WO2025088032A1

WO2025088032A1 - Gasification of solid waste for production of clean hydrogen, method and system

Info

Publication number: WO2025088032A1
Application number: PCT/EP2024/080061
Authority: WO
Inventors: Daniel Buchholz; Nadia ROMDHANE
Original assignee: Green Hydrogen Technology GmbH
Current assignee: Green Hydrogen Technology GmbH
Priority date: 2023-10-27
Filing date: 2024-10-24
Publication date: 2025-05-01
Anticipated expiration: 2026-04-27

Abstract

The present invention relates to a method for producing hydrogen in a gas production system, the method comprising producing a stream of hot gas, reacting a hydrocarbon carrier material with the hot gas to generate a gasified material, and separating hydrogen from the gasified material to produce a hydrogen gas containing product, wherein gasified material comprises a syngas in a syngas stream, wherein method comprises using heat from the hot gas for the reacting of the hydrocarbon carrier material The present invention also relates to a system for producing hydrogen, wherein the system is configured to produce a stream of hot gas, react a hydrocarbon carrier material with the hot gas to generate a gasified material, and separate hydrogen from the gasified material to produce a hydrogen gas containing product, wherein the system is configured to carry out any of the steps of the method of the present invention.

Description

Gasification of solid waste for production of clean hydrogen, method and system

Field

The invention lies in the field of solid waste processing and particularly in the field of production of hydrogen. The goal of the present invention is to provide a method for producing hydrogen. More particularly, the present invention relates to high purity grade hydrogen, a system to perform such a method and corresponding use of the system and method.

Introduction

The global challenge of waste management and the pressing need for sustainable energy solutions have converged to catalyze an innovative approach that holds immense promise: clean hydrogen production from solid waste. Amidst the urgent need to curb greenhouse gas emissions and transition to cleaner energy sources, the quest for sustainable alternatives has also led to a resurgence of interest in clean hydrogen production from biomass. Biomass, derived from organic matter such as agricultural residues, forest waste, and dedicated energy crops, stands as a renewable and abundant resource with the potential to revolutionize our energy landscape.

Solid waste, often viewed as a societal burden, harbors a hidden treasure trove of energy potential. Every discarded item, from organic matter to plastic waste, contains within it a reservoir of carbon-rich compounds that can be tapped into for energy generation. Clean hydrogen production from solid waste leverages innovative technologies to extract valuable energy from what was once considered refuse, sparking a paradigm shift in waste management strategies.

Conversion of solid waste and biomass into clean hydrogen involves a synergistic blend of thermal, chemical, and electrochemical processes. Thermochemical techniques, such as gasification and pyrolysis, subject waste materials to controlled high temperatures, liberating hydrogen-rich gases that can subsequently be purified and utilized. Chemical processes, including steam reforming, react waste-derived hydrocarbons with steam to produce hydrogen gas.

AT 524 123 Bl relates to a device for recycling process gas, converting waste materials and forming synthesis gas, comprises at least one vertical riser pipe configured along an axial direction, a feed line opening into the riser pipe, the process gas and an exhaust gas treatment system connected to the riser pipe and a feed device for the waste materials with at least one conveyor pipe protruding over a defined length into the riser pipe, the at least one the conveying pipe has an open end opening into the riser pipe and the supply line opens into the riser pipe below the open end in the axial direction, so that the at least one conveying pipe from the supply line into the riser entering the process gas can flow around.

Summary

In light of the above, it is therefore an object of the present invention to overcome or at least to alleviate the shortcomings and disadvantages of the prior art. More particularly, it is an object of the present invention to provide a method and a corresponding system for production of hydrogen with an improved purity grade and system less prompt to failures and with an extended lifespan.

These objects are met by the present invention.

In a first aspect, the invention relates to a method for producing hydrogen in a gas production system, the method comprising: producing a stream of hot gas, reacting a hydrocarbon carrier material with the hot gas to generate a gasified material, and separating hydrogen from the gasified material to produce a hydrogen gas containing product.

In one embodiment, the method may comprise using heat from the hot gas for the reacting of the hydrocarbon carrier material.

Furthermore, the gas production system may be a modular gas production system. The modular system may comprise a first module, a second module and/or a third module. Producing the hot gas may be carried out in the first module of the modular gas production system. Reacting the hydrocarbon carrier material to generate the gasified material may be carried out in the second module of the module gas production system. Separating hydrogen from the gasified material to produce the hydrogen gas containing product may be carried out in the third module of the modular gas production system.

Further, the gasified material may comprise a syngas in a syngas stream.

In one embodiment, the method may comprise at least partially recycling the syngas as a recycled syngas. Additionally, or alternatively, the method may comprise providing the recycled syngas to a burner comprised by the gas production system to further create the hot gas. At least partially recycling the syngas may comprise recycling at least 15% of the syngas, preferably at least 20% of the syngas, more preferably at least 25%, even more preferably at least 30% of the syngas.

Recycling the syngas is notably advantageous, as the recycled syngas may be used to produce hot gas, which allow replacing the gas source, e.g., natural gas, that may be used to ignite the modular system. This approach is particularly advantageous, as this allows the modular system to operate without needing extra fossil fuel or energy to produce the hot gas. As a result, the gasifier of the modular system may operate with only one feed stock, i.e., with waste as energy source, be a standalone gasifier.

The hydrocarbon carrier material may comprise at least one of: natural gas, fuel, recycled syngas, refuse derived fuel (RDF), biomass, waste oil, and non-recyclable material, coal and other solid material.

In one embodiment, the hydrogen containing product may comprise a hydrogen purity grade of at least IN, preferably at least 2N, more preferably at least 3N.

In a further embodiment, reacting the hydrocarbon carrier material to generate the gasified material may comprise producing the syngas by adding into the second module the hydrocarbon carrier material and the hot gas. Additionally or alternatively, the reacting step may take place in an entrained flow reactor.

In another embodiment, the method may comprise at least partially recycling the carbon dioxide gas in an upstream process.

Moreover, the method may comprise liquifying carbon dioxide gas that may be not recycled in the upstream process.

In a one embodiment, the method may comprise producing the hot gas at a hot gas temperature of between 1200°C and 1800 °C, preferably between 1400°C and 1700 °C, most preferable between 1500°C and 1600 °C.

Furthermore, combusting the syngas may take place at a lambda slightly lower than 1 and under an oxygen atmosphere.

It should be understood that lambda (A) intends to refer to an air-fuel equivalence ratio, which is a crucial parameter that indicates the ratio of an actual air-fuel mixture being burned in a combustion process to a stoichiometric air-fuel ratio, which is an ideal ratio for complete combustion. If lambda is 1 (A = 1), it means the mixture is exactly at stoichiometry; if lambda is greater than 1 (A > 1), it indicates an excess of air which may also be referred to as a lean mixture, while if lambda is less than 1 (A < 1), it indicates an excess of fuel which may also be referred to as a rich mixture.

It also should be understood that when the lambda value is slightly lower than 1 (A < 1), it indicates a mixture that is still fuel-rich but not as severely rich as when lambda is significantly less than 1, which means that there is a moderate excess of fuel compared to the amount of air needed for stoichiometric combustion.

In one embodiment, for producing the hot gas, the method may comprise burning at least one of: the natural gas, the fuel, the recycled syngas, biogas from other processes, and syngas from other processes. For instance, biogas from other process and/or syngas from other processes may comprise excess combustible gas from other processes such as glass industry.

In other embodiment, the method may comprise directly using the hot gas from a preceding process. Moreover, the method may comprise directly using the hot gas from a preceding process without combustion.

In a further embodiment, reacting the hydrocarbon carrier material with the hot gas to generate a gasified material may comprise reacting the hot gas with at least one of: the refuse derived fuel (RDF), the biomass, waste oil, and non-recyclable material, coal and other solid material.

In one embodiment, the second module may comprise the entrained flow reactor.

Further, for reacting the hydrocarbon carrier material to generate the gasified material, the method may comprise injecting the hydrocarbon carrier material to the hot gas with CO2, steam or an inert gas. It should be understood that the steam may also be made inert, and thus, used as inert steam.

Moreover, the method may comprise at least one of: superheating the hydrocarbon carrier material by the hot gas, gasifying the hydrocarbon carrier material, and at least partially oxidizing the hydrocarbon carrier material.

In one embodiment, the stream of hot gas may comprise at least one of: carbon dioxide and water. Moreover, the method may comprise converting the superheated hydrocarbon carrier material to syngas.

In one embodiment, the step of converting the gasified material to the synthesis gas may be an endothermic process.

In another embodiment, the method may comprise performing of a chemical cooling based on an endothermic reaction of the synthesis gas to a temperature of at least 1000°C, preferably at least 900 °C, more preferably at least 800 °C, most preferably at least 700 °C.

Moreover, the method may comprise cooling the synthesis gas by means of the endothermic process.

Furthermore, the reaction may comprise a combustion following a water-gas shift reaction of:

CO + H₂O CO₂ + H₂ AHO_R= -41,1 kJ mol

In one embodiment, the method may comprise reducing formation wall-adhering substances such as tar or soot. Additionally or alternatively, reducing the formation of walladhering substances using a high temperature.

In another embodiment, the method may comprise increasing a carbon conversion efficiency, wherein the method may comprise at least one of: controlling a reaction speed, and mixing of at one reactant comprising at least one of: oxygen and hydrocarbon carrier material. This is particularly advantageous, as it allows to homogenously mixing the reactants by means of turbulences caused by the thermo-chemical reaction.

Further, the method may comprise controlling the flow in the second module.

In one embodiment, the method may comprise forming, in the stream of hot gas, a protective layer around a solid stream by means of the stream of hot gas. This is notably advantageous, as it allows to prevent the liquid ash, i.e., slag, from adhering to the wall of the reactor. Moreover, this allows that later - further up in the reactor of the modular system - when solids of the solid stream may be more thoroughly mixed with the stream of hot gas, the stream of hot gas has cooled down to such an extent that the slag has solidified again and the risk of adhesion significantly reduced.

In another embodiment, the method may comprise centering, in the stream of hot gas, the solid streams in a reactor of the modular system. Additionally or alternatively, the method may comprise providing a laterally axial offset of solid stream inlet towards the direction of the laterally inflowing hot gas. This is notably advantageous, as it compensates the lateral shift of the vertical inflowing solid stream after immersing into the lateral inflowing hot gas stream. The centric alignment of the flow of solids can thus be ensured inside the subsequent vertical beginning of the reactor. The centric alignment is obligatory in terms of avoiding adhering melted solids at the reactor as far as possible and also to ensure an even temperature input into the stream of solids.

In one embodiment, the method may comprise supplying an oxygen carrier stream to the solid stream, wherein the oxygen carrier stream may be added centrally in the inlet of the solid stream. This is notably advantageous, as the central oxygen supply allows to improve the temperature input into the solid material through two particularly beneficial aspects. On the one hand, it spreads the stream of solids into a wider cross section by performing a cylindrical stream shape out of it. On the other hand, it permits an additional temperature input into the solid stream from the center, generated by the combustion of the solids with oxygen. Hence, the solids are not getting heated from outside by the radiant heat of the stream of hot gas only, they are also getting better distributed and heated which allows a faster and more complete gasification.

Moreover, the method may comprise removing an undesired material from the syngas comprising at least one of: ash, dust, and chemical component originating from waste. Additionally or alternatively, for removing the undesired, the method comprising using a filter and/or gas scrubber.

In one embodiment, in the second module, the method may comprise cooling the generated gas stream in a first stage of an economizer, or by injecting cooling water, from 1000°C to 400°C more preferably 900°C to 400°C more preferably 800°C to 400°C, most preferably 700°C to 400°C. Further, the cooling step precedes the removing step.

Moreover, the method may include cleaning the gas by removing unfiltered substances such as fly ash or chemical compounds such as tars, sulphur or others from the gas phase. This step can be performed with a chemical or water scrubber or both, depending on the waste feedstock and its impurities load.

Moreover, the method may include cooling and condensation of the water vapor gas phase resulting from the scrubber to further remove water content before being further desulfurized in an active carbon filter. That is, the method may comprise a second cooling stage after removal of fly ash or other chemical compounds as described above. Moreover, in some embodiments, the method may include using a storage tank for the cleaned syngas which may act like a buffer tank for the hot gas generation system in the first stage of the plant. After the recycling of a part of the syngas, the rest of the gas may undergo a water-gas-shift reaction.

Moreover, the method may comprise re-heating the gas stream coming out from the filter and/or the gas scrubber and/or the water scrubber and/or the chemical scrubber and/or the storage tank in a second stage of the economizer to a range of 400°C to 440°C. Additionally or alternatively, the method may comprise cooling the gas stream to a temperature between 300 °C and 350 °C by adding to the gas stream at least one of: water, and water vapor.

In some other embodiments, the method may comprise re-heating the gas stream coming out from the filter and/or the gas scrubber and/or the water scrubber and/or the chemical scrubber and/or the storage tank in a second stage of the economizer to a range of 300°C to 340°C. The method may further comprise adding to the gas stream at least one of: water, and water vapor.

Further, the method may comprise catalytically reacting carbon monoxide and water vapor using a water gas shift catalyst, wherein the reacting step yield to formation of hydrogen and carbon dioxide. Additionally or alternatively, the method may comprise performing the reacting step in two or more water-gas shift converter stages connected in series. Additionally or alternatively, in a first converter stage of the two converter stages, the gas stream heats up to 400 °C to 450°C. Additionally or alternatively, method may comprise cooling the gas stream to a temperature between 300 °C to 350 °C by injecting at least one of: water, and water vapor or by using a heat exchanger for heat recovery. Additionally or alternatively, the method yields the hydrogen gas containing product comprising a composition of 25 to 50 vol% H₂, 10 to 30 vol% H₂O and 20 to 40 vol% CO₂. Additionally or alternatively, the method may comprise purifying the hydrogen gas containing product.

In one embodiment, the method may comprise cooling the hydrogen gas containing product to a temperature between 10 °C and 60 °C, more preferably between 20 °C and 50 °C, such as 40°C.

In another embodiment, the method may comprise separating a precipitating condensate which can be called condensate generally, and feeding this condensate to a water treatment system. Additionally or alternatively, the method may comprise precipitating condensate resulting from a plurality of components of the modular system, the separating the precipitating condensate comprising at least one of: after the gas wash, after cooling the gas stream of the filter and the economizer, before introducing the gas stream into the gas scrubber to a temperature between 30 °C and 60 °C, before introducing the gas to the active carbon filter at a temperature of 5 to 10°C and after every compression combined with cooling and after the water gas shift catalysts.

In a further embodiment, the method may comprise cleaning a surplus of the precipitating condensate to generate cleaned water, and feeding the cleaned water to a water treatment system.

Furthermore, the method may comprise dividing the gas stream in at least two streams. Additionally or alternatively, these at least two streams may comprise a first syngas stream comprising syngas as an alternative gas source for the first module, and a second syngas stream comprising syngas for at least one of: direct combustion, e-fuel production, hydrogen production. Additionally or alternatively, the e-fuel production may comprise production of at least one of: methanol, ammonia, methane, and kerosene. Additionally or alternatively, the first syngas stream may comprise at least 10 vol% of syngas, preferable at least 15 vol% of syngas, more preferable at least 20 vol% of syngas such as 30 vol% of syngas. Additionally or alternatively, the second syngas stream may comprise at least 50 vol% of syngas, preferable at least 60 vol% of syngas, more preferable at least 70 vol% of syngas such as 75 vol% of syngas.

In one embodiment, the method comprising purifying the second syngas stream with a pressure swing adsorption of at least 10 bar, preferably at least 15, more preferably at least 25 bar, such between 10 and 25 bar, preferably between 20 and 25, more preferably between 25 and 30 bars.

In another embodiment, the method may comprise mixing a hydrogen enriched tail gas from a tail gas utilization into a syngas stream. Additionally or alternatively, the method may comprise compressing the syngas stream in three stages, the method comprising compressing to a pressure of: 1 to 3 bar in a first stage, 3 to 10 bar in a second stage, and 10 to 23 bar in a third. Additionally or alternatively, the compressing until 10 bar precedes the economizer and/or the water-gas-shift reactors. Additionally or alternatively, an aftercooler configured for separation of the condensate may be arranged downstream of each of the first stage, the second stage and the third stage. Additionally or alternatively, the method may comprise drying the gas before the first stage of adsorption.

In one embodiment, the method may comprise performing the first stage of adsorption in a plurality of absorber beds, preferably between 3 to 6 adsorber beds. In another embodiment, the method may comprise adsorbing carbon dioxide together with remaining carbon monoxide, nitrogen, and argon and other undesired gases to generate an adsorbed material, which may also be referred to as tail gas, discharging the adsorbed material from the gas stream as discharged adsorbed material.

Moreover, the method may comprise compressing the tail gas to an adsorption pressure of 1 to 23 bar, preferably 3 to 10 bar to yield an adsorbed tail gas. Additionally or alternatively, the method may comprise cooling the adsorbed tail gas, separating water from the adsorbed tail gas to yield an absorbed tail gas stream. Additionally or alternatively, the method may comprise separating the CO2 from the adsorbed tailgas in a second pressure swing adsorption before liquification to a purity of >95% and cooling the CO2 stream to a dew point of -21 °C to -56 °C. Additionally or alternatively, the method may comprise passing the adsorbed gas stream through a heat exchanger to yield a cooled tail gas stream, and feeding the cooled CO2 to a condenser, and at least partially condensing the cooled CO2 to yield a liquid CO2. Additionally or alternatively, the method may comprise separating a liquid phased CO? in a separator to yield separated CO2 and feeding the separated CO2 to a cryogenic storage tank.

In one embodiment, wherein the method comprising purifying the tail gas of the carbon dioxide PSA, feeding the tail gas to a membrane separation plant comprising at least one membrane. Additionally or alternatively, in the membrane separation plant, the method may comprise separating as retentate as least one of: carbon monoxide, nitrogen, and argon; passing through the at least one membrane at least one of: hydrogen and carbon dioxide; and recirculating the permeate as a second tail gas back upstream a gas treatment compressor comprised by the gas production system. Additionally or alternatively, the method comprising depressurizing the retentate to a normal pressure; and cooling the retentate, wherein the cooling of retentate take places simultaneously with the depressurizing step. The normal pressure may be between 1 and 3 bar, such as between 1 and 2 bar.

Moreover, the method may comprise heating to 250 °C to 350 °C the retentate; adding at least one of: metered oxygen, and air to output a retentate mix; and feeding to the retentate mix a catalytic oxidation system comprised by the gas production system, wherein adding at least one: the metered oxygen, and the air precedes feeding the retentate mix to the catalytic oxidation system.

Furthermore, the step of separating a gas phased tail gas may be performed by means of the pressure swing absorption. Moreover, the first module, the second module and the third module may be integrated in a gas production system.

It should be understood that when the first module, the second module and the third module are integrated in the gas production system, whenever an embodiment refers to a first module being configured to produce the stream of hot gas, a second module being configured to react the hydrocarbon carrier material with the hot gas to generate a gasified material, and a third module being configured to separate hydrogen from the gasified material to produce the hydrogen gas containing product, it is meant that the gas production system is configured to produce the stream of hot gas, react the hydrocarbon carrier material with the hot gas to generate a gasified material, and separate hydrogen from the gasified material to produce the hydrogen gas containing product. Moreover, it should be understood that when the first module, the second module and the third module are integrated in the gas product system, then components recited herein as components of the first module, the second module, and the third module should then be understood as component of the gas production system. It should also be understood that when the first module, the second module and the third module are integrated in the gas production system, whenever an embodiment refers to the method being performed in the first module, the second module and/or the third module, it should be understood that the method is performed in the gas production system or given components of the gas production system.

In a second aspect, the invention relates to a system for producing hydrogen, wherein the system is configured to: produce a stream of hot gas, react a hydrocarbon carrier material with the hot gas to generate a gasified material, and separate hydrogen from the gasified material to produce a hydrogen gas containing product.

In one embodiment, the system may be a modular gas producing system comprising: a first module configured to produce the stream of hot gas, a second module configured to react the hydrocarbon carrier material with the hot gas to generate a gasified material, and a third module configured to separate hydrogen from the gasified material to produce the hydrogen gas containing product.

Furthermore, the first module may be configured to generate a stream of hot gas by burning at least one of: the natural gas, the fuel, the recycled syngas, biogas from other processes, and syngas from other processes.

Moreover, the second module may comprise an entrained flow reactor configured to receive a mixture of the hydrocarbon carried material and the stream of hot gas. Additionally or alternatively, the entrained flow reactor may be configured to superheat stream of hot gas, and gasify and at least partially oxidize the mixture.

Furthermore, the entrained flow reactor may be configured to carry out a conversion the stream of hot gas into synthesis gas.

In one embodiment, the second module may be configured to operate at least in a first stage, a second stage, and a third.

Moreover, the second module may comprise a hot gas generator comprising a combustion chamber.

Furthermore, the second module may comprise a continuous entrained flow reactor with top deflection. Additionally or alternatively, the continuous entrained flow reactor may comprise a reactor section configured to guide a stream of hot gas. Additionally or alternatively, the continuous entrained flow reactor may comprise a flexible inlet configured to feed solid material into the reactor, wherein the inlet may comprise a flexible inlet angle of -15° to +15° between injection of solid stream and hot gas stream or reactor axis. Additionally or alternatively, the flexible inlet may comprise an axially offset respect to solid stream inlet towards the direction of a laterally inflowing hot gas.

In one embodiment, the third module may comprise pressure swing adsorption component configured to operate with a pressure swing adsorption of at least 10 bar, preferably at least 15, more preferably at least 25 bar, such between 10 and 25 bar, preferably between 20 and 25, more preferably between 25 and 30 bars.

Moreover, the system may comprise a plurality of at least one of: tubing, and pipes, configured to connect at least one component of the system.

Further, the first module, the second module and the third module may be integrated in the gas production system.

Furthermore, the system may be configured to carry out any of the steps of the method according to any of the preceding method embodiments.

In one embodiment, the system may be configured to produce the hydrogen containing product comprising a hydrogen purity grade of at least IN, preferably at least 2N, more preferably at least 3N. The method may comprise operating the modular system as recited herein to prompt the system to carry out any of the steps of the method as recited herein.

The system may comprise a plurality of components configured to allow the system to carry out any of the steps of the method as recited herein.

In a third aspect, the invention relates to the use of the system as recited herein for carrying out the method according to any of the preceding method embodiments, and the use of the method as recited herein for prompting the system as recited herein to carry out the method as recited herein.

The present technology is also described by the following numbered embodiments.

Below, method embodiments will be discussed. These embodiments are abbreviated by the letter "M" followed by a number. When reference is herein made to a method embodiment, those embodiments are meant.

Ml. A method for producing hydrogen in a gas production system, the method comprising producing a stream of hot gas, reacting a hydrocarbon carrier material with the hot gas to generate a gasified material, and separating hydrogen from the gasified material to produce a hydrogen gas containing product.

M2. The method according to the preceding embodiment, wherein the method comprises using heat from the hot gas for the reacting of the hydrocarbon carrier material.

M3. The method according to any of the preceding embodiments, wherein the gas production system is a modular gas production system.

M4. The method according to any of the preceding embodiments, wherein the modular gas production system comprises a first module.

M5. The method according to any of the preceding embodiments, wherein the modular gas production system comprises a second module.

M6. The method according to any of the preceding embodiments, wherein the modular gas production system comprises a third module.

M7. The method according to embodiment M4, wherein producing the hot gas is carried out in the first module of the modular gas production system. M8. The method according to embodiment M5, wherein reacting the hydrocarbon carrier material to generate the gasified material is carried out in the second module of the module gas production system.

M9. The method according to embodiment M6, wherein separating hydrogen from the gasified material to produce the hydrogen gas containing product is carried out in the third module of the modular gas production system.

MIO. The method according to any of the preceding embodiments, wherein the gasified material comprises a syngas in a syngas stream.

Mil. The method according to any of the preceding embodiments, wherein the method comprises at least partially recycling the syngas as a recycled syngas.

M12. The method according to the preceding embodiment, wherein the method comprises providing the recycled syngas to a burner comprised by the gas production system to further create the hot gas.

M13. The method according to the two preceding embodiments, wherein at least partially recycling the syngas comprises recycling at least 15% of the syngas, preferably at least 20% of the syngas, more preferably at least 25%, even more preferably at least 30% of the syngas.

M14. The method according to any of the preceding embodiments, wherein the hydrocarbon material comprises at least one of: natural gas, fuel, recycled syngas, refuse derived fuel (RDF), biomass, waste oil, non-recyclable material, coal, and other solid material.

M15. The method according to any of the preceding embodiments, wherein the hydrogen containing product comprises a hydrogen purity grade of at least IN, preferably at least 2N, more preferably at least 3N. M16. The method according to any of the preceding embodiments, wherein the step of reacting the hydrocarbon carrier material to generate the gasified material comprises producing the syngas by adding into the second module the hydrocarbon carrier material and the hot gas.

M17. The method according to the preceding embodiment, wherein the reacting step takes place in an entrained flow reactor.

M18. The method according to any of the preceding embodiments, wherein the method comprises at least partially recycling the carbon dioxide gas in an upstream process.

M19. The method according to any of the preceding embodiments and with features of the preceding embodiment, wherein the method comprises liquifying carbon dioxide gas that is not recycled in the upstream process.

M20. The method according to any of the preceding embodiments, wherein the method comprises producing the hot gas at a hot gas temperature of between 1200 °C and 1800 °C, preferably between 1400 °C and 1700 °C, most preferable between 1500 °C and 1600 °C.

M21. The method according to any of the preceding embodiments, wherein combusting the syngas takes place at a lambda slightly lower than 1 and under an oxygen atmosphere.

M22. The method according to any of the preceding embodiments and with the features of embodiment M14, wherein for producing the hot gas, the method comprises burning at least one of: the natural gas, the fuel, the recycled syngas, biogas from other processes, and syngas from other processes.

M23. The method according to any of the preceding embodiments and with the features of embodiment M14, wherein the reacting the hydrocarbon carrier material with the hot gas to generate a gasified material comprises reacting the hot gas with at least one of: the refuse derived fuel (RDF), the biomass, waste oil, and non-recyclable material, coal, and other solid material.

M24. The method according to any of the preceding embodiments and with the features of embodiments M5 and M16, wherein the second module comprises the entrained flow reactor.

M25. The method according to any of the preceding embodiments, wherein for reacting the hydrocarbon carrier material to generate the gasified material, the method comprises injecting the hydrocarbon carrier material to the hot gas with CO2, steam or an inert gas.

M26. The method according to any of the preceding embodiments, wherein the method comprises at least one of: superheating the hydrocarbon carrier material by the hot gas, gasifying the hydrocarbon carrier material, and at least partially oxidizing the hydrocarbon carrier material.

M27. The method according to any of the preceding embodiments, wherein the stream of hot gas comprises at least one of: carbon dioxide and water.

M28. The method according to any of the preceding embodiments and with features of embodiment M26, wherein the method comprises converting the superheated hydrocarbon carrier material to syngas.

M29. The method according to any of the preceding embodiments, wherein the step of converting the gasified material to the synthesis gas is an endothermic process.

M30. The method according to any of the preceding embodiments, wherein the method comprises performing of a chemical cooling based on an endothermic reaction of the synthesis gas to a temperature of at least 1000°C, preferably at least 900 °C, more preferably at least 800 °C, most preferably at least 700 °C.

M31. The method according to the preceding embodiment, wherein the method comprises cooling the hot gas by means of the endothermic process.

M32. The method according to any of the preceding embodiments, wherein the reaction comprises an oxidation following a water-gas shift reaction of: CO + H₂O CO₂ + H₂ AHO_R= -41,1 kJ mol

M33. The method according to any of the preceding embodiments, wherein the method comprises reducing formation wall-adhering substances such as tar or soot.

M34. The method according to the preceding embodiment, wherein reducing the formation of wall-adhering substances using a high temperature.

M35. The method according to according to any of two preceding embodiments, wherein when reducing the formation of wall-adhering substances, the method comprises increasing a conversion efficiency, wherein the method comprises at least one of: controlling a reaction speed, and mixing of at one reactant comprising at least one of: oxygen and hydrocarbon carrier material.

M36. The method according to any of the preceding embodiments and with features of embodiment M5 and embodiments M31 or M34, wherein the method comprises controlling the flow in the second module.

M37. The method according to any of the preceding embodiments, wherein the method comprises forming, in the stream of hot gas, a protective layer around a solid stream by means of the stream of hot gas.

M38. The method according to any of the preceding embodiments, wherein the method comprises centering, in the stream of hot gas, the solid streams in a reactor of the modular system.

M39. The method according to the preceding embodiment wherein the method comprises providing a laterally axial offset of solid stream inlet towards the direction of the laterally inflowing hot gas.

M40. The method according to any of the preceding embodiments, wherein the method comprises supplying an oxygen carrier stream to the solid stream, wherein the oxygen carrier stream is added centrally in the inlet of the solid stream.

M41. The method according any of the preceding embodiments, wherein the method comprises removing an undesired material from the syngas comprising at least one of: ash, dust, and chemical component originating from waste. M42. The method according to the preceding embodiment, wherein for removing the undesired, the method comprising using a filter and/or a gas scrubber and/or a water scrubber and/or a chemical scrubber.

M43. The method according to any of the preceding embodiments and with features of embodiment M5, wherein in the second module, the method comprises cooling the generated gas stream in a first stage of an economizer, or by injecting cooling water, from 1000°C to 400°C more preferably 900°C to 400°C more preferably 800°C to 400°C, most preferably 700°C to 400°C.

M44. The method according to the three preceding embodiments, wherein the cooling step precedes the removing step.

M44.1.The method according to the preceding embodiment and with the features of embodiment M42, wherein the method comprises cooling of the gas phase resulting from the filter and/or the gas scrubber and/or the water scrubber and/or the chemical scrubber to further remove water content.

M44.2.The method according to the preceding embodiment, wherein the method comprises removing sulphur from the cooled gas, preferably by means of an active carbon filter.

M44.3.The method according to any of the 3 preceding embodiments, wherein the method comprises storing the cleaned syngas in a storage tank.

M45. The method according to any of the five preceding embodiments, wherein the method comprises re-heating the gas stream coming out from the filter and/or the gas scrubber and/or the water scrubber and/or the chemical scrubber and/or the storage tank in a second stage of the economizer to a range of 400°C to 440°C, preferably to a range of 300°C to 340°C.

M46. The method according to the preceding embodiment, wherein the method comprises heating the gas stream to a temperature between 300 °C and 350 °C and adding to the gas stream at least one of: water, and water vapor.

M47. The method according to any of the preceding embodiments, wherein the method comprises catalytically reacting carbon monoxide and water vapor with a water gas shift catalyst, wherein the reacting step yield to formation of hydrogen and carbon dioxide. M48. The method according to the preceding embodiment, wherein the method comprises performing the reacting step in two water-gas shift converter stages connected in series.

M49. The method according to any of the two preceding embodiments, wherein in a first converter stage of the two converter stages, the gas stream heats up to 400 °C to 450°C.

M50. The method according to the preceding embodiment, wherein the method comprises cooling the gas stream to a temperature between 200 °C, preferably 300 °C. to 350 °C by injecting at least one of: water, and water vapor or by a heat exchanger for heat recovery purpose.

M51. The method according to the four preceding embodiments, wherein the method yields the hydrogen gas containing product comprising a composition of 25 to 50 vol% H₂, 10 to 30 vol% H₂O and 20 to 40 vol% CO₂.

M52. The method according to the preceding embodiment, wherein the method comprises purifying the hydrogen gas containing product.

M53. The method according to any of the preceding embodiments, wherein the method comprises cooling the hydrogen gas containing product to a temperature between 10°C and 60 °C, more preferably between 20°C and 50°C, such as 40°C.

M54. The method according to any of the preceding embodiments, wherein the method comprises separating a precipitating condensate as a condensate, and feeding the condensate to a water treatment system.

M55. The method according to the preceding embodiment and with the features of any of embodiments M42 and M45, wherein the method comprises separating the precipitating condensate resulting from a plurality of components of the modular system, the separating the precipitating condensate comprising at least one of: after the gas wash, after cooling the gas stream of the filter and the economizer, before the active carbon filter, before introducing the gas stream into the gas scrubber to a temperature between 30°C and 60 °C, and after every compression combined with cooling and after the water gas shift catalysts. M56. The method according to any of the two preceding embodiments, wherein the method comprises cleaning a surplus of the precipitating condensate to generate cleaned water, and feeding the cleaned water to a water treatment system.

M57. The method according to any of the preceding embodiments, wherein the method comprises dividing the gas stream in at least two streams when recycling syngas.

M58. The method according to the preceding embodiment and with features of embodiments M5, wherein the at least two streams comprise a first syngas stream comprising syngas as an alternative gas source for the first module, and a second syngas stream comprising syngas for at least one of: direct combustion, e-fuel production, hydrogen production.

M59. The method according to the preceding embodiment, wherein the e-fuel production comprises production of at least one of: methanol, ammonia, methane, and kerosene.

M60. The method according to any of the two preceding embodiments, wherein the first syngas stream comprises at least 10 vol% of syngas, preferable at least 15 vol% of syngas, more preferable at least 20 vol% of syngas such as 30 vol% of syngas.

M61. The method according to any of the two preceding embodiments, wherein the second syngas stream comprises at least 50 vol% of syngas, preferable at least 60 vol% of syngas, more preferable at least 70 vol% of syngas such as 75 vol% of syngas.

M62. The method according to any of the preceding embodiments, wherein the method comprising purifying the second syngas stream with a pressure swing adsorption of at least 10 bar, preferably at least 15, more preferably at least 25 bar, such between 10 and 25 bar, preferably between 20 and 25, more preferably between 25 and 30 bars.

M63. The method according to any of the preceding embodiments, wherein the method comprises mixing a hydrogen enriched tail gas from a tail gas utilization into a syngas stream.

M64. The method according to the preceding embodiment and with the features of embodiment M10, wherein the method comprises compressing the syngas stream in three stages, the method comprising compressing to a pressure of:

1 to 3 bar in a first stage, 3 to 10 bar in a second stage, and

10 to 23 bar in a third.

M65. The method according to the preceding embodiment and with the features of embodiment M43, wherein the compressing until 10 bar precedes the economizer.

M66. The method according to the preceding embodiment and with the features of embodiments M54 and M64, wherein an aftercooler configured for separation of the condensate is arranged downstream of each of the first stage, the second stage and the third stage.

M67. The method according to any of the three preceding embodiments, wherein the method comprises drying the gas before the first stage of adsorption.

M68. The method according to any of the preceding four embodiments, wherein the method comprises performing the first stage of adsorption in a plurality of absorber beds, preferably between 3 to 6 adsorber beds.

M69. The method according to any of the preceding embodiments and with features of embodiments M58 and M62, wherein the method comprises adsorbing carbon dioxide together with remaining carbon monoxide, nitrogen, and argon and other undesired gases to generate an adsorbed material, discharging the adsorbed material from the gas stream as discharged adsorbed material.

M70. The method according to any of the preceding embodiments and with features of embodiment M63, wherein the method comprises compressing the tail gas to an adsorption pressure of 1 to 23 bar, preferably 3 to 10 bar to yield an adsorbed tail gas.

M71. The method according to the preceding embodiment, wherein the method comprises cooling the adsorbed tail gas, separating water from the adsorbed tail gas to yield an absorbed tail gas stream, and cooling the adsorbed tail gas stream to a dew point of -21 to -56 °C.

M72. The method according to the preceding embodiment, wherein the method comprises passing the adsorbed gas stream through a heat exchanger to yield a cooled tail gas stream, and feeding the cooled tail gas to a condenser, and at least partially condensing the cooled tail gas to yield a condensed tail gas. M73. The method according to the preceding embodiment, wherein the method comprises separating a liquid phased tail gas in a CO? separator to yield separated CO2, and feeding the separated CO2 to a cryogenic storage tank.

M74. The method according to any of the preceding method embodiments, wherein the method comprising purifying the tail gas of carbon dioxide, heating the tail gas in a heat exchanger, and feeding the heated tail gas to a membrane separation plant comprising at least one membrane.

M75. The method according to the preceding embodiment, wherein in the membrane separation plant, the method comprises separating as retentate as least one of: carbon monoxide, nitrogen, and argon; passing through the at least one membrane at least one of: hydrogen and carbon dioxide; and recirculating the permeate as a second tail gas back upstream a gas treatment compressor comprised by the gas production system.

M76. The method according to any of the two preceding embodiments, wherein the method comprising depressurizing the retentate to a normal pressure; and cooling the retentate, wherein the cooling of retentate take places simultaneously with the depressurizing step.

M77. The method according to the preceding embodiment, wherein the normal pressure is between 1 and 3 bar, such as between 1 and 2 bar.

M78. The method according to any of the three preceding embodiments, wherein the method comprises heating to 250 to 350 °C the retentate; adding at least one of: metered oxygen, and air to output a retentate mix; and feeding to the retentate mix a catalytic oxidation system comprised by the gas production system, wherein adding at least one: the metered oxygen, and the air precedes feeding the retentate mix to the catalytic oxidation system.

M79. The method according to any of the preceding embodiments, wherein the method comprises directly using the hot gas from a preceding process.

M80. The method according to the preceding embodiment, wherein the method comprises directly using the hot gas from a preceding process without combustion.

M81. The method according to any of the preceding embodiments and with the features of embodiments M61 and M72, wherein separating a liquid phased tail gas is performed by means of the pressure swing absorption. M82. The method according to any of the preceding embodiments and with the features of embodiments M3 to M6, wherein the first module, the second module and the third module are integrated in a gas production system.

Below, system embodiments will be discussed. These embodiments are abbreviated by the letter "S" followed by a number. When reference is herein made to a system embodiment, those embodiments are meant.

51. A system for producing hydrogen, wherein the system is configured to produce a stream of hot gas, react a hydrocarbon carrier material with the hot gas to generate a gasified material, and separate hydrogen from the gasified material to produce a hydrogen gas containing product.

52. The system according to the preceding embodiment, wherein the system is a modular gas producing system comprising a first module configured to produce the stream of hot gas, a second module configured to react the hydrocarbon carrier material with the hot gas to generate a gasified material, and a third module configured to separate hydrogen from the gasified material to produce the hydrogen gas containing product.

53. The system according to the preceding embodiment, wherein the first module is configured to generate a stream of hot gas by burning at least one of: natural gas fuel, recycled syngas, biogas from other processes, and syngas from other processes.

54. The system according to any of the preceding system embodiments, wherein the second module comprises an entrained flow reactor configured to receive a mixture of the hydrocarbon carried material and the stream of hot gas.

55. The system according to the preceding embodiment, wherein the entrained flow reactor is configured to superheat stream of hot gas, and gasify and at least partially oxidize the mixture.

56. The system according to any of the two preceding embodiments, wherein the trained flow reactor is configured to carry out a conversion the stream of hot gas into synthesis gas. 57. The system according to any of the preceding system embodiment, wherein the second module is configured to operate at least in a first stage, a second stage, and a third.

58. The system according to any of the preceding system embodiments, wherein the second module comprises a hot gas generator comprising a combustion chamber.

59. The system according to any of the preceding system embodiments, wherein the second module comprises a continuous entrained flow reactor with top deflection.

510. The system according to the preceding embodiment, wherein the continuous entrained flow reactor comprises a reactor section configured to guide a stream of hot gas.

511. The system according to any of the two preceding embodiments, wherein the continuous entrained flow reactor comprises a flexible inlet configured to feed solid material into the reactor, wherein the inlet comprises a flexible inlet angle of -15° to +15° between injection of solid stream and hot gas stream or reactor axis.

512. The system according to the preceding embodiment, wherein the flexible inlet comprises is axially offset respect to solid stream inlet towards the direction of a laterally inflowing hot gas.

513. The system according to any of the preceding system embodiments, wherein the third module comprises pressure swing adsorption component configured to operate with a pressure swing adsorption of at least 10 bar, preferably at least 15, more preferably at least 25 bar, such between 10 and 25 bar, preferably between 20 and 25, more preferably between 25 and 30 bars.

514. The system according to any of the preceding system embodiments, wherein the system comprises a plurality of at least one of: tubings, and pipes, configured to connect at least one component of the system.

S15. The system according to any of the preceding system embodiments and with the features of embodiments SI and S2, wherein the first module, the second module and the third module are integrated in the gas production system. S16. The system according to any of the preceding system embodiments, wherein the system is configured to carry out any of the steps of the method according to any of the preceding method embodiments.

517. The system according to any of the preceding embodiments, wherein the hydrogen containing product comprises a hydrogen purity grade of at least IN, preferably at least 2N, more preferably at least 3N.

M83. The method according to any of the preceding method embodiments, wherein the method comprises operating the modular system according to any of the preceding system embodiments to prompt the system to carry out any of the steps of the method according to any of the preceding method embodiments.

518. The system according to any of the preceding system embodiments, wherein the system comprises a plurality of components configured to allow the system to carry out any of the steps of the method according to any of the preceding method embodiments.

Below, use embodiments will be discussed. These embodiments are abbreviated by the letter "U" followed by a number. When reference is herein made to a use embodiment, those embodiments are meant.

Ul. Use of the system according to any of the preceding system embodiments for carrying out the method according to any of the preceding method embodiments.

U2. Use of the method according to any of the preceding method embodiments for prompting the system according to any of the preceding system embodiments to carry out the method according to any of the preceding method embodiments.

The present invention will now be described with reference to the accompanying drawings which illustrate embodiments of the invention. These embodiments should only exemplify, but not limit, the present invention.

Fig. 1 schematically depicts a first module of the modular system according to embodiments of the present invention;

Fig. 2 schematically depicts a second module of the modular system according to embodiments of the present invention;

Fig. 3 schematically depicts a third module of the modular system according to embodiments of the present invention; Fig. 4 depicts a tail gas treatment performed in the third module of the modular system according to embodiments of the present invention;

Fig. 5 depicts a schematic of components of the system according to embodiments of the present invention;

Fig. 6 depicts zoom-in of a section of a continuous entrained flow reactor according to embodiments of the present invention.

It is noted that not all the drawings carry all the reference signs. Instead, in some of the drawings, some of the reference signs have been omitted for sake of brevity and simplicity of illustration. Embodiments of the present invention will now be described with reference to the accompanying drawings.

The present invention comprises a modular system configured to carry out the steps of the method according to the present invention. In simple terms, the modular system comprises three modules:

A first module configured to generate heat, which may subsequently serve as an energy source for a gasification process;

A second module configured to receive a hydrocarbon carrier material, for example, in the form of: fuel such as a non-recyclable plastic, or biogenic material such as biomass, which is added to the hot gas and processed in an entrained flow reactor. In the second module, the hydrocarbons are completely gasified in the process.

A third module configured to separate hydrogen from the rest of gases with a quality of at least IN. The carbon dioxide, which is not recycled in the upstream process is liquified and readily available for use in other systems, e.g., systems of the gas industry or system of the beverage industry.

It should be understood that the values given below for the different parameters are merely exemplary and these should be understood in the context of the embodiments of the present invention.

Fig. 1 schematically depicts the first module of the modular system according to embodiments of the present invention, which is configured to produce hot gas production for production of syngas. In simple terms, in the first module a hot gas at a temperature of, for example, 1500 °C to 1600°C is generated by burning, for example, natural gas or biogas. This hot gas is the source of energy to start the gasification process. Once the temperatures are reached at the gasifier and the syngas is produced, a part of this syngas (stream 419) may be recycled to a burner to create again the hot gas. As result, no extra fossil fuel or gas is needed. Fig. 2 schematically depicts the second module of the modular system according to embodiments of the present invention, which is configured to perform a gasification Process and a water-gas shift reaction, according to embodiments of the present invention. In simple terms, in the entrained flow reactor, the hydrocarbon carrier material, for example, in the form of fuel or biogenic material (stream 306) is fed to the hot gas. For instance, in one embodiment, the feed may be injected with a turbulent stream of steam or oxygen (stream 307), and the mixture be superheated by the hot gas, gasified, and partially oxidized, whereby the hot gas stream (309), which essentially consists of mixture of fuel, O2, CO2 and H₂O, may be endothermically converted to synthesis gas and cooled accordingly to 700 °C (stream 310). The formation of tar, soot or similar wall-adhering substances may be reduced by the process control, in particular by high turbulence, mixing and the high temperature. The adhesion of ash and slag to the inside of the second module shell may be counteracted by flow control, especially in the peripheral region of the superheated steam stream and/or the oxygen stream (stream 308). In this step, the synthesis gas already may react to form hydrogen and carbon dioxide with the hydrogen yield being only about two-thirds of the final yield. In a preferred embodiment, avoidance of buildup in the reactor may be carried out as described below in Fig. 6.

The gas stream generated from the second module is cooled in a first stage of an economizer from, for example, 700 °C to 450 °C (stream 402) for superheated steam generation (stream 416). Following the cooling, a gas scrubber is used to get rid of the ash, dust and chemical components originating from the waste (stream 403). The gas stream is then reheated in the second stage of the economizer back to 420°C (stream 405). Water is then added, and the gas is further cooled to 320 °C (stream 406), which is the temperature needed for the catalytical reaction. The water serves as hydrogen donor for the further reaction.

The further reaction takes place in two converter stages connected in series. In both converters, the carbon monoxide reacts with water in presence of an iron-based catalyst (e.g., Fe2O3/Cr₂O3) to form hydrogen and carbon dioxide. Due to the exothermic reaction, the gas in the first converter heats up by about 110K to approx. 420 °C according to the following reaction (stream 407):

CO + H₂O = CO₂ + H₂ AHO_R= -41,1 kJ mol

For the second converter stage, the process gas is cooled down again to 215 °C (stream 409) to convert as much of the remaining carbon monoxide as possible. The gas stream heats up only slightly in the second stage to 270°C (stream 410). The chemical reactions to obtain hydrogen are thus completed. The gas has a composition of, for example, about 40 vol% H₂, 20 vol% H₂O and 40 vol% CO₂ and is further cooled for gas purification (stream 413). The heat energy may be used to generate steam (stream 412) to the extent that the temperature differences allow.

Fig. 3 schematically depicts hydrogen separation in the third module of the modular system according to embodiments of the present invention. In simple terms, after initial cooling with steam generation, the gas is further cooled down to approx. 40 °C with cooling water (stream 503). The precipitating condensate is separated and fed to the water treatment system (stream 504). The aim is to reuse the treated water in the process, e.g., for injection cooling. The surplus is cleaned according to water treatment regulation and fed into the local wastewater system. The Gas stream may be then divided as follow: about 25 wt% of the Syngas stream (stream 419) is recycled and used as an alternative gas source for the gas burner and about 75% is used for hydrogen production.

Gas purification is performed with pressure swing adsorption, for example, at 23 bar. For efficient operation the gas should have the lowest possible temperature, which means close to ambient temperature. It must also be free of liquid. Tail gas 2 (stream 901) from the tail gas utilization is mixed into the gas stream. In the next step, the gas is compressed in two stages to the pressure of 23 bar. Downstream of the first stage and downstream of the second stage is an aftercooler in each case with separation of the condensate, which is also fed to the water treatment system (stream 512). In the first stage of adsorption, the gas is further dried to prevent moisture from entering the CO₂ adsorbers and deactivating them. Depending on the manufacturer of the system, the adsorbers can also be filled with different layers of adsorbents that have the same effect (stream 507). The CO₂ together with the remaining CO, N₂ and Ar is adsorbed and discharged from the gas stream. The purified hydrogen then has a selling quality of at least IN (stream 601). The residual gas from the adsorbers contains mainly CO₂, components CO, N₂ and Ar, as well as H₂ in an amount that makes the further processing of the tail gas reasonable.

Fig. 4 schematically depicts a tail gas treatment performed in the third module of the modular system according to embodiments of the present invention. In simple terms, the tail gas (stream 603) is compressed again to the pressure of the adsorption (stream 701). After cooling, the water is separated, and the gas stream is dried to a dew point of -50 °C (stream 705). The gas (stream 704) passes through a heat exchanger and is cooled, fed into the tail gas condenser (stream 705) and partially condensed there (stream 706). In the CO₂ separator, the liquid phase is separated (stream 708) and fed to the CO₂ storage tank. From there, the plant's CO₂ requirement is covered (stream 709). This cold stream is brought to near ambient temperature in the heat exchanger and thus serves to relieve the refrigeration circuit. Components of CO also dissolve in the CO2, which then preferentially re-enters the process from the gas phase. The remaining surplus can either be further processed to sales qualities or disposed of in the course of CO2 final deposit. In general, storing CO2 requires energy, either to compress the gas and store it at high pressure, or to store it cold- liquefied at low temperatures and pressures. The tail gas, which is further purified of CO2 (stream 707), is also heated in the heat exchanger and fed to a membrane separation plant (stream 710). In the separation plant, associated gases CO, N₂ and Ar are separated as retentate (stream 902). H₂ and CO2 pass through the membrane and are recirculated as permeate, tail gas 2 (stream 901) back upstream of the gas treatment compressor. The retentate is depressurized to normal pressure (stream

903). It cools down in the process. For final purification, it is first heated to 300 °C (stream

904) and metered oxygen is added before it is fed into the catalytic oxidation system. This process can also be carried out with air if necessary. The aftertreatment purifies the gas to the requirements of the clean air regulation so that it can be discharged into the atmosphere (stream 905).

Fig. 5 depicts a schematic of components of the system according to embodiments of the present invention. In simple terms, Fig. 5 depicts a hot gas generator with combustion chamber 2100, a continuous entrained flow reactor with top deflection 2200, a transition to cooling and water gas shift line 2300, and a section of a fuel feeding 2000.

Fig. 6 depicts zoom-in of the section of a fuel feeding 2000, such as a continuous entrained flow reactor with top reflection 2000. In particular, Fig. 6 depicts, a stream of hot gas 2010 comprising, for example, temperatures between 1500 °C and 1600 °C, an oxygen supply 2020 injected into the reactor 2000, and an inlet 2030 for pneumatically feeding solid material into the reactor 2000. The configuration in Fig. 6 allows prevention of slag residues inside the reactor 2000. In particular, the stream of hot gas 2010 forms a protective layer around the solids stream 2040, preventing liquid ash (slag) from adhering to the wall. Later, further up in the reactor 2000, when the solids are more thoroughly mixed with the stream of hot gas 2010, the stream of hot gas 2010 is cooled down to such an extent that the slag has solidified again, which surprisingly significantly reduces risk of adhesion.

In one embodiment, it is also possible to centering the solid stream 2040 in the reactor 2000 by the decentralized inlet 2030, which is configured to allow to permit pneumatically injecting solid material into the reactor 2000. In one embodiment, the inlet 2030 is axially offset so that it is positioned as far as possible in the center of the vertically ascending reactor 2000 after meeting the stream of hot gas 2010 laterally, as depicted by reference numeral 2050. Additionally or alternative, the inlet 2030 comprises a flexible angle. In a further embodiment, the configuration of the reactor 2000 allows to improve the temperature input through the central oxygen supply. In order to achieve the fastest possible and most uniform temperature input into the solids stream 2040, oxygen is added centrally through oxygen inlet 2020. This results in a cylindrical solids stream 2060 which is heated from the outside by the radiant heat of the hot gas stream and from the inside by the temperature generated by the combustion of solids with oxygen.

While in the above, a preferred embodiment has been described with reference to the accompanying drawings, the skilled person will understand that this embodiment was provided for illustrative purpose only and should by no means be construed to limit the scope of the present invention, which is defined by the claims.

Whenever a relative term, such as "about", "substantially" or "approximately" is used in this specification, such a term should also be construed to also include the exact term. That is, e.g., "substantially straight" should be construed to also include "(exactly) straight".

Whenever steps were recited in the above or also in the appended claims, it should be noted that the order in which the steps are recited in this text may be accidental. That is, unless otherwise specified or unless clear to the skilled person, the order in which steps are recited may be accidental. That is, when the present document states, e.g., that a method comprises steps (A) and (B), this does not necessarily mean that step (A) precedes step (B), but it is also possible that step (A) is performed (at least partly) simultaneously with step (B) or that step (B) precedes step (A). Furthermore, when a step (X) is said to precede another step (Z), this does not imply that there is no step between steps (X) and (Z). That is, step (X) preceding step (Z) encompasses the situation that step (X) is performed directly before step (Z), but also the situation that (X) is performed before one or more steps (Yl), ..., followed by step (Z). Corresponding considerations apply when terms like "after" or "before" are used.

Claims

1. A method for producing hydrogen in a gas production system, the method comprising producing a stream of hot gas, reacting a hydrocarbon carrier material with the hot gas to generate a gasified material, and separating hydrogen from the gasified material to produce a hydrogen gas containing product, wherein gasified material comprises a syngas in a syngas stream, wherein method comprises using heat from the hot gas for the reacting of the hydrocarbon carrier material.

2. The method according to the preceding claim, wherein the gas production system is a modular gas production system, wherein the modular gas production system comprises a first module, a second module, a third module, wherein producing the hot gas is carried out in the first module of the modular gas production system, reacting the hydrocarbon carrier material to generate the gasified material is carried out in the second module of the module gas production system, separating hydrogen from the gasified material to produce the hydrogen gas containing product is carried out in the third module of the modular gas production system, wherein the method comprises at least partially recycling the syngas as a recycled syngas, wherein the method comprises providing the recycled syngas to a burner comprised by the gas production system to further create the hot gas, wherein at least partially recycling the syngas comprises recycling at least 15% of the syngas, preferably at least 20% of the syngas, more preferably at least 25%, even more preferably at least 30% of the syngas.

3. The method according to any of the preceding claims, wherein the hydrocarbon material comprises at least one of: natural gas, fuel, recycled syngas, refuse derived fuel (RDF), biomass, waste oil, non-recyclable material, coal and other solid material, wherein the step of reacting the hydrocarbon carrier material to generate the gasified material comprises producing the syngas by adding into the second module the hydrocarbon carrier material and the hot gas, wherein the reacting step takes place in an entrained flow reactor, wherein the method comprises at least partially recycling the carbon dioxide gas in an upstream process, and combusting the syngas takes place at a lambda slightly lower than 1 and under an oxygen atmosphere.

4. The method according to any of the preceding claims, wherein for reacting the hydrocarbon carrier material to generate the gasified material, the method comprises injecting the hydrocarbon carrier material to the hot gas with CO2, steam or an inert gas, wherein the method comprises at least one of: superheating the hydrocarbon carrier material by the hot gas, gasifying the hydrocarbon carrier material, and at least partially oxidizing the hydrocarbon carrier material, wherein the stream of hot gas comprises at least one of: carbon dioxide and water.

5. The method according to any of the preceding claims, wherein the method comprises performing of a chemical cooling based on an endothermic reaction of the synthesis gas to a temperature of at least 1000°C, preferably at least 900 °C, more preferably at least 800 °C, most preferably at least 700 °C, wherein the method comprises cooling the synthesis gas by means of the endothermic process.

6. The method according to any of the preceding claims, wherein the method comprises reducing formation wall-adhering substances such as tar or soot, wherein reducing the formation of wall-adhering substances using a high temperature, wherein when reducing the formation of wall-adhering substances, the method comprises increasing a conversion efficiency, wherein the method comprises at least one of: controlling a reaction speed, and mixing of at one reactant comprising at least one of: oxygen and hydrocarbon carrier material.

7. The method according to any of the preceding claims, wherein the method comprises c controlling the flow in the second module, forming, in the stream of hot gas, a protective layer around a solid stream by means of the stream of hot gas, centering, in the stream of hot gas, the solid streams in a reactor of the modular system, providing a laterally axial offset of solid stream inlet towards the direction of the laterally inflowing hot gas, and supplying an oxygen carrier stream to the solid stream, wherein the oxygen carrier stream is added centrally in the inlet of the solid stream.

8. The method according to any of the preceding claims, wherein the method comprises cooling the generated gas stream in a first stage of an economizer, or by injecting cooling water, from 1000°C to 400°C more preferably 900°C to 400°C more preferably 800°C to 400°C, most preferably 700°C to 400°C, wherein the cooling step precedes the removing step, wherein the method comprises re-heating the gas stream coming out from a filter and/or the gas scrubber in a second stage of the economizer to a range of 400°C to 440°C, wherein the method comprises cooling the gas stream to a temperature between 300 °C and 350 °C by adding to the gas stream at least one of: water, and water vapor.

9. The method according to any of the preceding claims, wherein the method comprises catalytically reacting carbon monoxide and water vapor with a water gas shift catalyst, wherein the reacting step yield to formation of hydrogen and carbon dioxide, wherein the method comprises performing the reacting step in two water-gas shift converter stages connected in series, wherein in a first converter stage of the two converter stages, the gas stream heats up to 400 °C to 450°C, wherein the method comprises cooling the gas stream to a temperature between 300 to 350 °C by injecting at least one of: water, and water vapor, or by a heat exchanger for heat recovery purpose, wherein the method yields the hydrogen gas containing product comprising a composition of 25 to 50 vol% H₂, 10 to 30 vol% H₂O and 20 to 40 vol% CO₂, wherein the method comprises purifying the hydrogen gas containing product.

10. The method according to any of the preceding claims, wherein the method comprises cooling the hydrogen gas containing product to a temperature between 10 °C and 60 °C, more preferably between 20 °C and 50 °C, such as 40°C, separating a precipitating condensate as a condensate, and feeding the condensate to a water treatment system, wherein the method comprises separating the precipitating condensate resulting from a plurality of components of the modular system, the separating the precipitating condensate comprising at least one of: after the gas wash, after cooling the gas stream of the filter and the economizer, before the active carbon filter, before introducing the gas stream into the gas scrubber to a temperature between 30 °C and 60 °C, and after every compression combined with cooling and after the water gas shift catalysts, wherein the method comprises cleaning a surplus of the precipitating condensate to generate cleaned water, and feeding the cleaned water to a water treatment system.

11. The method according to any of the preceding claims, wherein the method comprises dividing the gas stream in at least two streams, wherein the at least two streams comprise a first syngas stream comprising syngas as an alternative gas source for the first module, and a second syngas stream comprising syngas for at least one of: direct combustion, e-fuel production, hydrogen production, wherein the first syngas stream comprises at least 10 vol% of syngas, preferable at least 15 vol% of syngas, more preferable at least 20 vol% of syngas such as 25 vol% of syngas, wherein the second syngas stream comprises at least 50 vol% of syngas, preferable at least 60 vol% of syngas, more preferable at least 70 vol% of syngas such as 75 vol% of syngas.

12. The method according to any of the preceding claims, wherein the method comprises mixing a hydrogen enriched tail gas from a tail gas utilization into a syngas stream; compressing the syngas stream in three stages, the method comprising compressing to a pressure of: 1 to 3 bar in a first stage, 3 to 10 bar in a second stage, and 10 to 23 bar in a third; adsorbing carbon dioxide together with remaining carbon monoxide, nitrogen, and argon and other undesired gases to generate an adsorbed material; discharging the adsorbed material from the gas stream as discharged adsorbed material; cooling the adsorbed tail gas; separating water from the adsorbed tail gas to yield an absorbed tail gas stream; cooling the adsorbed tail gas stream to a dew point of -21 °C to -56 °C; passing the adsorbed gas stream through a heat exchanger to yield a cooled tail gas stream; feeding the cooled tail gas to a condenser; at least partially condensing the cooled tail gas to yield a condensed tail gas; separating a liquid phased tail gas in a CO? separator to yield separated CO2; feeding the separated CO2 to a cryogenic storage tank; purifying the tail gas of carbon dioxide; heating the tail gas in a heat exchanger; feeding the heated tail gas to a membrane separation plant comprising at least one membrane; separating as retentate as least one of: carbon monoxide, nitrogen, and argon; passing through the at least one membrane at least one of: hydrogen and carbon dioxide; recirculating the permeate as a second tail gas back upstream a gas treatment compressor comprised by the gas production system; depressurizing the retentate to a normal pressure; cooling the retentate, wherein the cooling of retentate take places simultaneously with the depressurizing step, heating to 250 °C to 350 °C the retentate; adding at least one of: metered oxygen, and air to output a retentate mix; and feeding to the retentate mix a catalytic oxidation system comprised by the gas production system.

13. A system for producing hydrogen, wherein the system is configured to produce a stream of hot gas, react a hydrocarbon carrier material with the hot gas to generate a gasified material, and separate hydrogen from the gasified material to produce a hydrogen gas containing product, wherein the system is configured to carry out any of the steps of the method according to any of claims 1 to 12.

14. The system according to the preceding claim, wherein the system is a modular gas producing system comprising a first module configured to produce the stream of hot gas, a second module configured to react the hydrocarbon carrier material with the hot gas to generate a gasified material, and a third module configured to separate hydrogen from the gasified material to produce the hydrogen gas containing product.

15. The system according to the preceding claim, wherein the second module comprises a continuous entrained flow reactor with top deflection, wherein the continuous entrained flow reactor comprises a reactor section configured to guide a stream of hot gas, wherein the continuous entrained flow reactor comprises a flexible inlet configured to feed solid material into the reactor, wherein the inlet comprises a flexible inlet angle of -15° to +15° between injection of solid stream and hot gas stream or reactor axis, wherein the flexible inlet comprises is axially offset respect to solid stream inlet towards the direction of a laterally inflowing hot gas; and the third module comprises pressure swing adsorption component configured to operate with a pressure swing adsorption of at least 10 bar, preferably at least 15, more preferably at least 25 bar, such between 10 and 25 bar, preferably between 20 and 25, more preferably between 25 and 30 bars.