Steam Generator Placement in Reforming Reactor Heat Recovery
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Solution Overview
Problem
The existing methods for generating steam in steam reforming reactors face inefficiencies due to fluctuating heat supply in the flue gas duct, leading to increased operating costs and the need for additional heat sources, and the steam generated from process condensate is often not sufficient for all ancillary units.
Innovation Solution
An additional steam generator is placed before the carbon monoxide conversion unit to evaporate process condensate using the high-temperature synthesis gas, and the boiler feed water is heated using flue gas, allowing for more efficient heat utilization and reducing dependence on the flue gas duct's heat supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If process condensate is heated in the flue gas duct to generate steam, then steam can be generated from waste heat, but the fluctuating heat supply in the flue gas duct requires additional heat sources and increases operating costs
Solution Approach 1:
The steam generation system is segmented into two independent paths: one using the flue gas duct for boiler feed water and another using a dedicated heat exchanger for process condensate. This segmentation allows each path to be optimized independently, eliminating the problem of fluctuating heat supply affecting the entire system.
Solution Approach 2:
A dedicated heat exchanger is introduced as an intermediary device between the synthesis gas and process condensate, providing a stable heat transfer path that is independent of the flue gas duct's fluctuating heat supply.
2Productivity
If steam is generated from process condensate to meet the steam requirements of ancillary units, then steam supply can be increased, but the steam from process condensate is often insufficient and requires additional boiler feed water systems
Solution Approach 1:
The system utilizes parameter changes in the synthesis gas temperature profile, specifically utilizing the high-temperature synthesis gas before the converter to provide sufficient heat for evaporating process condensate, thereby increasing steam generation capacity without additional complexity.
3Area of stationary object
If the steam generator is placed after the converter to utilize cooled synthesis gas, then heat exchanger surface area is reduced, but the temperature difference for heat transfer is decreased
Solution Approach 1:
The steam generator for process condensate is placed before the converter, performing the evaporation action preliminarily when the synthesis gas temperature is still high. This preliminary action ensures sufficient temperature difference for efficient heat transfer while maintaining compact heat exchanger dimensions.
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 enables continuous steam generation from process condensate, reduces the need for additional heat sources, and improves economic efficiency by requiring smaller heat exchanger surfaces, thus lowering costs and maintaining a stable steam supply.
Implementation Method 1
the process condensate is evaporated by an additional steam generator located in front of the conversion unit
Implementation Method 2
evaporate process condensate using the high-temperature synthesis gas
Implementation Method 3
the boiler feed water is heated using flue gas
Implementation Method 4
enables continuous steam generation from process condensate, reduces the need for additional heat sources
Data Source
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AI summary
The invention relates to a method for producing process vapor and boiler feed steam in a heatable reforming reactor for producing synthesis gas. By means of the method according to the invention, the sensible heat of a synthesis gas produced from hydrocarbons and steam can be used so that two types of vapor are obtained, which are producing during the heating and evaporation of boiler feed water and process condensate, and wherein the method also comprises a conversion of the carbon monoxide contained in the synthesis gas, and wherein the method comprises an optional heating of the boiler feed water using the flue gas from the heating of the reforming reactor. By means of the method, the sensible heat of the synthesis gas and of the flue gas originating from the heating can be used more efficiently, wherein the disadvantages from the flue gas heating, which are caused by the fluctuating heat supply in the flue gas duct, are avoided. The invention further relates to a system by means of which said method can be carried out.