Pre-Reforming Catalyst Activation via Methanol Steam Reformation
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Solution Overview
Problem
The existing start-up methods for pre-reforming stages in integrated reforming plants require expensive and hazardous hydrogen for catalyst activation, involving high costs and safety risks, especially since hydrogen is not inherently available during the start-up process.
Innovation Solution
A method using a gas stream containing methanol and water to activate the nickel-containing catalyst in the pre-reforming stage, with the resulting hydrogen and carbon oxides being recycled and utilized for catalyst activation, desulfurization, and ignition of the autothermal reformer burner, eliminating the need for external hydrogen storage and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen is used for catalyst activation during start-up, then the catalyst can be activated effectively, but high costs and safety risks are incurred due to the need for external hydrogen storage and handling
Solution Approach 1:
The system uses itself to provide the necessary hydrogen for catalyst activation. The autothermal reformer generates hydrogen during normal operation, and this hydrogen is recycled back to the pre-reforming stage for catalyst activation, eliminating the need for external hydrogen supply and making the system self-sufficient
Solution Approach 2:
The method recovers and reuses hydrogen that would otherwise be wasted or require external supply. By recycling the hydrogen from the autothermal reformer output back to the pre-reforming stage, the system recovers valuable hydrogen and eliminates the need for external hydrogen storage and handling infrastructure
2Reliability
If external hydrogen storage and handling apparatuses are installed, then catalyst activation can be achieved, but investment costs increase
Solution Approach 1:
The system uses itself to provide the necessary hydrogen for catalyst activation. The autothermal reformer generates hydrogen during normal operation, and this hydrogen is recycled back to the pre-reforming stage for catalyst activation, eliminating the need for external hydrogen supply and making the system self-sufficient
Solution Approach 2:
The hydrogen produced by the autothermal reformer serves multiple functions: it is used for catalyst activation in the pre-reforming stage, and the remaining hydrogen is available for other process requirements. This multi-functional use of hydrogen eliminates the need for dedicated external hydrogen storage and handling infrastructure
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 approach reduces investment costs, minimizes hazards, and facilitates the start-up of the integrated reforming plant by using readily available and cost-effective methanol, ensuring efficient catalyst activation and desulfurization without introducing foreign substances that could poison the catalyst.
Implementation Method 1
supplying a first gas stream (activation stream), containing methanol and water, to the pre-reforming stage and converting the activation stream in the pre-reforming stage with the catalyst contained there under activation conditions
Implementation Method 2
Hydrocarbons can catalytically be converted with steam to obtain synthesis gas, i.e. mixtures of hydrogen (H2) and carbon monoxide (CO). As is explained in Ullmann's Encyclopedia of Industrial Chemistry, Sixth Edition, 1998 Electronic Release and 6th edition 2003, keyword 'Gas Production', this so-called steam reformation (steam reforming) is the most frequently used method for the production of synthesis gas
Implementation Method 3
Another frequently used reforming method is the so-called autothermal reformation (ATR), which represents a combination of steam reformation and partial oxidation, in order to optimize the efficiency. In the ATR, the steam reformation and the partial oxidation are combined with each other such that the advantage of the oxidation (provision of thermal energy) optimally complements the advantage of the steam reformation (higher hydrogen yield)
Implementation Method 4
The partial oxidation is effected by controlled combustion of a part of the feedstocks in a burner arranged at the entrance into the autothermal reformer, whereby the thermal energy required for the succeeding steam reformation also is provided
Data Source
AI summary
There is proposed a method for starting up a pre-reforming stage in an integrated reforming plant in which a hydrocarbonaceous feed stream, in particular natural gas, is converted into a reformation product containing carbon oxides, hydrogen and hydrocarbons. Before carrying out the start-up method, the catalyst contained in the pre-reforming stage is in an oxidized or passivated state. For its activation, the pre-reforming catalyst is charged with a methanol/steam mixture, from which by steam reformation of methanol in situ the hydrogen required for the activation of the catalyst is produced. Excess hydrogen is used for the hydrogen supply of the desulfurization stage arranged upstream of the pre-reforming stage.