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 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.

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.

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.

A process for providing a carbon monoxide-containing stream involves a separation of synthesis gas into a hydrogen-rich gas stream and a carbon monoxide-rich gas stream containing carbon monoxide to an extent of 85% by volume or more. The separation is effected in an arrangement composed of three membrane separation stages. Prior to the performance of the membrane separation, the synthesis gas is pretreated for removal of secondary components present in the synthesis gas.

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 method of processing stranded remote gas comprising (a) introducing stranded remote gas and steam to a reforming unit to produce synthesis gas (syngas), wherein the stranded remote gas comprises methane, carbon dioxide, and sulfur-containing compounds, and wherein the syngas is characterized by a molar ratio of hydrogen to carbon monoxide of from about 1.7:1 to about 2.5:1; (b) introducing at least a portion of the syngas to a Fischer-Tropsch (FT) unit to produce an FT syncrude product, FT water, and FT tail gas, wherein the FT syncrude product comprises FT hydrocarbon liquids, wherein the FT syncrude product comprises FT wax in an amount of less than about 5 wt. %, and wherein the FT unit is characterized by an FT reaction temperature of from about 300° C. to about 350° C.; and (c) blending the FT syncrude product with crude oil for storage and/or transport.

A process for separating two gaseous streams, including purifying a first gaseous stream in a first acid gas removal absorber, purifying in a first temperature swing adsorption unit, and then separating at a cryogenic temperature in a separation unit to produce a stream of fluid enriched in carbon monoxide and a stream of fluid enriched in hydrogen, sending a second gaseous stream containing at least carbon monoxide, hydrogen and at least one acid gas to a shift reaction unit, the shifted second stream is purified in a second acid gas removal absorber to remove carbon dioxide and the purified second stream is sent as a feed stream to a pressure swing adsorption unit to produce a hydrogen enriched stream, and sending at least part of the stream enriched in hydrogen from the separation unit as a feed stream to the pressure swing adsorption unit to produce the hydrogen-enriched stream.

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 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.

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 non-methane 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. The gas conversion system can have a modal design such that it can operate to form hydrogen gas or alternatively operate to form synthetic natural gas with the same unit operation components.

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.