primary reformer presentation - hedco int
TRANSCRIPT
![Page 1: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/1.jpg)
In The Name OF God
Hampa Energy Engineering &Hampa Energy Engineering &Hampa Energy Engineering & Hampa Energy Engineering & Design CompanyDesign Company
1www.hedcoint.comwww.hedcoint.com
![Page 2: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/2.jpg)
IntroductionAmmonia plantsMethanol plantsHydrogen PlantsHydrogen PlantsOther plants
2www.hedcoint.com
![Page 3: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/3.jpg)
A Brief historical ReviewGreater capacity
3300 mtpd 20 rows with a total of 960 tube
Improve efficiency
3www.hedcoint.com
![Page 4: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/4.jpg)
Reformer TypesTop Fired
Side FiredSide Fired
Terraced Wall
4www.hedcoint.com
![Page 5: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/5.jpg)
Design ParametersFunctionFeed
l
Heat FluxPressure Drop
FuelsType Pressure
CatalystTubes
PressureExit TemperatureInlet Temperature
BurnersFlow distributionH RInlet Temperature
Steam/Carbon Ratio
Heat Recovery
5www.hedcoint.com
![Page 6: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/6.jpg)
Function
6www.hedcoint.com
![Page 7: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/7.jpg)
FeedNatural gas
PropanePropane
LPG
Butane
Naphthap
7www.hedcoint.com
![Page 8: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/8.jpg)
FuelsNatural gas
Distillate fuelsDistillate fuels
8www.hedcoint.com
![Page 9: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/9.jpg)
Type : Top Fired The highest flue gas temperature when the intube process
gas temperature is lowestgas temperature is lowest
The lowest flue gas temperature when the intube process
i hi hgas temperature is highest
Uniform tubewall temperature over the length of the tube
Inherently stable furnace operation
9www.hedcoint.com
![Page 10: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/10.jpg)
PressureThe reforming reaction equilibrium is favored by low
pressurepressure
The shift reaction equilibrium is independent of pressure
Product hydrogen pressure requirement (down stream)
10www.hedcoint.com
![Page 11: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/11.jpg)
Exit TemperatureLower temperatures give insufficient conversion
Higher temperature increase metallurgical requirementsHigher temperature increase metallurgical requirements
Gas exit temperature typically runs between 800 to 900 °C
11www.hedcoint.com
![Page 12: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/12.jpg)
Inlet TemperatureThe reforming reaction rate becomes significant at about 540 °C
Higher reformer inlet temperature decrease the number of tubes, g p ,
the size of the furnace and fuel
Higher reformer inlet temperature decrease the steamHigher reformer inlet temperature decrease the steam
generation from WHR
M ll i l li iMetallurgical limits
Optimum reformer inlet temperature 560 °C
12www.hedcoint.com
![Page 13: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/13.jpg)
Steam/Carbon RatioSufficient steam to eliminate carbon formation
If proper catalyst is chosen 3 steam to carbon ratio isIf proper catalyst is chosen, 3 steam to carbon ratio is
applicable
13www.hedcoint.com
![Page 14: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/14.jpg)
Heat FluxA low heat flux provide extra catalyst volume and lower
tubewall temperaturetubewall temperature
A high heat flux has the advantage of reducing the number
f bof tubes
20000 to 28000 Btu/hr-ft2
14www.hedcoint.com
![Page 15: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/15.jpg)
Pressure DropLegnth of tubes
Tube diameterTube diameter
Catalyst selection
Approximately 3 Bar
15www.hedcoint.com
![Page 16: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/16.jpg)
CatalystReaction conversion
Nickel-alkaliNickel-alkali
shape
Catalyst pressure drop
Shapep
Key aspect of catalyst : formulation & shape
16www.hedcoint.com
![Page 17: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/17.jpg)
TubesTemperature condition : 850 to 920°CInside tube diameter : 4 to 5 in
Better heat transfer and cooler walls for lower IDBetter heat transfer and cooler walls for lower IDHigher pressure drop for lower IDMore required tubes for lower ID
T b l th tTube length : 12 to 13 mLonger tube reduces the flue gas exit temperatureLonger tube increases pressure drop Longer tube decreases required tube
Tube pitch : 2 to 3 tube diameterLane spacing : 1.8 to 2.4 mLane spacing : 1.8 to 2.4 m
17www.hedcoint.com
![Page 18: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/18.jpg)
BurnersUniform heat release
One burner for every 2 5 to 3 5 tubes is a good designOne burner for every 2.5 to 3.5 tubes is a good design
practice
18www.hedcoint.com
![Page 19: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/19.jpg)
Flow distributionSymmetrical piping design
Detailed pressure drop calculationDetailed pressure drop calculation
Properly designed flue gas tunnel
Properly fan design
19www.hedcoint.com
![Page 20: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/20.jpg)
Heat RecoveryInlet temperature of flue gas approximately 900°C
Reformer mixed feed preheater steam superheater steamReformer mixed feed preheater, steam superheater, steam
generation, boiler feedwater heater, feed heater,
b i i hcombustion air preheater
Exit temperature of flue gas approximately 200 °C
20www.hedcoint.com
![Page 21: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/21.jpg)
Overall view
21www.hedcoint.com
![Page 22: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/22.jpg)
Forced fan
22www.hedcoint.com
![Page 23: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/23.jpg)
Air Preheater
23www.hedcoint.com
![Page 24: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/24.jpg)
Air ducts
24www.hedcoint.com
![Page 25: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/25.jpg)
Fuel
25www.hedcoint.com
![Page 26: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/26.jpg)
Radiant box
26www.hedcoint.com
![Page 27: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/27.jpg)
Convection box
27www.hedcoint.com
![Page 28: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/28.jpg)
Heat recovery
28www.hedcoint.com
![Page 29: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/29.jpg)
Induced fan and stack
29www.hedcoint.com
![Page 30: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/30.jpg)
Feed
30www.hedcoint.com
![Page 31: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/31.jpg)
Catalyst tubes
31www.hedcoint.com
![Page 32: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/32.jpg)
Tube supports
32www.hedcoint.com
![Page 33: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/33.jpg)
Radiant SectionConsiderations
Variation of heat demand from inlet to outletUniformity of heat distribution along the length of the furnaceUniformity of heat distribution along the length of the furnaceUniformity of circumferential heat flux Flow distribution in reactors for lowest turn downA d iti l h t fl i th f fi bAverage and critical heat flux in the reformer firebox
CFD modeling
33www.hedcoint.com
![Page 34: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/34.jpg)
Casing Design
Design Temp 80 °C
Designed for deflection to minimize refractory damage
N d b i i h iNeeds to be an air tight construction
Resistant to wind loads and other imposed loads
34
![Page 35: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/35.jpg)
Reformer TubesCreep
Bending stress
Thermal cycles
El iElongation
35www.hedcoint.com
![Page 36: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/36.jpg)
Reformer TubesTube material
Tube Strength
36www.hedcoint.com
![Page 37: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/37.jpg)
Catalyst DevelopmentControl tube wall temperature
Achieved the required conversionAchieved the required conversion
Have a low and stable pressure drop
Avoid carbon formation
Operation over a larger feed compositionp g p
37www.hedcoint.com
![Page 38: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/38.jpg)
Catalyst shapeActivity
Heat Transfer CoefficientHeat Transfer Coefficient
Pressure Drop
38www.hedcoint.com
![Page 39: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/39.jpg)
RefractoryCeramic fiber
ModuleBl kBlanket
CastBrickBrick
39www.hedcoint.com
![Page 40: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/40.jpg)
Transfer lineDesign ConditionsProblems
E iErosionPipe failureCondensationCondensation
RefractoryDesignDesignAnchoring
40www.hedcoint.com
![Page 41: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/41.jpg)
Sample Reformer Process Requirements:
(2050 TPD AMMONIA PRIMARY(2050 TPD AMMONIA PRIMARY REFORMER)
41www.hedcoint.com
![Page 42: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/42.jpg)
Process Gas174 ton/h520 °C39 Bar
Super Heated SteamSuper Heated Steam353 ton/h510 °C5117 Bar
Process Air Heater/h105 ton/h
540 °C37 Bar37 Bar
42www.hedcoint.com
![Page 43: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/43.jpg)
HEDCO Specifications For :Specifications For :
2050 TPD AMMONIAPRIMARY REFORMER
43www.hedcoint.com
![Page 44: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/44.jpg)
C l T bCatalyst Tubes48 tube @ 7 rowID 114 3ID = 114.3Effective Tube Length : 12.5 mInlet Temperature : 520Inlet Temperature : 520Outlet Temperature : 800Design Temperature : 920Max Wall Thickness : 890Thickness : 12 mmDesign Pressure : 41 BarMax Pressure Drop : 3 BarR S iRow Spacing : 2.1 m
44www.hedcoint.com
![Page 45: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/45.jpg)
Catalyst Tubes
capacitytotal
tubes rowtubes in
row riser ID Thk Eff Lengthcapacity tubes row row riser ID Thk Eff LengthKellogg-Ghadir 187 336 6 56 6 110 12 11.8
Linde-LindeRazi 132 235 5 47 102.2 7.9 10.9
Linde-Lordegan 174 336 7 48 114.3 12 12.5
KTI-Shiraz 174 320 8 40 114.3 10.2 12.6HEDCO D i 174 336 8 42 114 3 12 12 5Design 174 336 8 42 114.3 12 12.5
45www.hedcoint.com
![Page 46: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/46.jpg)
Tube Wall Temperature
it I TOut
TDes
TMax
TID f capacity InTemp Temp Temp Temp surface
Kellogg-Ghadir 187 620 812 924 889 1370
Linde Razi 132 620 775 845 817 822 4Linde-Razi 132 620 775 845 817 822.4
Linde-Lordegan 174 520 800 920 824 1507
KTI-Shiraz 174 520 800 914 889 1447 8KTI-Shiraz 174 520 800 914 889 1447.8
HEDCO Design 174 520 800 920 889 1507.4
46www.hedcoint.com
![Page 47: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/47.jpg)
BurnersArch Burners
Inner burners Number : 12 @ 7 row = 84Inner burners Duty = 2 MVO t B N b @Outer Burners Number: 12 @ 2 row = 24 Outer Burners Duty = 1.73
Tunnel BurnersTunnel BurnersTunnel Burners Number = 8 @ 1 rowTunnel Burners Duty = 0.53 MWy 53
Auxiliary BurnersAuxiliary Burners Number : 10 @ 5 rowAuxiliary Burners Duty = 4.26 MW
47www.hedcoint.com
![Page 48: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/48.jpg)
Burners
capacity Arch burner Auxiliary Tunnel N D t N D t N D t No Duty No Duty No Duty
Kellogg-Ghadir 187 80/32 1.8/1.17 19 1.44 7 0.63
132 60/30 1 42/85 6 2 05Linde-Razi 132 60/30 1.42./85 6 2.05 Linde-Lordegan 174 72/24 2.3/1.38 6 7.8
KTI-Shiraz 174 84/24 16 9 HEDCO Design 174 84/24 2/1.38 10 4.25 8 0.53
48www.hedcoint.com
![Page 49: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/49.jpg)
49www.hedcoint.com
![Page 50: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/50.jpg)
50www.hedcoint.com
![Page 51: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/51.jpg)
51www.hedcoint.com
![Page 52: Primary Reformer Presentation - HedCo Int](https://reader030.vdocument.in/reader030/viewer/2022012715/61ad5b8f733309662369c7c7/html5/thumbnails/52.jpg)
Thank YouThank You
52www.hedcoint.com