Parallel Electric and Autothermal Reforming Reactors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current chemical plants for producing synthesis gas through autothermal reforming face challenges in reducing energy consumption, increasing capacity, achieving flexibility in gas composition, and minimizing harmful emissions like CO2 and NOx.
Innovation Solution
Incorporating an electrically heated reforming reactor in parallel with an autothermal reforming reactor to produce a combined synthesis gas stream, which reduces hydrocarbon consumption for heating, allows for higher temperatures and pressures, and adjusts the H2/CO ratio, thereby reducing emissions and increasing production capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fired reforming reactor is used, then the plant structure is simple, but the energy consumption is high and emissions are high
Solution Approach 1:
The reforming process is divided into two separate parallel reactors: a fired reforming reactor and an electrically heated reforming reactor. This segmentation allows each reactor to serve a specific function - the fired reactor handles the bulk reforming while the electrically heated reactor provides precise temperature control and reduces hydrocarbon consumption for heating, thereby reducing energy loss and emissions.
Solution Approach 2:
The patent replaces part of the thermal heating system (fired heater) with an electrical heating system. The electrically heated reforming reactor uses electricity instead of combustion to provide heat, which eliminates the associated hydrocarbon consumption and emissions from the heating process, directly addressing the energy loss and emission problems.
2Device complexity
If a single fired reforming reactor is used, then the equipment configuration is simple, but the production capacity is limited
Solution Approach 1:
The patent combines two different reforming technologies (fired reforming and electrical heating reforming) into a parallel configuration. This merging of systems allows the plant to leverage the advantages of both technologies - the established reliability of fired reforming and the efficiency of electrical heating - while achieving higher overall synthesis gas production capacity than a single reactor could provide.
3Ease of operation
If a single fired reforming reactor is used, then the process is simple to operate, but the flexibility in gas composition is limited
Solution Approach 1:
The parallel reactor configuration introduces dynamic control capability to the system. By independently adjusting the feed distribution and operating parameters of each reactor, the plant can dynamically control the H2/CO ratio and other gas composition parameters in the combined synthesis gas stream, providing flexibility while maintaining operational simplicity through automated control.
4Quantity of substance
If more hydrocarbons are consumed for heating, then the reforming reactions can proceed, but the emissions of CO2 and other pollutants increase
Solution Approach 1:
The patent replaces the combustion-based heating system with an electrical heating system in one of the reactors. This substitution eliminates the need to consume additional hydrocarbons for heating purposes, directly reducing CO2 and other pollutant emissions while still providing the necessary thermal energy for the reforming reactions through electrical energy conversion.
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 reduces overall energy consumption and emissions, increases synthesis gas production capacity, and allows for flexible control of gas composition, enhancing the efficiency and environmental sustainability of the chemical plant.
Implementation Method 1
an electrically heated reforming reactor housing a first catalyst, said electrically heated reforming reactor being arranged for receiving a first part of said feed gas
Implementation Method 2
an autothermal reforming reactor in parallel with said electrically heated reforming reactor, said autothermal reforming reactor housing a second catalyst
Implementation Method 3
said electrically heated reforming reactor being arranged for receiving a first part of said feed gas and generating a first synthesis gas stream
Implementation Method 4
The steam reforming reaction is accompanied by the water gas shift reaction
Data Source
AI summary
A chemical plant including: a reforming section arranged to receive a feed gas comprising hydrocarbons and provide a combined synthesis gas stream, wherein the reforming section includes: an electrically heated reforming reactor housing a first catalyst, an autothermal reforming reactor in parallel with the electrically heated reforming reactor, wherein the reforming section is arranged to output a combined synthesis gas stream including at least part of the first and/or second synthesis gas streams, an optional post processing unit downstream the reforming section, a gas separation unit arranged to separate a synthesis gas stream into a water condensate and an intermediate synthesis gas, and a downstream section arranged to receive the intermediate synthesis gas and to process the intermediate synthesis gas to a chemical product and an off-gas. Also, a process for producing a chemical product from a feed gas comprising hydrocarbons.