Gas-Heated Reformer Outlet Alignment
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Solution Overview
Problem
The original design of gas-heated reformers for hydrogen production has limitations, including a limited number of reformer tubes due to hot process gas contact with the tube sheet and the need for expensive brick lining to insulate the gas inlet chamber, which increases costs and complexity.
Innovation Solution
A reformer arrangement with a gas-heated reformer (GHR) product outlet arranged parallel to the heat exchanger, minimizing the thermal insulation required for the heat channel connection between the main reformer and heat exchanger, eliminating the need for corner pieces and reducing insulation costs by simplifying the heat channel structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gas-heated reformer is designed with conventional configuration, then the reforming capacity can be increased, but the number of reformer tubes is limited due to hot process gas contact with the tube sheet and expensive brick lining is required for insulation
Solution Approach 1:
The patent positions the GHR product outlet on a plane parallel to the heat exchanger, with height difference within ±20%, creating a direct vertical alignment. This spatial reconfiguration eliminates the need for complex horizontal connections and corner pieces, reducing structural complexity while maintaining reforming capacity.
Solution Approach 2:
The patent extracts and eliminates the gas inlet chamber and its associated expensive brick lining by directly connecting the GHR product outlet to the heat exchanger. This removal of unnecessary components simplifies the overall structure and reduces material costs.
2Reliability
If the gas-heated reformer uses conventional design, then it can operate, but expensive brick lining is required to insulate the gas inlet chamber, increasing costs
Solution Approach 1:
The patent removes the gas inlet chamber and its expensive brick lining insulation by establishing a direct connection between the GHR product outlet and the heat exchanger. This elimination of unnecessary components significantly reduces manufacturing costs while maintaining operational reliability through the optimized parallel plane configuration.
3Adaptability or versatility
If the GHR product outlet is not aligned parallel to the heat exchanger, then connection flexibility is maintained, but extensive thermal insulation and corner pieces are required, increasing complexity and cost
Solution Approach 1:
The patent establishes a direct vertical connection by positioning the GHR product outlet on a plane parallel to the heat exchanger with height difference within ±20%. This alignment eliminates the need for corner pieces and extensive horizontal insulation, reducing insulation complexity while maintaining adequate connection flexibility for installation tolerances.
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 allows for increased reforming capacity and improved heat balance while minimizing expensive thermal insulation, reducing costs and complexity in the reformer design.
Implementation Method 1
minimizing the thermal insulation required for the heat channel connection between the main reformer and heat exchanger
Implementation Method 2
The heat required for this endothermic conversion is provided, for example, by utilizing the heat from the synthesis gas produced in the primary reformer
Data Source
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AI summary
The invention discloses a reformer arrangement for production of synthesis gas and/or hydrogen, at least comprising the following elements: - a main reformer (1) connected to a main reformer reactant feed (2) and a main reformer product outlet (3); - a gas-heated reformer (GHR) (4) comprising a GHR reformer interior (4h) with GHR reformer tubes (4a) disposed therein, a GHR raw gas inlet (4b) connected to the GHR reformer tubes (4a); a GHR shell (4c) of the GHR reformer tubes (4a); a GHR main reformer product gas inlet (4d) connected to the main reformer product outlet (3) and the GHR shell (4c); a GHR product outlet (4e); - a heat transferrer (5) with a heat transferrer inlet opening (5a) and a heat transferrer outlet opening (5c), wherein a heat duct (5b) is disposed between the heat transferrer inlet opening (5a) and the GHR product outlet (4e); characterized in that the GHR product outlet (4e) is disposed in a plane parallel with the heat transferrer (5) and the height measured from the base up to the centre axis of the GHR product outlet (4e) is not more than plus/minus 20% the height measured from the base up to the centre axis of the heat transferrer inlet opening (5a).