Gas Heated Reforming - An Overview
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The document discusses the evolution and design improvements of a gas heated reformer (GHR) system, highlighting the transition from a complex original design to a simplified new design (AGHR) introduced by BHPP in 1998. Key components such as various tube elements and their fabrication challenges are detailed, emphasizing high tolerance and careful handling requirements. Additionally, the text outlines operational issues related to reliability and start-up processes in steam systems.
Gas Heated Reforming - An Overview
- 1. By Gerard B. Hawkins Managing Director, CEO
- 2. Oxidant Steam Steam Natural Gas Air Secondary Steam MP Steam 800°C 1000°C 500°C
- 3. Fired-box reformer ◦ Intrinsically unreliable, relies on reaction in tubes to prevent damage ◦ Relatively labour intensive ◦ Start-up / shut-down are high risk Big steam system ◦ slow to start up ◦ another major source of unreliability Limitations on capacity
- 9. Plant Location Started up Terra LCA#1 UK 1988 Terra LCA#2 UK 1988 Coogee Energy MRP Australia 1994 Mississippi Chems LCA#1 USA 1998
- 10. The original GHR was a complex device to fabricate. Desire to simplify the design: ◦ eliminate the bayonet tubes ◦ simplify the upper (triple) tubesheet In 1998, BHPP replaced the original GHR with the new AGHR.
- 11. The AGHR
- 14. • Part of major component combined with the sheath tubeplate • Low alloy plate P4 group materials • Machined Fabrication • Weight 28 tonnes
- 15. Part of major component combined with catalyst tubeplate sub-assembly Low alloy plate P4 group materials Machined Fabrication Weight 17 tonnes
- 16. Major element of the AGHR Large Fabrication, critical machined features Support platform for the bundle Key item with two tiers of close tolerance tube hole arrays. Weight 45 tonnes
- 17. Fabricated tube component with laser welded fins. High tolerance required, needs to fit precisely with corresponding components Relatively flimsy assembly careful handling required
- 18. Fabricated tube component High tolerance required on outside & inside diameters to achieve fit with corresponding components
- 21. Large plate fabrication. Grillage aperture centres to be in line with tube array. High level of accuracy required
- 24. TCC Purge Fuel Comp. MUG Circ. Recycle H2 Distillation Reboilers To Topping Column Flash Gas Saturator Water Heater
- 25. 0 2 4 6 8 10 12 14 16 210 220 230 240 250 260 270 Exit Temperature (°C) %MeOHexitConverter
- 26. 0 1 2 3 4 5 6 7 8 4 5 6 7 8 9 10 11 12 13 % MeOH exit Converter RecycleRatio
- 27. 0 20 40 60 80 100 120 140 160 4 6 8 10 12 14 % MeOH exit Converter CatalystVolume(m3/ktpd)
- 28. TCC Purge Fuel Comp. MUG Circ. Recycle H2 Distillation Reboilers To Topping Column Flash Gas Saturator Water Heater
- 29. TCC WCR Purge Fuel Comp. MUG Circ. Recycle H2 To Topping Column Flash Gas Distillation Reboilers
- 30. MUG Compressor Circulator Interchanger In Circ Recycle BFW Heater Compressed MUG Purge Gas ex WCC Membrane R202 R201 In Conv Saturator Water Process Condy Water to Saturator H2Permeate Natural Gas RCRB RC Feed Vaporizer TCRB E3 R102 R103 R101 C101 B101 B102 ToB101 ToC101 ToR101 Gas to E3 Ex AGHR Shell Sat Gas ex E3 To AGHR Tubes Gas ex ATR Gas to ATR Oxygen to ATR Gas To HT Sat Wat Heater HP Waste Gas Water to WCC Make-up Water MUGtoComp Crude MeOH