Integrated pressurized steam hydrocarbon reformer and combined cycle process

1. A process for the co-production of hydrogen and power comprising:

supplying a feed stream to a hydrogen production unit comprising a gas heated reformer, a water gas shift reactor, and a hydrogen separator, said feed stream comprising a first portion of a high-BTU hydrocarbon fuel and steam;

producing a hydrogen-containing stream and a low-BTU hydrocarbon fuel stream in said hydrogen production unit, said low-BTU hydrocarbon fuel having an average BTU content per SCF that is lower than that of said high-BTU hydrocarbon fuel;

supplying a second portion of said high-BTU hydrocarbon fuel and an oxygen-containing gas to a power generation unit comprising a combustion gas turbine engine and combusting said second portion of high-BTU hydrocarbon fuel within said engine to generate power;

extracting a portion of compressed oxygen-containing gas from said combustion gas turbine engine, passing said portion of compressed oxygen-containing gas through a compressor to increase the pressure thereof, and directing said portion of compressed oxygen-containing gas from said compressor to a pressurized partial combustion unit contained within said hydrogen production unit;

combusting said low-BTU hydrocarbon fuel and, a third portion of said high-BTU hydrocarbon fuel, in said pressurized partial combustion unit to produce a high-pressure partial combustion gas stream; and

using said high-pressure combustion gas stream as a heat source for said gas heated reformer.

2. The process according to claim 1 , wherein said high-BTU hydrocarbon fuel is selected from the group consisting of natural gas, propane, LPG, butane, pentane, diesel oil, and combinations thereof.

3. The process according to claim 1 , wherein said high-BTU hydrocarbon fuel presents an average energy content of at least 150 BTU/SCF.

4. The process according to claim 1 , wherein the pressure of said hydrogen production unit feed stream within said gas heated reformer is greater than the pressure of said high-pressure partial combustion gas stream within said gas heated reformer.

5. The process according to claim 1 , wherein said low-BTU hydrocarbon fuel presents an average energy content that is less than half of the average energy content of said high-BTU hydrocarbon fuel.

6. The process according to claim 1 , wherein said power generation unit comprises a combined cycle process including said combustion gas turbine engine and a heat recovery steam generator, and a steam turbine operating in a Rankine cycle using at least a portion of the steam generated in the heat recovery steam generator.

7. The process according to claim 6 , wherein the exhaust gas from said combustion gas turbine engine is used to supply heat to said heat recovery steam generator for the production of steam.

8. The process according to claim 7 , wherein at least some of said steam produced by said heat recovery steam generator is used to generate power in said steam turbine operating in a Rankine cycle.

9. The process according to claim 1 , wherein said compressed oxygen-containing gas extracted from said combustion gas turbine engine is cooled by one or more heat exchangers prior to being passed through said compressor.

10. The process according to claim 1 , wherein said gas heated reformer comprises a tube and shell reactor, said tubes containing a reforming catalyst through which said hydrogen production unit feed stream is passed, and wherein said high-pressure partial combustion gas stream from said pressurized partial combustion unit is delivered to the shell-side of said reactor.

11. The process according to claim 10 , wherein the pressure of said hydrogen production unit feed stream is within about 10 inches of water gauge of the pressure of said high-pressure partial combustion gas stream.

12. The process according to claim 1 , wherein at least a portion of said high-pressure combustion gas stream is returned to at least one combustor within said combustion gas turbine engine following passage through said gas heated reformer.

13. The process according to claim 1 , wherein said gas heated reformer produces a reformer product stream comprising a quantity of hydrogen and carbon monoxide, said reformer product stream being fed to said water gas shift reactor for the production of carbon dioxide and additional quantities of hydrogen.

14. The process according to claim 13 , wherein said shift reactor produces a shift reactor product stream which is fed to said hydrogen separator thereby producing said hydrogen-containing stream and said low-BTU hydrocarbon fuel stream.

15. The process according to claim 14 , wherein said hydrogen separator comprises a pressure swing adsorber.

16. A process for the co-production of hydrogen and power comprising:

supplying a feed stream to a hydrogen production unit comprising a gas heated reformer, a water gas shift reactor, and a hydrogen separator, said feed stream comprising a first portion of a high-BTU hydrocarbon fuel and steam;

producing a hydrogen-containing stream and a low-BTU hydrocarbon fuel stream in said hydrogen production unit, said low-BTU hydrocarbon fuel having an average BTU content per SCF that is lower than that of said high-BTU hydrocarbon fuel;

supplying a second portion of said high-BTU hydrocarbon fuel and an oxygen-containing gas to a power generation unit comprising a gas turbine engine and combusting said second portion of high-BTU hydrocarbon fuel within said gas turbine engine to generate power;

extracting a portion of compressed oxygen-containing gas from said gas turbine engine; cooling said extracted portion of compressed oxygen-containing gas thereby forming a cooled stream of oxygen-containing gas;

compressing said cooled stream of oxygen containing gas thereby forming a high-pressure, oxygen-containing gas stream; directing said high-pressure, oxygen-containing gas stream to a pressurized partial combustion unit contained within said hydrogen production unit;

combusting said low-BTU hydrocarbon fuel and, a third portion of said high-BTU hydrocarbon fuel, in said pressurized partial combustion unit to produce a high-pressure partial combustion gas stream; and

using said high-pressure combustion gas stream as a heat source for said gas heated reformer.

17. The process according to claim 16 , wherein said high-BTU hydrocarbon fuel is selected from the group consisting of natural gas, propane, LPG, butane, pentane, diesel oil, and combinations thereof.

18. The process according to claim 16 , wherein said high-BTU hydrocarbon fuel presents an average energy content of at least 150 BTU/SCF.

19. The process according to claim 16 , wherein the pressure of said hydrogen production unit feed stream within said gas heated reformer is greater than the pressure of said high-pressure partial combustion gas stream within said gas heated reformer.

20. The process according to claim 16 , wherein said low-BTU hydrocarbon fuel presents an average energy content that is less than half of the average energy content of said high-BTU hydrocarbon fuel.

21. The process according to claim 16 , wherein said power generation unit comprises a combined cycle process that includes said gas turbine engine and a heat recovery steam generator.

22. The process according to claim 21 , wherein the exhaust gas from said gas turbine engine is used to supply heat to said heat recovery steam generator for the production of steam.

23. The process according to claim 21 , wherein at least a portion of said high-pressure partial combustion gas stream is returned to said combined cycle process following passage through said gas heated reformer.

24. The process according to claim 16 , wherein said gas heated reformer comprises a tube and shell reactor, said tubes containing a reforming catalyst through which said hydrogen production unit feed stream is passed, and wherein said high-pressure combustion gas stream from said pressurized partial combustion unit is delivered to the shell-side of said reactor.

25. The process according to claim 16 , wherein said gas heated reformer produces a reformer product stream comprising a quantity of hydrogen and carbon monoxide, said reformer product stream being fed to said water gas shift reactor for the production of carbon dioxide and additional quantities of hydrogen.

26. The process according to claim 25 , wherein said shift reactor produces a shift reactor product stream which is fed to said hydrogen separator thereby producing said hydrogen-containing stream and said low-BTU hydrocarbon fuel stream.

27. The process according to claim 26 , wherein said hydrogen separator comprises a pressure swing adsorber.

28. A system for the co-production of hydrogen and power comprising:

a hydrogen production unit including:

a gas heated reformer including a reforming catalyst through which a stream comprising a first portion of a high-BTU hydrocarbon fuel and steam is passed;

a pressurized partial combustion unit that supplies a high-pressure combustion gas stream to said gas heated reformer, a water gas shift reactor

a hydrogen separator that produces a low-BTU hydrocarbon fuel stream and a hydrogen containing stream; and

a power generation unit including:

a combustion gas turbine engine that combusts an oxygen containing gas and a second portion of the high-BTU hydrocarbon fuel for generating power;

a compressed oxygen-containing gas stream that is extracted from said combustion gas turbine engine;

a compressor for further compressing said compressed oxygen-containing gas extracted from said combustion gas turbine engine; and

said low-BTU hydrocarbon fuel stream and said compressed oxygen-containing gas stream being fluidly coupled with said pressurized partial combustion unit.

29. The system according to claim 28 , wherein said high-BTU hydrocarbon fuel is selected from the group consisting of natural gas, propane, LPG, butane, pentane, diesel oil, and combinations thereof.

30. The system according to claim 28 , wherein said gas heated reformer comprises a tube and shell reactor, said tubes containing said reforming catalyst and said high-pressure combustion gas stream being delivered to the shell-side of said reactor.

31. The system according to claim 30 , wherein said high-pressure combustion gas stream exits said gas heated reformer as a cooled combustion gas stream, said cooled combustion gas stream being fluidly coupled with said combustion gas turbine engine.

32. The system according to claim 28 , wherein said power generation unit comprises a combined cycle process including said combustion gas turbine engine and a heat recovery steam generator.

33. The system according to claim 32 , wherein an exhaust gas stream exits said combustion gas turbine engine, said exhaust gas stream being fluidly coupled with and supplying heat to said steam generator for the production of steam.

34. The system according to claim 28 , wherein said power generation unit further comprises at least one heat exchanger for cooling said compressed oxygen-containing gas extracted from said combustion gas turbine engine, said heat exchanger being located upstream from said compressor.