Steam Reformation Plant Heat Recovery Segmentation
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Solution Overview
Problem
Existing processes for catalytic steam reformation of hydrocarbonaceous feed gases inefficiently utilize heat from synthesis gas and flue gas for steam generation, with excess heat not being optimally harnessed for process steam production, leading to suboptimal steam pressure and increased costs.
Innovation Solution
A process and plant design that utilizes synthesis gas and flue gas heat to generate pure steam, with adjustable steam pressures for internal and external use, employing a plate heat exchanger and stainless steel components to enhance condensation enthalpy and reduce equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If indirect heat exchange between synthesis gas/flue gas and process condensate/boiler feed water is used for steam generation, then heat transfer efficiency is improved, but the amount of pure steam required for process steam generation increases and equipment costs increase
Solution Approach 1:
The steam generation process is segmented into two distinct paths: (1) process condensate is directly heated by flue gas to generate process steam, and (2) boiler feed water is heated by synthesis gas to generate pure steam for export. This segmentation allows each stream to be optimized independently, reducing the amount of pure steam needed for process steam generation while maintaining efficient heat transfer.
Solution Approach 2:
The patent introduces separate heat exchange pathways where flue gas directly heats process condensate, and synthesis gas directly heats boiler feed water. These direct heat exchange pathways act as intermediaries that eliminate the need for pure steam as a heat transfer medium for process steam generation, thereby reducing pure steam consumption.
2Power
If steam pressure is increased for external use, then export steam utility value is improved, but the complexity of pressure adjustment and equipment requirements increases
Solution Approach 1:
The steam distribution system is segmented into separate pressure zones: process steam is generated and distributed at process pressure, while pure steam for export is generated and distributed at export pressure. Independent pressure adjustment devices are installed on each steam line, allowing each zone to be optimized for its specific pressure requirements without affecting the other, thereby simplifying overall system complexity.
Solution Approach 2:
The patent implements dynamic pressure adjustment capabilities with independent control devices on process steam and pure steam lines. This allows the system to adaptively maintain optimal pressures for different steam uses, with each line independently regulated according to its specific requirements, simplifying the overall pressure management system.
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
The process reduces the amount of pure steam required for process steam generation, optimizing steam pressure and reducing equipment costs, while maintaining efficient heat transfer and minimizing environmental impact.
Implementation Method 1
by utilizing the heat contained in the synthesis gas and in the flue gas, a pure steam is generated from boiler feed water and a process steam is generated from process condensate
Implementation Method 2
employing a plate heat exchanger and stainless steel components to enhance condensation enthalpy
Implementation Method 3
catalytic steam reformation of a hydrocarbonaceous feed gas
Implementation Method 4
the heat of burners required for the chemical reforming reactions to take place
Data Source
AI summary
A plant for producing a synthesis gas chiefly consisting of hydrogen and carbon monoxide by catalytic steam reformation of a hydrocarbonaceous feed gas, wherein the heat of burners required for the chemical reforming reactions to take place is generated by producing a flue gas and wherein, by utilizing the heat contained in the synthesis gas and in the flue gas, a pure steam is generated from boiler feed water and a process steam is generated from process condensate, wherein for the generation of the pure steam synthesis gas and flue gas are used and for the generation of the process steam a part of the pure steam is used as heat-transfer medium and the remaining part of the pure steam is discharged from the process as export steam.