Methods and systems are provided for the conversion of waste plastics into various useful downstream recycle-content products. More particularly, the present system and method involves pyrolyzing one or more waste plastics into various pyrolysis products, including pyrolysis gas, and then subjecting the pyrolysis gas to partial oxidation (POX) gasification to thereby form a syngas composition.

A method of using a feedstock gas reactor is described. A hydrocarbon, such as methane, is chemical decomposed in the feedstock gas reactor using heat of combustion generated from the combustion of a combustible gas. A mixed product stream is extracted from the feedstock gas reactor. The mixed product stream comprises hydrogen, carbon, and water. At least a portion of the one or more combustion product gases are vented from the combustion chamber. At least some of the carbon is activated using the vented one or more combustion product gases. At least some of the activated carbon is recycled to the feedstock gas reactor.

A reforming method may include: reforming a hydrocarbon with steam plasma to generate a first synthetic gas, which includes hydrogen and carbon dioxide, from the hydrocarbon; cooling the first synthetic gas to a predetermined temperature, removing water vapor included in the first synthetic gas, and separating hydrogen from the first synthetic gas; reforming the first synthetic gas, from which hydrogen is separated, and a hydrocarbon with steam plasma to generate hydrogen, and generating a second synthetic gas in which carbon dioxide is decreased; and cooling the second synthetic gas to a predetermined temperature, removing water vapor included in the second synthetic gas, and separating hydrogen from the second synthetic gas.

A hydrogen production apparatus includes a heating furnace that burns fuel supplied by a fuel supply unit and heats catalyst particles, a cyclone that is connected to a downstream side of the heating furnace and separates the catalyst particles and a combustion exhaust gas, and a thermal decomposition furnace including a storage tank that stores the catalyst particles separated by the cyclone and a raw material gas introduction unit that introduces a raw material gas containing at least hydrocarbon from a lower portion of the storage tank.

Embodiments of the invention relate to systems and methods for cracking hydrocarbons into hydrogen gas and carbon using heating of a fluidized bed. The systems and methods utilize electrically conductive carbon or graphite particles as a fluidized bed material for heating hydrocarbon feedstock to at least a pyrolysis temperature. The electrically conductive carbon, graphite, or other particles may be heated by electrically powered sources that include induction heating, microwave heating, millimeter wave heating, joule heating and/or plasma heating. Combustion heating may also be employed in varying amounts with varying combinations of electrically powered heating sources.

A residue stream comprising liquid hydrocarbons and metal-rich solid particles is reacted with an oxidant stream in a gasifier to produce a syngas stream that is quenched in a water bath. The risk of plugging in the water lines is reduced by removing solids from the recycled water streams. Acid gases are stripped from at least a portion of the recycled water to reduce the risk of precipitates forming from the reaction of dissolved acid gases with metal ions.

The present subject matter relates to co-producing H-CNG and CNTs. The process comprises adding catalyst to a first reactor (110) and activating the catalyst and performing a reaction to obtain H-CNG and CNTs. At a first predetermined time after reaction has progressed in the first reactor (110), catalyst is added to a second reactor (120), activated, and then the reaction proceeds simultaneously in the first reactor (110) and second reactor (120). The use of multiple reactors with staggered start times helps in the continuous co-production of H-CNG and CNTs. Catalyst preparation process is integrated with the co-production process for efficient heat recovery. The first and second reactors are fluidized bed reactors with cantilever trays having weirs for controlling the residence time of the catalyst in the reactor and thereby controlling the purity of CNTs produced.

The present invention provides a process for the manufacture of a useful product from carbonaceous feedstock of fluctuating compositional characteristics, the process comprising the steps of: continuously providing the carbonaceous feedstock of fluctuating compositional characteristics to a gasification zone; gasifying the carbonaceous feedstock in the gasification zone to obtain raw synthesis gas; sequentially removing ammoniacal, sulphurous and carbon dioxide impurities from the raw synthesis gas to form desulphurised gas and recovering carbon dioxide in substantially pure form; converting at least a portion of the desulphurised synthesis gas to a useful product. Despite having selected a more energy intensive sub-process i.e. physical absorption for removal of acid gas impurities, the overall power requirement of the facility is lower on account of lower steam requirements and thereby leading to a decrease in the carbon intensity score for the facility.

A method of using a feedstock gas reactor is described. A hydrocarbon, such as methane, is chemical decomposed in the feedstock gas reactor using heat of combustion generated from the combustion of a combustible gas. A mixed product stream is extracted from the feedstock gas reactor. The mixed product stream comprises hydrogen, carbon, and water. At least a portion of the one or more combustion product gases are vented from the combustion chamber. At least some of the carbon is activated using the vented one or more combustion product gases. At least some of the activated carbon is recycled to the feedstock gas reactor.

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.