Steam reformer surveyHALDOR TOPSØE A/S

Improving steam reformer operationThe steam reforming process is considered the heart of the plant and is used in Topsøe-licensed technologies for the production of hydrogen, carbon monoxide, synthesis gas, methanol, and ammonia.

Topsøe’s radiant wall reforming technology results in high energy efficiency and covers a wide range of capacities and client requirements.

As a global supplier of both licensed technology and high-quality catalysts, Topsøe has extensive knowledge and vast experience in reformer operation.

Influencing reformer performanceA continuously efficient, stable and high-throughput operation is dependent on the overall reformer performance. Several factors are involved, such as:

• interaction between the radiant chamber and heat transfer to the tube

• the heat consumed by reactions inside the tube

• the heat going to the waste heat section

• catalyst activity

A thorough reformer survey, which includes the process side as well as the flue gas side, provides detailed insight into actual reformer operation and opportunities for trimming the reformer to enhance the reformer performance.

Performance simulationA reformer survey is an advanced performance evaluation, where Topsøe’s experts carry out a series of on-site measurements using diagnostic equipment. Subsequently, advanced reformer simulations including the process and fuel sides are performed. The simulations illustrate catalyst performance and show the maximum tube wall temperature (TWT) along with its location.

Topsøe provides a full mass and heat balance in order to reconcile key plant parameters with design calculations using proprietary computer models. The result of the measurements, observations, and simulations are summarized in a detailed report, providing specific advice on optimization of reformer operation.

Topsøe also offers the option of a performance evaluation of the reformer convection section. A thorough simulation of the coils in the waste heat section is performed in order to study the individual coil performance by determining the skin metal temperature and fouling factor. Topsøe can tailor the reformer survey to the client’s needs, for both the basic and advanced reformer performance evaluations.

Survey benefitsConducting a reformer survey has a number of potential benefits, the most attractive being:

• Determination of existing bottlenecks Clients often experience operational challenges in reaching maximum product output. Topsøe can help identify existing bottlenecks by evaluating the overall reformer operation and thereby maximizing performance.

• Energy and utilities savings Many factors influence operating costs. Topsøe evaluates factors such as firing profile and burner condition, excess air, waste heat section and stack condition in order to gain fuel savings, as well as minimize energy waste.

• Increasing tube lifetime It is important to avoid premature tube failure and subsequent replacement by eliminating hot zones and increasing throughput. Topsøe determines the actual TWT considering correction of furnace wall radiation and actual tube wall emissivity.

• Optimization of normal operation Optimization of operating conditions increases throughput and/or improves conversion, e.g. by reducing methane slip.

Steam reformer survey

3 |

975

935

Tube

wal

l tem

pera

ture

, °C

895

855

815

7750 6 12 18

Tube no.

Avg. C-D

Avg. A-B

C-D

Design

A-B

24 30 36

Graphs show TWTs before and after reformer furnace improvements. The first graph indicates a high and fluctuating TWT and the second graph shows a much more consistent TWT resulting in reliable and optimal performance.

A reformer survey often results in enhanced safety of operation, as it includes personnel training in good reformer practice, insight in catalyst performance and improvement of combustion conditions in the chamber via burner management and control.

Survey scopeThe typical scope of a reformer survey includes a number of features:

• Visual inspection of the primary reformer The color and shape of the tubes are checked. The burner condition is observed with respect to flames, and the refractory around the burners is observed for indication of the heat distribution pattern.

• TWT measurements Maximum TWT is identified and all TWTs are measured using a pyrometer.

• Flue gas analysis The flue gas is analyzed for O2, CO and NOX for indication of the combustion conditions in the chamber, which in turn indicate the excess air sufficiency.

• Furnace draft profile The furnace draft is measured at different levels of the furnace box in order to give a picture of the actual vacuum profile in the furnace box.

• Check of combustion air and fuel header pressures The air and fuel distribution in the reformer is checked through measurements.

• Data collection A complete set of data at the highest possible load under stable conditions will be collected along with client’s laboratory gas analyses for feed, fuels, flue gas, reformed gas, etc.

• Performance evaluation Performance evaluations are made by data evaluation and processing using our unique Topsøe in-house computer programs.

• Final report The survey is finalized with a report showing measurement results, an assessment of the condition of the reformer, and suggestions for adjustments/trimming, modifications, maintenance and possible repair work.

HALDOR TOPSØE A/S | Steam reformer survey | 4

Avg. C-D

Avg. A-B

C-D

Design

A-B

975

935

Tube

wal

l tem

pera

ture

, °C

895

855

815

7750 6 12 18

Tube no.

24 30 36

Bottleneck identification

Safety

Environment

Energy savingsProcess optimization

Capacity increase

Lifetime

Steam reformer survey benefits

Haldor Topsøe A/S

Nymøllevej 55 2800 Kongens Lyngby Denmark Tel +45 4527 2000 topsoe.com

Corporate Communications & Marketing 10.2013.2000

Technical supportTopsøe’s technical support is available 365 days a year. We will provide you with direct access to more than 50 engineers dedicated to technical support, backed by the expertise of the entire Topsøe organization. Topsøe’s experts also supply troubleshooting on a day-to-day basis.

Contact

Would you like to learn more about how Topsøe can optimize your operations and ensure that your performance is up-to-date?

Please contact techservice@topsoe.dk