Reforming Device Multilayer Pipe Cooling Inlet Carbon Deposition
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Solution Overview
Problem
In methane reforming processes, the deposition of solid carbon in reforming catalysts leads to reduced catalyst efficiency, increased pressure loss, and blocked pores, especially when the carbon dioxide content is high, resulting in decreased hydrogen production and increased temperature gradients within the reforming reaction tube.
Innovation Solution
A reforming device with a catalyst layer and a spray device or heat insulator to reduce heat flux at the catalyst layer inlet, promoting turbulence and using a multilayer pipe configuration to suppress heat transfer, thereby preventing rapid temperature rises and solid carbon deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the content ratio of carbon dioxide to methane is increased to increase hydrogen production, then hydrogen production amount is improved, but specific heat of methane-containing gas decreases causing rapid temperature rise and solid carbon deposition
Solution Approach 1:
The patent applies local quality by introducing a cooling fluid through cooling holes formed in the reforming reaction tube at the catalyst layer inlet portion. This creates a localized cooling zone specifically where solid carbon deposition is most problematic, allowing the rest of the system to operate at high temperatures for efficient hydrogen production while preventing carbon deposition at the critical inlet region.
Solution Approach 2:
The patent implements preliminary action by cooling the methane-containing gas before it enters the catalyst layer through the cooling holes. This pre-cooling prevents the gas from reaching temperatures that would cause thermal decomposition and solid carbon deposition, addressing the problem before it occurs in the catalyst layer.
2Productivity
If heat flux at catalyst layer inlet is high, then reforming reaction efficiency is improved, but rapid temperature rise causes thermal decomposition of methane and solid carbon deposition
Solution Approach 1:
The patent applies local quality by introducing a cooling fluid through cooling holes formed in the reforming reaction tube at the catalyst layer inlet portion. This creates a localized cooling zone specifically where solid carbon deposition is most problematic, allowing the rest of the system to operate at high temperatures for efficient hydrogen production while preventing carbon deposition at the critical inlet region.
Solution Approach 2:
The patent implements preliminary action by cooling the methane-containing gas before it enters the catalyst layer through the cooling holes. This pre-cooling prevents the gas from reaching temperatures that would cause thermal decomposition and solid carbon deposition, addressing the problem before it occurs in the catalyst layer.
3Object-affected harmful factors
If cooling fluid is sprayed at catalyst layer inlet, then solid carbon deposition is suppressed, but heat transfer to catalyst is reduced
Solution Approach 1:
The patent applies local quality by introducing a cooling fluid through cooling holes formed in the reforming reaction tube at the catalyst layer inlet portion. This creates a localized cooling zone specifically where solid carbon deposition is most problematic, allowing the rest of the system to operate at high temperatures for efficient hydrogen production while preventing carbon deposition at the critical inlet region.
Solution Approach 2:
The patent uses a multilayer pipe configuration where an outer pipe surrounds the inner pipe containing the catalyst layer. This outer pipe acts as a thermal barrier, copying the cooling effect at the inlet while allowing heat to reach the catalyst in the inner pipe, thus maintaining heat transfer efficiency while suppressing carbon deposition.
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 effectively increases hydrogen production while suppressing solid carbon deposition, even with high carbon dioxide content in the methane-containing gas, by maintaining a lower temperature and reducing thermal decomposition.
Implementation Method 1
a spray device for spraying a cooling fluid to an outer peripheral surface of the reforming reaction tube
Implementation Method 2
a reforming catalyst for reforming the methane-containing gas
Implementation Method 3
a heat insulator disposed on an outer peripheral surface of the reforming reaction tube
Implementation Method 4
methane contained in the methane-containing gas is thermally decomposed particularly in the vicinity of the inside of the tube wall, so that solid carbon is easily deposited
Data Source
AI summary
A reforming device 1 for producing a reformed gas from a methane-containing gas containing methane and carbon dioxide includes a reforming reaction tube 10 containing a catalyst layer 12 filled with a reforming catalyst 12a for reforming the methane-containing gas, and a multilayer pipe 103 for spraying a cooling fluid to an outer peripheral surface of the reforming reaction tube 10 at a position corresponding to a gas inlet of the catalyst layer 12 in a length direction of the catalyst layer 12.