03 Secondary Reforming

2011 S nthe nt hesi sis s Ga Gas Se Semina mi narr – Mar arita ri ta Second co nda ary Reform fo rme er  November 2–4, 2011

Typical NH3 Process Flowsheet Steam

Air

 

HC Feed

H TS

P u r if ic ati on

P r e R efo r m er

Primary Reformer 

S eco n d ar y R efo r m er  

C O2

Reforming

 A m m o n ia

H T CO S h if t

L T C O Sh i ft

C O 2 Rem o v al

Met han ati o n

NH3 Synthesis Loop

Overview

•Chemistry a a ys an

oa ng

• •Common Problems/Troubleshootin

Chemistry

Secondary Reforming: Chemistry 1) Allows introduction of N2 (via Air) required to make NH3 2) Combustion of O2 generates heat which results in additional reforming resu ng n re uce purg ng rom e yn oop

Combustion 4

2

2

H2 + 0.5O2

2

H2O + HEAT

Reforming CH4 + H2O + HEAT

CO+ 3H2

Water Gas Shift +

2

2+

2+

Secondary Reforming: Loading Diagram Reactor Diagram

Inlet Gas Entrance Zone  TARGET BRICK 

Combustion Zone ReforMax

Gas Phase Reactor Zone

ReforMax

Secondary Reforming Catalysts

•Typical Loading ¾  Approximately

top 1 foot of  catalyst; ~10% - ReforMax 400GG

¾

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

High Geometric Surface Area Catalyst

•High GSA of our 19 x 16 mm LDP shape ¾ Allows



Lower Catalyst Volume

Increasing the Combustion Zone Volume

ReforMax ® 410 LDP

Loading Process

an ar xe e oa ng u z ng a hopper feed system and a flexible sock

• Key Notes: ¾ Maintain good catalyst flow

evenly

Operating Considerations

e ane ea age s pr mary n ca on o performance (typically 0.20-0.50 mole%) 

 Air/Gas Ratio = Exit Temperature



Inlet Methane from Primary



Poor burner mixing / Channeling



Catalyst Activity

• Catalyst replacement is usually due to: ¾

Pressure drop build-up from fusion / erosion

Common Problems

• Volume , High ATE, High Pressure Drop

¾

Results in High Wall ,

• Burner Problems ¾

Results in Poor Combustion, Poor Flow Distribution, High

Questions?