Steam methane reforming method

Abstract

A steam methane reforming method in which a feed stream is treated in a reactor containing a catalyst that is capable of promoting both hydrogenation and partial oxidation reactions. The reactor is either operated in a catalytic hydrogenation mode to convert olefins into saturated hydrocarbons and / or to chemically reduce sulfur species to hydrogen sulfide or a catalytic oxidative mode utilizing oxygen and steam to prereform the feed and thus, increase the hydrogen content of a synthesis gas produced by a steam methane reformer. The method is applicable to the treatment of feed streams containing at least 15% by volume of hydrocarbons with two or more carbon atoms and / or 3% by volume of olefins, such as a refinery off-gas. In such case, the catalytic oxidative mode is conducted with a steam to carbon ratio of less than 0.5, an oxygen to carbon ratio of less than 0.25 and a reaction temperature of between about 500° C. and about 860° C. to limit the feed to the steam methane reformer to volumetric dry concentrations of less than about 0.5% for the olefins and less than about 10% for alkanes with two or more carbon atoms.

Description

RELATED APPLICATIONS [0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 10 / 990,485, filed Nov. 18, 2004, now abandoned.FIELD OF THE INVENTION [0002] The present invention relates to a steam methane reforming method in which a hydrocarbon feed stream containing methane and / or hydrocarbons with two or more carbon atoms is converted into an intermediate product within a catalytic reactor and the intermediate product is subsequently reformed in a steam methane reformer to in turn produce a synthesis gas product. More particularly, the present invention relates to such a method in which the catalytic reactor is capable of operating in either a mode involving the hydrogenation of hydrocarbons and sulfur compounds into saturated hydrocarbons and hydrogen sulfide or an alternative mode involving the use of oxygen to produce additional hydrogen. BACKGROUND OF THE INVENTION [0003] In a typical steam methane reformer operation for the production of hyd...

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Benefits of technology

[0017] As may be appreciated by those skilled in the art, the present invention contemplates a reactor operating at a space velocity of 5 to 50 times that of a conventional hydrotreater and therefore, such reactor can be a smaller and less expensive unit than a hydrotreater utilizing a conventional hydrotreater catalyst. Therefore, the application of the present invention to a steam methane reformer is more cost effective than obtaining a conventional hydrotreater when streams containing olefins and / or sulfur are to be treated. It is also to be noted that since higher operational temperatures are possible, much higher concentrations of olefins are able to be treated.

[0022] In yet a further aspect, the present invention provides a steam methane reforming method in which the hydrogen content of the reformed product stream can be economically adjusted by operating in either the hydrogenation mode selected for lower hydrogen production or oxidative mode selected for higher hydrogen production. Alternatively the oxidation mode can be selected in order to reduce the firing rate of the steam methane reformer when producing a constant quantity of hydrogen, or in other words the amount of fuel consumed thereby can be cut back. The conventional hydrotreater can be eliminated. In such aspect of the invention, a feed stream that comprises hydrocarbons, sulfur compounds and hydrogen is heated to a temperature of no greater than about 600° C. An intermediate product stream is produced by catalytically reacting the hydrogen with the hydrocarbons and the sulfur compounds without oxygen. As a result, the intermediate product stream contains saturated hydrocarbons and hydrogen sulfide formed from hydrogenation of the hydrocarbons and the sulfur compounds, respectively. The heating of the feed stream and / or the hydrogenation of the hydrocarbons being sufficient to produce the intermediate product stream at a temperature of greater than about 400° C.

[0028] In the foregoing two aspects of the present invention during both of the catalytic reactions, the steam methane reformer can be operated at a firing rate that remains substantially unchanged. As a result, the additional hydrogen produced during the catalytic reaction of the oxygen, steam, hydrocarbons and sulfur compounds increases the moles of synthesis gas product stream and the hydrogen production rate over that produced when the hydrogen, hydrocarbons and sulfur compounds are catalytically reacted without adding oxygen. In an alternative operation, during the catalytic reaction of the oxygen, steam, hydrocarbons and sulfur compounds, the steam methane reformer is operated at a lower firing rate than during the catalytic reaction of the hydrogen, hydrocarbons and sulfur compounds. This allows for reduced fuel usage to the steam methane reformer and with of course, a lower total product synthesis gas and hydrogen production rate than when the steam methane reformer is operated at constant firing. The steam production rate can be equivalent to that obtained during the hydrogenation mode.

[0029] In any embodiment of the present invention involving the catalytic hydrogenation mode of operation, steam may be introduced into the reactor to engage in reforming reactions with the hydrocarbons. Furthermore, in any embodiment of the present invention, hydrogen can be added to a natural gas stream to allow the natural gas stream to be treated by hydrogenating the sulfur compounds contained therein into hydrogen sulfide and then removing the hydrogen sulfide so that the natural gas stream contains less than about 0.1 ppm by volume on a dry basis of hydrogen sulfide. The reformer feed stream is formed in part by combining the natural gas stream with the intermediate product stream. Alternatively, the feed stream can further comprise natural gas. For example, a natural gas stream can be combined with a refinery off-gas stream and the resulting combined stream can be treated in the reactor to reduce olefins and / or higher order hydrocarbons and sulfur compounds to hydrogen sulfide. As may be appreciated, such embodiment of the present invention would not require an expensive and large hydrotreater.

Problems solved by technology

In this regard, although higher order hydrocarbons might be tolerated through adjustment of the steam to carbon ratio, olefins cannot be tolerated.

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