Production of synthesis gas using convective reforming

• US 4,824,658 A
• Filed: 12/19/1986
• Issued: 04/25/1989
• Est. Priority Date: 06/27/1985
• Status: Expired due to Term

• Current Assignee: Stone & Webster Process Technology, Inc. (Technip Energies NV)
• Original Assignee: Stone & Webster Engineering Corporation
• Inventors: Karafian, Maxim, Tsang, Irving C.
• Primary Examiner(s): KRATZ, PETER F
• Application Number:
  US06/944,327
• Time in Patent Office: 858 Days
• Field of Search: 422/190, 422/196, 422/197, 422/198, 422/203, 422/204, 48/196 A, 48/214 A, 423/651, 423/652, 252/373
• US Class Current: 423/652
• CPC Class Codes: B01J 2208/00212 Plates; Jackets; Cylinders
• CPC Class Codes: B01J 2208/00221 comprising baffles for guiding the flow of the heat exchange medium
• CPC Class Codes: B01J 2219/00777 horizontal
• CPC Class Codes: B01J 8/062 being installed in a furnace
• CPC Class Codes: B01J 8/067 Heating or cooling the reactor B01J8/062 takes precedence
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/0816 Heating by flames
• CPC Class Codes: C01B 2203/0822 the fuel containing hydrogen
• CPC Class Codes: C01B 2203/0827 at least part of the fuel being a recycle stream
• 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 2203/0866 by combination of different heating methods
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: C01B 3/386 Catalytic partial combustion
• CPC Class Codes: Y02E 60/32 Hydrogen storage
• CPC Class Codes: Y02P 20/10 Process efficiency
• CPC Class Codes: Y02P 20/129 Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines

Abstract

A convective reformer device is provided which is useful for partially reforming a feed mixture of hydrocarbons and steam. The device includes an outer shell enclosure and a tubular inner core assembly and is specifically adapted to support heat exchange between a heating fluid, which may be an effluent from downstream, and the hydrocarbon-steam feed mixture. The convective reformer is used in a system and process for the steam reformation of hydrocarbons, in which the partially reformed effluent from the convective reformer is further reformed in a steam reforming furnace, or an auto-thermal reformer, or a steam reforming furnance followed by an auto-thermal reformer. The fully reformed effluent from the steam reformer, or auto-thermal reformer, is directed back to the convective reformer to supply the heat of reaction for the partial reformation of the feed mixture. This heating fluid may be directed through the tube portion of the convective reformer, or alternatively, through the shell portion, either of which may be filled with catalyst. The gas that emerges from the convective reformer, which has undergone heat exchange with the feed mixture may be used to preheat the feed mixture to the convective reformer.

Claims

1. A process for the convective reformation of a mixture of hydrocarbons and steam into a hydrogen-rich gas, comprising the steps of

(a) delivering substantially all of a feed mixture of hydrocarbons and steam to a first reformation zohe which comprises convective reformation means;

(b) partially reforming the feed mixture in the first reformation zone at a temperature sufficient to reform from about 15% to about 25% of the hydrocarbon in the feed mixture;

(c) delivering the partially reformed effluent from the first reformaton zone to one or more additional reformation zones;

(d) completely reforming the partially reformed effluent into a hydrogen-rich gas in the additional reformation zones;

(e) directing at least a portion of the hydrogen-rich gas from step (d) back to the first reformation zone of step (a);

(f) effecting heat-exchange between the hydrogen-rich gas from step (e) and the feed mixture of hydrocarbons and steam in the first reformation zone, the hydrogen-rich gas being initially at a higher temperature than the feed mixture, such that the heat of reaction for the partial reformation is thus supplied from this exchange; and

(g) passing at least a portion of the heat-exchanged hydrogen-rich gas from step (f) to one or more additional heat-exchange zones located upstream of the first reformation zone of (a) for use as a heating fluid therein.

2. A process according to claim 1, in which in step (g) the hydrogen-rich gas is used as a heat-exchange medium for the generation of high pressure process steam for the process.

3. A process according to claim 1, in which in step (g) the hydrogen-rich gas is used as a heat-exchange medium for the preheating of the feed mixture to step (a).

4. A process according to claim 1, in which the partial reformation reaction in step (a) is conducted at a temperature of about 1150°

to about 1250°

F.

5. A process according to claim 1, in which the feed mixture is characterized by a steam to carbon ratio from 3:

1 to 4.5;

1.