Hydrogen generation process using partial oxidation/steam reforming

1. An efficient, integrated process for generating hydrogen from a hydrocarbon-containing feedstock in the essential absence of a shift reaction zone comprising:

a. passing to a partial oxidation reformer at a pressure of between about 400 and 1500 kPa absolute feed comprising hydrocarbon-containing feedstock, air, and steam wherein the molar ratio of steam to carbon in the hydrocarbon-containing feedstock is at least about 4:1, said reformer being at partial oxidation/steam reforming conditions to provide a reforming effluent stream comprising at least about 40 volume percent (dry basis) hydrogen, nitrogen, steam, carbon monoxide and carbon dioxide;

b. cooling the reforming effluent stream by indirect heat exchange with a stream containing liquid water to provide a steam-containing stream which is cycled to the partial oxidation/steam reforming zone wherein at least about 40 percent of the steam in the feed mixture is produced by said indirect heat exchange;

c. further cooling the cooled reforming effluent stream to pressure swing adsorption conditions, said cooling being sufficient to condense water;

d. during or after the further cooling separating the condensed water;

e. subjecting the further cooled reforming effluent stream to pressure swing adsorption such that a purified hydrogen stream is produced which (i) is at least about 98 mole percent hydrogen, and (ii) contains less than about 10 ppmv carbon monoxide, and a sorption purge gas is produced at a pressure between about 5 and 100 kPa gauge which comprises less than about 30 volume percent hydrogen (dry basis) and nitrogen, carbon dioxide and carbon monoxide;

f. withdrawing at least a portion of the purified hydrogen stream as hydrogen product;

g. combusting in the substantial absence of added fuel, the sorption purge gas with an oxygen-containing gas in the presence of an oxidation catalyst to provide a combustion gas having a temperature of less than about 800° C.;

h. subjecting the combustion gas to at least one indirect heat exchange with a liquid water-containing stream to generate steam which is cycled to the reformer;

and

i. exhausting the cooled combustion gas, wherein the Net Hydrogen Efficiency is at least about 50 percent.

2. The process of claim 1 wherein in step (g) at least two indirect heat exchanges occur wherein the combustion gas is in a first heat exchange with steam and the oxygen-containing stream and in a subsequent heat exchange, the combustion gas is used to vaporize water for steam which is used as a feed to the partial oxidation reformer.

3. The process of claim 1 wherein the pressure swing absorption comprises four absorbent beds and two pressure equalizations.

4. The process of claim 1 wherein the purified hydrogen product comprises at least about 99.9 volume percent hydrogen.

5. The process of claim 1 wherein the pressure drop through the oxidation catalyst of step (g) is less than 5 KPa.