Steam Methane Reforming With Parallel Electric and Fired Reactors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing synthesis gas plants using fired steam methane reformers consume large amounts of fuel, emit high levels of carbon dioxide and other pollutants, and have limited capacity due to mechanical constraints on heat flux.
Innovation Solution
A synthesis gas plant with parallel electrically heated and fired reforming reactors, where off-gas is recycled to burners, minimizing fuel use and emissions, and utilizing a combined synthesis gas stream for efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fired steam methane reformers are used to provide heat for reforming reactions, then high temperatures are achieved, but large amounts of fuel are consumed and high emissions of carbon dioxide and pollutants occur
Solution Approach 1:
The reforming process is segmented into multiple reactors with different heating methods. The first reforming reactor uses electricity heating for partial reforming, while the second reforming reactor uses fired heating. This segmentation allows optimization of each reactor's function, reducing overall fuel consumption and emissions while maintaining high reforming temperatures where needed.
Solution Approach 2:
The invention changes the heating parameter from exclusively fired heating to a combination of electrical and fired heating. By introducing electrical heating as a controllable parameter, the system can adjust the proportion of electrical energy input to minimize fuel consumption and emissions while achieving the required reforming temperatures.
2Productivity
If fired reforming reactors operate at maximum heat flux, then reforming capacity is increased, but mechanical constraints limit further capacity increases
Solution Approach 1:
The single large-scale fired reforming reactor is segmented into multiple smaller reactors with different heating methods. This allows the system to increase total capacity without proportionally increasing furnace size, as electrical heating reactors have simpler construction and can be more compact.
Solution Approach 2:
Electrical heating systems replace parts of the mechanical fired heating system. Electrical heating elements can be directly embedded in the reactor, eliminating the need for large furnaces and complex tube arrangements, thereby increasing capacity without proportional increases in mechanical complexity.
3Reliability
If more fuel is supplied to fired reforming reactors, then reforming reaction efficiency is improved, but overall energy consumption increases
Solution Approach 1:
The energy input parameter is changed from exclusively chemical energy (fuel) to a combination of electrical energy and chemical energy. Electrical heating provides precise, controllable energy input that can maintain optimal reforming conditions without the inefficiencies of combustion, thereby improving reaction efficiency while reducing overall energy consumption.
Solution Approach 2:
Electrical heating systems replace fired heating systems in the first reforming reactor. Electrical heating is more efficient as it directly converts electrical energy to heat without combustion losses, improving energy utilization efficiency while reducing overall energy consumption compared to fuel-based heating.
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
Reduces overall energy consumption and emissions while increasing capacity by optimizing temperature control and maximizing hydrocarbon utilization through synergy between electrically heated and fired reactors.
Implementation Method 1
an electrically heated reforming reactor housing a first catalyst and arranged for receiving a first part of said feed gas comprising hydrocarbons and generating a first synthesis gas stream
Implementation Method 2
a fired reforming reactor in parallel with said electrically heated reforming reactor, said fired reforming reactor comprising one or more tubes housing a second catalyst, said fired reforming reactor further comprising one or more burners for providing heat to said one or more tubes
Implementation Method 3
a synthesis gas plant and a process for producing synthesis gas by steam methane reforming of feed gasses comprising hydrocarbons
Data Source
AI summary
A synthesis gas plant for producing a synthesis gas, where the synthesis gas plant includes a reforming section arranged to receive said feed gas and provide a combined synthesis gas, wherein said reforming section includes an electrically heated reforming reactor, a fired reforming reactor and an optional third reforming reactor. The reforming section is arranged to output a combined synthesis gas. An optional post processing unit downstream the reforming section is arranged to receive said combined synthesis gas stream and provide a post processed synthesis gas stream. A gas separation unit arranged to separate the combined synthesis gas stream or the post processed synthesis gas stream into a condensate, a product synthesis gas and an off-gas. At least a part of the off-gas is recycled from said gas separation unit to said one or more burners. Also, a process for producing synthesis gas from a feed gas comprising hydrocarbons.