Heat exchange reforming as intergratedpart of a new plant and as revamp option

Henrik Olsson

Agenda

� Introduction to heat exchange reforming

� Flue gas heated reformers - HTCR– HTCR Revamp options

� Process gas heated reformers - HTER– HTER Revamp options

– New plants with HTER

� Conclusions, Q&A

Introduction

� Heat exchange reforming

– Compact

– Highly efficient

– Reduction of fuel consumption

– Export steam reduction

– Operating cost savings

– � 30% capacity revamp option

Idea of heat exchange reforming

� Utilise heat from process gas heat d/s reforming section for reforming instead of steam production

� The main challenge in heat exchange reformer has been to overcome metal dusting

Metal temperature vs. attack

0

20

40

60

Atta

ck, %

500 600 700 800Temperature, °C

Flue gas heated reformers - HTCR(Haldor Topsøe Convection Reformer)

Flue gas heated reformers - HTCRFlue gas outlet (600 °C)

Flue gas inlet (1200 °C)

Flue gas entering the flue gas annulus

Process gas outlet (600 °C)

Process gas inlet (450 °C)

Flue gas tube

Flue gas annulus

Reformer tube

Catalyst bed

Center tube

Revamp options - HTCR

Revamp options - HTCR

� The HTCR revamp option

– Optimal reuse of existing unit

– Minimum down time and interferencewith existing unit

– Improved plant efficiency

– Flexible and trouble free capacityadjustment

– Compact

Process gas heated reformers - HTER(Haldor Topsøe Exchange Reformer)

Feed gas

Product gas

SMR effluent

Process gas heated reformers - HTER

Catalystbed 2

outside tubes

Heating/cooling gas

Outer tubeInner tube

Catalystbed 1

inside tubes

Feed gas

Revamp options - HTER

Fuel

Feed

Processsteam

Pre-reformer

Tubularreformer

HTER

Revamp options - HTER

-21%30,00038,000Steam export, kg/h

0 %4444SMR duty, Gcal/h

21%2530021,000NG consumption, Nm3/h

25%62,50050,000H2 production, Nm3/h

Relativechange

Afterrevamp

Beforerevamp

Revamp options - HTER

� The HTER revamp option– �30% capacity increase

– Improved plant efficiency

– Reduction of steam export

– Compact plot area

– Easy to operate

New plants with HTER

� SMR + HTER– Complete integration of technologies

– Easy to operate and maintain

– Decreased fuel and power consumption

– Reduction of steam export

– Competitive capital investment

– Operating cost reduction

New plants with HTER

211.11214.62Total annual operating cost, M USD/yr*

100100Capital investment, index

-12.70-20.95Steam credit, M USD/yr

2.242.56Electric power, M USD/yr

8.8921.59Cost of fuel, M USD/yr

212.68211.42Cost of feed, M USD/yr

860900CO2 emissions kg/ 1,000 Nm3

1416Power consumption kW/1,000 Nm3 H2

0.400.66Steam export, Gcal/1,000 Nm3

0.140.34Fuel, Gcal/ 1,000Nm3 H2

3.353.33Feed, Gcal/ 1,000 Nm3 H2

HTER + SMRTraditional SMRCase

*Based on a NG prize of 10 USD/MBtu, a steam price of 16 USD/tonn and an electric power price of 0.1 USD/kWh

Heat exchange reforming references� >40 references for heat exchange reformers

On-going projects with HTER:

� 7 HTERs for synthesis gas to synfuel plants,South Africa

� 2 HTERs for hydrogen plants of 206,000 Nm3/h,KNPC Kuwait

� 3 HTERs for hydrogen plants of 130,000 Nm3/h,Essar Oil Vadinar

� HTER for 25% capacity revamp of 50,000 Nm3/h, Numaligarh Refinery

Conclusions� HTER as revamp option

– �30% capacity increase– Compact and easy to operate– Optimal reuse of existing unit– Improved plant efficiency, lower feed + fuel consumption

� HTER in new hydrogen unit– Easy to operate and maintain– Reduced fuel and power consumption– Reduction/elimination of export steam– Competitive capital investment– Operating cost reduction

� >40 Heat exchange reforming references