Steam Methane Reformer Burner Throttling Map
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Solution Overview
Problem
In steam methane reforming (SMR) furnaces, the inhomogeneous heat transfer among tubes limits the efficiency and lifetime of the process due to temperature discrepancies, which existing methods struggle to address efficiently and quickly, especially in large-scale operations.
Innovation Solution
A method that rapidly determines a suitable map of burners to throttle by using a simplified physical model and optimization algorithms to adjust burner power ratios, reducing temperature spread and improving heat distribution among tubes, allowing for real-time adjustments without extensive on-site manpower or complex data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional methods are used to determine burner throttling maps, then comprehensive data processing can be performed, but it requires extensive on-site manpower and complex data processing which reduces operational efficiency
Solution Approach 1:
The patent extracts only the essential data elements needed for burner throttling optimization (tube temperatures and burner positions) while discarding unnecessary complex processing steps. This extraction approach reduces the data processing burden while maintaining the precision needed for accurate temperature measurement and burner control.
Solution Approach 2:
The patent creates a universal burner throttling map that can be applied across different operating conditions and furnace configurations. This multi-functional approach allows the same methodology to determine optimal burner settings for various scenarios, reducing the need for repeated complex measurements and analyses.
2Stability of the object's composition
If comprehensive data processing is performed to optimize heat distribution, then temperature homogenization can be achieved, but it requires extensive on-site manpower and complex processing
Solution Approach 1:
The patent segments the furnace into discrete zones with individual tube-burner relationships, allowing independent analysis and optimization of each segment. This segmentation simplifies the overall complex system into manageable units that can be processed independently, reducing the computational burden while achieving global temperature homogenization.
Solution Approach 2:
The patent applies partial action by focusing only on the critical burners and tubes that have the greatest impact on temperature distribution. Rather than processing all data points equally, the method identifies and optimizes the key influencers, achieving effective temperature homogenization with reduced processing complexity.
3Duration of action of stationary object
If burner power is adjusted to homogenize temperatures, then tube lifetime is extended, but it requires rapid determination of burner maps which traditional methods cannot provide
Solution Approach 1:
The patent performs preliminary analysis of the furnace geometry, burner positions, and tube configurations to pre-calculate optimal throttling strategies. This preliminary action allows rapid determination of burner maps when temperature homogenization is needed, eliminating the need for time-consuming on-site measurements and complex real-time processing.
Solution Approach 2:
The patent creates simplified computational models that copy the essential thermal relationships of the furnace without requiring full-scale complex simulations. These simplified models enable rapid calculation of optimal burner throttling maps while maintaining sufficient accuracy for practical temperature homogenization and tube protection.
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 significantly reduces the time required to establish a map of burners to throttle, enabling rapid mitigation of temperature discrepancies, thereby enhancing furnace performance and extending tube lifetime by homogenizing tube skin temperatures and reducing syngas collector temperature spread.
Implementation Method 1
heat being transferred from the burners to the tubes
Implementation Method 2
The reaction is endothermic and slow and requires additional heat input
Data Source
AI summary
A method of improving an endothermic process in a furnace utilizing steps a) calibrating the simplified physical model of step c3) by measuring one or more tube temperature for at least a tube impacted by the throttling of a burner in standard and in throttled state, b) acquiring information on a tube temperature for the tubes present in the furnace with all the burners present in the furnace under standard non-throttled conditions, c) getting a map of burners to throttle including c1) choosing at least one parameter representative of the performances of the furnace with a target of improvement, c2) choosing at least one or more power ratio for the burner throttling, c3) utilizing the information of step b) and a simplified physical model of the impact of throttling a burner on the tube temperature, c4) getting a map of burners to throttle, step d) throttling the burners.