Reformer Apparatus and Method

Abstract

A multiple adiabatic bed reforming apparatus and process are disclosed in which stage-wise combustion, in combination with multiple reforming chambers with catalyst, utilize co-flow and cross-flow under laminar flow conditions, to provide a reformer suitable for smaller production situations as well as large scale production. A passive stage by stage fuel distribution network suitable for low pressure fuel is incorporated and the resistances in successive fuel distribution lines control the amount of fuel delivered to each combustion stage.

1 - 27 . (canceled) 
     
     
         28 . A reactor system, comprising:
 i) at least one pre-reformer stage configured to convert at least a portion of a gaseous hydrocarbon-steam stream to form a pre-reformed stream;   ii) a printed circuit reformer system configured to form a flue gas stream and to convert the pre-reformed stream into a syngas stream, the syngas stream at a temperature above metal dusting conditions; and   iii) a first heat integration system configured to heat the at least one pre-reformer stage with at least a portion of the flue gas stream.   
     
     
         29 . The printed circuit reactor system of  claim 28 , wherein the printed circuit reformer system comprises a heat exchanger configured to bring a heated air stream and the pre-reformed stream into thermal communication to form a partially cooled heated air stream and a heated pre-reformed stream. 
     
     
         30 . The printed circuit reactor system of  claim 29 , wherein the printed circuit reformer system comprises a printed circuit reformer stage configured to at least partially reform the heated pre-reformed stream. 
     
     
         31 . The printed circuit reactor system of  claim 30 , wherein the printed circuit reformer stage comprises a catalytic reforming bed. 
     
     
         32 . The printed circuit reactor system of  claim 28 , further comprising a preheater configured to heat a fuel stream to form a heated fuel stream, wherein the fuel stream is at a temperature below metal dusting conditions and the heated fuel stream is at a temperature above metal dusting conditions. 
     
     
         33 . The printed circuit reactor system of  claim 32 , wherein the heated fuel stream is formed by partially combusting a portion of fuel in the fuel stream. 
     
     
         34 . The printed circuit reactor system of  claim 32 , wherein the printed circuit reformer system comprises a combustion chamber configured to combust a portion of the cooled heated air stream with a portion of the heated fuel stream. 
     
     
         35 . The printed circuit reactor system of  claim 28 , further comprising a quench heat exchanger configured to cool the syngas stream from above metal dusting conditions to below metal dusting conditions. 
     
     
         36 . The printed-circuit reactor system of  claim 28 , wherein the printed-circuit reactor system is in fluid communication with a stranded gas source. 
     
     
         37 . The printed-circuit reactor system of  claim 28 , wherein the printed-circuit reactor system is configured to operate at less than full capacity. 
     
     
         38 . The printed-circuit reactor system of  claim 28 , wherein the printed-circuit reactor system is configured for modulated throughput. 
     
     
         39 . The printed-circuit reactor system of  claim 28 , wherein printed-circuit reactor system is configured for automated operation. 
     
     
         40 . The printed-circuit reactor system of  claim 28 , wherein the printed-circuit reactor system is at least partially passively controlled. 
     
     
         41 . The printed circuit reactor system of  claim 28 , wherein the printed-circuit reactor system has an operating cost proportionate to the quantity of syngas produced. 
     
     
         42 . The printed circuit reactor system of  claim 28 , wherein the printed-circuit reactor system has an initial cost proportionate to the quantity of syngas produced. 
     
     
         43 . An on-site production facility comprising the printed-circuit reactor system of  claim 28 . 
     
     
         44 . The on-site production facility of  claim 43 , wherein there is no export destination for excess steam. 
     
     
         45 . The on-site production facility of  claim 43 , wherein the on-site production facility produces hydrogen. 
     
     
         46 . The on-site production facility of  claim 43 , wherein the on-site production facility produces ammonia. 
     
     
         47 . The on-site production facility of  claim 43 , wherein the on-site production facility produces methanol.