Electrical Steam Methane Reformer Temperature Control
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Solution Overview
Problem
Convective reformers, such as bayonet reformers, are limited by their maximum operating temperature due to the need for energy transfer between the convective medium and the heated zone, constraining product quality control in chemical plants.
Innovation Solution
A process and plant configuration that combines a heat exchange reformer with an electrical steam methane reformer (e-SMR) in series, allowing for improved energy utilization and product quality control by using the e-SMR to elevate temperatures and reduce energy consumption, with the e-SMR receiving a portion of the synthesis gas stream as heating fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a convective bayonet reformer is used to achieve better energy utilization, then energy efficiency is improved, but the maximum operating temperature is constrained due to the requirement for a driving force for energy transfer
Solution Approach 1:
The reforming process is divided into two separate stages: a convective bayonet reformer for initial reforming and an electrical steam methane reformer for final conversion. This segmentation allows each reactor type to operate in its optimal temperature range, with the convective reformer handling energy-efficient preliminary reforming and the electrical reformer achieving high-temperature completion without convective heat transfer constraints.
Solution Approach 2:
The patent replaces the convective heating mechanism in the second reforming stage with electrical heating. This substitution eliminates the dependency on convective heat transfer driving forces, enabling the electrical steam methane reformer to operate at higher temperatures where convective reformers would be limited, while maintaining energy efficiency through direct electrical energy input.
2Productivity
If the maximum operating temperature of a convective reformer is constrained, then product quality control is limited, but increasing temperature would improve conversion efficiency
Solution Approach 1:
The two-stage reforming system segments the temperature increase into two phases: moderate temperature rise in the convective reformer for energy efficiency, followed by a second temperature increase in the electrical reformer to achieve high conversion. This allows the system to reach high overall conversion without requiring the convective reformer to operate at temperatures where convective heat transfer becomes inefficient.
Solution Approach 2:
The patent changes the heating parameter from convective to electrical in the second stage, enabling the system to operate at higher temperatures for improved conversion. The electrical heating mechanism allows temperature to be increased beyond the convective reformer's limitations while maintaining process control through electrical power regulation.
3Manufacturing precision
If product quality is controlled by adjusting feed or convective process parameters, then temperature control is possible, but energy utilization efficiency decreases
Solution Approach 1:
The patent substitutes electrical heating for convective heating in the second reforming stage, enabling precise product quality control through electrical power adjustment without compromising energy utilization. Electrical heating provides direct, controllable energy input that can be precisely regulated to achieve target product specifications while avoiding the energy losses associated with adjusting convective process parameters.
Solution Approach 2:
The control parameter for product quality is changed from convective process parameters to electrical power input. This allows precise control of the second reforming stage's output by adjusting electrical power, which directly controls the temperature and conversion level without the energy penalties associated with modifying convective flow rates or temperatures in the first stage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances feedstock conversion and energy recovery, achieving lower operating costs and more precise product quality control by optimizing the synergy between convective and electrical heating methods.
Implementation Method 1
electrical steam methane reformer (e-SMR) arranged downstream of said heat exchange reformer... converting at least a portion of the first synthesis gas stream from said heat exchange reformer to a second synthesis gas stream
Implementation Method 2
heat exchange reformer comprising a housing and one or more reactor tubes arranged within said housing... one or more first catalyst bed(s) are arranged inside said heat exchange reformer, said catalyst bed(s) being arranged to be heated by a heating fluid
Implementation Method 3
one or more first catalyst bed(s) are arranged inside said heat exchange reformer, said catalyst bed(s) being arranged to receive a first portion of the hydrocarbon-containing feed and convert said first portion of the hydrocarbon-containing feed to a first synthesis gas stream
Data Source
AI summary
A plant is provided which comprises a reforming section, a gas separation section and a hydrocarbon-containing feed. The reforming section includes a heat exchange reformer and an electrical steam methane reformer (e-SMR) arranged downstream of said heat exchange reformer. The gas separation section is arranged to receive a synthesis gas stream from the reforming section and separate it into at least a condensate and a product gas. The plant is controlled by feedback control on the e-SMR.