In The Name OF God

Hampa Energy Engineering &Hampa Energy Engineering &Hampa Energy Engineering & Hampa Energy Engineering & Design CompanyDesign Company

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IntroductionAmmonia plantsMethanol plantsHydrogen PlantsHydrogen PlantsOther plants

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A Brief historical ReviewGreater capacity

3300 mtpd 20 rows with a total of 960 tube

Improve efficiency

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Reformer TypesTop Fired

Side FiredSide Fired

Terraced Wall

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Design ParametersFunctionFeed

l

Heat FluxPressure Drop

FuelsType Pressure

CatalystTubes

PressureExit TemperatureInlet Temperature

BurnersFlow distributionH RInlet Temperature

Steam/Carbon Ratio

Heat Recovery

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Function

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FeedNatural gas

PropanePropane

LPG

Butane

Naphthap

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FuelsNatural gas

Distillate fuelsDistillate fuels

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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

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PressureThe reforming reaction equilibrium is favored by low

pressurepressure

The shift reaction equilibrium is independent of pressure

Product hydrogen pressure requirement (down stream)

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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

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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

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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

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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

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Pressure DropLegnth of tubes

Tube diameterTube diameter

Catalyst selection

Approximately 3 Bar

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CatalystReaction conversion

Nickel-alkaliNickel-alkali

shape

Catalyst pressure drop

Shapep

Key aspect of catalyst : formulation & shape

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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

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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

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Flow distributionSymmetrical piping design

Detailed pressure drop calculationDetailed pressure drop calculation

Properly designed flue gas tunnel

Properly fan design

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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

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Overall view

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Forced fan

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Air Preheater

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Air ducts

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Fuel

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Radiant box

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Convection box

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Heat recovery

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Induced fan and stack

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Feed

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Catalyst tubes

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Tube supports

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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

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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

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Reformer TubesCreep

Bending stress

Thermal cycles

El iElongation

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Reformer TubesTube material

Tube Strength

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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

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Catalyst shapeActivity

Heat Transfer CoefficientHeat Transfer Coefficient

Pressure Drop

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RefractoryCeramic fiber

ModuleBl kBlanket

CastBrickBrick

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Transfer lineDesign ConditionsProblems

E iErosionPipe failureCondensationCondensation

RefractoryDesignDesignAnchoring

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Sample Reformer Process Requirements:

(2050 TPD AMMONIA PRIMARY(2050 TPD AMMONIA PRIMARY REFORMER)

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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

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HEDCO Specifications For :Specifications For :

2050 TPD AMMONIAPRIMARY REFORMER

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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

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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

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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

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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

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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

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Thank YouThank You

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