Delphi Technologies, Inc.

Praxair Technology, Inc.

Delco Electronics Corporation

Gm Global Technolgoy Operations, Inc.

Bayerische Motoren Werke Aktiengesellschaft

Sean Michael Kelly

Karl Jacob Haltiner, Jr

Gervase Maxwell Christie

Charles Robinson

Brian R Kromer

Jamie R Wilson

Diane M England

Michael Thomas Faville

Subhasish Mukerjee

Lee Jonathan Rosen

Michael M Litwin

Shrikar Chakravarti

Uttam R Doraswami

Lawrence W Kosowski

Javier E Gonzalez

Christopher M Mergler

Raymond Francis Drnevich

Kevin J Hawes

Kevin Richard Keegan

Haskell Simpkins

Bernhard A Fischer

John Lawrence Pawlak, Iii

Gail E Geiger

John Alan MacBain

David R Schumann

David Jay Vess

Trevor T Grover

Jiefeng Lin

Gary Blake

Juan Li

Minish Mahendra Shah

Joseph Howard Gladd

Thomas Martin Urbank

Andrew Frank Rodondi

Jonathan Andrew Lane

Karma Vir Sangwan

Jeffrey Michael Hickox

John P Absmeier

Bob Xiaobin Li

Ernesto Jose Gutierrez

Ines C Stuckert

Joachim Tachtler

John Charles Weber

John D Peck

Pawel J Plonczak

Curtis A Richardson

Christopher M DeMinco

John M Kirchberger

Sadashiv M Swami

Steven R Shaffer

Keith A Craigie

Malcolm J Grieves

Kenneth L Burgers

Chris M DeMinco

Bernard Edlinger

Larisa S Bobrov

Bernhard Edlinger

Bernie Fischer

Wladimir Y Sarmiento-Darkin

Kiran R Patel

William Shane Murphy

Karl Jacob Haltiner Jr

Karl J Haltiner Jr

John A Macbain

Gary D Blake

The present invention generally relates to an oxygen transport membrane syngas panel whereby the reformer layer of the panel is eliminated, and the primary reforming function is integrated into the manifold as a gas heated reformer with product syngas as the source of heat.

OTM syngas panel with gas heated reformer

A system and method for oxygen transport membrane enhanced Integrated Gasifier Combined Cycle (IGCC) is provided. The oxygen transport membrane enhanced IGCC system is configured to generate electric power and optionally produce a fuel/liquid product from coal-derived synthesis gas or a mixture of coal-derived synthesis gas and natural gas derived synthesis gas.

Method and system for oxygen transport membrane enhanced integrated gasifier combined cycle (IGCC)

A dual function composite oxygen transport membrane having a layered structure of mixed conducting oxygen transport materials on a first side of a porous substrate and a reforming catalyst layer on an opposing second side of the porous substrate. The layered structure of the mixed conducting oxygen transport materials contains an intermediate porous layer of mixed conducting oxygen transport materials formed on the porous substrate with a dense impervious layer of mixed conducting oxygen transport materials over the intermediate porous layer, and an optional surface exchange layer of mixed conducting oxygen transport materials over the dense impervious layer. The layered structure and the reforming catalyst layer are formed in separate steps.

Dual function composite oxygen transport membrane

A method of operating an oxygen transport membrane based reforming system employing one or more packs of thermally coupled panels of reformer tubes and oxygen transport membrane ('OTM') reactors close to thermo-neutral point is provided. The method produces syngas by converting a hydrocarbon-containing feed, such as natural gas in the reformer tubes of a pack by endothermic steam reforming reactions. The heat required for endothermic reforming reactions is provided by exothermic oxidizing reactions occurring inside the OTM reactors of the pack. At a thermo-neutral point the heat released by exothermic reactions matches the heat required to support endothermic reactions and heat losses in the pack. The method modulates the flow rate of hydrocarbon-containing feed and/or steam-to-carbon ratio of the combined feed to the pack to maintain the surface temperature of oxygen transport membrane reactors below a target maximum temperature. The syngas product oxygen-to-carbon ratio is maintained within a desired target range such that the OTM based reforming system is operated close to thermo-neutral point.

Method of thermally-stabilizing an oxygen transport membrane-based reforming system

The present invention relates to high efficient tubular catalytic steam reforming reactor configured from about 0.2 inch to about 2 inch inside diameter high temperature metal alloy tube or pipe and loaded with a plurality of rolled catalyst inserts comprising metallic monoliths. The catalyst insert substrate is formed from a single metal foil without a central supporting structure in the form of a spiral monolith. The single metal foil is treated to have 3-dimensional surface features that provide mechanical support and establish open gas channels between each of the rolled layers. This unique geometry accelerates gas mixing and heat transfer and provides a high catalytic active surface area. The small diameter, high aspect ratio tubular catalytic steam reforming reactors loaded with rolled catalyst inserts can be arranged in a multi-pass non-vertical parallel configuration thermally coupled with a heat source to carry out steam reforming of hydrocarbon-containing feeds. The rolled catalyst inserts are self-supported on the reactor wall and enable efficient heat transfer from the reactor wall to the reactor interior, and lower pressure drop than known particulate catalysts. The heat source can be oxygen transport membrane reactors.

High aspect ratio catalytic reactor and catalyst inserts therefor

The invention relates to a commercially viable modular ceramic oxygen transport membrane system for utilizing heat generated in reactively-driven oxygen transport membrane tubes to generate steam, heat process fluid and/or provide energy to carry out endothermic chemical reactions. The system provides for improved thermal coupling of oxygen transport membrane tubes to steam generation tubes or process heater tubes or reactor tubes for efficient and effective radiant heat transfer.

Ceramic oxygen transport membrane array reactor and reforming method

A system and method for temperature control in an oxygen transport membrane based reactor is provided. The system and method involves introducing a specific quantity of cooling air or trim air in between stages in a multistage oxygen transport membrane based reactor or furnace to maintain generally consistent surface temperatures of the oxygen transport membrane elements and associated reactors. The associated reactors may include reforming reactors, boilers or process gas heaters.

System and method for temperature control in an oxygen transport membrane based reactor

A carbon capture enabled system and method for generating electric power and/or fuel from methane containing sources using oxygen transport membranes by first converting the methane containing feed gas into a high pressure synthesis gas. Then, in one configuration the synthesis gas is combusted in oxy-combustion mode in oxygen transport membranes based boiler reactor operating at a pressure at least twice that of ambient pressure and the heat generated heats steam in thermally coupled steam generation tubes within the boiler reactor; the steam is expanded in steam turbine to generate power; and the carbon dioxide rich effluent leaving the boiler reactor is processed to isolate carbon. In another configuration the synthesis gas is further treated in a gas conditioning system configured for carbon capture in a pre-combustion mode using water gas shift reactors and acid gas removal units to produce hydrogen or hydrogen-rich fuel gas that fuels an integrated gas turbine and steam turbine system to generate power. The disclosed method and system can also be adapted to integrate with coal gasification systems to produce power from both coal and methane containing sources with greater than 90% carbon isolation.

Oxygen transport membrane reactor based method and system for generating electric power

The invention relates to a commercially viable modular ceramic oxygen transport membrane reforming reactor configured using repeating assemblies of oxygen transport membrane tubes and catalytic reforming reactors.

A commercially viable modular ceramic oxygen transport membrane reforming reactor for producing a synthesis gas that improves the thermal coupling of reactively-driven oxygen transport membrane tubes and catalyst reforming tubes required to efficiently and effectively produce synthesis gas.

A method and system for generating electrical power in which a high pressure synthesis gas stream generated in a gasifier is partially oxidized in an oxygen transport membrane based reactor, expanded and thereafter, is combusted in an oxygen transport membrane based boiler. A low pressure synthesis gas slip stream is split off downstream of the expanders and used as the source of fuel in the oxygen transport membrane based partial oxidation reactors to allow the oxygen transport membrane to operate at low fuel pressures with high fuel utilization. The combustion within the boiler generates heat to raise steam to in turn generate electricity by a generator coupled to a steam turbine. The resultant flue gas can be purified to produce a carbon dioxide product.

Oxygen transport membrane based advanced power cycle with low pressure synthesis gas slip stream

A system and method for air temperature control in an oxygen transport membrane based reactor is provided. The system and method involves introducing a specific quantity of cooling air or trim air in between stages in a multistage oxygen transport membrane based reactor or furnace to maintain generally consistent surface temperatures of the oxygen transport membrane elements and associated reactors. The associated reactors may include reforming reactors, boilers or process gas heaters.

System and method for air temperature control in an oxygen transport membrane based reactor

A method and system for producing a synthesis gas in an oxygen transport membrane based reforming system that utilizes a combined feed stream having a steam to carbon ratio between about 1.6 and 3.0 and a temperature between about 500&#xb0; C. and 750&#xb0; C. The combined feed stream is comprised a pre-reformed hydrocarbon feed, superheated steam, and a reaction product stream created by the reaction of a hydrogen containing stream reacted with the permeated oxygen at the permeate side of the oxygen transport membrane elements and wherein the hydrogen containing stream is a recycled portion of the synthesis gas.

Method and system for producing a synthesis gas in an oxygen transport membrane based reforming system with recycling of the produced synthesis gas

A method and apparatus for producing heat used in a synthesis gas production process is provided. The disclosed method and apparatus include a plurality of tubular oxygen transport membrane elements adapted to separate oxygen from an oxygen containing stream contacting the retentate side of the membrane elements. The permeated oxygen is combusted with a hydrogen containing synthesis gas stream contacting the permeate side of the tubular oxygen transport membrane elements thereby generating a reaction product stream and radiant heat. The present method and apparatus also includes at least one catalytic reactor containing a catalyst to promote the steam reforming reaction wherein the catalytic reactor is surrounded by the plurality of tubular oxygen transport membrane elements. The view factor between the catalytic reactor and the plurality of tubular oxygen transport membrane elements radiating heat to the catalytic reactor is greater than or equal to 0.5.

Oxygen transport membrane system and method for transferring heat to catalytic/process reactors

A method and apparatus for producing a synthesis gas product having one or more oxygen transport membrane elements thermally coupled to one or more catalytic reactors such that heat generated from the oxygen transport membrane element supplies endothermic heating requirements for steam methane reforming reactions occurring within the catalytic reactor through radiation and convention heat transfer. A hydrogen containing stream containing no more than 20 percent methane is combusted within the oxygen transport membrane element to produce the heat and a heated combustion product stream. The heated combustion product stream is combined with a reactant stream to form a combined stream that is subjected to the reforming within the catalytic reactor. The apparatus may include modules in which tubular membrane elements surround a central reactor tube.

Synthesis gas method and apparatus

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Pittsford, NY, United States of America

Sean Michael Kelly