Steam Cracker and Reformer for Hydrogen Production
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Solution Overview
Problem
The energy-intensive nature of hydrogen production through steam reforming, coupled with the risk of coke formation and catalyst sensitivity to sulfur-containing components, poses challenges in efficiently producing hydrogen while maintaining process efficiency and preventing unwanted thermal cracking.
Innovation Solution
A steam reforming system comprising a steam cracker and a steam reformer, where the steam cracker produces a methane-rich stream that is preheated without risking coke formation, allowing for lower fuel consumption and reduced sulfur content, enabling efficient steam reforming to produce hydrogen and CO2 at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If natural gas feed is preheated in the convection section using hot flue gas, then the feed temperature increases for steam reforming, but thermal cracking occurs leading to coke formation on preheating tubes
Solution Approach 1:
The invention extracts the harmful C2+ hydrocarbon components from the natural gas feed through a separate steam cracking unit and demethanizer before the feed enters the reformer preheating section. This removal of problematic components prevents coke formation on preheating tubes while allowing effective heat recovery from flue gas to raise the feed temperature to required levels for steam reforming
2Stability of the object's composition
If sulfur-containing components are present in the feed, then the feed composition remains unchanged, but catalyst deactivation and equipment corrosion occur
Solution Approach 1:
The invention performs preliminary cleaning of the natural gas feed by removing sulfur-containing components through the steam cracking and separation process before the feed enters the reformer. This pre-treatment protects the reformer catalyst from sulfur poisoning and prevents equipment corrosion downstream, ensuring reliable operation without requiring additional sulfur removal units
3Quantity of substance
If heavy hydrocarbons are thermally cracked at high temperature, then hydrogen and methane are produced, but energy consumption increases and process complexity increases
Solution Approach 1:
The invention merges the steam cracking unit with the existing steam reformer system, using the same furnace and flue gas heat recovery network. The steam cracking unit shares infrastructure with the reformer, including the furnace for heating and the convection section for heat recovery, thereby producing additional hydrogen and methane without proportionally increasing energy consumption or process complexity
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 fuel requirements for heating and minimizes sulfur-related issues, enabling efficient hydrogen production with high purity methane streams and low C2+ hydrocarbon content, thus enhancing the overall energy efficiency and operational stability of the steam reforming process.
Implementation Method 1
steam cracking a steam cracking feed stream to produce a steam cracking product stream comprising hydrogen, methane and C2+ hydrocarbons
Implementation Method 2
a heat exchanger for cooling the steam cracking product stream to provide a cooled steam cracking product stream
Implementation Method 3
heating the preheated stream to a temperature of at least 800° C. and steam reforming the heated stream to obtain a steam reforming product stream comprising hydrogen and CO2
Data Source
AI summary
Steam reforming system having a steam cracker and a steam reformer. The steam cracker includes a steam cracking unit to steam crack a feed stream to produce a stream comprising hydrogen, methane and C2+ hydrocarbons; a heat exchanger for cooling the steam cracking product stream; a separation unit for separating the cooled steam cracking product stream into a gas stream including hydrogen and methane and a liquid stream including methane and C2+ hydrocarbons, a demethanizer which is fed the liquid stream producing a third stream containing at least 95% methane and a fourth stream comprising C2+ hydrocarbons. The steam reformer includes a feed preheater which is fed the third stream and steam to provide a preheated stream and a steam reforming unit arranged for heating the preheated stream to at least 800° C. to steam reforming the heated stream and obtain a product stream containing hydrogen and CO2.