Combined Reformer With Staged Catalyst Tubes for Hydrocarbon Conversion
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Solution Overview
Problem
The related art steam methane reforming apparatus (SMR) is complicated due to the need for a preliminary reformer to convert high carbon-number hydrocarbons into methane, requiring a complex structure and process.
Innovation Solution
A combined reformer with two or more catalyst tubes operating at different temperatures, allowing sequential heat supply and easy catalyst replacement, eliminating the need for a preliminary reformer by integrating catalyst tubes that can be detachably installed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a preliminary reformer is used to convert high carbon-number hydrocarbons into methane, then the reforming process can handle high carbon-number hydrocarbons, but the structure and process become complicated
Solution Approach 1:
The patent combines the functions of a preliminary reformer and a steam methane reformer into a single integrated reformer. The reformer includes a first reaction zone for converting high carbon-number hydrocarbons into methane and a second reaction zone for converting methane into synthesis gas, eliminating the need for separate preliminary reforming equipment and simplifying the overall process structure.
Solution Approach 2:
The reformer is divided into multiple reaction zones with different catalysts and temperature conditions. The first reaction zone uses a catalyst suitable for hydrocarbon conversion, while the second reaction zone uses a catalyst for methane reforming. This segmentation allows different reforming reactions to occur simultaneously in different zones, enabling the device to handle high carbon-number hydrocarbons without requiring a separate preliminary reformer.
2Reliability
If catalyst tubes are fixed inside the body, then the reforming process is stable, but catalyst replacement becomes difficult
Solution Approach 1:
The catalyst tubes are designed with detachable connections to the reformer body, allowing them to be easily removed and replaced. The tubes can be connected and disconnected through coupling mechanisms that maintain sealing, enabling quick catalyst replacement without disrupting the overall system structure or requiring complex disassembly procedures.
3Quantity of substance
If multiple catalyst tubes are integrated in one body, then equipment quantity is reduced, but heat supply complexity increases
Solution Approach 1:
A single combustion unit serves multiple functions by sequentially supplying heat to different catalyst tubes at different stages of the reforming process. The combustion unit can heat the first catalyst tube for hydrocarbon conversion and then heat the second catalyst tube for methane reforming, eliminating the need for separate heating systems for each reaction zone and reducing overall equipment quantity.
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
Simplifies the structure and process of gas reforming by enabling continuous reforming reactions without additional equipment, allowing easy catalyst replacement and reducing the need for separate carbon dioxide removal steps.
Implementation Method 1
a combustion unit configured to supply heat to the first catalyst tube and the second catalyst tube
Implementation Method 2
a first catalyst tube disposed inside the body and reacting at a first temperature; a second catalyst tube disposed inside the body and reacting at a second temperature higher than the first temperature
Data Source
AI summary
Disclosed is a combined reformer including two or more catalyst tubes reacting at different temperatures, having different reforming reactions continuously performed as a combustion gas sequentially supplies heat to two or more catalyst tubes, and capable of easily replacing a catalyst, and a catalyst replacement method thereof.