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Steam Reforming - Types of Reformer Design
1. Types of Reformer Design
Gerard B. Hawkins
Managing Director
GBH Enterprises Ltd.
2. Four main types
• Pre reformers
• Primary reformers
◦ Main different designs
• Secondary reformers
• Compact reformers
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3. • Need
◦ To contain the catalyst - use tubes
◦ High heat transfer area - lots of narrow ID tubes
◦ To supply heat - combustion of fuel
◦ To distribute feed - headers
◦ To collect effluent - headers
◦ To supply fuel/combustion air - headers & duct
◦ To contain combustion gases - casing
◦ To recover heat - flue gas duct and coils
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4. • Three main types considered
◦ Top Fired
◦ Foster Wheeler Terrace Wall
◦ Side Fired
• Many other types
◦ Not considered
◦ Not encountered frequently
◦ Same principles still apply
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8. Nearly all heat transfer is by
radiation
Radiation from the flue gas to
the tubes
Little direct radiation from
refractory to tube
Refractory acts as a reflector
Radiation from flame to tube at
tube top
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9. Top Fired Temperature Profiles
800
900
1000
1100
1200
1300
1400
1500
1600
0 20 40 60
Distance Down Tube (ft)
ProcessandOutside
TubeWall
Temperature(°F)
1400
1600
1800
2000
2200
2400
2600
2800
FluegasTemperature
(°F)
Outside Tube Wall
Temperature
Process Gas
Temperature
Fluegas Temperature
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10. • The key advantages of this design are
• Small catalyst volume
• A relative small number of burners
• Combustion air preheat is simple to install
• The key disadvantages of this design are
◦ High heat fluxes at the top of the tubes can lead to carbon
formation and hence to hot bands
• The heat flux down the tube can not be varied
• Burner control is coarse due to the low number of burners
used on top fired reformers
• A temperature pinch between the flue gas and process gas at
the exit of the tubes
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14. • Nearly all heat transfer is by
radiation from flames and
refractory
◦ Major portion is from
refractory
◦ Some from flame
◦ Some from flue gas
• Heat is transferred from
flame to the walls
◦ By convection/radiation
Radiative
heat flows
Convection
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15. Foster Wheeler Temperature Profiles
800
1000
1200
1400
1600
1800
2000
0 20 40 60
Distance Down Tube (ft)
Temperature(°F)
FluegasTemperature
(°F)
Outside Tube Wall
Temperature
Process Gas
Temperature
Fluegas Temperature
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16. • The key advantages of this design are,
◦ Ability to alter the firing between the two levels to either,
Reduce methane slip,
Or increase the flue gas temperature and hence raise more
steam,
◦ A low heat flux which means carbon formation should not be
an issue.
• The key disadvantages of this design are,
◦ Relatively high catalyst volume,
◦ The feed and fuel gases must be balanced between the two
cells,
◦ A large number of burners.
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17. Convection section is placed
above transfer duct
Elevated - makes
modifications difficult
Long tubes in coil
Multiple fans in some cases
Can include auxiliary burners
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21. • Nearly all heat transfer is by
radiation from flames and
refractory
◦ Major portion is from
refractory
◦ Some from the flames - less
than for Foster Wheeler
• Some from flue gas
• Heat is transferred from flame
to the walls
◦ By convection/radiation
Convection
Radiative
heat flows
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22. Side Fired Temperature Profiles
800
900
1000
1100
1200
1300
1400
1500
1600
1700
0 10 20 30 40
Distance Down Tube (ft)
ProcessandOutside
TubeWall
Temperature(°F)
1400
1500
1600
1700
1800
1900
2000
2100
2200
FluegasTemperature
(°F)
Outside Tube Wall
Temperature
Process Gas
Temperature
Fluegas Temperature
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GBH Enterprises Ltd.
23. • The key advantages of this design are,
◦ Ability to alter the firing between the burner levels to either,
Reduce methane slip,
Or increase the flue gas temperature and hence raise more
steam,
◦ A low heat flux which means carbon formation should not be
an issue.
• The key disadvantages of this design are,
◦ Relatively high catalyst volume,
◦ The feed and fuel gases must be balanced between the two
cells,
◦ A large number of burners.
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25. Issues
• Variation of tube wall temperature
• Tubes are at different distances from burners
• Leads to high methane slip
• Variability of tube life
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28. • Most of these reformers are
◦ Upfired
◦ Upflow
◦ Therefore same as a top fired
reformer
• Small plant capacities
• Always have uneven heat flux and
therefore un-even temperatures
• One side hotter than the other
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29. Offered by
• Howmar
◦ Now designing Top Fired furnaces
• Howe Baker
◦ Now designing Top Fired furnaces
• Chemico
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31. • Use low grade heat from
flue gas duct to preheat air
• Maximize efficiency as stack
temperature is reduced
• Minimizes fuel used
• No preheating in primary of
the combustion air
• Must ensure symmetry
◦ Prevents mal-distribution
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42. Main types include
• Gas Heated Reformer (GHR)
• Advanced Gas Heat Reformer (AGHR)
• Enhanced Heat Transfer Reformer (EHTR)
• KRES
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43. Aim is to
• Minimize plot area
◦ Eliminate large fired box
◦ Eliminate convection section
• Maximise heat integration
• Eliminate HP steam system
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44. • Developed for ammonia process - LCA
• Early 1980’s - Paper exercise
• Mid 1980's - Sidestream unit at Billingham
• Mid 1980's - LCA design developed
• Late 1980's - ICI Severnside plants start up
• 1991 - BHPP LCM plant designed
• 1994 - BHPP plant start up
• 1998 - AGHR Start Up
• 1998 - MCC Start Up
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48. • Shellside heat transfer usually poor
• Minimize tube count with expensive alloys
• Tubes are externally finned
• Designed as double tubes
• Sheath tube
• Produces much smaller tube bundle
• Allows scale up to higher capacities
Catalyst tube Fins
Double tube
Hot shellside gas
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52. • GHR operates in extremely corrosive duty
• Metal dusting - catastrophic carburization
• Need for materials research
• Suitable high temperature alloys identified
• Many years of operation in LCA plants
• Also confirmed in Methanol plant
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53. • Retain
• Series reforming scheme
• Shellside heat transfer enhancement
• Mechanical & process design methods
• Change to
• Non bayonet design
• Hot end tubesheet
• Sliding seal system
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54. • Novel seal system
• Prevents leakage from tubeside to shellside
• Not sensitive to wear of sliding surfaces
• Allows independent tube expansion
• Proven in full scale pilot plant tests
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55. • Easier to replace tubes
• Easier to load catalyst
• Capacity of up to 6,500 mtpd in single shell
◦ Would need 2 conventional primaries
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