Partial oxidation reformer-reforming exchanger arrangement for hydrogen production

• US 20080047197A1
• Filed: 09/22/2006
• Published: 02/28/2008
• Est. Priority Date: 03/16/2003
• Status: Abandoned Application

• Current Assignee: Kellogg Brown & Root LLC (KBR Incorporated)
• Original Assignee: Kellogg Brown & Root LLC (KBR Incorporated)
• Inventors: Knez, Stanislaus A.
• Application Number:
  US11/526,152
• Publication Number:
  US 20080047197A1
• 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

A method for retrofitting a syngas process entails converting a first hydrocarbon stream to a first reactor effluent through partial oxidation; cooling the first reactor effluent and producing steam with recovered heat; and receiving the cooled reactor effluent and producing a product syngas of enhanced hydrogen content. The downstream processing entails cooling the first reactor effluent to a temperature from about 650 to about 1000 degrees C. The first reactor effluent is diverted to a reforming exchanger. A second hydrocarbon portion with steam is passed through a catalyst zone in the reforming exchanger forming a second reactor effluent. The second reactor effluent is discharged from the catalyst zone forming an admixture with the first reactor effluent. The admixture is passed across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone. The cooled admixture is supplied back to the reforming exchanger.

Claims

1. ) A method for retrofitting a syngas process comprising

a partial oxidation reaction step for converting a first hydrocarbon stream to a first reactor effluent through partial oxidation;

a heat recovery step for cooling the first reactor effluent and producing steam with recovered heat; and

a downstream processing step for receiving the cooled reactor effluent and producing a product syngas of enhanced hydrogen content, wherein the downstream processing step comprises;

cooling the first reactor effluent to a temperature from about 650 degrees C. to about 1000 degrees C.;

diverting 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;

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

2. ) The method of claim 1, further comprising introducing water into the first reactor effluent as a quench fluid.

3. ) The method of claim 1, further comprising cooling the first reactor effluent by indirect heat exchange.

4. ) The method of claim 1, further comprising heating the second hydrocarbon portion by indirect heat exchange before supplying the second hydrocarbon portion to the reforming exchanger.

5. ) The method of claim 1, further comprising introducing the second hydrocarbon portion to a tube side inlet of the reforming exchanger.

6. ) The method of claim 1, further comprising supplying the first reactor effluent to a shell side inlet of the reforming exchanger.

7. ) The method of claim 6, wherein the shell side inlet is adjacent an outlet end of the catalyst tubes.

8. ) The method of claim 1, wherein the catalyst zone comprises catalyst tubes.

9. ) The method of claim 1, wherein the indirect heat exchange comprises heating the second hydrocarbon portion in a cross exchange.

10. ) The method of claim 1 further comprising supplying the first and second hydrocarbon portions in a weight ratio of ranging from about 40:

60 to about 95;

5.

11. ) The method of claim 1, further comprising supplying the first and second hydrocarbon portions in a weight ratio of ranging from about 40:

60 to about 60;

40.

12. ) The method of claim 1, further comprising supplying the first and second hydrocarbon portions in a weight ratio of ranging from about 95:

5 to about 80;

20.

13. ) A method for retrofitting a syngas process comprising

cooling the first reactor effluent to a temperature from about 650 degrees C. to about 1000 degrees C.;

diverting 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; and

supplying the cooled admixture from the reforming exchanger for cooling the first reactor effluent and producing steam with recovered heat.