Direct thermal decomposition of hydrocarbons into solid carbon and hydrogen is performed by a process and a device. The process comprises preheating a hydrocarbon gas stream to a temperature between 500 C. and 700 C. and injecting the pre-heated hydrocarbon gas stream into the reactor pool of a liquid metal reactor containing a liquid media; forming a multi-phase flow with a hydrocarbon gas comprising hydrogen and solid carbon at a temperature between 900 C. and 1200 C.; forming a carbon layer on the free surface of the liquid media made up of solid carbon particles which are then displaced into at least one carbon extraction system and at least one recipient for collecting them; and, at the same time, the gas comprising hydrogen leaves the reactor pool through a porous rigid section, being collected at a gas outlet collector from where the gas comprising hydrogen finally leaves the liquid metal reactor.

The invention relates to a process to convert hydrocarbons into hydrogen and a separate carbon phase, whereby in step a) the hydrocarbons are contacted with a molten salt, preferably comprising Zinc Chloride, at temperatures preferably above 500 C. and in step b) a solid or liquid carbon phase is separated from the molten salt at a lower temperature, preferably below 150 C. The molten salt is then preferably re-heated to the desired temperature and recycled to step a). The process avoids the emission of CO.sub.2, making the hydrogen produced in this way a zero CO.sub.2 emission fuel and which also produces a carbon product produced having a use value.

The following describes a reconfigurable set of industrial processing techniques which, when appropriately combined, enable zero-emissions reforming, utilizing a wide range of conventional and unconventional feedstocks. Hydrocarbons, harvested or refuse biomass, as well as assorted byproducts and wastes are reformed through tightly integrated processing. The system is designed to incorporate alternative energy sources such as renewables or nuclear for high-density energy utilization and storage. Central to the processing methodology is a novel molten salt electrochemical reactor designed as a modular system for high-throughput carbochlorination and resource recovery. Such a configuration drastically reduces or eliminates waste while improving efficiency and realizing vast new economic incentives.

A method of generating syngas as a primary product from renewable feedstock, fossil fuels, or hazardous waste with the use of a cupola. The cupola operates on inductive heat alone, chemically assisted heat, or plasma assisted heat. Cupola operation is augmented by employing carbon or graphite rods to carry electrical current into the metal bath that is influenced by the inductive element. The method includes the steps of providing a cupola for containing a metal bath; and operating an inductive element to react with the metal bath. A combination of fossil fuel, a hazardous waste, and a hazardous material is supplied to the cupola. A plasma torch operates on the metal bath directly, indirectly, or in a downdraft arrangement. Steam, air, oxygen enriched air, or oxygen are supplied to the metal bath. A pregassifier increases efficiency and a duct fired burner is added to a simple cycle turbine with fossil fuel augmentation.

Process and apparatus for producing a H.sub.2-containing product and a CO-containing product with CO-containing product turndown capability. The H.sub.2-containing product is produced in a process train with a shift reactor and pressure swing adsorption unit. The CO-containing product is produced in a process train with a CO.sub.2 removal unit and a cryogenic separation unit. During the CO-containing product turndown mode, a portion or all of the CO-containing product is passed to the shift reactor in the H.sub.2-containing product train to form additional H.sub.2.

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.

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.

Process and apparatus for producing a H.sub.2-containing product and a CO-containing product with CO-containing product turndown capability. The H.sub.2-containing product is produced in a process train with a shift reactor and pressure swing adsorption unit. The CO-containing product is produced in a process train with a CO.sub.2 removal unit and a cryogenic separation unit. During the CO-containing product turndown mode, a portion or all of the CO-containing product is passed to the shift reactor in the H.sub.2-containing product train to form additional H.sub.2.

A method of generating syngas as a primary product from renewable feedstock, fossil fuels, or hazardous waste with the use of a cupola. The cupola operates on inductive heat alone, chemically assisted heat, or plasma assisted heat. Cupola operation is augmented by employing carbon or graphite rods to carry electrical current into the metal bath that is influenced by the inductive element. The method includes the steps of providing a cupola for containing a metal bath; and operating an inductive element to react with the metal bath. A combination of fossil fuel, a hazardous waste, and a hazardous material is supplied to the cupola. A plasma torch operates on the metal bath directly, indirectly, or in a downdraft arrangement. Steam, air, oxygen enriched air, or oxygen are supplied to the metal bath. A pregassifier increases efficiency and a duct fired burner is added to a simple cycle turbine with fossil fuel augmentation.

The invention relates to a process to convert hydrocarbons into hydrogen and a separate carbon phase, whereby in step a) the hydrocarbons are contacted with a molten salt, preferably comprising Zinc Chloride, at temperatures preferably above 500 C. and in step b) a solid or liquid carbon phase is separated from the molten salt at a lower temperature, preferably below 150 C. The molten salt is then preferably re-heated to the desired temperature and recycled to step a). The process avoids the emission of CO.sub.2, making the hydrogen produced in this way a zero CO.sub.2 emission fuel and which also produces a carbon product produced having a use value.