Hampa Energy Engineering &Hampa Energy Engineering ... · Convection box 27. ... Radiant Section...
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Transcript of Hampa Energy Engineering &Hampa Energy Engineering ... · Convection box 27. ... Radiant Section...
In The Name OF God
Hampa Energy Engineering &Hampa Energy Engineering &Hampa Energy Engineering & Hampa Energy Engineering & Design CompanyDesign Company
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IntroductionAmmonia plantsMethanol plantsHydrogen PlantsHydrogen PlantsOther plants
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A Brief historical ReviewGreater capacity
3300 mtpd 20 rows with a total of 960 tube
Improve efficiency
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Reformer TypesTop Fired
Side FiredSide Fired
Terraced Wall
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Design ParametersFunctionFeed
l
Heat FluxPressure Drop
FuelsType Pressure
CatalystTubes
PressureExit TemperatureInlet Temperature
BurnersFlow distributionH RInlet Temperature
Steam/Carbon Ratio
Heat Recovery
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Function
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FeedNatural gas
PropanePropane
LPG
Butane
Naphthap
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FuelsNatural gas
Distillate fuelsDistillate fuels
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Type : Top Fired The highest flue gas temperature when the intube process
gas temperature is lowestgas temperature is lowest
The lowest flue gas temperature when the intube process
i hi hgas temperature is highest
Uniform tubewall temperature over the length of the tube
Inherently stable furnace operation
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PressureThe reforming reaction equilibrium is favored by low
pressurepressure
The shift reaction equilibrium is independent of pressure
Product hydrogen pressure requirement (down stream)
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Exit TemperatureLower temperatures give insufficient conversion
Higher temperature increase metallurgical requirementsHigher temperature increase metallurgical requirements
Gas exit temperature typically runs between 800 to 900 °C
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Inlet TemperatureThe reforming reaction rate becomes significant at about 540 °C
Higher reformer inlet temperature decrease the number of tubes, g p ,
the size of the furnace and fuel
Higher reformer inlet temperature decrease the steamHigher reformer inlet temperature decrease the steam
generation from WHR
M ll i l li iMetallurgical limits
Optimum reformer inlet temperature 560 °C
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Steam/Carbon RatioSufficient steam to eliminate carbon formation
If proper catalyst is chosen 3 steam to carbon ratio isIf proper catalyst is chosen, 3 steam to carbon ratio is
applicable
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Heat FluxA low heat flux provide extra catalyst volume and lower
tubewall temperaturetubewall temperature
A high heat flux has the advantage of reducing the number
f bof tubes
20000 to 28000 Btu/hr-ft2
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Pressure DropLegnth of tubes
Tube diameterTube diameter
Catalyst selection
Approximately 3 Bar
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CatalystReaction conversion
Nickel-alkaliNickel-alkali
shape
Catalyst pressure drop
Shapep
Key aspect of catalyst : formulation & shape
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TubesTemperature condition : 850 to 920°CInside tube diameter : 4 to 5 in
Better heat transfer and cooler walls for lower IDBetter heat transfer and cooler walls for lower IDHigher pressure drop for lower IDMore required tubes for lower ID
T b l th tTube length : 12 to 13 mLonger tube reduces the flue gas exit temperatureLonger tube increases pressure drop Longer tube decreases required tube
Tube pitch : 2 to 3 tube diameterLane spacing : 1.8 to 2.4 mLane spacing : 1.8 to 2.4 m
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BurnersUniform heat release
One burner for every 2 5 to 3 5 tubes is a good designOne burner for every 2.5 to 3.5 tubes is a good design
practice
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Flow distributionSymmetrical piping design
Detailed pressure drop calculationDetailed pressure drop calculation
Properly designed flue gas tunnel
Properly fan design
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Heat RecoveryInlet temperature of flue gas approximately 900°C
Reformer mixed feed preheater steam superheater steamReformer mixed feed preheater, steam superheater, steam
generation, boiler feedwater heater, feed heater,
b i i hcombustion air preheater
Exit temperature of flue gas approximately 200 °C
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Overall view
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Forced fan
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Air Preheater
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Air ducts
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Fuel
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Radiant box
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Convection box
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Heat recovery
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Induced fan and stack
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Feed
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Catalyst tubes
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Tube supports
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Radiant SectionConsiderations
Variation of heat demand from inlet to outletUniformity of heat distribution along the length of the furnaceUniformity of heat distribution along the length of the furnaceUniformity of circumferential heat flux Flow distribution in reactors for lowest turn downA d iti l h t fl i th f fi bAverage and critical heat flux in the reformer firebox
CFD modeling
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Casing Design
Design Temp 80 °C
Designed for deflection to minimize refractory damage
N d b i i h iNeeds to be an air tight construction
Resistant to wind loads and other imposed loads
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Reformer TubesCreep
Bending stress
Thermal cycles
El iElongation
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Reformer TubesTube material
Tube Strength
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Catalyst DevelopmentControl tube wall temperature
Achieved the required conversionAchieved the required conversion
Have a low and stable pressure drop
Avoid carbon formation
Operation over a larger feed compositionp g p
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Catalyst shapeActivity
Heat Transfer CoefficientHeat Transfer Coefficient
Pressure Drop
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RefractoryCeramic fiber
ModuleBl kBlanket
CastBrickBrick
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Transfer lineDesign ConditionsProblems
E iErosionPipe failureCondensationCondensation
RefractoryDesignDesignAnchoring
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Sample Reformer Process Requirements:
(2050 TPD AMMONIA PRIMARY(2050 TPD AMMONIA PRIMARY REFORMER)
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Process Gas174 ton/h520 °C39 Bar
Super Heated SteamSuper Heated Steam353 ton/h510 °C5117 Bar
Process Air Heater/h105 ton/h
540 °C37 Bar37 Bar
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HEDCO Specifications For :Specifications For :
2050 TPD AMMONIAPRIMARY REFORMER
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C l T bCatalyst Tubes48 tube @ 7 rowID 114 3ID = 114.3Effective Tube Length : 12.5 mInlet Temperature : 520Inlet Temperature : 520Outlet Temperature : 800Design Temperature : 920Max Wall Thickness : 890Thickness : 12 mmDesign Pressure : 41 BarMax Pressure Drop : 3 BarR S iRow Spacing : 2.1 m
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Catalyst Tubes
capacitytotal
tubes rowtubes in
row riser ID Thk Eff Lengthcapacity tubes row row riser ID Thk Eff LengthKellogg-Ghadir 187 336 6 56 6 110 12 11.8
Linde-LindeRazi 132 235 5 47 102.2 7.9 10.9
Linde-Lordegan 174 336 7 48 114.3 12 12.5
KTI-Shiraz 174 320 8 40 114.3 10.2 12.6HEDCO D i 174 336 8 42 114 3 12 12 5Design 174 336 8 42 114.3 12 12.5
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Tube Wall Temperature
it I TOut
TDes
TMax
TID f capacity InTemp Temp Temp Temp surface
Kellogg-Ghadir 187 620 812 924 889 1370
Linde Razi 132 620 775 845 817 822 4Linde-Razi 132 620 775 845 817 822.4
Linde-Lordegan 174 520 800 920 824 1507
KTI-Shiraz 174 520 800 914 889 1447 8KTI-Shiraz 174 520 800 914 889 1447.8
HEDCO Design 174 520 800 920 889 1507.4
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BurnersArch Burners
Inner burners Number : 12 @ 7 row = 84Inner burners Duty = 2 MVO t B N b @Outer Burners Number: 12 @ 2 row = 24 Outer Burners Duty = 1.73
Tunnel BurnersTunnel BurnersTunnel Burners Number = 8 @ 1 rowTunnel Burners Duty = 0.53 MWy 53
Auxiliary BurnersAuxiliary Burners Number : 10 @ 5 rowAuxiliary Burners Duty = 4.26 MW
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Burners
capacity Arch burner Auxiliary Tunnel N D t N D t N D t No Duty No Duty No Duty
Kellogg-Ghadir 187 80/32 1.8/1.17 19 1.44 7 0.63
132 60/30 1 42/85 6 2 05Linde-Razi 132 60/30 1.42./85 6 2.05 Linde-Lordegan 174 72/24 2.3/1.38 6 7.8
KTI-Shiraz 174 84/24 16 9 HEDCO Design 174 84/24 2/1.38 10 4.25 8 0.53
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Thank YouThank You
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