Reformer Tubes with Enlarged Outer Surface Area
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Solution Overview
Problem
Current reforming reactors face limitations in achieving high reformer efficiency and methane conversion rates while minimizing the number of tubes, which can lead to increased pressure drop and reduced tube lifetime due to temperature peaks and heat transfer issues.
Innovation Solution
The use of reformer tubes with structured catalysts and elements that enlarge the outer surface area, such as fins, to enhance heat transfer and reduce the number of tubes required, maintaining high efficiency and methane conversion rates while minimizing temperature peaks and pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the number of reformer tubes is reduced to achieve a more compact reactor design, then the reactor volume and capital costs are reduced, but the pressure drop increases and tube lifetime decreases due to temperature peaks and heat transfer issues
Solution Approach 1:
The patent applies this principle by adding external fins to the reformer tubes, which increases the outer surface area available for heat transfer. This dimensional extension allows heat to be transferred more efficiently from the combustion zone to the tube interior, enabling the use of fewer tubes while maintaining adequate heat supply and avoiding temperature peaks that would reduce tube lifetime.
2Volume of moving object
If the number of reformer tubes is reduced to achieve a more compact reactor design, then the reactor volume and capital costs are reduced, but the heat transfer efficiency decreases
Solution Approach 1:
The patent applies this principle by adding external fins to the reformer tubes, which increases the outer surface area available for heat transfer. This dimensional extension allows heat to be transferred more efficiently from the combustion zone to the tube interior, enabling the use of fewer tubes while maintaining adequate heat supply and avoiding temperature peaks that would reduce tube lifetime.
3Productivity
If elements for enlarging outer surface area (such as fins) are added to reformer tubes, then heat transfer is enhanced and fewer tubes are needed, but the device complexity increases
Solution Approach 1:
The patent applies this principle by adding external fins to the reformer tubes, which increases the outer surface area available for heat transfer. This dimensional extension allows heat to be transferred more efficiently from the combustion zone to the tube interior, enabling the use of fewer tubes while maintaining adequate heat supply and avoiding temperature peaks that would reduce tube lifetime.
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 combination allows for a more compact and efficient reforming reactor with improved heat transfer, maintaining high reformer efficiency and methane conversion rates, and reducing the number of tubes, thus lowering capital and maintenance costs.
Implementation Method 1
elements for enlarging the outer surface area of a reformer tube... to enhance heat transfer
Implementation Method 2
The conversion reaction needs to be conducted at high temperatures, for example temperatures of at least 700° C. The heat necessary for the endothermic conversion of the process gas
Implementation Method 3
the reformer tubes contain in their interior a catalyst for the conversion of said hydrocarbons and said at least one further fluid to synthesis gas
Data Source
AI summary
A reforming reactor for an endothermic process including a plurality of reformer tubes allowing a flow of hydrocarbons and at least one further fluid inside the tubes is provided. Wherein the reformer tubes contain in their interior a catalyst for the conversion of the hydrocarbons and the at least one further fluid to synthesis gas, and a means for heating the reformer tubes. Wherein at least a portion of the plurality of reformer tubes is provided with one or more elements for enlarging the outer surface area of a reformer tube, and the catalyst includes a structured catalyst. Also an endothermic process for the production of synthesis gas, including allowing a flow of hydrocarbons and at least one further fluid inside a plurality of reformer tubes, and heating the plurality of reformer tubes to convert said hydrocarbons and the at least one further fluid to synthesis gas.