Syngas Steam Reforming with Separate Pure and Process Steam Generation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for producing synthesis gas and process steam are inefficient and contaminate pure steam with impurities from process condensate, lacking a simple and flexible method to generate pure and process steam separately.
Innovation Solution
A process and plant design that utilizes a single PC-boiler to generate pure steam from boiler feed water and process steam from process condensate, using synthesis gas and/or flue gas as heat exchange media, without direct contact, in a single step, thereby avoiding contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If process condensate is stripped with steam in a PC-stripper and mixed with BFW for steam production, then steam generation is achieved, but impurities from process condensate contaminate the pure steam
Solution Approach 1:
The patent divides the steam generation system into two separate streams: a pure steam stream generated from BFW by cooling synthesis gas, and a process steam stream generated by evaporating process condensate using the same cooling medium. This segmentation prevents contamination of pure steam while maintaining efficient steam generation for both export and process use.
Solution Approach 2:
The patent introduces synthesis gas as an intermediary cooling medium that transfers thermal energy to evaporate process condensate without direct mixing with the pure steam stream. This intermediary approach enables heat transfer while maintaining steam purity, resolving the contamination issue.
2Manufacturing precision
If separate steam streams are generated using multiple units, then steam purity is maintained, but device complexity and equipment size increase
Solution Approach 1:
The patent combines the cooling of synthesis gas and the evaporation of process condensate into a single integrated unit (PC-boiler), eliminating the need for separate PC-stripper and BFW-preheating units. This merging reduces equipment complexity while maintaining steam purity through the separate stream architecture.
Solution Approach 2:
The PC-boiler is designed as a multi-functional unit that simultaneously performs synthesis gas cooling and process condensate evaporation, replacing multiple dedicated units. This universal approach simplifies the overall steam generation system while preserving the ability to produce both pure and process steam streams.
3Productivity
If process condensate is evaporated using pure steam, then process steam is generated, but thermal efficiency is reduced due to heat exchange requirements
Solution Approach 1:
The patent employs synthesis gas, which is already cooled during the steam reforming process, as the heat exchange medium to evaporate process condensate. This self-service approach utilizes waste heat from the synthesis gas cooling process, improving overall thermal efficiency without requiring additional energy input.
Solution Approach 2:
The patent recovers thermal energy from the synthesis gas stream by using it to evaporate process condensate in the PC-boiler. This energy recovery approach transforms what would be wasted heat into a useful function, significantly improving thermal efficiency while generating process steam.
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
Achieves efficient and separate generation of pure steam suitable for export and process steam, reducing equipment size and operational costs while maintaining steam quality.
Implementation Method 1
boiler feed water is used to indirectly cool the produced synthesis gas by means of so-called BFW-preheating units. The BFW is thereby transformed into a saturated steam
Implementation Method 2
process steam stream which is generated by evaporating at least a portion of the process condensate by the cooling of synthesis gas
Implementation Method 3
evaporating the process condensate by the cooling of synthesis gas
Implementation Method 4
water is removed from the synthesis gas as a process condensate
Data Source
AI summary
Process and plant for producing a synthesis gas by catalytic steam reforming of a hydrocarbon feedstock in a steam reforming unit, wherein water is removed from the synthesis gas as a process condensate, wherein boiler feed water is introduced in the process, and wherein said process or plant produces at least two separate steam streams: a pure steam which is generated from at least a portion of said boiler feed water by the cooling of synthesis gas, and a process steam which is generated by evaporating at least a portion of the process condensate by using synthesis gas, optionally together with pure steam and/or flue gas from the steam reforming unit.