Low pressure drop reforming exchanger
First Claim
1. A syngas production process, comprising:
- passing a first portion of a hydrocarbon feed mixed with steam and oxidant through an autothermal catalytic steam reforming zone to form a first reformed gas of reduced hydrocarbon content;
passing a second portion of the hydrocarbon feed mixed with steam through an endothermic catalytic steam reforming zone to form a second reformed gas of reduced hydrocarbon content;
mixing the first and second reformed gases and passing the resulting gas mixture through a heat exchange zone for cooling the gas mixture and supplying heat to the endothermic catalytic steam reforming zone;
wherein the endothermic catalytic steam reforming zone and the heat exchange zone are respectively disposed tube side and shell side within a shell-and-tube reforming exchanger comprising a plurality of tubes packed with catalyst-bearing monolithic structures, the tubes having an inside diameter that is not more than 4 times a maximum edge dimension of the catalyst structures; and
recovering syngas comprising the cooled gas mixture.
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Accused Products
Abstract
Syngas production process and reforming exchanger. The process involves passing a first portion of hydrocarbon feed mixed with steam and oxidant through an autothermal catalytic steam reforming zone to form a first reformed gas of reduced hydrocarbon content, passing a second portion of the hydrocarbon feed mixed with steam through an endothermic catalytic steam reforming zone to form a second reformed gas of reduced hydrocarbon content, and mixing the first and second reformed gases and passing the resulting gas mixture through a heat exchange zone for cooling the gas mixture and thereby supplying heat to the endothermic catalytic steam reforming zone. The endothermic catalytic steam reforming zone and the heat exchange zone are respectively disposed tube side and shell side within a shell-and-tube reforming exchanger. The reforming exchanger comprises a plurality of tubes packed with low pressure drop catalyst-bearing monolithic structures wherein an inside diameter of the tubes is less than 4 times a maximum edge dimension of the catalyst structures.
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Citations
33 Claims
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1. A syngas production process, comprising:
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passing a first portion of a hydrocarbon feed mixed with steam and oxidant through an autothermal catalytic steam reforming zone to form a first reformed gas of reduced hydrocarbon content;
passing a second portion of the hydrocarbon feed mixed with steam through an endothermic catalytic steam reforming zone to form a second reformed gas of reduced hydrocarbon content;
mixing the first and second reformed gases and passing the resulting gas mixture through a heat exchange zone for cooling the gas mixture and supplying heat to the endothermic catalytic steam reforming zone;
wherein the endothermic catalytic steam reforming zone and the heat exchange zone are respectively disposed tube side and shell side within a shell-and-tube reforming exchanger comprising a plurality of tubes packed with catalyst-bearing monolithic structures, the tubes having an inside diameter that is not more than 4 times a maximum edge dimension of the catalyst structures; and
recovering syngas comprising the cooled gas mixture. - View Dependent Claims (4, 7, 10, 11, 16, 17, 22, 23, 24, 31)
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2. Apparatus for reforming a hydrocarbon to produce syngas, comprising:
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means for passing a first portion of a hydrocarbon feed mixed with steam and oxidant through an autothermal catalytic steam reforming zone to form a first reformed gas of reduced hydrocarbon content;
means for passing a second portion of the hydrocarbon feed mixed with steam through an endothermic catalytic steam reforming zone to form a second reformed gas of reduced hydrocarbon content;
means for mixing the first and second reformed gases and passing the resulting gas mixture through a heat exchange zone for cooling the gas mixture and supplying heat to the endothermic catalytic steam reforming zone;
wherein the endothermic catalytic steam reforming zone and the heat exchange zone are respectively disposed tube side and shell side within a shell-and-tube reforming exchanger comprising a plurality of tubes packed with catalyst-bearing monolithic structures, the tubes having an inside diameter that is not more than 4 times a maximum edge dimension of the catalyst structures; and
means for recovering syngas comprising the cooled gas mixture. - View Dependent Claims (5, 8, 12, 13, 18, 19, 25, 26, 27, 32)
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3. A syngas reforming exchanger, comprising:
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an elongated shell having relatively high and low temperature ends;
a shell side fluid inlet adjacent the high temperature end for receiving a hot gas feed;
a tube side fluid inlet adjacent the low temperature end for receiving a feed mixture of hydrocarbon and steam;
a shell side fluid outlet fluidly isolated from the tube side fluid inlet by a tube sheet adjacent the low temperature end for discharging cooled gas;
a tube bundle comprising a plurality of tubes and one or more longitudinally-spaced transverse baffle plates, wherein the tubes have an inlet end secured to the tube sheet for receiving the feed mixture and an outlet end adjacent the shell side fluid inlet for discharging reformed gas into the hot gas feed;
catalyst-bearing monolithic structures disposed within the tubes for converting the gas feed mixture to reformed gas, wherein the tubes have an inside diameter that is not more than 4 times a maximum edge dimension of the catalyst structures. - View Dependent Claims (6, 9, 14, 15, 20, 21, 28, 29, 30, 33)
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Specification