Reactor for producing hydrogen from hydrocarbon fuels

A reformer reactor for producing hydrogen gas from hydrocarbons comprising:

• (a) a first zone having a partial oxidation reaction vessel, the vessel having an opening for emission of reactants into the first zone;
• (b) a second zone adjacent the first zone, the second zone containing a first catalyst suitable for promoting an endothermic reaction;
• (c) a first partition separating the first and second zones, the first partition having a plurality of spaced openings to permit the flow of the reaction stream therethrough;
• and
• (d) a flow path for directing flow of a reaction stream in diverging directions from the first zone into the second zone, the flow of the reaction stream continuing in the same general diverging directions through the second zone and the reactor being configured such that during operation, heat from the reaction stream after partial oxidation reaction is transferred to the first catalyst sufficient to support a temperature to promote steam reforming in the presence of the first catalyst, wherein the first partition being constructed of material composition, thickness, and finish to assist in controlling heat transfer between the reaction vessel and the second zone.

A reactor for reforming hydrocarbons to produce hydrogen having one or more inlets to permit entry of hydrocarbons, an oxygen-containing gas, and water in the form of steam, comprising:

• a first zone for receiving the hydrocarbons, oxygen-containing gas, and water, in the form of steam, the first zone including a vessel for conducting partial oxidation of the hydrocarbons to form a partially oxidized reformate;
• a second zone containing a catalyst having the characteristic of promoting the reforming the partially oxidized hydrocarbon reformate, in the presence of steam, into carbon monoxide and hydrogen;
• a third zone containing a catalyst having the characteristic of promoting a water-gas-shift reaction with respect to the carbon monoxide and hydrogen in the reformate at temperature in a first shift-temperature range;
• a fourth zone containing a catalyst having the characteristic of promoting a water-gas-shift reaction with respect to the carbon monoxide and hydrogen in the reformate at a second temperature within a second shift-temperature range, which range is lower than the first shift-temperature range;
• first heat exchange tubes in at least one of the the third and fourth zoness for preheating at least one of the hydrocarbons, the oxygen-containing gas, or water, a reaction flow path that is radially away from the first zone into the second, third and fourth zones, respectively;
• and,
• partitions separating the first, second, third, and fourth zones, each partition having a plurality of openings to permit reformate to pass from the first zone and through the subsequent zones.