PARTIAL OXIDATION REFORMER-REFORMING EXCHANGER ARRANGEMENT FOR HYDROGEN PRODUCTION

• US 20040177555A1
• Filed: 03/15/2004
• Published: 09/16/2004
• Est. Priority Date: 03/16/2003
• Status: Active Grant

• Current Assignee: Kellogg Brown & Root LLC (KBR Incorporated)
• Original Assignee: Kellogg Brown & Root LLC (KBR Incorporated)
• Inventors: Knez, Stanislaus A., Van Sickels, Martin J., Malhotra, Avinash, Mann, David P.
• Granted Patent: US 7,138,001 B2
• Time in Patent Office: Days
• US Class Current: 48/198.3
• CPC Class Codes: B01J 2208/00309 with two or more reactions in heat exchange with each other, such as an endothermic reaction in heat exchange with an exothermic reaction
• CPC Class Codes: B01J 2208/0053 Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
• CPC Class Codes: B01J 2219/00024 Revamping, retrofitting or modernisation of existing plants
• CPC Class Codes: B01J 8/067 Heating or cooling the reactor B01J8/062 takes precedence
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/025 containing a partial oxidation step
• CPC Class Codes: C01B 2203/0283 containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/0475 the impurity being carbon dioxide
• CPC Class Codes: C01B 2203/0844 the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 2203/141 At least two reforming, decomposition or partial oxidation steps in parallel
• CPC Class Codes: C01B 2203/142 At least two reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 3/36 using oxygen or mixtures containing oxygen as gasifying agents
• CPC Class Codes: C01B 3/382 Multi-step processes
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: C01B 3/48 followed by reaction of water vapour with carbon monoxide
• CPC Class Codes: Y02P 20/10 Process efficiency

Abstract

Low-energy hydrogen production is disclosed. A reforming exchanger is placed in parallel with a partial oxidation reactor in a new hydrogen plant with improved efficiency and reduced steam export, or in an existing hydrogen plant where the hydrogen capacity can be increased by as much as 20-30 percent with reduced export of steam from the hydrogen plant.

Claims

1. A process for preparing syngas, comprising:

partially oxidizing a first hydrocarbon portion with oxygen in a partial oxidation reactor to produce a first reactor effluent;

cooling the first reactor effluent to a temperature from 650° and

1000°

C.;

supplying the first reactor effluent to a reforming exchanger;

passing a second hydrocarbon portion with steam through a catalyst zone in the reforming exchanger to form a second reactor effluent;

discharging the second reactor effluent from the catalyst zone to form an admixture with the first reactor effluent;

passing the admixture across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone;

collecting the cooled admixture from the reforming exchanger.

2. The process of claim 1, wherein water is introduced into the first reactor effluent as a quench fluid.

3. The process of claim 2, wherein the cooling further comprises indirect heat exchange.

4. The process of claim 3, wherein the indirect heat exchange comprises heating the second hydrocarbon portion in a cross exchange.

5. The process of claim 1, wherein the cooling comprises heat exchange.

6. The process of claim 5, wherein the indirect heat exchange comprises heating the second hydrocarbon portion in a cross exchanger.

7. The process of claim 1, wherein the catalyst zone comprises catalyst tubes.

8. The process of claim 5, wherein the second hydrocarbon portion is supplied to a tube side of the reforming exchanger and passed through the catalyst tubes.

9. The process of claim 5, wherein the cooled first reactor effluent is supplied to a shell side inlet of the reforming exchanger.

10. The process of claim 7, wherein the shell side inlet is adjacent an outlet end of the catalyst tubes.

11. The process of claim 1 wherein the first and second hydrocarbon portions are supplied in a weight ratio of from 40:

60 to 95;

5.

12. The process of claim 1, wherein the first and second hydrocarbon portions are supplied in a weight ratio of from 40:

60 to 60;

40.

13. The process of claim 1, wherein the first and second hydrocarbon portions are supplied in a weight ratio of from 95:

5 to 80;

20.

17. The method of claim 11, wherein the first reactor effluent is cooled by indirect heat exchange.

18. The method of claim 17, wherein the second hydrocarbon portion is heated by indirect heat exchange before being supplied to the reforming exchanger.

19. The method of claim 17 wherein water is introduced into the first reactor effluent.

20. The method of claim 11, wherein the catalyst zone further comprises catalyst tubes.

21. The method of claim 18, wherein the second hydrocarbon portion is introduced to a tube side inlet of the reforming exchanger.

14. An apparatus for producing syngas, comprising:

partial oxidation reactor means for partially oxidizing a first hydrocarbon portion with oxygen to produce a first reactor effluent;

means for cooling the first reactor effluent to a temperature from 650°

to 1000°

C.;

means for supplying the first reactor effluent to a reforming exchanger;

means for passing a second hydrocarbon portion with steam through a catalyst zone in the reforming exchanger to form a second reactor effluent;

means for discharging the second reactor effluent from the catalyst zone to form an admixture with the first reactor effluent;

means for passing the admixture across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone;

means for collecting the cooled admixture from the reforming exchanger.

15. A method for retrofitting a syngas process comprising a partial oxidation reaction step for converting a first hydrocarbon stream to a first reactor effluent, a heat recovery step for cooling the first reactor effluent and producing steam with the recovered heat, and a downstream processing step for receiving the cooled reactor effluent and producing a product syngas of enhanced hydrogen content, comprising:

a step for cooling the first reactor effluent to a temperature from 650°

to 1000°

C.;

a step for diverting the cooled first reactor effluent to a reforming exchanger;

a step for passing a second hydrocarbon portion with steam through a catalyst zone in the reforming exchanger to form a second reactor effluent;

a step for discharging the second reactor effluent from the catalyst zone to form an admixture with the first reactor effluent;

a step for passing the admixture across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone;

a step for supplying the cooled admixture from the reforming exchanger to the heat recovery step.

a step for cooling the first reactor effluent to a temperature from 650°

to 1000°

C.;

16. The method of claim 15, wherein water is introduced into the first reactor effluent as a quench fluid.