In a hydrocarbon-fed steam methane reformer hydrogen-production process and system, carbon dioxide is recovered in a pre-combustion context, and optionally additional amounts of carbon dioxide are recovered in a post-combustion carbon dioxide removal, to provide the improved carbon dioxide recovery or capture disclosed herein.

A hydrocarbon is reacted with water in the presence of a catalyst to form hydrogen, carbon monoxide, and carbon dioxide. Hydrogen is selectively allowed to pass through a hydrogen separation membrane to a permeate side of a reactor, while water and carbon-containing compounds remain in a retentate side of the reactor. An outlet stream is flowed from the retentate side to a heat exchanger. The outlet stream is cooled to form a cooled stream. The cooled stream is separated into a liquid phase and a vapor phase. The liquid phase is flowed to the heat exchanger and heated to form steam. The vapor phase is cooled to form condensed water and a first offgas stream. The first offgas stream is cooled to form condensed carbon dioxide and a second offgas stream. The steam and the second offgas stream are recycled to the reactor.

A hydrogen generator having a reforming catalyst that causes hydrocarbon gas and steam to carry out a reforming reaction and reform into a hydrogen rich reformed gas, a reformer that is filled with said reforming catalyst and in which said reforming reaction is carried out, and a combustion chamber for combusting a fuel gas and obtaining reaction heat that is applied to said reforming reaction. At least the reforming region carrying out the reforming reaction is disposed inside the combustion chamber. A steam generator that introduces steam into the reformer is provided outside the combustion chamber.

A process is proposed for producing synthesis gas with reduced steam export by catalytic steam reforming of a hydrocarbonaceous feed gas with steam in a multitude of reformer tubes in a burner-heated reformer furnace to form a steam reforming flue gas. This process includes a configuration of the reformer tubes as reformer tubes with internal heat exchange and the use of a structured catalyst. For amounts of export steam between 0 and 0.8 kg of export steam per m.sub.N.sup.3 of hydrogen produced, these features interact synergistically when particular steam reforming conditions are selected.

The system includes a methane reformer, a combined cycle power generator, and a switch. The reformer is configured to react methane with steam. The combined cycle power generator includes a steam turbine, a gas turbine, a power generator, and a water boiler. The steam turbine is configured to rotate in response to receiving steam. The gas turbine is configured to rotate in response to receiving a mixture of fuel and air. The power generator is configured to convert rotational energy from the steam turbine and the gas turbine into electricity. In a first position, the switch is configured to direct exhaust from the gas turbine to the reformer, thereby providing heat to the reformer. In a second position, the switch is configured to direct exhaust from the gas turbine to the water boiler, thereby providing heat to the water boiler to generate steam.

Modified red mud catalyst compositions, methods for production, and methods for use, a composition including red mud material produced from an alumina extraction process from bauxite ore; nickel oxide, the nickel oxide present at between about 5 wt. % to about 40 wt. % of the modified red mud catalyst composition; and a Periodic Table Group VIB metal oxide, the Group VIB metal oxide present at between about 1 wt. % and about 30 wt. % of the modified red mud catalyst composition.

A high-pressure steam stream produced from the waste heat recovery system of a syngas producing unit may be superheated and then supplied to a steam turbine in a hydrocarbon production plant to produce an expanded steam stream and shaft power. A portion of the expanded stream can be fed into the reforming reactor in the syngas producing unit. The shaft power can be used to drive compressors and pumps in an olefins production plant. Considerable energy efficiency and capital investment savings can be realized by such steam integration compared to running the olefins production plant separately.

Chemical processors are configured to reduce mass, work in conjunction with solar concentrators, and/or house porous inserts in microchannel or mesochannel devices made by additive manufacturing. Methods of making chemical processors containing porous inserts by additive manufacturing are also disclosed.

A steam methane reformer (SMR) system includes an outer tube, wherein a first end of the outer tube is closed; an inner tube disposed in the outer tube, wherein a first end of the inner tube is open. A flow channel is defined within the inner tube and an annular space is defined between the outer tube and the inner tube, the flow channel being in fluid communication with the annular space. The SMR system includes a catalytic foam disposed in the annular space between the outer tube and the inner tube, the catalytic foam comprising a catalyst.

A method and a device for detecting internal carbon deposition of a solid oxide fuel cell system. The method comprises the following steps: adjusting a temperature in a reformer of the solid oxide fuel cell system so that a mixed gas discharged from the reformer is at a detection temperature; sampling the mixed gas; detecting a gas sample to obtain a mole fraction of each gas, and calculating an equilibrium constant K1 of a Boudouard reaction according to the obtained mole fraction; calculating an equilibrium constant K2 of the Boudouard reaction according to thermodynamics; comparing K1 and K2, if K1 is less than K2, determining that there will be no carbon deposition in the solid oxide fuel cell system; and if K1 is greater than K2, determining that there will be carbon deposition in the solid oxide fuel cell system. By using the method, a carbon deposition condition in the solid oxide fuel cell system can be detected to effect early warning regarding the solid oxide fuel cell system and take preventive measures