Method and apparatus for producing hydrogen using thermal energy generated in a rotary device

Abstract

A method of inputting thermal energy into a fluid medium in a process related to the production of hydrogen is provided. The method includes generating a heated fluid medium by at least one rotating device including a casing with at least one inlet and at least one outlet, a rotor including at least one rotor blade row arranged around a rotor hub mounted on a rotor shaft, and a stator formed as a stationary vane assembly arranged at least upstream of the at least one rotor blade row. In the method, a quantity of thermal energy is imparted to a fluid medium flow guided along a flow path formed within the rotating device by a series of energy transformations that occur as the fluid medium flow passes through stationary and rotating components of the rotating device, respectively. The method further includes incorporating the at least one rotating device into a heat-consuming process facility formed as a hydrogen production facility and further formed to perform a heat-consuming process related to producing hydrogen at a temperature essentially equal to or greater than about 500° C., and directing an input amount of energy into the at least one rotating device incorporated into the heat-consuming process facility, the input energy including electrical energy. Related methods, configurations, and equipment for hydrogen production are also provided.

Description

[Technical field]

[0001] The present invention relates generally to systems and methods for inputting thermal energy (heat) into fluids, and more particularly to tools and processes for optimizing energy efficiency and reducing greenhouse gas and particulate emissions in heat-consuming industrial processes related to the production of hydrogen, which are carried out at high and very high temperatures. [Background technology]

[0002] Industry and governments are struggling to find technologies to significantly reduce greenhouse gas (GHG) emissions. With the aim of limiting global warming, decarbonization measures must be undertaken across many key industrial sectors, for example those related to the production of energy carriers. Many decarbonization scenarios involve the use of hydrogen as a feedstock and / or fuel. Around 90% of the world's hydrogen production utilises methane, which is the main component of natural gas.

[0003] Steam methane reforming (SMR) is seemingly the most notable and widely used example of C1 chemistry, and it is the primary process for producing hydrogen from methane (see Equation 1a). Up to 95% of the world's hydrogen is produced through SMR. In steam methane reforming, pretreated natural gas or other suitable feed gas, such as shale gas, refinery off-gas, or biogas, is first pre-reformed with steam to crack the long-chain hydrocarbons into methane and syngas, which is then introduced into the primary reforming reactor, where methane is converted to hydrogen and carbon monoxide. Hydrogen yield can be further increased in a water-gas shift (WGS) unit, where a portion of the carbon monoxide reacts with water to produce hydrogen and carbon dioxide (Equation 1b). [ka]

[0004] The reforming reaction (Equation 1a) is endothermic, so it requires a heat source. In the case of a conventional SMR production plant, the heat is provided by an external furnace, which is typically fuel-fired. In the absence of a carbon capture device, after hydrogen recovery, the remaining methane-containing stream, CO2 and CO are routed to be used as fuel for the furnace, and all the CO2 is released to the atmosphere. On the other hand, carbon capture is more efficient, and therefore more common, from the SMR product stream (Equation 1b), which contains almost pure CO2, compared to the flue gas exhaust stream, which is a very dilute source of CO2. As a result, even the SMR process employs carbon capture. The CO2 originating from the fuel burned in the furnace is still released to the atmosphere. Thus, the SMR process is one of the most important sources of carbon dioxide in the atmosphere.

[0005] An alternative to SMR is the autothermal reforming (ATR) process (Equation 2a). This process produces synthesis gas, which is provided as a mixture of hydrogen and carbon monoxide in different ratios. The main difference between ATR and SMR is that SMR does not use or require oxygen. In reaction 2a, heat is produced by the partial oxidation of methane in the hydrocarbon feed stream. [ka]

[0006] If methane and oxygen could be directly converted to CO and H2 without side reactions, the equilibrium conversion would be nearly 100%, but in such a case the reaction would require extremely high temperatures. In most cases, the ATR process proceeds through a series of reactions (Equations 2a-2c). These reactions produce carbon monoxide and hydrogen as well as carbon dioxide and water. [ka]

[0007] Optimal conversion of methane is usually achieved by its partial oxidation at high temperatures (Equation 2a). Compared to SMR (Equation 1a), the partial oxidation reaction in ATR is exothermic and does not require an external heat source. Nevertheless, the reaction yield is lower because a portion of the feed (methane / natural gas) is used as fuel. However, there is no tail gas and all of the CO2 is concentrated in the product stream for carbon capture.

[0008] On the other hand, CO2-free hydrogen can be produced by converting / decomposing methane (which can be obtained from natural gas or biogas) into hydrogen through the methane pyrolysis process, specifically if renewable energy sources are used to supply the heat required by the pyrolysis process. The methane pyrolysis process produces solid carbon as the only by-product. Thus, the need for separation and storage of carbon oxides (CO, CO2) is eliminated, and the process is less complicated compared to SMR. Therefore, the energy requirement per H2 molecule produced through methane pyrolysis is almost half of that produced by SMR. Taking the above into account, the methane pyrolysis process has great potential in producing sustainable hydrogen.

[0009] Methane cracking (pyrolysis) is considered a bridge technology for CO2-free hydrogen production. In pyrolysis, methane and / or heavier hydrocarbons produce elemental carbon and CO2 in the absence of oxygen and at high temperatures. During the methane cracking process, unreacted methane is separated from the hydrogen gas and recycled to the pyrolysis reactor. Although the gas feed for methane cracking consists mainly of CH4, other hydrocarbons that may also be present are cracked in the same way as CH4 by thermal splitting of the C-H bonds.

[0010] The primary reaction in methane pyrolysis is endothermic and ideally produces gaseous hydrogen and solid carbon according to Equation 3. [ka]

[0011] Process concepts for methane pyrolysis can be broadly divided into three categories: (i) thermal (non-catalytic), (ii) (thermo) catalytic, and (iii) plasma. In the absence of a suitable catalyst, the decomposition reaction starts at temperatures above approximately 700° C. However, to achieve technically relevant reaction rates and methane conversions, these temperatures must be significantly higher, i.e. above approximately 800° C. in catalytic processes, above approximately 1000° C. in thermal processes, and up to about 2000° C. in plasma decomposition. Conventional gas reactor systems used for the pyrolysis and (thermo)catalytic decomposition of methane typically include tubular fixed bed, moving bed, and fluidized bed reactors.

[0012] In the conventional systems, the thermodynamic equilibrium between hydrogen and carbon is approached at temperatures between 500 and 1100° C. with residence times provided between 10 and 300 seconds, depending on the type of catalyst. In the absence of a catalyst, the residence time is significantly longer. Overall, in methane pyrolysis, the residence time is a critical parameter that influences the product distribution and selectivity. The residence time and temperature influence the properties of the carbon product and therefore its further applications.

[0013] Methane pyrolysis may also be used for the production of benzene and C2-hydrocarbons. Pyrolysis of methane at high temperatures can yield ethylene, acetylene, benzene, and hydrogen as main products, provided that the reaction can be stopped before carbon is formed. In fact, methane can be directly converted to acetylene with high yields by pyrolysis or thermal coupling. The reaction is highly endothermic and requires a high heat supply. The main products of the reaction are typically acetylene and hydrogen. Short reaction times and low partial pressures of methane, preferably by hydrogen dilution of the feed, can be used to avoid excessive carbon formation. Rapid quenching of the reaction mixture is also crucial as suggested.

[0014] Thus, steam methane reforming can be carried out with or without the use of a catalyst. Non-catalytic reforming reactions proceed via a pathway that starts with methane pyrolysis, but upon the presence of steam, the intermediate products rapidly convert to CO and H2. Non-catalytic reforming therefore proceeds at temperatures above 800°C. These temperatures are similar to those required for methane pyrolysis and are typically higher than those of catalytic methane reforming (starting at about 700°C).

[0015] However, existing heating technologies used to reach high temperatures during methane pyrolysis are hampered by several common problems. In the case of pyrolysis and thermocatalytic decomposition, for example, the heat required for the process is typically provided by (fuel-driven) external heaters as mentioned above. The transfer of thermal energy through the reactor walls leads to the rapid formation of carbonaceous deposits, such as coke and soot, on the hot surfaces. This causes operational difficulties and severely impairs the heat transfer. In solutions that involve heating the gas in a reactor or that utilize concentrated solar power (solar pyrolysis), the pyrolysis process often proceeds in an uncontrolled manner (in some cases the pyrolysis reaction may already be initiated during (pre)heating), thus leading to fouling of the reactor parts.

[0016] On the other hand, the high temperatures required to produce hydrogen from natural gas / methane by the above processes are generally one of the main reasons limiting the electrification of these processes. Although suitable solutions to reduce GHG emissions have been considered, the electrification of industrial processes remains hindered because current technologies and existing installation infrastructure cannot meet the need to obtain sufficiently high temperatures.

[0017] For heating purposes, several rotary solutions have been proposed. The hydrodynamic heater pump apparatus disclosed in U.S. Pat. No. 11,098,725 (Sanger et al.) is operable to selectively generate a flow of heated and / or pressurized fluid. The aforementioned hydrodynamic heater pump is designed to be installed within the cooling system of an automotive vehicle to provide heat for the passenger compartment of the vehicle and to enable other capabilities such as window de-icing and engine cooling. The disclosed apparatus can also provide a pressurized fluid flow for engine cooling. Because the disclosed technology is friction based and the fluid to be heated is a liquid, the presented design is not suitable for conditions involving extreme turbulence of gas aerodynamics.

[0018] US Patent No. 7,614,367 (Frick) discloses a system and method for flameless heating, condensing or vaporizing a fluid by converting rotational kinetic energy into heat. A system configured for fluid heating may include a rotational kinetic energy generator, a rotary heating device, and a primary heat exchanger, all in closed-loop fluid communication. The rotary heating device may be a water brake dynamometer. The specification discloses the use of the system for heating water on an offshore drilling or oil production platform. However, the presented system is not suitable for heating gaseous media and is not feasible for use with high and extremely high temperatures (based on liquid stability, vapor pressure, etc.).

[0019] In addition, several rotating turbomachinery type devices are also known to carry out the process of hydrocarbon (steam) cracking, with the goal of maximizing the yield of target products, such as ethylene and propylene.

[0020] In this regard, updates in the art related to designing and manufacturing efficient heating systems, particularly systems suitable for producing hydrogen on an industrial scale at high and very high temperatures, are still desirable in view of efficiently and environmentally addressing the challenges associated with increasing temperatures of fluid materials. Summary of the Invention [Problem to be solved by the invention]

[0021] It is an object of the present invention to solve or at least mitigate at least some of the problems resulting from limitations and drawbacks of the related art. One or more of the objects are achieved by the various embodiments of the method for producing a heated fluid medium, the rotating device and the related uses defined herein, as described herein. [Means for solving the problem]

[0022] In one embodiment, a method is provided for inputting thermal energy into a process associated with producing hydrogen in a hydrogen production facility. Effect of the Invention

[0023] In an embodiment, the method includes generating a heated fluid medium by at least one rotating device incorporated into the hydrogen production facility, the at least one rotating device including a casing with at least one inlet and at least one outlet, a rotor including at least one rotor blade row arranged around a rotor hub mounted on a rotor shaft, and a plurality of stationary vanes arranged in an assembly at least upstream of the at least one rotor blade row, the hydrogen production facility being configured to perform a process relating to producing hydrogen at a temperature essentially equal to or greater than about 500°C. and directing an input energy amount into the at least one rotating device integrated into the hydrogen production facility, wherein the input energy comprises electrical energy, and operating the at least one rotating device integrated into the hydrogen production facility such that a series of energy transformations occurring as the fluid medium flow passes through the fixed vanes and the at least one rotor blade row, respectively, imparts an amount of thermal energy to a fluid medium flow directed along a flow path formed within the casing between the inlet and the outlet, thereby generating a heated fluid medium flow.

[0024] In one embodiment, the method includes connecting the at least one rotating device to at least one reactor or furnace configured to produce hydrogen from a hydrocarbon-containing gas, e.g., a hydrocarbon-containing feed gas, within the hydrogen production facility. In an embodiment, the at least one reactor or furnace is configured to perform a thermal and / or catalytic process to produce hydrogen from the hydrocarbon-containing gas. In an embodiment, the hydrogen production facility is a methane pyrolysis plant or a steam methane reforming (SMR) plant. In one embodiment, the hydrocarbon-containing gas is methane, natural gas, or a mixture thereof.

[0025] In an embodiment, the method includes producing the fluid medium heated to a temperature essentially equal to or greater than about 500° C., or essentially equal to or greater than about 1200° C., or essentially equal to or greater than about 1700° C., by at least one rotating device.

[0026] In an embodiment, this includes adjusting the velocity and / or pressure of a fluid medium stream propagating through the rotating device to create conditions under which the heated fluid medium is generated.

[0027] In an embodiment, in the method, the heated fluid medium is generated by at least one rotating device including two or more rows of rotor blades arranged successively along the rotor axis.

[0028] In an embodiment, the method includes operating the at least one rotating device further including a diffuser region disposed downstream of at least one rotor blade row, the method including operating the at least one rotating device incorporated in the hydrogen production facility such that a quantity of thermal energy is imparted to a fluid medium flow guided along a flow path formed inside the casing between the inlet and the outlet by a series of energy conversions occurring as the fluid medium flow passes successively through the fixed vanes, the at least one rotor blade row, and the diffuser region, thereby generating a heated fluid medium flow. The diffuser region may be formed with or without fixed vanes.

[0029] In an embodiment, in the method, the amount of thermal energy added to the fluid medium flow propagating through the rotating device is controlled by adjusting the amount of input energy directed into the at least one rotating device incorporated into the hydrogen production facility.

[0030] In an embodiment, the method further comprises arranging an additional heating device downstream of the at least one rotating device and introducing a reactive compound or a mixture of reactive compounds into the fluid medium stream propagating through the additional heating device, whereupon the amount of thermal energy is added to the fluid medium stream through an exothermic reaction. In an embodiment, the reactive compound or mixture of reactive compounds is introduced into the fluid medium stream preheated to a predetermined temperature. In an embodiment, the reactive compound or mixture of reactive compounds is introduced into the fluid medium stream preheated to a temperature essentially equal to or greater than about 1700° C. In an embodiment, the preheating of the fluid medium to the predetermined temperature is performed in a rotating device.

[0031] In an embodiment, the method includes incorporating at least two rotating devices into the hydrogen production facility, the rotating devices being connected in parallel or in series. In an embodiment, the heated fluid medium is produced by at least two rotating devices connected in series, the fluid medium stream being preheated to a predetermined temperature in at least a first rotating device in the series, and the fluid medium stream being further heated in at least a second rotating device in the series by inputting an additional amount of heat energy into the preheated fluid medium stream propagating through the second rotating device. In an embodiment, the method includes preheating the fluid medium stream to a temperature essentially equal to or greater than about 1700° C. in at least the first rotating device in the series. In an embodiment, the method includes adding an additional amount of heat energy to the fluid medium stream propagating through the at least a second rotating device in the series by introducing the reactive compound or a mixture of reactive compounds into the stream.

[0032] In an embodiment, the method includes introducing the reactive compound or mixture of reactive compounds into the process associated with producing hydrogen.

[0033] In an embodiment, in the method, the heated fluid medium produced by the at least one rotating device is selected from the group consisting of a feed gas, a recycle gas, a make-up gas, and a process fluid.

[0034] In an embodiment, in the method, the fluid medium entering the rotating device is an essentially gaseous medium.

[0035] In an embodiment, the method includes generating the heated fluid medium in the rotating device. In an embodiment, the heated fluid medium generated in the rotating device is a hydrocarbon-containing (feed) gas. In an embodiment, the heated fluid medium comprises or consists of methane, natural gas, or a mixture of methane and natural gas. In an embodiment, the heated fluid medium contains any one of C2-C4 alkanes (ethane, propane, butane), or mixtures thereof, and / or any one of longer chain hydrocarbons as appropriate. In an embodiment, the heated fluid medium generated in the rotating device is any one of gaseous media other than a hydrocarbon-containing (feed) gas, such as air, steam (H2O), nitrogen gas (N2), or any combination thereof. In an embodiment, the heated fluid medium generated in the rotating device is a recycled gas recycled from exhaust gas generated during a hydrogen production process in a hydrogen production incineration facility.

[0036] In an embodiment, the method further comprises generating the heated fluid medium outside the rotating device through a heat transfer process between the heated fluid medium produced within the rotating device and a fluid medium stream bypassing the rotating device.In an embodiment, the method further comprises generating the heated fluid medium provided as a hydrocarbon-containing (feed) gas outside the rotating device through a heat transfer process between the heated fluid medium other than a hydrocarbon-containing (feed) gas produced within the rotating device and a fluid medium stream provided as a hydrocarbon-containing (feed) gas and bypassing the rotating device.

[0037] In an embodiment, the method further comprises increasing pressure in the fluid medium stream propagating through the rotating device.

[0038] In an embodiment, the method further comprises directing an amount of electrical energy as an input energy into the at least one rotating device incorporated in the hydrogen production facility in a range of about 5 percent to 100 percent.

[0039] In an embodiment, in the method, the amount of electrical energy introduced as input energy into the at least one rotating device integrated in the hydrogen production facility can be derived from a renewable energy source or from different energy sources, optionally a combination of renewable energy sources.

[0040] In an embodiment, the method includes incorporating the at least one rotating device together with at least one heater device capable of operating with non-electrical energy into the hydrogen production facility to be utilized to balance fluctuations, such as surpluses and shortages, in the amount of electrical energy (e.g. obtained through supply and / or production), optionally renewable electrical energy.

[0041] According to one embodiment, a method of inputting thermal energy into a process related to hydrogen production, the method including generating a heated fluid medium by at least one rotating device integrated into the hydrogen production facility, improves energy efficiency or reduces greenhouse gas emissions and / or particulate emissions.

[0042] In another aspect, a hydrogen production facility is provided that, in accordance with the present disclosure, includes at least one rotating device configured to generate a heated fluid medium and at least one heat consuming unit configured as a reactor or furnace configured to carry out a process related to hydrogen production.

[0043] In one embodiment, the hydrogen production facility includes at least one reactor or furnace configured to produce hydrogen from a hydrocarbon-containing gas at a temperature essentially equal to or greater than about 500° C.; and at least one rotating device configured to produce a heated fluid medium for inputting thermal energy into the at least one reactor or furnace, the at least one rotating device including a casing with at least one inlet and at least one outlet, a rotor including at least one rotor blade row disposed about a rotor hub mounted on a rotor shaft, and at least one rotor blade row having at least one rotor blade. and a plurality of stationary vanes arranged in an assembly at least upstream of the at least one rotor blade row, the at least one rotating device being configured to receive an input energy amount, the input energy including electrical energy, and the at least one rotating device being further configured to operate such that a series of energy transformations occurring as the fluid medium flow passes through the stationary guide vanes and the at least one rotor blade row, respectively, imparts an amount of thermal energy to a fluid medium flow channeled along a flow path formed within the casing between the inlet and the outlet, thereby generating a heated fluid medium flow.

[0044] In some embodiments, the at least one rotating device is further configured to supply heated fluid medium into at least one heat consuming unit configured as any one of a heater, a burner, an oven, an incinerator, a dryer, a boiler, a conveyor device, or any combination thereof within the hydrogen production facility, and the at least one rotating device is connected to any one of the heat consuming units, or any combination thereof within the hydrogen production facility.

[0045] In an embodiment, in the hydrogen production facility, the at least one rotating device includes two or more rotor blade rows arranged consecutively along the rotor axis. In one embodiment, a fixed vane arranged in the assembly upstream of the at least one rotor blade row is formed as a fixed guide vane. In one embodiment, the at least one rotating device further includes a diffuser area arranged downstream of the at least one rotor blade row. The diffuser area may be formed with or without a fixed diffuser vane. In some configurations, a vaned diffuser may be realized as a plurality of fixed vanes arranged in the assembly downstream of the at least one rotor blade row.

[0046] In one embodiment, the at least one rotating device disposed within the hydrogen production facility is further configured to increase pressure in the fluid medium stream propagating through the rotating device.

[0047] In some embodiments, the at least one rotating device within the hydrogen production facility is configured to provide fluid flow between an inlet and an outlet along a flow path established based on one of an essentially helical orbit within an essentially helical casing, an essentially helical orbit within an essentially tubular casing, an essentially radial orbit, and along a flow path established by a fluid medium flow in the form of two spirals wound up as side-to-side vortex rings.

[0048] In an embodiment, the hydrogen production facility is configured to carry out processes relating to the production of hydrogen through methods according to the above aspects and related embodiments. In an embodiment, the hydrogen production facility is configured as a methane pyrolysis plant or a steam methane reforming (SMR) plant.

[0049] In a further embodiment, an assembly is provided, said assembly comprising at least two rotating devices according to any of the above embodiments, said rotating devices being connected in parallel or in series.

[0050] In a further embodiment, an array is provided, said array comprising at least one rotating device according to any of the embodiments, said at least one rotating device being connected to at least one reactor or furnace.

[0051] In a further aspect, a hydrogen production facility is provided, the hydrogen production facility configured to perform a hydrogen production process through a method according to any of the preceding aspects and embodiments, and the hydrogen production facility includes at least one rotating device described herein.

[0052] In some further aspects, there is provided the use of methods and apparatus according to some of the above aspects and embodiments, as set out in independent claims 40 to 44.

[0053] In a further aspect, a method for producing hydrogen is provided according to what is claimed in independent claim 45. The method comprises inputting thermal energy into a process associated with producing hydrogen in a hydrogen production facility according to any of the methods described in any of the preceding aspects and related embodiments.

[0054] In one aspect, a method of producing hydrogen is provided, the method comprising generating a heated fluid medium by at least one rotating device incorporated into a hydrogen production facility, the at least one rotating device comprising a casing with at least one inlet and at least one outlet, a rotor including at least one rotor blade row disposed circumferentially about a rotor hub mounted on a rotor shaft, and a plurality of stationary vanes disposed in an assembly at least upstream of the at least one rotor blade row, wherein a series of energy generated as the fluid medium flow passes through the stationary vanes and the at least one rotor blade row, respectively. the conversion imparts an amount of thermal energy to a fluid medium stream directed along a flow path formed within the casing between the inlet and the outlet, thereby generating a heated fluid medium stream, the method further comprising directing an amount of input energy into the at least one rotating device incorporated into the hydrogen production facility, the input energy comprising electrical energy, supplying the heated fluid medium stream generated within the at least one rotating device into the hydrogen production facility, and operating the at least one rotating device and the hydrogen production facility to perform hydrogen production at a temperature essentially equal to or greater than about 500°C.

[0055] The usefulness of the present invention arises for a variety of reasons, depending on each particular embodiment thereof.

[0056] Overall, embodiments of the present invention provide an electrified rotating fluid heater for producing high temperature fluids, e.g., gas. The heater can further be used in various heat consuming processes related to hydrogen production, e.g., in place of fuel-fired heaters. Hydrogen production typically employs fuel-fired heaters to heat fluids to temperatures required for, e.g., converting methane to hydrogen. The present invention presented herein allows for the use of a rotating device in place of a conventional fuel-fired heater. The presented method further allows for input of thermal energy into heat consuming utilities, e.g., reactors and / or furnaces, configured to accommodate reactions related to hydrogen production and operating at high and very high temperatures, e.g., temperatures generally above 500°C. These reactors and / or furnaces have a high demand for thermal energy and therefore heat consumption. The present invention provides an apparatus and method for heating a fluid material to temperatures in the range of about 500°C to about 2000°C for use in the hydrogen production industry.

[0057] The advantages associated with using a rotating device instead of a combustion type heater in the method include at least: - Support electrified heating; - Greenhouse gases (NO, CO2, CO, NO X elimination or at least significant reduction of harmful emissions of fuels (such as HCl, H2S, SO2 and heavy metals), particulate emissions and smoke emissions; - the heater volume is reduced, i.e. the volume of the rotating equipment is at least an order of magnitude smaller compared to conventional process heaters or heat exchangers; - Lower investment costs; - Improved safety when using flammable and hazardous fluids / gases; - The handling of large volumes of gas is feasible; - there is no pressure drop, - the possibility of using the rotary (heater) device also for gas compression (blower function); - No dependency on temperature differences for direct heating of gases. Temperature rises in the rotating equipment can range from about 10 to 1700°C or more; - the possibility of using rotating devices for indirect heating of fluids, optionally by optimizing the temperature difference in the heat exchanger; - at least partial recycling of hot process gases is possible, thus improving and making heat recovery simpler and improving energy efficiency; It is possible to further increase the temperature of the gas to be heated by adding reactive chemicals which further increase the gas temperature by an exothermic reaction, for example up to 2000°C or more; This includes:

[0058] In an embodiment, the rotating machine can be used to replace conventional fired heaters or process furnaces for direct or indirect heating in various process applications related to hydrogen production. Traditionally, such heat is mainly produced through the combustion of fossil fuels, which results in significant CO2 emissions. The use of wood or other bio-based materials instead of fossil fuels has significant resource limitations and other significant impacts on the environment, such as those associated with sustainable land use. As the development of renewable electricity becomes more cost-effective, for example with the rapid development of wind, piezoelectric and solar power generation, it is possible to use rotating machines powered by renewable electricity instead of fossil fuel combustion. This would significantly reduce greenhouse gas emissions. The rotating machine allows for the electric heating of fluids to temperatures of up to 1700°C or more. Such temperatures are difficult or impossible to reach using current electrical heating.

[0059] The present invention therefore reduces greenhouse gas emissions (CO, CO2, NO x) and reduced particle emissions. The use of rotating equipment also makes it possible to have a closed or semi-closed heating loop for the hydrogen production processes and to further improve the energy efficiency of these processes by reducing heat losses through recycling flue gases. In contrast, in conventional heaters, flue gases can only be partially recycled.

[0060] In the case of steam methane reforming, which is performed by providing an (electrified) rotating fluid heater device instead of a conventional furnace, the formation of flue gas and thus a dilute CO2 source (typically resulting from fuel combustion) can be avoided. In combination with already available carbon capture technology from the SMR reaction (see Equation 1b, which provides a pure CO2 source), the method disclosed here allows the achievement of hydrogen production without CO2 emissions.

[0061] The incorporation of a rotating device into methane pyrolysis eliminates or at least reduces the problems associated with the formation of carbon deposits on high-temperature heated surfaces in furnaces or other types of heaters due to long residence times. The residence time of the feed gas, here methane, in the device can be minimized so that the magnitude of carbon formation is significantly reduced. Additionally or alternatively, the temperature of said feed gas propagating through the rotating device can also be increased by arranging a rotor unit inside the device so that the conversion rate of the reaction is improved and carbon deposits do not block the rotating parts of the machine. The rotating device can be used in methane pyrolysis in connection with different types of pyrolysis reactors, with or without a catalyst to reach a sufficient conversion of methane.

[0062] The rotating equipment can be used to directly heat a process gas, an inert gas, air, or any other gas, or to indirectly heat a process fluid (liquid, vapor, gas, vapor / liquid mixture, etc.) For example, the rotating equipment can be used to directly heat recycle gas recycled from the tail gas generated during hydrogen production.

[0063] The heated fluid generated in the rotary device can be further used to heat any one of gas, vapor, liquid, and solid materials. Thus, the hot gas generated in the rotary device can be used to heat solid materials or can be used to heat the feed in a packed reactor configured for any one of catalytic and thermal processes. The method provided herein further allows for the use of the hot gas as a heating medium in a heat exchanger to indirectly heat a process gas or a process liquid. Additional uses, such as in an evaporator, are not excluded.

[0064] The rotating equipment can at least partially replace or be combined with many types of furnaces, heaters, kilns, gasifiers, and reactors that are traditionally burned or heated (e.g., as preheaters) with solid, liquid, or gaseous fossil fuels, and in some cases bio-based fuels, including reactors and furnaces used in hydrogen production. The heated gases can be flammable, reactive, or inert, and can be recycled back to the rotating equipment. In addition to its heating function, the rotating equipment can act as a blower (combined heater-blower function), thus increasing pressure and allowing the gas to be recycled in various applications, for example, in catalytic fluidized bed reactors.

[0065] In the method provided herein, the rotary device can be used to heat the methane-containing feed to the required operating temperature with almost complete absence of CO2 emissions (this is possible if the rotary device uses renewable electricity). The residence time in the rotary device is significantly shorter, which improves the selectivity and reduces the formation of reaction by-products. The short residence time also minimizes coke formation and increases the operating period between scheduled decoking procedures. In the method according to the present disclosure, the reactor for the actual hydrogen production (e.g. methane steam reformer) and the heater (rotary device) are separated. This allows additional flexibility in operation. According to an embodiment, the reactor or furnace for hydrogen production can be connected in parallel or in series to the rotary device. This further allows switching between a thermal reactor for carbon removal and a catalytic reactor for decoking and cleaning in the same production process.

[0066] In addition, the solution allows for improved optimization of the temperature difference in the heat exchanger during indirect heating.

[0067] The present invention further provides the flexibility to use electrical energy, for example electrical energy obtained from renewable sources, which vary from day to day and even hour to hour. The present invention allows for balancing of renewable electrical production by integrating the rotating equipment disclosed herein with conventional fuel-operated (fuel-burning) heaters to provide heat for the various processes involved in hydrogen production.

[0068] The present invention further allows for reduced on-site capital costs compared to traditional fossil-fired furnaces.

[0069] The phrase "a number of" as used herein means any positive integer starting from 1, for example, 1, 2, or 3. The term "a plurality of" as used herein means any positive integer starting from 2, for example, 2, 3, or 4. The terms "first" and "second" are used only to distinguish one element from another, without denoting any order or importance, unless otherwise expressly stated.

[0070] The term "gasification" is utilized herein to indicate that a substance is converted into a gaseous form by any possible means.

[0071] Various embodiments of the invention become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0072] [Figure 1] FIG. 1 is a block diagram generally at 1000 illustrating the layout of a hydrogen production facility configured to implement a method according to an embodiment. [Figure 2A] FIG. 2A illustrates an exemplary layout of a rotating device 100 within a hydrogen production facility, according to an embodiment. [Figure 2B] FIG. 2B illustrates an exemplary layout of rotating equipment 100 within a hydrogen production facility, according to an embodiment. [Figure 2C] FIG. 2C illustrates an exemplary layout of rotating equipment 100 within a hydrogen production facility, according to an embodiment. [Figure 2D] FIG. 2D illustrates an exemplary layout of rotating equipment 100 within a hydrogen production facility, according to an embodiment. [Figure 2E] FIG. 2E illustrates an exemplary layout of rotating equipment 100 within a hydrogen production facility, according to an embodiment. [Figure 2F]FIG. 2F illustrates an exemplary layout of rotating equipment 100 within a hydrogen production facility, according to an embodiment. [Diagram 3] FIG. 3 is a schematic diagram illustrating an apparatus and method for hydrogen production via a methane pyrolysis process, according to an embodiment. [Figure 4A] FIG. 4A is a schematic diagram illustrating an apparatus and method for hydrogen production via a steam methane reforming process, according to an embodiment. [Figure 4B] FIG. 4B is a schematic diagram illustrating an apparatus and method for hydrogen production via a steam methane reforming process, according to an embodiment. [Figure 4C] FIG. 4C is a schematic diagram illustrating an apparatus and method for hydrogen production via a steam methane reforming process, according to an embodiment. [Figure 5A] FIG. 5A is a diagram illustrating a layout for incorporating the rotation device 100 into an apparatus and method according to an embodiment. [Figure 5B] FIG. 5B is a diagram illustrating a layout for incorporating the rotation device 100 into an apparatus and method according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0073] Detailed embodiments of the present invention are disclosed herein with reference to the accompanying drawings.

[0074] FIG. 1 is a block diagram generally at 1000 illustrating the layout of a hydrogen production facility configured to implement methods according to embodiments. FIGS. 2-4 describe apparatus and methods according to embodiments. FIGS. 1-4 and the associated examples are for illustrative purposes and are not intended to limit the applicability of the inventive concepts to the layouts explicitly depicted in this disclosure. Block diagram sections shown with dashed lines may be optional in some embodiments.

[0075] In an embodiment, the heat-consuming facility 1000 is represented by an industrial plant, a factory, or essentially any industrial system including equipment designed to perform an industrial process or a series of industrial processes aimed at producing hydrogen and optionally synthesis gas (syngas) from raw materials, such as natural gas, biogas, and / or any other hydrocarbon-containing feedstock. In an embodiment, the facility can be further configured to produce fuels and hydrocarbons, such as ethane, ethylene, acetylene, benzene, and the like. In this context, the term "fuel" refers to products used as energy carriers, and the term "chemical products" refers to any other products not used as fuels. The heat-consuming processes and the operating units, called heat-consuming process units and / or utilities, configured to perform heat-consuming processes related to at least the production of hydrogen within the facility 1000 are collectively indicated by the reference number 101. The facility 1000 may include several operating units 101 configured to perform the same or different heat-consuming processes. In an embodiment, the operating unit 101 includes or consists of at least one heat-consuming device configured to perform a heat-consuming process. In an embodiment, the operating unit 101 is configured as a reactor apparatus configured to carry out a reaction or a series of reactions aimed at producing hydrogen from methane and / or a feedstock, such as natural gas or biogas, through thermal and / or catalytic processes.

[0076] The heat consuming process facility 1000 is thus configured to perform the heat consuming process 101 at a temperature essentially equal to or greater than about 500° C. In the present disclosure, the heat consuming industrial process is a process that involves producing hydrogen, carbon, and optionally synthesis gas from a hydrocarbon feedstock through a process of methane steam reforming or methane pyrolysis. In an embodiment, the facility 1000 is configured to perform the heat consuming industrial process at a temperature in the range of 500-1700° C. In an embodiment, the facility 1000 is configured to perform the heat consuming industrial process that essentially starts at a temperature in the range of about 800-900° C. or more. In an embodiment, the facility 1000 is configured to perform the heat consuming industrial process at a temperature essentially equal to or greater than 1000° C. In an embodiment, the facility 1000 is configured to perform the heat consuming industrial process that essentially starts at a temperature in the range of about 1100-1200° C. or more. In embodiments, the facility 1000 is configured to perform a heat consuming industrial process at a temperature essentially equal to or greater than 1200°C. In embodiments, the facility is configured to perform a heat consuming industrial process at a temperature in the range of about 1300-1700°C. In embodiments, the facility is configured to perform a heat consuming industrial process at a temperature essentially equal to or greater than 1500°C. In embodiments, the facility is configured to perform a heat consuming industrial process at a temperature essentially equal to or greater than 1700°C. In some embodiments, the facility can be configured to perform an industrial process at a temperature greater than 1700°C, such as at or above 2000°C, such as in the range of about 1700°C to about 2500°C. The equipment can be configured to perform the industrial process at about 1700° C., about 1800° C., about 1900° C., about 2000° C., about 2100° C., about 2200° C., about 2300° C., about 2400° C., about 2500° C., and any temperature value included between the aforementioned temperature points. It is noted that the equipment 1000 is not precluded from performing at least a portion of the industrial process at a temperature below 500° C.

[0077] Hydrogen production is typically associated with high thermal energy demand and consumption, and conventional solutions generate significant industrial emissions, such as carbon dioxide, into the atmosphere. The present disclosure provides methods and apparatus for injecting thermal energy into hydrogen production-related processes 101 that have high thermal energy demands, thereby significantly improving the energy efficiency of the process and / or reducing the amount of air pollutants emitted into the atmosphere. Layout 1000 (FIG. 1) shows these improved equipment and methods in a schematic manner.

[0078] In an embodiment, the method includes producing a heated fluid medium by a rotary heater unit 100 that includes or consists of at least one rotating device (hereinafter, device 100). For clarity, the rotary heater unit is designated in this disclosure by the same reference number 100 as the rotating device. The rotary heater unit is preferably integrated into a process facility 1000. In an embodiment, the heated fluid medium is produced by at least one rotating device, although multiple rotating devices may be used in parallel or series.

[0079] The rotating machines 100 can be provided as stand-alone machines or as several machines arranged in series (in series) or in parallel. One or more machines may be connected to a common heat consuming unit 101.

[0080] The heat consuming unit 101 is configured to carry out a reaction aimed at producing hydrogen from a hydrocarbon-containing feed, e.g. a methane-containing feed, and is provided as one or more reactors and / or furnaces operating with and / or without a catalyst to carry out catalytic and / or thermal processes, respectively. The reactors can be, for example, fixed bed reactors, fluidized bed reactors, or any other suitable type of reactor device. In some configurations, the fluid heated in 100, e.g. a gas, is directly used to carry out the endothermic reaction in the unit 101. In such cases, the fluid heated in 100 at least partially forms the process fluid of 101. In some other configurations, the fluid heated in 100 transfers its thermal energy to the process fluid used in the heat consuming unit / process 101, thereby indirectly providing the heat of reaction to said process. In the case of indirect heating, the fluid heated in 100 can be the same or different from the process fluid used in the heat consuming unit / process 101. Typically, however, it is different. In the configuration with indirect heating, the thermal energy added into the fluid in the rotating equipment 100 is transferred to the heat consuming unit / process 101 through the use of a so-called "heat exchanger" type configuration, which in this context is represented by any existing fired heater, reactor or furnace, or any conventional heat exchanger device. All these devices are considered to be heat consuming units 101. In a further configuration, the fluid, e.g. gas, heated in the rotating equipment 100 does not necessarily transfer its thermal energy to the heat consuming unit 101, but the heat is used to perform an endothermic reaction inside the same or a subsequent rotating equipment unit 100.

[0081] In some embodiments, several devices 100 can be connected to several heat consuming units 101 (e.g. reactors for hydrogen production). Different embodiments, for example n+x rotating devices may be connected to n units 101, where n is equal to or greater than zero and x is equal to or greater than 1. Thus, in some embodiments, the installation 1000 may include 1, 2, 3 or 4 parallel rotating devices 100 connected to a common heat consuming unit 101. Numbers of rotating devices greater than 4 are not excluded.

[0082] In an embodiment, the amount of input energy E1 is directed into at least one rotating device 100 incorporated as a (rotary) heater unit into the heat-consuming process facility 1000. The input energy E1 preferably comprises electrical energy. In some embodiments, the amount of electrical energy directed as input energy into the at least one rotating device incorporated into the heat-consuming process facility is provided in the range of about 5 to about 100 percent, preferably in the range of about 50 to about 100 percent. Thus, the amount of electrical energy directed as input energy into the at least one rotating device incorporated into the heat-consuming process facility may account for any one of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 percent (from the total input energy), or any intermediate value included between the above points.

[0083] Electrical energy can be supplied from external or internal sources. In practice, the electrical input energy E1 supplied into the device can be defined in terms of power, the latter being defined as the rate of energy transfer (measured in watts) per unit time.

[0084] Details of some embodiments of the present invention implemented in the facility layout of Figure 1 are described along the lines below, with the following reference numbers used for components:

[0085] Streams: 1. Feed, 2. Preheated feed or feed mixture, 3. Feed heated by the rotating device 100, 4. Feed further heated in an additional (booster) heater unit designed to raise / boost the temperature, for example through an (exothermic) chemical reaction, 5. Hot fluid medium leaving the heat consuming process 101, 6. Fluid medium led to the purification section, 7. Product stream and / or exhaust gas, 8. Reactive compound or mixture of compounds, for example reactive chemicals, or support fuel used to increase the temperature of the fluid / gas in the additional heater unit 103, 9. Process stream (solid, liquid, gas, steam, or mixture thereof) to be heated by the hot fluid medium during the heat consuming process 101 (indirect heater application), 10. Heated process stream (solid, liquid, gas, steam, or mixture thereof) sent for further processing and / or storage (indirect heater application), 11. Recycle stream leaving the purification section, 12. Feed stream to the heat recovery section, 13. Hot fluid stream from the heat recovery section. Divisions (units): 100. Rotary heater unit (rotating device), 101. Heat consuming operation (process) unit, 102. Preheater unit, 103. Additional heating device (booster heater), 104. Heat recovery unit, 105. Purification unit.

[0086] The rotating device 100 is configured to receive a feed stream 1, hereafter feed 1. Overall, the feed 1 can comprise or consist of any suitable fluid, such as liquid or gas, or a combination thereof, provided as a pure component or a component mixture. The feed can be a feed liquid or a feed gas, such as methane, natural gas, a mixture of methane and natural gas, shale gas, refinery off-gas, liquefied petroleum gas, naphtha, or any other suitable hydrocarbon-containing feed, process gas / working gas, make-up gas (so-called replacement / supplement gas), recycle gas, and the like. The gaseous feed can comprise an inert gas (steam, air, nitrogen gas, and the like), or a reactive gas (e.g. oxygen), a flammable gas, such as a hydrocarbon, or any other gas. The feed is selected depending on the process. Thus, the nature of the heat-consuming process 101, and indeed the specific industry / industry field to which the heat-consuming process 101 belongs, implies specific requirements and / or limitations on the selection of the feed material. Additionally or alternatively, Feed 1 may comprise any one of (water) steam, nitrogen (N2), hydrogen (H2), carbon dioxide (CO2), and carbon monoxide (CO).

[0087] Feed 1 preferably enters the apparatus 100 in essentially gaseous form. Preheating of the feed or conversion of a liquid or essentially liquid feed into gaseous form can be carried out in an optional preheater unit 102. The preheater unit is formed as a (pre)heater device or group of devices. In the preheater unit 102, the feed stream initially provided in gaseous form (e.g. process gas) can be further heated (e.g. superheated). In the preheater unit 102, feed 1 can be evaporated if it is not already in gaseous form and, optionally, superheated.

[0088] The preheater unit 102 may be any conventional device / system configured to provide heat to a fluid material. In some configurations, the preheater unit 102 may be a fired heater (i.e., a direct fired heat exchanger that uses hot combustion gases (flue gases) to increase the temperature of the fluid feed flowing through coils disposed within the heater). Additionally or alternatively, the preheater unit 102 may be configured to utilize energy made available by other units in the heat consuming facility (e.g., by extracting thermal energy from the hot stream 13 arriving from a heat recovery section). The preheater unit 102 may thus be configured to utilize other steam streams, electricity, and / or waste heat streams (not shown), for example.

[0089] Depending on the heat consuming process and associated equipment related to hydrogen production, the feed stream 1 used to produce the heated fluid medium by the rotary heater unit (apparatus 100) may comprise unused feed (fresh feed) and / or recycle streams. Thus, feed 1 may consist of any one of fresh feed, recycle (fluid) streams, and mixtures thereof. Stream 2, representing the (pre)heated feed, may comprise, in addition to feed 1, all recycle streams, e.g. arriving from the purification section 105 and / or the heat recovery section 104.

[0090] In the rotating heater unit / rotating device 100, the temperature is increased to the level required by the heat consuming process 101 or to the maximum level achieved by the rotating device. If the temperature increase achieved by the rotating device 100 is not sufficient for the heat consuming process and / or if, for example, the temperature of the fluid needs to be increased again after it has transferred its heat to the heat consuming process, the temperature can be further increased downstream of the rotating heater unit 100 (100A) by additional heater units (100B, 103), further called "booster" heaters. See the explanation regarding FIG. 2B. Each additional heater unit comprises or consists of an additional heating device realized according to:

[0091] In heat consuming processes associated with hydrogen production, the primary sources of heat consumption are heating of working fluids and / or associated equipment, and endothermic reactions (reactions that require external energy to proceed). In some applications, heat can be recovered from the heat consuming process 101. The heat recovery section is shown in FIG. 1 at 104. The recovered heat can be further used to heat the feed stream 1 and / or the recycle stream (a separate recycle stream is shown in FIG. 1 at 11).

[0092] Heat recovery may be provided through collecting gases exiting the process unit 101 and recycling these gases to the preheater unit 102 and / or the rotary device 100. The heat recovery unit 104 may be represented by at least one heat exchange unit (not shown). Heat exchangers based on any suitable technology may be utilized. Heat recovery may be optional in heating the feed gas if the heat is consumed elsewhere or if it is not possible to recover the heat for safety or other reasons.

[0093] In the plant layout 1000, the heat recovery unit 104 can be located before and / or after the preheater 102. In the latter configuration, the heat recovery unit 104 is arranged to recover heat from the hot fluid medium (stream 5) flowing from the hydrogen production process 101. This heat may be further utilized to heat the feed stream 1 and the recycle stream 11. On the other hand, if the heat recovery unit 104 is located before the preheater 102, the feed 1 is first conducted to the unit 104 (as stream 12) and then returned to the preheating section 102 as stream 13. In such a case, the unit 104 acts as a first preheater.

[0094] In some cases the gases require purification, e.g. from dust and particulates, before being led to the heat recovery section. Purification can be achieved, e.g., by a series of filters arranged before the heat recovery section 104 (not shown). Additionally or alternatively, the gases leaving the process unit 101 may be led to a purification unit 105 (bypassing unit 104) and returned to the heat recovery section after purification (not shown).

[0095] In addition to value products, the process gas may also contain unwanted impurities and by-products. Impurities and by-products may be harmful to the process unit 101 by accumulating and / or causing corrosion in the heater devices 100, 103 and poisoning the catalyst beds. Purification and separation of the stream discharged from the heat consuming process 101 is performed in the purification unit 105. The unit 105 may include several appliances, such as filters, cyclones, etc., configured to mechanically remove dust and solid particles. Any conventional purification / separation method and device may be utilized. Exemplary purification / separation methods include cryogenic separation, membrane processing, pressure swing adsorption (PSA), distillation, absorption, and any combination of these methods. The unit 105 may include devices configured to increase the gas pressure, for example by compression. Typically, the purification unit 105 operates at a lower temperature than the process unit 101. Therefore, the product gas stream is cooled (for example in the heat recovery section 104) before entering the purification unit. It is also important to control the composition of the recycle gas 11 in order to minimize the extent of reactor bed fouling at 101 .

[0096] The purification unit 105 can be further configured to purify the exhaust gas, e.g., carbon dioxide, for further carbon capture. The exhaust gas discharged from the hydrogen production facility as stream 7 (FIG. 1) can be further directed to a carbon capture section (not shown). Suitable exhaust gas purification methods include, e.g., PSA, distillation, absorption, etc.

[0097] The heated fluid medium required to carry out the heat consuming process 101 is generated by at least one rotating device 100 .

[0098] In one embodiment, the heated fluid medium is generated in the rotating device 100. Here, a quantity of thermal energy is added directly into the fluid medium propagated through said device. In such a case, the heated fluid medium generated in the rotating device can be, for example, a process gas, such as a hydrocarbon-containing gas (e.g. a methane-containing feed gas, natural gas or a mixture thereof) (see FIG. 1, streams 1-4, in particular stream 2), whereas the hot fluid medium 5 leaving the heat consumption unit 101 can be a product-containing stream, such as a hydrogen-containing stream. In the case of direct heating, streams 1-5 are associated with working or process fluids.

[0099] The heated fluid medium produced in the rotating device can further be used as a carrier to transfer thermal energy to the heat consuming unit / process 101. The carrier is configured to perform or mediate the conversion of a hydrocarbon-containing feed, e.g., a methane-containing feed, to hydrogen. For example, an inert gas, e.g., air, nitrogen, or steam (H2O), is heated in the rotating device 100 and the inert gas is further used to transport the heat produced by the rotating device to a reactor or furnace configured to perform the hydrogen production process 101. In this regard, the generation of a heated medium (e.g., utilized by the process 101) fluid stream can be performed outside the rotating device through a heat transfer process between the heated fluid medium produced in the rotating device and an appropriate medium utilized by the process 101 and thus bypassing the rotating device. For example, in the case of processes related to hydrogen production, the generation of heated hydrocarbon-containing (feed) gas (e.g. methane) outside the rotary device is carried out through a heat transfer process between a heated fluid medium (e.g. steam, air, nitrogen, etc.) other than the hydrocarbon-containing (feed) gas generated in the rotary device and a hydrocarbon-containing (feed) gas stream bypassing the rotary device. FIG. 1 shows such a stream (process stream) 9 bypassing the rotary device 100 and meaning in this context the hydrocarbon-containing feed / process stream, whereas streams 1-4 arriving at the process unit 101 via the rotary heater 100 mean the fluid medium (e.g. steam or other inert heating medium) led to the process unit 101 to heat the "cold" process stream 9. When the process fluid to be heated (e.g. methane or natural gas) is under high pressure or vacuum, an inert hot gas is preferably used as the heating medium in indirect heating applications. Streams 10 each represent a "hot" process stream. In the case where unit 101 is a methane conversion unit, stream 10 represents the product (hydrogen) containing stream and stream 5 represents the inert fluid medium stream (same as 1-4) exiting unit / process 101. In indirect heating, streams 9 and 10 relate to working or process fluids, whereas streams 1-5 represent heat transfer media. Thus, in indirect heating, unit 101 acts as a "heat exchanger" type device.The device allows for the transfer of thermal energy between two fluids flowing through the device without direct contact between the fluids.

[0100] Exemplary steam methane reforming processes employing apparatus 100 for direct heating of a process fluid are presented in Figures 4A and 4B, and an exemplary steam methane reforming process employing apparatus 100 for indirect heating of a process fluid is presented in Figure 4C, respectively.

[0101] According to an embodiment, a rotating device 100 configured to generate a heated fluid medium to be fed into a hydrogen production facility includes a rotor including a plurality of rotor blades arranged in at least one row around a rotor hub or rotor disk mounted on a rotor shaft, and a casing with at least one inlet and at least one outlet, the rotor being enclosed within the casing. In the device 100, a quantity of thermal energy is imparted to a fluid medium flow guided along a flow path formed within the casing between the inlet and the outlet by a series of energy transformations that occur when the fluid medium flow propagates between the inlet and the outlet within the casing of the rotating device and passes through the at least one row of rotor blades, thereby generating a heated fluid medium flow.

[0102] The embodiment of the rotary device 100 generally follows the disclosures of rotary reactor devices according to U.S. Pat. No. 7,232,937 (Bushuev), U.S. Pat. No. 9,494,038 (Bushuev), and U.S. Pat. No. 9,234,140 (Seppala et al.), and radial reactor devices according to U.S. Pat. No. 10,744,480 (Xu and Rosic), the entire contents of which are incorporated herein by reference. Any other embodiment that can be configured to employ the method according to the embodiment may also be utilized.

[0103] In the above referenced patents, rotating turbomachinery type devices are designed as reactors for processing hydrocarbons, specifically for steam cracking. The general requirements for these applications are rapid heating of the gases, high temperatures, short residence times, and plug flow (a flow model that does not imply axial mixing). These requirements lead to designs in which the turbomachinery type reactors have several heating stages housed in a relatively small volume.

[0104] The present disclosure can be used as a heater to electrify rotating equipment (including but not limited to those referenced above) and generate a heated fluid medium that is further fed in a heat consuming process 101, such as a process related to the production of hydrogen. Greenhouse gas and particulate emissions can be significantly reduced by incorporating a rotating equipment heater unit into a heat consuming process. As an example, the rotating equipment can replace a fuel-fired heater in the steam methane reforming process described below. The temperature range can be extended from about 1000° C. (generally achievable with the reactor device referenced above) to at least about 1700° C. and even up to 2500° C. Rotating equipment configurations that can achieve these high temperatures are possible due to the absence of aerodynamic hurdles.

[0105] The rotating device 100, which is adapted to be incorporated into a hydrogen production facility according to the embodiment and to generate a heated fluid medium for the method according to the embodiment, thus comprises a rotor shaft positioned along a horizontal (longitudinal) axis with at least one rotor unit mounted on the rotor shaft. The rotor unit comprises a plurality of rotor (working) blades arranged around a rotor hub or rotor disk. Together, the rotor blades form a rotor blade cascade. The rotating device 100 thus comprises a plurality of rotor (working) blades arranged in at least one row around a rotor hub or rotor disk mounted on the rotor shaft, which rotor blades form an essentially annular rotor blade assembly or rotor blade cascade.

[0106] In an embodiment, the apparatus further comprises a plurality of stationary vanes arranged in an assembly at least upstream of the at least one row of rotor blades, in which the rotating apparatus is operated such that a quantity of thermal energy is imparted to a fluid medium flow channeled along a flow path formed within the casing between the inlet and the outlet by a series of energy conversions occurring as the fluid medium flow passes through the stationary vanes and the at least one row of rotor blades, respectively, thereby generating a heated fluid medium flow.

[0107] In some embodiments, the stationary vanes may be arranged in a stationary vane cascade (stator). The stationary vane cascade may be provided in an essentially annular assembly upstream of at least one row of rotor blades. The stationary vanes arranged in the assembly upstream of at least one row of rotor blades may be provided as stationary guide vanes, e.g., inlet guide vanes (IGVs), and may be configured with a profile, size, and arrangement about a central axis to direct fluid flow into the rotor in a predetermined direction, e.g., to control, and in some cases maximize, the inherent work input capability of the rotor.

[0108] The rotating machine is formed with two or more essentially annular rotor blade rows (rotor blade cascades) arranged consecutively on / along the rotor shaft. In such a case, the fixed guide vanes may be provided upstream of the first rotor blade row, upstream of each rotor blade row in turn, or upstream of any selected rotor blade row in the consecutive arrangement of rotor blade rows.

[0109] In an embodiment, the rotary device 100 further comprises a diffuser region arranged downstream of at least one rotor blade row (rotor blade cascade). In this embodiment, the rotary device is operated such that a quantity of thermal energy is imparted to the fluid medium flow guided along a flow passage formed inside the casing between the inlet and the outlet by a series of energy transformations occurring as the fluid medium flow passes successively through the stationary guide vanes, the at least one rotor blade row, and the diffuser region, thereby generating a heated fluid medium flow. The diffuser region can be formed with or without stationary diffuser vanes. In some embodiments, a vaned or vaneless diffuser is arranged in the diffuser region downstream of at least one rotor blade cascade. In some embodiments, the diffuser can be realized as a plurality of stationary (stator) vanes. These stationary vanes are arranged to form a diffuser vane cascade, which is provided as an essentially annular assembly downstream of the rotor.

[0110] The rotor, stationary guide vanes, and diffuser region are enclosed within an internal passage (duct) formed within the casing.

[0111] In some configurations, such as that described in U.S. Pat. No. 10,744,480 (Xu and Rosic), the provision of a diffuser may be omitted and the diffuser area may be formed by an essentially vane-free portion of the duct (the so-called vaneless space) located downstream of the rotor and configured with respect to its geometry and / or dimensional parameters to diffuse the high velocity fluid flow arriving from the rotor.

[0112] The provision of a vaneless section of the duct is common to all the configurations of the rotating device 100. Depending on the configuration, the vaneless section (vaneless space) is located downstream of the rotor blades (see U.S. Pat. No. 10,744,480 to Xu and Rosic) or downstream of the diffuser vane cascade (see U.S. Pat. No. 9,494,038 to Bushuev and U.S. Pat. No. 9,234,140 to Seppala et al.). In some configurations, such as those described by Seppala et al., the rotating and fixed blade rows in the internal passage inside the casing are arranged such that a vaneless section is formed between the outlet from the fixed diffuser vanes located downstream of the rotor blades and the inlet to the fixed guide blades located upstream of the rotor blades of the following rotor blade cascade unit.

[0113] The terms "upstream" and "downstream" as used herein refer to the spatial and / or functional location of a given part or component, here a structural part or component relative to the rotor, in the direction of fluid flow (from inlet to outlet) through the entire device.

[0114] Overall, a rotor with a working blade cascade may be positioned between rows of fixed (stator) vanes arranged in an essentially annular assembly (called a cascade) on one or both sides of the working blade row. Configurations including two or more rows of rotor blades / rotor blade cascades arranged consecutively (sequentially) on / along the rotor shaft are conceivable, with or without fixed blades between them. If there are no fixed vanes between the rows of rotor blades, the velocity of the fluid medium propagating through the duct increases in each subsequent row. In such a case, a number of stationary vanes may be arranged in said sequence upstream of the first rotor blade cascade (as fixed guide vanes) and downstream of the last rotor blade cascade (as fixed diffuser vanes).

[0115] A rotor blade row (rotor blade cascade), optionally enclosed inside a casing with a fixed diffuser vane assembly (diffuser region), and a portion of the duct downstream of said rotor blades, can be considered as a minimum process stage (hereafter stage) configured to mediate a complete energy conversion cycle. Thus, the amount of kinetic energy added to the fluid medium flow by at least one rotating blade row is sufficient to raise the temperature of the fluid medium to a predetermined value when said fluid medium flow leaves the rotor blades and propagates in the duct towards the following rotor blade row or enters the same rotor blade row following an essentially helical trajectory formed inside the essentially toroidal shaped casing. The duct (confining the rotor circumference) is preferably shaped in such a way that as the fluid flow propagates in the duct, it slows down, dissipates kinetic energy into the internal energy of the fluid medium, and adds an amount of thermal energy to the fluid medium flow.

[0116] A fixed guide blade row, located upstream of at least one rotor blade row, provides the required flow conditions at the entry of the rotating blade rows (cascade) during the energy conversion cycle.

[0117] In some configurations, the process stage is established by an assembly consisting of a fixed guide vane (upstream of the rotor blades), a row of rotor blades and a diffuser area arranged downstream of said rotor blades. The diffuser area is optionally provided as an essentially vane-free part of the tact provided with the diffuser vanes. During the energy conversion cycle enabled by the successive controlled propagation of the fluid medium flow through the fixed guide vanes, at least one row of rotor blades and the diffuser area, respectively, the mechanical energy of the rotor shaft is converted into kinetic energy and then into the internal energy of the fluid, which subsequently increases the fluid temperature. The amount of kinetic energy imparted to the fluid medium flow by the rotating blade row is sufficient to raise the temperature of the fluid medium to a predetermined value when said fluid medium flow leaves the rotor blades and passes through the diffuser area in a duct, the fluid decelerates, dissipates the kinetic energy into the internal energy of the fluid medium and an amount of thermal energy is added to the fluid medium flow. Within the rotor blade rows, the flow accelerates and the mechanical energy of the shaft and the rotating blades is transferred to the fluid flow. In at least a portion of each rotor blade row, the flow can reach supersonic flow conditions. In the diffuser region, the high-speed fluid flow arriving from the rotor is diffused with a significant entropy increase. This causes the flow to dissipate kinetic energy into the internal energy of the fluid material, which in turn provides thermal energy to the fluid. If the flow upstream of the diffuser is supersonic, the kinetic energy of the fluid flow is converted into the internal energy of the fluid through a system of multiple shocks and viscous mixing and dissipation. The increase in the internal energy of the fluid results in an increase in the fluid temperature. The energy conversion function can be performed, for example, by a vaneless section of a duct located downstream of the rotor blades (see U.S. Pat. No. 10,744,480 to Xu and Rosic) and / or by a diffuser vane assembly (see U.S. Pat. No. 9,234,140 to Seppala et al.).

[0118] The rotating machine 100 can be formed as a multi-stage or single stage solution. A multi-stage configuration can be considered to include several rotor units (e.g. 1-5 rotor blade rows arranged consecutively on / along the rotor shaft) alternating with a common diffuser area (vaned or vaned).

[0119] The incorporation of the rotary device 100 into high-temperature processes related to hydrogen production makes it possible to avoid or at least significantly reduce the formation of carbon deposits on high-temperature heated surfaces in furnaces or other types of heaters due to long residence times. The residence time of the feed gas, e.g. methane, in the rotary device can be minimized so that the magnitude of carbon formation is significantly reduced. Additionally or alternatively, the temperature of the feed gas propagating through the rotary device can be increased to a level at which the reaction proceeds with a sufficiently high conversion rate and essentially without the presence of carbon deposits. This can be achieved by providing inside the device a single rotor unit or several rotor units arranged in series before the diffuser region.

[0120] In an exemplary embodiment outlined in US Pat. No. 9,234,140 to Seppala et al., the rotating device 100 can be realized substantially in the shape of a ring torus, where the cross section of the duct in the meridian plane forms a ring-like profile. The device includes a rotor unit arranged between stationary guide vanes (nozzle vanes) and stationary diverging vanes. Stages are formed with rows of stationary nozzle vanes, rotor blades, and diverging vanes. Through these the fluid flow propagates successively according to a flow path established on the basis of an essentially helical trajectory. In this embodiment, the fluid flow circulates through the rotating rotor blade cascade several times, propagating between an inlet and an outlet inside the device. A similar ring-shaped embodiment is described in US Pat. No. 9,494,038 to Bushuev.

[0121] In another exemplary configuration, as outlined in U.S. Patent No. 9,234,140 to Seppala et al., the rotating machine 100 may be configured as an essentially tubular, axial-type turbomachine. In such a configuration, the machine includes an elongated (elongated) rotor hub along which a plurality of rotor blades are arranged in several successive rows. The rotor is enclosed within a casing, the inner surface of which includes stationary (stator) vanes and diffuser vanes. The stationary and diffuser vanes are positioned longitudinally (from inlet to outlet along the length of the rotor shaft) along the rotor hub, alternating with the blades / vanes of the stator, rotor cascade, and diffuser cascade. The blades of the rotor cascade at a particular location longitudinally along the rotor form a stage together with adjacent pairs of stationary guide (nozzle) vanes and diffuser vanes, respectively.

[0122] In the described configuration, subsequent stages have blade / vane-free spaces between them.

[0123] In yet another exemplary configuration outlined in U.S. Pat. No. 10,744,480 to Xu and Rosic, the rotary machine 100 may be configured as a radial turbomachine. Radial turbomachines generally follow the design for centrifugal compressors or centrifugal pumps. The term "centrifugal" implies that the fluid flow inside the machine is radial, and thus the machine may be referred to as a "radial flow machine" in this disclosure. The machine includes several rotor units mounted on an elongated shaft. Each rotor unit is preceded by a fixed guide vane. A vaneless section of duct (e.g., a U-bend or S-bend) shaped in a manner that allows for energy conversion is disposed after the rotor units. Additionally, the configuration may include a separate diffuser device (vaned or vaneless) disposed downstream of the rotor.

[0124] In all the above forms, the rotating device 100 functions in the same way in the method disclosed herein. During operation, an amount of input energy directed into at least one rotating device incorporated in a heat consuming process installation is converted into mechanical energy of the rotor. Conditions in the rotating device are adjusted to create flow conditions. In this flow condition, the amount of kinetic energy imparted to the fluid medium flow by the rotating blades of the rotor is sufficient to raise the temperature of the fluid medium to a predetermined value when said fluid medium flow leaves at least one rotor blade row and enters a subsequent or the same rotor blade row by passing through a duct and / or a diffuser region. The rotor blade row may be preceded by a fixed guide vane. Conditions that can be adjusted therefore include at least adjusting the fluid medium flow propagating between an inlet and an outlet inside the casing of the rotating device. Adjusting the flow may include adjusting an operation-related parameter of such device, such as temperature, mass flow rate, pressure, etc. Additionally or alternatively, the flow conditions can be adjusted by changing the shape of a duct formed inside the casing.

[0125] In some exemplary configurations, the rotating device can be configured to achieve fluid flow between the inlet and the outlet along a flow path established based on any one of an essentially helical orbit formed inside an essentially toroidal shaped casing as discussed in either one of U.S. Patent No. 9,494,038 to Bushuev and U.S. Patent No. 9,234,140 to Seppala et al., an essentially helical orbit formed inside an essentially tubular casing as discussed in U.S. Patent No. 9,234,140 to Seppala et al., an essentially radial orbit as discussed in U.S. Patent No. 10,744,480 to Xu and Rosic, and a flow path established by a fluid medium flow in the form of two spirals rolled up as side-to-side vortex rings as discussed in U.S. Patent No. 7,232,937 to Bushuev. The aerodynamic design of the rotating device can be varied.

[0126] The rotating devices utilize a drive engine. In a preferred embodiment, the devices utilize electrical energy as input energy, and thus the devices are electric motor driven. For the purposes of this disclosure, any suitable type of electric motor (i.e., a device capable of transferring energy from a power source to a mechanical load) can be utilized. Suitable couplings disposed between the motor drive shaft and the rotor shaft, as well as various appliances such as power converters, controllers, and the like, are not described herein. Additionally, the devices can be directly driven, for example, by a gas or steam turbine, or any other suitable drive device. In a layout involving the parallel connection of several rotating devices 100 to a common heat consuming unit 101, one or more of the devices may utilize different types of drive engines, for example, electric motor driven devices can be combined with devices driven by steam turbines, gas turbines, and / or gas engines.

[0127] Electric power (defined as the rate of energy transfer per unit time) can be provided into the rotating equipment through the supply of electrical current to an electric motor used to drive the rotating shaft of the equipment. The supply of electrical power into the rotating equipment can be achieved from an external source (relative to the rotating heater unit / apparatus 100 and / or the heat consuming process equipment 1000). Additionally or alternatively, electrical energy can be produced within the equipment 1000.

[0128] The external source includes various support facilities provided for sustainable energy production. Thus, the power can be provided from a power generation system utilizing at least one renewable energy source, or a combination of power generation systems utilizing different renewable energy sources. The external source of renewable energy can be provided as solar power, wind power, and / or hydroelectric power. Thus, power can be received into the process from at least one of the following units: a solar power generation system, a wind power generation system, and a hydroelectric power generation system. In some exemplary examples, a nuclear power plant can be provided as an external power source. Nuclear power plants are generally considered to be emission-free. "Nuclear power plant" should be interpreted as using traditional nuclear power, and additionally or instead of nuclear fusion power.

[0129] Electricity can be provided from a power plant that utilizes a turbine as a kinetic energy source to drive a generator. In some cases, the power for driving at least one device 100 can be provided from at least one gas turbine (GT), for example provided as a separate unit or within a cogeneration unit and / or within a combined cycle power plant. The power can thus be provided from at least one of the following units: a combined cycle gas turbine plant (CCGT), and / or a cogeneration unit configured for electricity production combined with heat recovery and utilization through combined heat and power (CHP). In some examples, the CHP plant can be a biomass combustion plant to increase the share of renewable energy in the described process. Additionally or alternatively, the supply of power can be realized from a spark ignition engine, for example a gas engine, and / or a compression engine, for example a diesel engine, optionally provided as part of an engine power plant. Additionally, any conventional power plant configured to produce electrical energy from fossil feedstocks such as coal, oil, natural gas, gasoline, and the like, typically mediated through the use of steam turbines, may be used to generate electrical energy as an input energy for the rotating machine 100. Hydrogen may also be utilized as a renewable energy source and reconverted, for example, to electricity using fuel cells.

[0130] Any combination of the above power sources implemented as external and internal sources is contemplated. Capturing low emission power from another (external) source improves the energy efficiency of heat consuming process equipment.

[0131] The introduction of input energy, including electrical power, into the driving engine of the rotating equipment may be further accompanied by directing mechanical shaft power from a power turbine to the driving engine, optionally utilizing thermal energy generated elsewhere in the plant 1000 or external to the plant. Shaft power is defined as the mechanical power transferred from one rotating element to another, calculated as the sum of the shaft torque and the rotational speed. Mechanical power is defined as the amount of work or energy (measured in watts) per unit time.

[0132] In practice, the shaft power from, for example, the electric motor and the power turbine may be split so that either one of them may provide the total shaft power or a portion thereof.

[0133] 2A-2D show an exemplary layout of a rotating device 100 forming a rotary heater unit inside a facility 1000 with respect to a preheater unit 102, a temperature booster section 103 and a heat recovery unit 104. The following reference symbols are used for the components: 100, 100A, 100B - rotary heater unit (rotating device), 101 - heat consuming unit / process, 102 - preheater unit, 103 - additional heating device (booster heater).

[0134] FIG. 2A shows a schematic representation of a basic embodiment of a rotating device 100 configured to inject heat into a fluid medium stream (feed stream 1) conducted through the rotating device. The heated streams leaving the device 100 are respectively indicated with the reference number 2. In the basic embodiment, the rotor system of the rotating device 100 is aerodynamically configured so that a volume of fluid is heated to a predetermined temperature while propagating along a flow path formed between an inlet and an outlet in the casing of the device 100 (so-called "one-pass" embodiment). The device 100 allows a temperature increase (delta T, ΔT) in one stage in the range of about 10° C. to about 120° C., in some embodiments up to about 500° C. Thus, in the case of multi-stage embodiments, the fluid can be heated up to 1000° C. in a "one-pass" implementation (a temperature increase of 100° C. per stage in the case of a 10-stage device). Since the residence time that the fluid medium spends passing through the device stages is on the order of a few seconds, for example on the order of about 0.01 to 1.0 milliseconds, already in the basic form a fast and efficient heating can be achieved. The temperature increase can be optimized as needed.

[0135] 2B illustrates the basic concept involved in so-called booster heating, which is any method of heating a fluid medium, e.g., a process gas, beyond the capabilities of a stand-alone heating device 100.

[0136] The temperature boost can be considered thermal, chemical or both. In the first configuration, also called "thermal boost", an additional rotary heater device (shown as 100B in Figs. 2B, 2C and 2D) is placed downstream of the "primary" rotary heater device (shown as 100A in Figs. 2B, 2C and 2D). The devices 100A, 100B are generally recognized within the scope of this disclosure as rotary heater unit 100. The production of a heated fluid medium can thus be achieved by providing at least two rotary devices 100A, 100B connected in series. A fluid medium stream (feed stream 1) is heated to a predetermined temperature in at least the first rotary device (100A) in the series, referred to here as the primary heater. The fluid medium flow (see flow 2) is then further heated in at least the second rotating device (100B) in the series by injecting an additional amount of thermal energy into the fluid medium flow (see flow 3) propagating through the second rotating device 100B, "preheated" in the first rotating device 100A. The device 100B is therefore called a booster heater. The devices 100A, 100B may be identical or may vary in terms of size or internal design. A train of two or more booster devices, for example 100B, may be arranged after the primary heater 100A. The booster devices may be arranged in parallel or in series, or in any combination that allows the optimization of their rotational speed and aerodynamic characteristics.

[0137] In a second additional or alternative configuration (also referred to as "chemical boost"), an additional heating device, designated by the numeral 103 (FIGS. 1, 2B), is configured to receive a reactive component 5, such as a combustible fuel, into the fluid media stream propagating therethrough, thereby providing heat by exothermic reaction prior to directing said fluid media stream to the heat consuming process 101 of hydrogen production. In this configuration, a temperature boost can be achieved by introducing (e.g. injecting) a reactive chemical 5 into the fluid media stream directed through the additional heater unit / heating device 103. Note that stream 5 in FIG. 2B corresponds to stream 8 shown in FIG. 1.

[0138] The reactive chemical-based booster heater unit 103 may be placed after the thermal booster heater unit 100, 100B (FIG. 2B) or immediately after the primary heater 100, 100A (FIG. 1). The reactive chemicals (reactants) 5 may include combustion gases, such as hydrogen gas, hydrocarbons, ammonia, oxygen, air, other gases and / or any other suitable reactive compounds, optionally with a catalyst. In the unit 103, by exothermic reactions, the fluid stream can be heated to a level that typically cannot be achieved by a single rotating device that does not participate in chemical-mediated heating (see stream 4). For example, a fuel gas, such as hydrogen, can be introduced into an oxygen-containing process gas, such as air. At high temperatures, hydrogen and oxygen enter into an exothermic reaction to produce water molecules (hydrogen combustion).

[0139] The temperature of the gas may be increased by injecting fuel gas with air (or enriched oxygen) through a burner into the booster heater unit 103. Air and / or oxygen may be added if the heated gas contains flammable gases and these gases may be consumed only for heating. The process gas may contain H2, NH3, CO, fuel gases (methane, propane, etc.) that may be combusted to produce heat. If feasible, heat may also be produced by injecting other reactive gases.

[0140] The additional heater 103 configured for chemical boosting may be formed as a piece of pipe or as a chamber in which an exothermic reaction takes place and / or may include at least one rotating device 100 arranged to receive a reactive compound for supporting an exothermic reaction to produce additional heat energy. The booster section 103 may thus include at least one rotating device 100. Optionally, the reactive chemical may be injected directly into the heat consuming process 101 (not shown). Additionally or alternatively, reactive chemical mediated boosting may also be implemented in a single device 100, 103 modified accordingly.

[0141] In a configuration involving booster heating, the temperature of a fluid medium stream preheated to a predetermined temperature in a first rotating device (100A) can be further increased to a maximum limit in a subsequent heater unit (100B, 103). As an example, the temperature of a fluid medium stream preheated to about 1700° C. in the primary heater (100A) can be further increased to 2500° C. or more in a subsequent heater unit (100B, 103).

[0142] The above concepts can be used separately or in combination to introduce reactive chemicals 5 into any one of the parallel or series (continuous) connected devices 100. A booster heater is optional.

[0143] Additionally or alternatively, pre-heating and additional heating may be performed in the same apparatus 100 (not shown). This may be accomplished in a multi-stage configuration, which includes several rotor units (e.g., 1-5 rotor blade rows arranged consecutively on / along the rotor shaft) alternating with a common diffuser region (vaned or vaned).

[0144] Additionally or alternatively, booster heating can be used, for example, when the temperature of a fluid once heated in a rotating device 100 needs to be increased again after the fluid has transferred its heat to a heat consuming process 101. An exemplary configuration is shown in FIG. 2E, which includes several rotating heater devices 100 (100A, 100B and / or optionally 103) alternating with heat consuming units 101. Such a configuration can be utilized, for example, for a series of successive catalytic endothermic reactors, where the temperature is reduced from reactor to reactor and needs to be increased again between reactors (see discussion of FIG. 5).

[0145] A rotating device assembly can be established when at least two rotating devices, e.g. 100A, 100B and optionally 103 (if 103 is implemented as a rotating device 100), are connected in parallel or in series (see e.g. Figs. 2B-2D). The connection between the rotating devices 100 realized as "primary" heaters 100A or "booster" heaters 100B, 103 can be mechanical and / or functional. A functional connection (e.g. in terms of achievable heat input) can be established when at least two individual, physically integrated or not integrated, individual equipment units are coordinated. In the latter case, the coordination between the at least two rotating devices can be established via some auxiliary equipment (not shown). In some forms, the assembly includes at least two devices connected in a mirror-like manner to each other. Thereby, said at least two devices are at least functionally connected via their central (rotor) axis. Such a mirrored configuration may be further defined as having at least two rotating devices 100 mechanically connected in series (in series), while the functional connection may be considered as a parallel (array) connection. In some cases, the "mirrored" array may be further modified to include at least two inlets and a common exhaust (ejection) module located essentially at the center of the array.

[0146] The rotating devices (see 100A, 100B, 103 in FIG. 2B) can be assembled on the same (rotor) shaft. Each rotating device can optionally be equipped with a separate drive (motor) allowing independent optimization of the device. If two or more separate rotating devices are used, the construction costs (materials, etc.) can be optimized in terms of operating temperatures and pressures.

[0147] Additionally or alternatively, at least one rotating device within the assembly can be designed to increase the pressure of the fluid flow, and thus at least one rotating device within the assembly can be assigned a combination of heater and blower functions.

[0148] Additionally or alternatively, a stream containing a reactive or inert gas can be fed to the rotating device 100 (not shown) or to any equipment downstream of said device (e.g., in the heat-consuming process section 101). Thus, the reactive gas can be injected directly into the heat-consuming process unit 101 if the heat-consuming process unit 101 is configured as a heat-consuming unit, e.g., a reactor. In some applications, a supporting fuel can be injected directly into the process unit 101 to generate heat and / or participate in the reaction.

[0149] FIG. 2C shows the use of the rotary heater arrangement 100A, optionally 100B, with indirect process heating. The rotary arrangement 100 (100A, 100B) can be used for indirect heating of a fluid in a heat consuming unit 101. Heat is transferred between two immiscible fluids in a heat exchanger type configuration. Thus, a fluid, e.g., a gas or a liquid, can be evaporated (vaporized) or superheated in the heat exchanger arrangement 101, which can be realized for the fluid heated in the rotary arrangement 100. The heat consuming unit 101, which is configured to correspond to a heat consuming process, can be represented by any (existing) fired heater, reactor or furnace, or any conventional heat exchanger arrangement. The "heat exchanger" configuration (101) can be selected as required for optimal heat transfer. The heating gas (see streams 1-3) can be selected to be optimal for heating and safety (e.g. steam, N2, air). The gas heated in rotating units 100A, 100B can be at near atmospheric pressure or the pressure can be increased to improve heat transfer. The heat transfer medium 3 heated in unit 100 (Stream 3 exiting 100B) is directed to a heat consuming process 101, where heat is transferred from stream 3 to a "cold" process stream 6, thereby producing a "hot" process stream 7. Stream 4 represents the (inert) heat transfer medium effluent, respectively. If unit 101 were a methane to hydrogen conversion unit, then stream 6 would represent a methane containing feed stream and stream 7 would represent a hydrogen containing product stream.

[0150] Process streams 6 and 7 in FIG. 2C thus correspond to streams 9 and 10, respectively, in FIG. 1 (indirect heating configuration), whereas heat transfer medium streams 3 and 4 in FIG. 2C correspond to streams 3 (optionally 4) and 5, respectively (indirect heating configuration).

[0151] Another exemplary configuration layout for indirect heating of a process fluid by means of a rotating device 100 is presented in Fig. 2F. A heat consuming unit 101 is set up to act as a heat exchanger designed to heat a process inlet stream to a predetermined temperature by means of a heating medium stream (heat transfer medium) provided by the rotating device 100. The configuration of Fig. 2F may be applied to heating a gaseous medium, e.g. hydrogen (gas) and / or a hydrogen-containing gas stream, in the heat exchanger 101 inside a hydrogen production facility. The same layout may be applied to increase the temperature of any other process stream flowing through the heat exchanger device.

[0152] Although the heating of a gaseous medium, e.g. hydrogen gas, can be performed in the rotary device 100 simply by using steam as a heating fluid (not shown), in cases where the pressure of the hydrogen stream is increased, e.g. above 10 bar, or where the temperature of the hydrogen stream is very high, e.g. up to about 1000°C, it is beneficial to apply the indirect heating concept shown in FIG. 2F. Designing a rotary device to operate at high pressure and / or high temperature can increase its material requirements and complicate its technical solution. This again increases the overall cost of the device. However, designing a device for low pressure heating of an inert gas, e.g. air, nitrogen, carbon dioxide or steam, and using the heated gas to heat hydrogen or other process streams in the process unit 101 (in the form of a heat exchanger) can result in a lower overall cost of the heating system.

[0153] In FIG. 2F, the rotating device 100 is used to heat a non-working fluid (e.g., an inert fluid), such as air, (water) steam, carbon dioxide, or nitrogen gas (N2), at low pressure, e.g., less than 10 bar. Such a non-working fluid is further called the "heat transfer medium." The temperature of the inlet stream 4 (heat transfer medium, cold) entering the device 100 is about 200-1100°C, and the temperature of the outlet stream 3 (heat transfer medium, hot) leaving 100 is about 800-1200°C. Also, the temperature of the "cold" process fluid 6 (e.g., hydrogen) entering the heat consuming unit 101 is about 20-500°C, whereas the temperature of the "hot" process fluid outlet stream 7 leaving 101 is about 700-1000°C. To allow heat transfer from the heat transfer fluid into the process stream, the temperature of the heated fluid discharged from the rotating device 100 must exceed the target temperature of the heated process fluid (e.g., hydrogen).

[0154] The "hot" fluid 3 discharged from the rotating device 100 is introduced into a heat consuming unit 101, which is provided in the layout of FIG. 2F as a heat exchanger that allows the transfer of thermal energy from the heat transfer medium (the inert fluid heated in 100) through a heat transfer surface to a process fluid, e.g. a hydrogen stream, thereby heating the hydrogen stream. The heat transfer medium cools as it donates its heat to the process fluid. By reintroducing the cooled heat transfer medium 4 into the rotating device 100, the thermal efficiency of the system can be improved.

[0155] The materials of the heat exchanger 101 are selected to withstand high temperatures, hydrogen atmosphere, and / or high pressures. However, for stationary equipment such as a heat exchanger, this is a more cost-effective option than for the rotating equipment 100.

[0156] The use of the rotating machine 100 allows the optimization of the temperature difference of the heat exchanger form (here represented by the heat consuming unit 101) to minimize the size of the unit 101 (formed as a heat exchanger, reactor, furnace, heater, etc.) and the undesirable reactions (fouling, coking) that occur on the surface due to excessively high surface temperatures, which may cause excessive fouling in the process heater. The use of indirect heating allows the replacement of process heaters in various applications related to the production of hydrogen.

[0157] FIG. 2D shows the rotary heater apparatus 100A with a preheater 102 and a recycled process fluid (stream 4) recycled from a heat consuming process (not shown). The preheater can be electric, fired, a combustion engine, a gas turbine, etc., and it can be a heat exchanger to recover excess heat from any hot stream in the process. The presence of the preheater 102 is optional. This concept can include an optional booster heater 100B located downstream of the apparatus 100A. Stream 1′ represents the (feed) fluid sent to the preheater 102. The fluid is further propagated through the rotary apparatus 100A, 100B, where the feed is heated and sent in stream 3 to the heat consuming process.

[0158] Any one of the rotating devices 100A, 100B can be equipped with a fluid recycle device (see flow 4 in FIG. 2D). Any combination of rotating devices and fluid recycle devices is contemplated. Recycling is made possible through recirculation of the fluid media stream through at least one rotating device.

[0159] In some configurations, the rotary device 100 can utilize low oxygen content flue gas discharged from a conventional combustion heater. In such cases, the hot flue gas discharged from the combustion heater is mixed with recycle gas (stream 4 in FIG. 2D) and used for heating in the rotary heater 100, 100A. The oxygen content in the flue gas used in the described case is preferably below the flammability limit to allow safe heating.

[0160] The method according to the embodiment can be fully or partially applied to various heat consuming processes 101 related to the production of hydrogen, as will be made clear below on the basis of some non-limiting examples.

[0161] Please refer to Figure 3. There is shown a schematic of the incorporation of a rotating device 100 into a process for direct conversion of methane through methane pyrolysis, which produces hydrogen and carbon. This process can be expanded to produce useful hydrocarbons, such as fuels and / or chemicals. With the exception of reference numbers 9 and 10, the designations of the components are the same as in Figure 1.

[0162] In such a process, the feed 1 and / or the recycle gas stream 11 (returning from the purification unit 105) are (pre)heated in the heat recovery section 104 and subsequently in the preheater 102. Alternatively, streams 1, 11 are first heated in the preheater 102 and subsequently in the heat recovery section 104. In a process for direct conversion of methane through pyrolysis, the raw feed, e.g. natural gas or biogas, is typically purified (not shown) to the extent required for the process. If the feed is pure methane, no purification (such as desulfurization) is required.

[0163] For the production of hydrogen and carbon, methane is heated to a given temperature in at least one rotating device 100 acting as a heating device (see FIG. 3, stream 2). This temperature is adjusted to a level at which the relevant conversion ratio can be achieved in the downstream methane conversion process 101. For thermal conversion processes, said temperature level is above 1000° C., preferably in the range of about 1300° C. to about 1700° C. In catalytic processes, the temperature depends on the selected catalyst. One recommended temperature value is about 800° C., but some catalysts already operate above about 500° C. The expected residence time in the device 100 is short, for example in the range of about 1 to 20 milliseconds. A short residence time is important to avoid coke formation in the heater (i.e. in the device 100). The rotating device 100 may be followed by an optional additional heating device 103, where the heating is mediated by injection of reactive chemicals 8 (see stream 3) into the device 103 or upstream. Additionally or alternatively, the temperature boost can be performed by several rotating devices 100A, 100B, optionally 103, in a rotating configuration, assembled as described above.

[0164] Methane (Stream 4), heated to a given temperature, proceeds to a heat consuming process / unit 101. The heat consuming process / unit can be represented by several different types of reactor apparatus (101A and 101B in this example) arranged in series or parallel. Either one of the reactors 100A, 100B, or both, are configured to perform the thermal conversion / decomposition of methane to hydrogen (methane pyrolysis). In this example, the first reactor 100A is a thermal reactor. The reactor 100A can be, for example, of a cyclone type, allowing separation of carbon by velocity and gravity. Other reactor types can also be utilized. In the reactor 101A, the stream temperature can be reduced to a level of about 700-900°C, which results in a low decomposition reaction rate. Subsequent reactor units, for example 101B, can include a reactor supplied with a catalyst suitable for high temperature pyrolysis of methane and a reactor supplied with a different type of catalyst suitable for low temperature pyrolysis of methane, thereby maximizing the conversion of methane in the reactor.

[0165] The temperature of the fluid (here methane gas) heated in the rotary device and the residence time that said fluid spends in the device are adjusted below the threshold at which a heat consuming process (here pyrolysis) occurs, thereby avoiding the initiation of a heat consuming process before the fluid enters the heat consuming unit 101 (formed here as a reactor for methane pyrolysis) as stream 4. Overall, the typical multi-stage device 100 is designed to increase the temperature of the fluid passing through it in stages. The flow of the fluid stream propagating through the device 100 can thus be adjusted in such a way that at the last working stage of the device, after the fluid has passed the rotor of said last working stage, the threshold temperature (at which a heat consuming process, for example methane pyrolysis in this case, occurs in the heat consuming unit 101) is reached. The temperature of the methane gas effluent (stream 4) released from the rotary device 100 is thus approximately the temperature of methane pyrolysis. This temperature may again vary depending on the presence / absence of a catalyst in the downstream equipment 101. The described arrangement further makes it possible to avoid the formation of carbonaceous deposits inside the rotating device 100.

[0166] Stream 9 represents the coke that is removed from the thermal reactor 101A. The catalytic reactor 101B may require mechanical decoking of the catalyst. Thus, stream 10 discharged from reactor 100B may contain the catalyst for mechanical decoking along with the liberated carbon.

[0167] Depending on the type of catalyst, the temperature of the stream 5 discharged from the reactor unit 101B may be approximately 500° C. or higher. The product stream 5 containing hydrogen is led to a heat recovery unit 104, where the hot product gas is cooled before a purification unit 105. The purification unit may consist of a hydrogen separation unit, for example by pressure swing adsorption (PSA), and may include further appliances for hydrogen purification and methane recycling. Stream 7 thus denotes the product gas (hydrogen) discharged from the purification unit 105, and stream 11 denotes the recycled gas (for example methane, and in some cases hydrogen). The recycled gas can be (re)used to heat fluids / gases in the rotary heater 100 (as stream 13). The recycled gas 11 can also be (re)used as a reactant in processes involving direct heating of methane as a process fluid. It is therefore important to adjust the composition of the recycled gas stream 11 (for example the amount of hydrogen and heavier hydrocarbons in the recycled gas stream) in order to achieve favorable conversions and selectivities.

[0168] In addition to hydrogen, the process shown diagrammatically in Figure 3 allows the production of other useful chemicals, including, by way of example, ethane, ethylene, acetylene, and benzene. The production of said compounds can be achieved by pyrolysis of methane obtained from natural gas or biogas at high temperatures, preferably above 1500°C. This requires very short residence times to minimize carbon production. Any other suitable hydrocarbon-containing feedstock can also be utilized as indicated above. Thermal and / or catalytic pyrolysis is carried out in reactors 101A, 101B, while heating to the required temperature can be carried out in the rotating device 100 (with optional booster heating in 103).

[0169] Quenching is required to stop the reaction immediately after the reactor 101A to avoid loss of selectivity to useful hydrocarbons and carbon formation. To minimize residence time and optimize selectivity, only one reactor 101A can be used. In the case of thermal pyrolysis, a quench unit can be placed immediately after the reactor 101A to stop the reaction and thus avoid loss of selectivity to useful hydrocarbons and carbon formation. The quench unit is not shown in FIG. 3, but such a quench unit is a conventional part of the heat recovery section 104 and typically consists of a high pressure steam generator or with direct injection of a cooling medium. If a catalyst is used, the temperature in the reactor 101 (101A, 101B) can be lower and quenching may not be required. The provision of a quench unit, which is typically required in hydrocarbon production processes, can be omitted in the production of hydrogen.

[0170] It should be noted that both processes depicted in Figure 3 (hydrogen production, and other hydrocarbon / chemical production) support the recycling of gases, e.g., methane and hydrogen fractions. In hydrogen production, the recycle gas is typically methane, whereas in processes configured for hydrocarbon production, the recycle gas is a mixture of hydrogen and methane.

[0171] Air or pure oxygen (8) can be optionally injected into the stream 3 exiting the rotary heater device 100 to increase the temperature of the methane gas before the pyrolysis reactor 101 (101A). In some cases, a portion of the hydrogen product can be combusted with oxygen in a separate chamber (not shown), and the hot steam thus formed can be mixed with the steam entering the reactor 101 (101A). Alternatively, oxygen 8 alone can be injected into the hot methane gas directed to the reactor 101. The latter procedure will produce (water) steam and carbon oxides (CO and CO2). However, this may put an additional burden on the purification section 105 to remove CO / CO2 from the product gas 6. In the described procedure with the injection of air / oxygen between 100 and 101, the stream 3 exiting the rotary device 100 can be directly transmitted to the hydrogen production section 101, and thus the provision of a booster heater 103 may be optional.

[0172] 4A-4C show a schematic of the incorporation of the rotating device 100 into a hydrogen production process via the process of steam methane reforming (SMR). The same process can be used for the production of synthesis gas.

[0173] In conventional steam methane reforming, methane is passed along with steam through a catalyst bed located in reformer tubes that are externally heated by a fuel-fired heater. This disclosure teaches that a rotating device can replace the fuel-fired heater in catalytic and non-catalytic SMR processes.

[0174] This disclosure describes at least two separate methods of incorporating the rotating device 100 into a steam methane reforming process.

[0175] In one embodiment, the rotating device acts as a (direct) heater. This heater increases the temperature of the methane or natural gas vapor mixture propagating through the device to the level required by the reforming reaction to be carried out. If the catalytic reforming reaction occurs at about 800-900°C, the rotating device 100 is needed to heat the methane-vapor mixture to a temperature above about 1000°C, because the endothermic reforming reaction, which reduces the temperature of the mixture, reduces the temperature of the mixture in the catalyst bed as the reaction proceeds. The non-catalytic reforming reaction occurs at about 1100°C. In this case, the rotating device 100 is needed to heat the methane-vapor mixture to a temperature above about 1300°C.

[0176] Figure 4A thus illustrates the application of a rotating device as a direct heater in steam methane reforming. The equipment layout of Figure 4A is applicable to either catalytic or non-catalytic SMR.

[0177] For example, the arrangements shown in Figures 2A and 2B can be used. Reference numeral 101 denotes a heat consuming unit / utility, which in this embodiment is formed as a reactor configured to perform steam reforming of methane to produce hydrogen and carbon oxides. In some cases, the reactor 101 is formed as a catalytic reforming reactor.

[0178] Direct heating involves propagating an optionally preheated feed-containing process fluid, e.g. a mixture of methane and steam, or a mixture of natural gas and steam, through a rotating device 100. The mixture is heated to a predetermined temperature. A preheater 102 is not shown. A preheated and desulfurized feed, e.g. natural gas (NG), is heated in at least one device 100, which is further led into a process unit 101, represented by an SMR reactor. In some configurations, the device 100 can act as a pre-reformer. The pre-reformer is configured to pre-reform natural gas with steam (see FIG. 4A, "high pressure steam" stream), thereby cracking long-chain hydrocarbons into methane and synthesis gas. Synthesis gas can be withdrawn from the process at this stage (not shown). Alternatively, the pre-reformer can be located inside the unit 101.

[0179] The SMR reactor (unit 101) may be any conventional reactor configured to carry out a reforming reaction. The reactor may be designed for catalytic steam methane reforming or non-catalytic steam methane reforming processes. An exemplary SMR reactor may be a packed bed reactor. A mixture of methane and steam is heated in the unit 100 to about 1000° C. (this temperature may vary depending on the presence / absence of a catalyst) and is then directed into the SMR reactor 101, where the reforming reaction occurs (based on equation 1a). The rotating unit 100 thus replaces the fuel-fired heater that normally surrounds the reformer tubes (101). A high-temperature water-gas shift (WGS) unit / reactor may be located downstream of the main SMR reactor to increase the hydrogen yield (equation 1b). The product stream discharged from the SMR reactor 101 or from the water-gas shift reactor proceeds to the heat recovery section 104 and then to the purification section 105. The heat recovery section may involve cooling and condensation of water and includes a chiller / water condenser unit. Purification may be accomplished via pressure swing adsorption (PSA), or any other suitable method. Purified hydrogen may be sent from unit 105 for utilization / storage (see "hydrogen product" stream) and for recycling (see "hydrogen recycle" stream). Unconverted methane may also be sent from unit 105 for recycling ("methane recycle" stream).

[0180] In some cases, it may be beneficial to use additional "Turntable 100-SMR reactor 101" trains (see dashed boxes in FIG. 4A) to bring the reforming reaction to completion and / or to reach the desired reaction scale. Such SMR reactors in the train may be catalytic bed reactors 101. Even in the case of non-catalytic reforming, several trains of 100 and 101 may be useful to optimize the residence time required for the reaction to proceed to completion. As an example, 1 to 10 such trains may be arranged in series within the facility 1000.

[0181] Taking into account the two main reactions SMR (Equation 1a) and WGS (Equation 1b), a simulation is performed in which the reactor 101 is assumed to reach equilibrium, to estimate the number of trains required. The simulation takes into account a pressure of 20 bar and a steam to methane ratio of 3:1. The feed to the system is 370° C., at which temperature the desulfurization is carried out (see FIG. 4A).

[0182] For catalytic reforming with sequence 100-101, heating the feed to 1000° C. (reactor inlet temperature) in rotary device 100 results in a methane conversion of about 37% at the outlet of reactor 101. At this point, the temperature will drop to about 650° C. Using three (i-iii) consecutive sequences 100-101 (FIG. 5A) where the inlet to each reactor 101 is heated to 1000° C. results in a methane conversion of 78%, which is more conventional at the pressure levels tested.

[0183] FIG. 5A shows diagrammatically an alternating series (i-iii) of rotating devices 100 and catalytic gas-phase reactors 101. The rotating devices 100 are used as direct heating devices for the gaseous feed and other reactants. The gaseous feed is thus heated to a maximum allowable temperature (often set by the catalyst temperature tolerance and the rate of undesired side reactions) and is fed into the first catalytic reactor 101 according to FIG. 5A. The reactants are thus heated before they enter the reactor 101, where the adiabatic temperature is reduced as a result of the reaction. If the desired conversion is not reached, the effluent is then reheated in the next rotating device 100 to be fed into the next reactor 101.

[0184] In the case of non-catalytic reforming with sequence 100-101, a reactor inlet temperature of 1300°C can result in a maximum methane conversion of 59%. At this point, the temperature will drop to about 745°C. Adding a second train can increase the conversion rate to 95%. The process can be optimized by using a series of rotary device reactors (100-101) and by adjusting the temperature and / or residence time allowed for reaction before the next heating stage. The number of trains and temperature levels can be adjusted to optimize the process yield and cost, while the total power required for heating is determined by the heat of reaction of the endothermic reaction and the reaction scale / conversion.

[0185] In some cases, the combination of the two processes (heating at 100 and reacting at 101) may be accomplished in a single unit. Heating and reacting occur in the same piece of equipment. Such an arrangement is particularly beneficial in non-catalytic SMRs (FIG. 4B).

[0186] An exemplary plant layout designed specifically for non-catalytic SMR is shown in more detail in FIG. 4B. In a non-catalytic SMR plant, the rotary heater 100 and the SMR reactor 101 may be combined in a single piece of equipment. In the case of a configuration including at least one rotary device 100 that combines the functions of a heater (feed preconditioner) and a reactor, the provision of a preheater 102 may be omitted. The combined solution 100-101 utilizes lower pressures, which improves the reaction yield. Furthermore, the layout of FIG. 4B allows the sulfur removal step to be moved downstream of the reformer 101, since there is no catalyst to weaken. The presence of sulfur in the feed can further reduce coking.

[0187] In another embodiment, the rotating device 100 is an indirect heater configured to heat any suitable gas (heat transfer medium), and then the hot gas heated in 100 is fed into a hydrogen production process / unit 191, for example into a reformer furnace. The hot gas produced in the rotating device 100 enters the inner space of the furnace and heats the reformer tubes to the required reaction temperature. Thus, the device 100 can replace fuel-fired external burners in the furnace. Such an arrangement is advantageous in the sense that it can utilize most of the existing infrastructure.

[0188] Figure 4C illustrates the application of a rotating device as an indirect heater in steam methane reforming. The rotating device replaces the fired heater in the reformer furnace 101. The layout of Figure 4C can utilize the configurations shown in Figures 2C, 2D and / or 2F, for example.

[0189] The main difference between the layout shown in Figures 4A, 4B (direct heating) and the layout shown in Figure 4C (indirect heating) is that in the layouts of Figures 4A and 4B the rotating device is used to (directly) heat a feed-containing process fluid (e.g. methane stream mixture) from which the heated fluid is led into the steam reformer 101, whereas in the layout of Figure 4C the rotating device 100 is formed to heat a fluid medium other than the feed / process fluid (which for clarity can also be called heat transfer medium). It can be observed from Figure 4C that any suitable gas (e.g. make-up gas, air, nitrogen or steam) can be used as the heat transfer medium to be heated in the device 100. The heat transfer medium is further led to a heat consuming unit 101, e.g. a reformer furnace, for external heating of the reformer tubes. The methane-containing feed and optionally the steam required for the reforming reaction are fed into the reformer 101 from elsewhere (thus bypassing the rotating device 100). The heat required for the endothermic reforming reactions to proceed in the reformer 101 is thus supplied into the reformer 101 through a heat transfer process between the heated fluid medium (air, nitrogen, steam, etc.) generated in the rotating device 100 and the process stream (methane, steam) that bypasses the rotating device 100.

[0190] Recycling of the heat transfer medium can be carried out, for example, in an indirect heating arrangement, as shown in Fig. 2D. The heat transfer medium cooled in unit 101 (here in the reformer furnace) as a result of the heat transfer between said heat transfer medium and the process fluid (methane, steam) can be sent for reheating (as stream 9 shown in Fig. 2D). Heat losses can thus be minimized. Correspondingly, the hydrogen product and the unreacted feedstock can also be recycled (methane recycling is not shown in Fig. 4C).

[0191] Figure 5B is a simplified layout illustrating the retrofit of a rotating device 100 to an existing reformer furnace 101, where the device 100 replaces a fired heater. Figure 5B illustrates a schematic arrangement including at least one reactor or furnace 101 configured to carry out a process related to hydrogen production at a temperature essentially equal to or greater than about 500°C, and at least one rotating device 100 configured to generate a heated fluid medium for inputting thermal energy into the at least one reactor or furnace.

[0192] In the layout of FIG. 5B, at least one rotating device 100 is used to replace fuel-fired radiant heater burners outside the furnace / reactor 101. The rotating device 100 is used as an indirect heater to heat an inert gas, e.g. steam, air, or nitrogen. The inert gas is further fed into the refractory space of the furnace 101, similar to the fuel in the fired heater. The hot gas from the rotating device allows heating to the catalytic reactor tubes inside the furnace. The inert gas heated by the device 100 now acts as a heating medium / heat transfer medium for the process fluid propagating through the tubes / coils inside the furnace 101. The process fluid can be a gas (e.g. methane gas), a liquid, or a gas-liquid mixture.

[0193] In addition, in the embodiment of FIG. 5B, the flue gas (e.g., N2, CO2, HO, NO x , S.O. x , particulate matter) may further be used as input stream to the rotating device for reheating (see Figure 5B, flue gas recycle line).

[0194] An additional advantage of the rotating machine 100 here is that it acts as a blower, providing the pressure rise necessary for the fluid to circulate, thus this layout eliminates the need for a separate air blower (typical of conventional fired furnaces).

[0195] The use of a rotating device as a recycle heater allows for optimal heat recovery from the flue gas and ensures that heat losses are minimized. This embodiment also avoids the emission of harmful environmental emissions such as carbon dioxide, nitrogen oxides, sulfur oxides, and particulate matter.

[0196] Circulating an inert gas, such as steam or nitrogen, within the rotating apparatus 100 is advantageous, particularly when the fluid to be heated is at high pressure and / or is flammable, as this improves process safety by providing an inert atmosphere within the furnace.

[0197] Overall, Figures 5A and 5B provide an overview of the integration of a rotating device 100 with a catalytic reactor configured for endothermic reactions. Combustion-type heaters and furnaces providing heat for high-temperature endothermic catalytic reactions are the major contributor to the majority of all emissions in the hydrogen production industry, for example through (catalytic) methane steam reforming. The rotating device 100 can be used to provide thermal energy to such catalytic reactions by heating the feed of the catalytic reactor 101 and introducing the hot feed into a catalyst bed with an ascending temperature profile. To maintain the reaction rate and bring the reaction to completion, the rotating device can act as a reheater between said catalyst beds (see Figures 2E, 5A).

[0198] 5A and 5B show the incorporation of the rotary device 100 into the most common pathways for providing reaction heat during endothermic solid catalytic reaction processes: 1) to expose the catalyst-containing tubes to an external heating device to continuously introduce heat through the reactor tubes to the catalyst bed and the reactants along the length of the catalyst bed (FIG. 5B, indirect heating), and 2) to heat the reactants to a high temperature before entering the reactor, allowing the reaction to occur with a resulting adiabatic temperature drop, and then to reheat the reactants for the next reactor if the desired conversion is not achieved (FIG. 5A, direct heating). The concept of FIG. 5B is suitable for retrofitting existing furnaces. For new "greenfield" installations, direct heating of the gas in the rotary device can also be applied (FIG. 5A). The layout of FIG. 5A can be incorporated into a catalytic gasoline reforming process (typically implemented in a semi-regenerative catalytic reformer unit in an oil refinery). The rotating device 100 can be directly adapted to replace a fired heater as described above.

[0199] As is clear to those skilled in the art, with the development of technology the basic idea of ​​the invention can be realized and combined in various ways, the invention and its embodiments are thus not limited to the above examples, which may vary widely within the scope of the appended claims.

Claims

1. A method of introducing thermal energy into a process related to producing hydrogen within a hydrogen production facility, the method including generating a heated fluid medium by at least one rotating device incorporated within the hydrogen production facility, the at least one rotating device comprising a casing having at least one inlet and at least one outlet, a rotor including at least one row of rotor blades disposed around a rotor hub mounted on a rotor shaft, a plurality of stationary vanes arranged to form an assembly at least upstream of the at least one row of rotor blades, and comprising the method comprising - incorporating the at least one rotating device into the hydrogen production facility configured to carry out a process related to hydrogen production at a temperature essentially equal to or exceeding about 500 °C, - introducing an amount of input energy into the at least one rotating device incorporated within the hydrogen production facility, wherein the input energy includes electrical energy, and - operating the at least one rotating device incorporated within the hydrogen production facility such that an amount of thermal energy is imparted to a fluid medium flow guided along a flow path formed within the casing between the inlet and the outlet by a series of energy conversions occurring as the fluid medium flow passes through the stationary vanes and the at least one row of rotor blades, thereby generating a flow of heated fluid medium. A method further comprising.

2. The method according to claim 1, including connecting the at least one rotating device within the hydrogen production facility to at least one reactor or furnace configured to produce hydrogen from a hydrocarbon-containing gas.

3. The method according to claim 1 or 2, wherein the at least one reactor or furnace is configured to carry out a thermal and / or catalytic process to produce hydrogen from the hydrocarbon-containing gas.

4. The method according to claim 1 or 2, wherein the hydrogen production facility is a methane pyrolysis plant or a steam methane reforming (SMR) plant.

5. The method according to claim 1 or 2, comprising generating the fluid medium heated to a temperature essentially equal to or exceeding about 500 °C, preferably essentially equal to or exceeding about 1200 °C, more preferably essentially equal to or exceeding about 1700 °C, by means of at least one rotating device.

6. The method according to claim 1 or 2, comprising adjusting the velocity and / or pressure of the fluid medium flow propagating through the rotating device in order to create the conditions under which the heated fluid medium is generated.

7. The method according to claim 1 or 2, wherein the heated fluid medium is generated by means of at least one rotating device comprising two or more rotor blade rows arranged continuously along the rotor shaft.

8. The heated fluid medium is generated by means of at least one rotating device further comprising a diffuser region arranged downstream of at least one rotor blade row, and the method comprises operating the at least one rotating device incorporated into the hydrogen production facility such that an amount of thermal energy is imparted to the fluid medium flow guided along the flow path formed inside the casing between the inlet and the outlet by a series of energy conversions occurring when the fluid medium flow successively passes through the stationary vanes, the rotor blades, and the diffuser region, thereby generating a flow of heated fluid medium.

9. The method according to claim 1 or 2, wherein within the rotating device the diffuser region is formed with or without stationary diffuser vanes.

10. The method according to claim 1 or 2, wherein the amount of thermal energy added to the fluid medium flow propagating through the rotating device is controlled by adjusting the amount of input energy guided into the at least one rotating device incorporated into the hydrogen production facility.

11. The method according to claim 1 or 2, further comprising arranging an additional heating device downstream of the at least one rotating device and introducing a reactive compound or a mixture of reactive compounds into the fluid medium flow propagating through the additional heating device, whereby immediately an amount of thermal energy is added to the fluid medium flow through an exothermic reaction.

12. The method according to claim 11, wherein the reactive compound or mixture of reactive compounds is introduced into the fluid medium stream preheated to a predetermined temperature.

13. The method according to claim 12, wherein the reactive compound or mixture of reactive compounds is introduced into the fluid medium stream preheated to a temperature essentially equal to or exceeding about 1700 °C.

14. The method according to claim 11, wherein the preheating of the fluid medium to the predetermined temperature is carried out in a rotating device.

15. The method according to claim 1 or 2, comprising generating the heated fluid medium by at least two rotating devices incorporated into the hydrogen production facility, the at least two rotating devices being connected in parallel or in series.

16. The method according to claim 15, wherein the heated fluid medium is generated by at least two continuously connected rotating devices, the fluid medium stream being preheated to a predetermined temperature in at least a first rotating device within the continuum and additional amounts of thermal energy being introduced into the preheated fluid medium stream propagating through the second rotating device, whereby the fluid medium stream is further heated in at least a second rotating device within the continuum.

17. The method according to claim 16, wherein in at least the first rotating device within the continuum, the fluid medium stream is preheated to a temperature essentially equal to or exceeding about 1700 °C.

18. The method according to claim 16, wherein by introducing the reactive compound or mixture of reactive compounds into the stream, the additional amounts of thermal energy are added to the fluid medium stream propagating through at least the second rotating device within the continuum.

19. The method according to claim 1 or 2, comprising introducing the reactive compound or mixture of compounds into the process related to hydrogen production.

20. The method according to claim 1 or 2, wherein the heated fluid medium generated by the at least one rotating device is selected from the group consisting of a feed gas, a recycle gas, a makeup gas, and a process fluid.

21. The method according to claim 1 or 2, wherein the fluid medium entering the rotating device is an essentially gaseous medium.

22. The method according to claim 1 or 2, comprising generating the heated fluid medium within the rotating device.

23. The method according to claim 22, wherein the heated fluid medium generated in the rotating device is a hydrocarbon-containing gas.

24. The method according to claim 23, wherein the heated fluid medium generated in the rotating device comprises or consists of methane, natural gas, or a mixture thereof.

25. The heated fluid medium generated within the rotary device is a gaseous medium other than a hydrocarbon-containing gas, such as air, steam (H ２ O), nitrogen (N ２ ), or any combination thereof, or consists of these, the method according to claim 22.

26. The method according to claim 22, wherein the heated fluid medium generated in the rotating device comprises or consists of recycled gas recycled from the exhaust gas generated during the hydrogen production process in a hydrogen production incineration facility.

27. The method according to claim 1 or 2, further comprising generating the heated fluid medium outside the rotating device through a heat transfer process between the heated fluid medium generated in the rotating device and a fluid medium flow bypassing the rotating device.

28. The method according to claim 27, further comprising generating the heated fluid medium provided as a hydrocarbon-containing gas outside the rotating device through a heat transfer process between the heated fluid medium other than the hydrocarbon-containing gas generated in the rotating device and a fluid medium flow provided as a hydrocarbon-containing gas and bypassing the rotating device.

29. The method according to claim 1 or 2, further comprising increasing the pressure in the fluid medium flow propagating through the rotating device.

30. The method according to claim 1 or 2, wherein the amount of electrical energy introduced as input energy into the at least one rotating device incorporated in the hydrogen production facility is in the range of about 5 percent to 100 percent.

31. The method according to claim 1 or 2, wherein the amount of electrical energy introduced as input energy into the at least one rotating device incorporated in the hydrogen production facility can be obtained from a renewable energy source, or various different energy sources, optionally a combination of renewable energy sources.

32. The method according to claim 1 or 2, wherein the at least one rotating device is incorporated into the hydrogen production facility together with at least one heater device operable with non-electrical energy, thereby being utilized to balance fluctuations in the amount of electrical energy, optionally renewable electrical energy, such as supply surpluses and shortages.

33. A hydrogen production facility, comprising at least one reactor or furnace configured to produce hydrogen from a hydrocarbon-containing gas at a temperature essentially equal to or exceeding about 500°C, and at least one rotating device configured to generate a heated fluid medium for introducing thermal energy into the at least one reactor or furnace, wherein the at least one rotating device comprises a casing having at least one inlet and at least one outlet, a rotor including at least one row of rotor blades disposed around a rotor hub mounted on a rotor shaft, a plurality of fixed vanes disposed upstream of at least the upstream side of the at least one row of rotor blades to form an assembly, and is further configured such that an amount of input energy is received by the at least one rotating device, the input energy including electrical energy, and an amount of thermal energy is imparted to a fluid medium flow guided along a flow path formed inside the casing between the inlet and the outlet by a series of energy conversions occurring when the fluid medium flow passes through the fixed guide vanes and the at least one row of rotor blades, thereby generating a flow of the heated fluid medium. A hydrogen production facility.

34. The hydrogen production facility according to claim 33, wherein the at least one rotating device includes two or more rows of rotor blades continuously arranged along the rotor shaft.

35. The hydrogen production facility according to claim 33, wherein the at least one rotating device further includes a diffuser region disposed downstream of at least one row of rotor blades.

36. The hydrogen production facility according to claim 33, wherein the rotating device includes the diffuser region formed with or without fixed diffuser vanes.

37. The hydrogen production facility according to claim 33, wherein the at least one rotating device is further configured to increase the pressure in the fluid medium flow propagating through the rotating device.

38. The hydrogen production facility according to any one of claims 33 to 37, wherein the at least two rotating devices are disposed in an assembly and connected in parallel or in series.

39. ​ The hydrogen production facility according to any one of claims 33 to 37, formed as a methane pyrolysis plant or a steam methane reforming (SMR) plant.

40. A hydrogen production facility formed to carry out a process related to the production of hydrogen through the method according to claim 1 or 2.

41. Optionally, the use of the hydrogen production facility according to any one of claims 33 to 37 for carrying out a process related to the production of hydrogen and / or synthesis gas through the process of steam methane reforming.

42. The use of the hydrogen production facility according to any one of claims 33 to 37 for carrying out a process related to the conversion of methane to hydrogen, fuel, and / or chemicals.

43. Optionally, the utilization of the method according to claim 1 or 2 for a process related to the production of hydrogen and / or synthesis gas through the process of steam methane reforming and / or within a heat consumption facility formed within said process.

44. The utilization of the method according to claim 1 or 2 for a process related to the conversion of methane to hydrogen, fuel, and / or chemicals and / or within a heat consumption facility formed within said process.

45. The utilization of the method according to claim 1 or 2 for improving the energy efficiency of a hydrogen production facility and / or for reducing greenhouse gas emissions and particulate emissions within said hydrogen production facility.

46. A method of producing hydrogen, comprising introducing thermal energy into a process related to producing hydrogen within a hydrogen production facility based on the method according to claim 1 or 2.

47. A method of manufacturing hydrogen, the method comprising generating a heated fluid medium by at least one rotating device incorporated within a hydrogen production facility, the at least one rotating device comprising a casing having at least one inlet and at least one outlet, a rotor including at least one row of rotor blades disposed around a rotor hub mounted on a rotor shaft, a plurality of fixed vanes disposed upstream of at least said at least one row of rotor blades to form an assembly, and including. An amount of thermal energy is imparted to a fluid medium flow guided along a flow path formed inside the casing between the inlet and the outlet by a series of energy conversions that occur when the fluid medium flow passes through the fixed vanes and the at least one rotor blade row, respectively, thereby generating a flow of heated fluid medium, the method comprising: - introducing an amount of input energy into the at least one rotating device incorporated into the hydrogen production facility, wherein the input energy includes electrical energy; - supplying the flow of heated fluid medium generated by the at least one rotating device into the hydrogen production facility; and - operating the at least one rotating device and the hydrogen production facility to carry out hydrogen production at a temperature essentially equal to or exceeding about 500°C. Further comprising: A method for producing hydrogen.

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