently use multiple refrigerants is provided; a first refrigerant supply device provided to supply a first refrigerant for the cooler; and a second refrigerant supply device configured to supply, to the cooler, a fuel gas for a burner, including an off-gas and NG which has not passed through the compressor, as a second refrigerant for the cooler.

Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

There is disclosed a furnace (10), a fluid feed component, a fluid reforming system, and a method of reforming a fluid (20). The furnace (10) comprises a vessel (12) that defines a chamber (14) for holding a body of liquid (16). A fluid inlet (18) is provided for introducing a fluid (20) into the chamber (14) below a level (22) of the body of liquid (16) to cause the fluid (20) to interact with the liquid (16) and to migrate therethrough towards an outlet (24) for discharging a product (26) of the interaction from the chamber (14). A liquid circulation passage (28) is implemented, having a weir (30) which is operatively located near the level of the body of liquid (16), and a port (34) which is located remote from the weir (30) and in fluid (20) communication with the fluid inlet (18) so as to enable the liquid (16) to flow over the weir (30) through the liquid circulation passage (28) and through the port (34).

Devices and methods for reducing the specific energy required to reform or pyrolyze reactants in plasmas operating at high flow rates and high pressures are presented. These systems and methods include 1) introducing electrons and/or easily ionized materials to a plasma reactor, 2) increasing turbulence and swirl velocity of the flows of feed gases to have improved mixing in a plasma reactor, and 3) reducing slippage from a plasma reactor system. Such plasma systems may allow plasma reactors to operate at lower temperatures, higher pressure, with improved plasma ignition, increased throughput and improved energy efficiency. In preferred embodiments, the plasma reactors are used to produce hydrogen and carbon monoxide, hydrogen and carbon, or carbon monoxide through reforming and pyrolysis reactions. Preferred feedstocks include methane, carbon dioxide, and other hydrocarbons.

A method of continuously performing one or more heat-consuming processes, where at least one heat-consuming process is electrically heated. The maximum temperature in the reaction zone of the heat-consuming process is higher than 500° C., at least 70% of products of the heat-consuming process are continuously processed further downstream and/or fed to a local energy carrier network, and the electrical energy required for the heat-consuming process is drawn from an external power grid and from at least one local power source. The local power source is fed by at least one local energy carrier network and by products from the heat-consuming process. The local energy carrier network stores natural gas, naphtha, hydrogen, synthesis gas, and/or steam as energy carrier, and has a total capacity of at least 5 GWh. The local energy carrier network is fed with at least one further product and/or by-product from at least one further chemical process.

Ammonia, methanol, Fischer Tropsch products, and derivatives thereof are made by using hydrogen and oxygen supplied from an electrolyzer that is at least partially powered by renewable power, resulting in green process and systems that produce green products disclosed herein. A process using biomass and renewable energy includes producing an unshifted syngas from biomass and oxygen in a gasification unit, introducing water into an electrolyzer to produce an oxygen product and a hydrogen product, and introducing the oxygen product to the gasification unit. The electrolyzer is powered by renewable energy, and the oxygen product supplies at least a portion of the oxygen to the gasification unit.