2011 Synthesis y Gas Seminar Margarita g Secondary Reformer

November 24, 2011

Syngas Seminar | Margarita | Nov 2-4, 2011

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Typical NH3 Process Flowsheet

Steam HC Fe ed Air

H TS

P u rification

P re R efo rm er

P rim ar y Ref or m er

S eco n d ary R efo rm er

C O2

R ef o rm in g

A mm on ia

H T CO S h if t

L T C O Sh ift

C O 2 Rem o val

M ethan atio n

N H 3 Syn th esis Lo o p

Syngas Seminar | Margarita | Nov 2-4, 2011

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Overview

Chemistry Catalyst C t l t and d Loading L di Operation Common Problems/Troubleshooting g

Syngas Seminar | Margarita | Nov 2-4, 2011

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Secondary Reforming: Chemistry

Secondary Reformer Serves Two purposes: 1) Allows introduction of N2 (via Air) required to make NH3 2) Combustion of O2 generates heat which results in additional reforming resulting lti in i reduced d d purging i f from th the S Syn l loop

Chemistry

Combustion
CH4 +2O2 CO2 + 2H2O + HEAT H2 + 0.5O2 H2O + HEAT

Reforming
CH4 + H2O + HEAT CO+ 3H2

Water Gas Shift

CO H2O CO2+ H2 + HEAT CO+
Syngas Seminar | Margarita | Nov 2-4, 2011 Page 4

Secondary Reforming: Loading Diagram Reactor Diagram

Inlet Gas Entrance Zone TARGET BRICK

Combustion Zone ReforMax 400 GG Gas Phase Reactor Zone

ReforMax 410 LDP

Syngas Seminar | Margarita | Nov 2-4, 2011

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Secondary Reforming Catalysts

Typical Loading
Approximately top 1 foot of catalyst; ~10% - ReforMax 400GG 33 x 18 mm 6-Hole Ring

Bottom 90% - ReforMax 410 LDP 19 x 16 mm 10-Hole Ring

Syngas Seminar | Margarita | Nov 2-4, 2011

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High Geometric Surface Area Catalyst

High GSA of our 19 x 16 mm LDP shape

Provides Higher Activity Allows Lower Catalyst Volume
Lowering DP and Increasing the Combustion Zone Volume

Achieves long lives!

ReforMax 410 LDP

Syngas Seminar | Margarita | Nov 2-4, 2011 Page 7

Loading Process

Standard St d d fi fixed db bed dl loading di utilizing tili i a hopper feed system and a flexible sock Key Notes:

Minimize catalyst free fall Maintain good catalyst flow distribution and spread catalyst evenly Verify outages

Syngas Seminar | Margarita | Nov 2-4, 2011

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Operating Considerations

Methane Leakage is primary indication of

performance (typically 0.20-0.50 mole%)
It can be affected by:
Air/Gas Ratio = Exit Temperature Inlet Methane from Primary Poor burner mixing / Channeling Catalyst Activity

Catalyst replacement is usually due to:

Pressure drop build-up from fusion / erosion Age / need for vessel inspection
Syngas Seminar | Margarita | Nov 2-4, 2011 Page 9

Common Problems

Insufficient Combustion Zone

Volume
Results in Catalyst Fusing Fusing, High ATE, High Pressure Drop

Refractory Wall Bypassing

Results in High Wall Temperatures High ATE Temperatures,

Burner Problems
Results in Poor Combustion, Poor Flow Distribution, High ATE
Syngas Seminar | Margarita | Nov 2-4, 2011 Page 10

Questions?

Syngas Seminar | Margarita | Nov 2-4, 2011

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