SELAS-LINDE GmbH The Furnace Company Furnace Technology Meet Steam Reformers Tuesday, 23 April 2013 Mumbai Thursday, 25 April 2013 New Delhi
Linde Reformer Technology
— General — Process Design — Mechanical Design — Control and Safety Philosophy — References — Competing Reformer Technologies
Linde Reformer Technology
Gas Generation by Steam Reforming is applied for the production of — Hydrogen — Carbon Monoxide — Synthesis Gas — Reducing Gas — Ammonia — Methanol — Hydrocarbons
Reformer Design Application - Fundamental Reforming Chemistry Basic Chemistry: nCO + (n+m/2) H 2
endothermic
CH4 + H2O
CO + 3 H 2
endothermic
CO + H2O
CO2 + H2
exothermic
CnHm + mH2O
Overall endothermic
Internal Heat Supply by partial combustion of feedstock
External Heat Supply
Linde Reformer Technology Tubular Reformer Types
Top-Fired Reformer
Side-Fired Reformer
Terraced-Wall Reformer
Bottom-Fired Reformer
Linde Reformer Technology
— General — Process Design — Mechanical Design — Control and Safety Philosophy — References — Competing Reformer Technologies
Linde Reformer Technology
Owner Design Criteria
Unit Cost of Feed/Fuel/Power
Export Steam Flow Rate
Desired Payback
Process Design Variables
Mechanical Design Variables
Steam/ Carbon Ratio
Heat Flux
Pressure
Tube Inner Diameter
Tube Exit Temperature
Heated Tube Length
Tube Inlet Temperature
Tube Material
Air Preheat Temperature
Overall Arrangement
Excess Air
Linde Reformer Technology Process Design Variables
Steam / Carbon Ratio
• feedstock • catalyst type • demand of downstream units
Pressure
• downstream process units (e.g. PSA) • feed supply pressure • tube material
Tube Exit Temperature
• Reformer application • tube material
Tube Inlet Temperature
• type of feedstock • material limits
Air Preheat Temperature
• export steam demand • NOx limitations
Excess Air
• • • •
forced or induced draught fuel type quality of distribution export steam demand
Linde Reformer Technology Challenges in Reformer Design
To cope with the more stringent request on the process variables like
— — — — — — — — — — —
Low
Steam / Carbon Ratio
High
Pressure
High
Tube Exit Temperature
High
Tube Inlet Temperature
High
Air Preheat Temperature
Low
Excess Air
High
Heat Flux
Design limits are approached Design margins have to be reduced More sophisticated design tools have to be used Environmental limits have to be considered
Linde Reformer Technology Top Fired Reformer Principle
Co-current flow permits – The highest flue gas temperature when the tube process gas temperature is lowest – The lowest flue gas temperature when the tube process gas temperature is highest
This is accomplished by – Supplying the upper portion of the catalyst tubes with the most heat (where a maximum heat flux is desired) – Limiting the supply of heat at the bottom portion (where most of the reforming reaction has already taken place) where the heat flux is low
Linde Reformer Technology Catalyst Tube Design Circumference Temperature Distribution T
T x u l F m u m i x a m f o n o i t c e r i D
DT
h c t i P
e b u T
Radiation from two sides
D i r e c t i o n o f m a x i m u m F l u x
x u l F m u m i x a m f o n o i t c e r i D
DT
Radiation from one side
Linde Reformer Technology Catalyst Tube Design
Tubewall Temperature Profiles 880 870 860 > C ° <
850 840
e r u 830 t a r e p 820 m e T 810
800 790
Calc.average TWT
780 770 0,0
2,0
4,0
6,0
Heated Tube Length
8,0
10,0
12,0
Linde Reformer Technology Catalyst Tube Design
Tubewall Temperature Profiles 960 940
> C ° < e r u t a r e p m e T
920
900 880
Calc.max TWT with maldistribution allowance Calc. max TWT
860
Calc.average TWT
840 820 0,0
2,0
4,0
6,0
Heated Tube Length
8,0
10,0
12,0
Linde Reformer Technology
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General
—
Process Design
—
Mechanical Design
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Control and Safety Philosophy
—
References
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Competing Reformer Technologies
Linde Reformer Technology Mechanical Design Variables
Typical Basic Dimensions: Spacing row to row: Spacing wall to row: Spacing tube to tube:
2100 - 2300 mm 1600 - 1800 mm 260 - 300 mm
Tube inside diameter: Ratio Tube spacing:
4 - 4.5 inch 1.8 - 2.0
max. tubes/burner max. No. of tubes/row
4-5 54
Linde Reformer Technology Top Fired Reformer - General Arrangement
Linde Reformer Technology Radiant Box Sectional View
Inlet Section
Radiant Section
Outlet Section
Linde Reformer Technology Hot System
Inlet Main Header Inlet Sub Header Inlet Pigtail
Reformer Tube
Feed Line
Outlet Pigtail Hot outlet Header Cold outlet Header
Linde Reformer Technology Top Fired Reformer - Inlet Section
Key Design Elements — Penthouse Ventilation
— Tube Suspension System — Feed Distribution System — Fuel and Combustion Air Distribution System
Linde Reformer Technology Tube Suspension System
Linde Reformer Technology Top Fired Reformer - Radiant Section
Key Design Elements — Burners — Insulation — Catalyst Tubes
Linde Reformer Technology Row Wise Modular Burner Design
Linde Reformer Technology Row Wise Modular Burner Design
Linde Reformer Technology Row Wise Modular Burner Design Concept
Linde Reformer Technology Burners
Linde Reformer Technology Harped Catalyst Tube Design
Linde Reformer Technology Installed Catalyst Tube Harps
Linde Reformer Technology Top Fired Reformer - Outlet Section
Key Design Elements — Fluegas Collecting System — Hot Collecting System
— Cold Collecting System
Linde Reformer Technology Cold Collecting System
Linde Reformer Technology Waste Heat Recovery Unit Modular Design
Key Design Elements — Modular Components — Integrated SCR Design
— Completely Insulated/Painted
Overview of technologies: DeNOx System
Nitrogen compounds
NOx
Selective Catalytic Reduction (SCR)
Selective Non-Catalytic Reduction (SNCR)
+ High NOx reduction rates + Lower operating temperature - High investment costs - Catalyst has to be replaced - Sensitivity of catalyst
+ + + -
-
Low investment costs Easy maintenance No major replacement parts Lower reduction rates Higher operating temperature Potential problems with WHR
DeNOx
Overview of technologies: DeNOx - Chemistry
•
Organic Nitrogen compounds in waste streams NOx-formation
•
•
Injection of NH3 or urea solution: CO(NH2)2 + 2 NO + ½ O 2
=> 2 N2 + CO2 + 2 H2O
4 NH3 + 4 NO + O2
=> 4 N2 + 6 H2O
Injection controlled by downstream NOx-analyser Minimisation
of ammonia slip
DeNOx
Linde Reformer Technology Waste Heat Recovery Unit Modular Design
Linde Reformer Technology
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General
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Process Design
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Mechanical Design
—
Control and Safety Philosophy
—
References
—
Competing Reformer Technologies
Linde Reformer Technology Emergency Shut-Down System Combustion Air Fan TRIP
Process Feed Flow LOW
Furnace Flame Detector FAILURE
Steam/ Carbon Ratio LOW
Fluegas Fan TRIP
Reformer Fuel Pressure LOW
Reformer Furnace Pressure HIGH
Combustion Air Flow LOW
Steam Drum Level LOW
TRIP
Instrument Air Failure
Isolates Process Feed to Reformer
Opens Vent between Fuel Valves
Reformer exit temperature HIGH
Power Failure
Closes Process Steam to a minimum stop
Isolates Reformer Fuel
Local and Panel Hand TRIPS
Stops Hydrogen Compressor
Stops PSA Program
Closes Valve inlet PSA
Linde Reformer Technology
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General
—
Process Design
—
Mechanical Design
—
Control and Safety Philosophy
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References
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Competing Reformer Technologies
Linde Reformer Technology Application Ranges
Application Ranges of Top Fired Reformers and Linde‘s Experience
No. of Catalyst Tubes
436 1000
No. of Tube Rows
9 16
Pressure (bar)
41 45
Exit Temperature (°C)
945 1000
Reformer Design Data – very large Inner Tube Diameter
mm
127
Outer Tube Diameter
mm
151
Tube Length (heated)
mm
13750
Absorbed Heat
MW
356.00
Average Flux density (inside)
W/m²
84495
Selected Number of Tubes
-
768
Number of Rows
-
16
Tubes per Row
-
Distance Tube/Tube (Center)
Process Pressure
bar
20
Design Pressure
barg
22.7
Process Temperature
°C
875
Design Temperature
°C
975
Total Heat Release
MW
672.00
Number of Burners (100%)
180
Number of Burners (60%)
24
Burner Capacity (100%)
MW
3.05 + 10 %
48
Burner Capacity (60%)
MW
1.83 + 10 %
mm
290
Total Burner Capacity
MW
592.80
Distance Row/Wall (Long Side)
mm
1850
Distance Row/Wall (Short Side)
mm
400
Distance Row/Row
mm
2300
Fire Box Width (inside)
mm
38200
Fire Box Length (inside)
mm
14850
Combustion Air Excess Combustion Air Temperature
10% °C
360
Reformer Plot Plan – Side View
Reformer Plot Plan – Top View
SMR Process Flow Scheme
Reformer Section View
Reformer Side View
Reformer penthouse insight
Reformer Process Gas Piping
Feed Distribution System
Linde Catalyst tube design Top Flange Thermal Plug
Gas inlet through Top Flange
Catalyst Tube Material: Material: Inner diameter: Heated Length:
2535 CrNiNbTi Microallo Microalloyy R 4 to 4.5 inches 12 to 14 metres
Catalyst Grid Outlet Pigtail Material: Inner diameter: Length:
Incoloy 800H 30 mm 600 to 800 mm
Linde Catalyst tube design
Burner Design
204 forced draft Low-NOx arch burners in total Callidus, Zeeco, Bloom 17 rows á 12 burners
15 rows with 100% burners á 3.05MW 2 rows with 60% burners á 1.83MW One burner per row equipped with UV flame supervision (Fire-Eye Phoenix 85UV kompakt, with vortex cooling box) air pressure at 110% duty: 20 mbar Fuel gas pressure at 110% duty: max. 1.75 bar-g
Firebox temperature 1060°C Staged combustion air headers
Radiant Zone Optimization - optional
Computational Fluid Dynamics Fluid dynamics optimization • Software: FLUENT • SL is equipped with 4 Workstations
Flue Gas ducting
Heat input in upper section of furnace
Uniform flue gas flow over length and width of furnace Flue Gas ducting designed for < ± 3% maldistribution
Linde Reformer Technology Top Fired Reformer in Italy - 4 rows -
Linde Reformer Technology Top-Fired Reformer in USA - 7 rows -
Linde Reformer Technology Top-Fired Reformer in India - 8 rows -
Linde Reformer Technology Summary
—
Use of sophisticated design tools
—
Use of most advanced metallurgy
—
Constant hanger support for inlet system and catalyst tubes
—
Outlet header system installed in radiant floor „coffin“ to minimize heat loss
—
Flexibility with regard to top or side entry of reformer tubes
—
Use of short outlet pigtails to minimize elevation
—
Modular penthouse and WHR design for cost effective construction
—
Penthouse cooling for operator safety
—
Flexibility with regard to convection section arrangements
—
Single lance combination fuel burner system
—
Balanced draft for high system efficiencies
COST EFFECTIVE, RELIABLE AND MECHANICALLY ADVANCED DESIGN
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General
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Process Design
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Mechanical Design
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Control and Safety Philosophy
—
References
—
Competing Reformer Technologies
Competing Reformer Technologies
Top-Fired Reformer
Side-Fired Reformer
Terraced-Wall Reformer
SIDE FIRED STEAM REFORMER
Competing Reformer Technologies
Top Fired
Side-/Terraced Fired
Rectangular Box
Long & Narrow Box
Single
Single or Multiple
Tube Arrangement
Several Parallel Rows
One Row per Cell
Process Flow
Down
Down
Flue Gas Flow
Co-Current
Counter-Current
Horizontal at grade Vertical along side box
Elevated above Radiant Vertical Down
Balanced or induced
Balanced, Induced or Natural
Shape No. of Cells
Convection Section Draft
Reformer Design Application SMR Configuration Comparisons Top
Side
Terraced
Natural Draft Operation
no
yes
yes
Heat input Control along tube
no
yes
yes
Maintenance Cost Control Complexity No. of Burners Burner Access Piping mass Surface Area (box)
Investment Cost Ease of expansion high
low
Steam Reformer
STEAM REFORMER Urea/Ammonia Key Data - No. 336 tubes - No. 7 rows of tubes - inner tube id. 4,5”
- Heated tube length 12,5m - tube spacing 260 mm
Steam Reformer for a Urea/Ammonia Project(2050MTPD)
Reformer: - 723 to steel - 160 to catalyst tube system - 55 to piping - 480 to Inner lining and refractory WHR-System: -320 to ducts & steel casing -250 to coil
Steam Reformer for 7000 MTPD Methanol Plant
-
Modularization drivers – Quality and Safety
Quality increases under which construction is accomplished
Well-rehearsed assembly process in workshop Established quality control system in place No weather impact
Safety
With prework, workers face less exposure due to weather, heights, harzadous operation and neighboring construction activities
Less workers at onsite translate into reduced craft congestion and exposure to ongoing operations
Further potential for modularization Increase
the modularization in the reformer section by: modularize entire Penthouse section with entire inlet system components modularize radiant box panels with ceramic fibre pre-installed convection coils can be pre-assembled and shop hydrotested The inlet manifold and outlet system can be harped into shippable assemblies the refractory lined transfer line can be shop fabricated sectional pre-fabrication of ladders, platforms and stair towers
Linde Ammonia Concept
Linde Ammonia Concept (LAC) Simplified Block Diagram
H2 Unit with Hydrocarbon PSA Purification Feed
Ammonia Synthesis Loop N2 Unit
Atmospheric Air
Ammonia Product
Linde Ammonia Concept (LAC) Possible valuable By-Products CO2
CO
H2
CO Recovery
Hydrocarbon Feed
H2 Unit with PSA Purification Ammonia Synthesis Loop
MEOH Unit
Methanol
N2 Unit Atmospheric Air
Rare Gases
Ar
O2
N2
Ammonia Product
Linde Ammonia Concept (LAC) A combination of proven technologies
50 units, up to 125.000 Nm3/h Casale: 125 converters +loops Linde: 6 complete Ammonia Plants
2.400 units,up to 340.000 Nm3/h
Linde Ammonia Concept (LAC) Comparison of LAC process with conventional scheme Conventional Ammonia Plant CO2
Feed
Desulfurization
Primary Reformer
Secondary Reformer
HT Shift
LT Shift
CO2 Removal
Methanation
Ammonia Synthesis NH3
Air Inertgas Unit
Purgegas Separation
Linde Ammonia Concept (LAC) H2 - Unit Feed
Air
Desulfurization
Primary Reformer
Nitrogen Unit
Isothermal Shift
PSA
Ammonia Synthesis
NH3
Linde Ammonia Concept (LAC) Comparison of LAC process with conventional scheme Figure 1 Feed
Conventional Ammonia Plant Desulfurization
Primary Reformer
Secondary Reformer
HT Shift
LT Shift
CO2 Removal
Methannation
Ammonia Synthesis
Air
Feed
Air
Primary Reformer
NH3
Purgegas Separation
Linde Ammonia Concept (LAC) Desulfurization
CO2
Isotherma l Shift
PSA
Ammonia Synthesis
Nitrogen Unit
Downstream this point the flowrate of a conventional plant is 30 to 80% higher compared to the LAC-process
NH3
Cost related facts:
• number of temperature changes • temperture levels • flowrate • number of equipment and catalyst Efficiency related facts:
• heat exchange losses • pressure drops Conventional Plant
LAC-Process 0 Purgegas Separation
Linde Ammonia Concept (LAC) Linde Isothermal Reactor Steam
Figure 4
Circulating Water
Boiler Feed Water Gas Entry
Circulating Water
Gas Exit
Linde Ammonia Concept (LAC) Comparision of Equipment Items Conventional Plant
LAC Plant
Exchangers Vessels Columns Reactors Big Machines (Compressors,Turbines Generator) Pumps Other Machines Air Separation Unit Inert Gas Unit Purge gas separator PSA Unit
60 25 8 8 6
34 19 4 5 4
35 11 1 1 -
25 12 1 1
Totals
155
105
Common for both plants, and not included in above count, are: Refrigeration Unit, Ammonia storage, Cooling Water System, Flare System, Effluent Collection, Instrument Air Unit
Linde Ammonia Concept (LAC) Comparision of Catalyst volumes 1350 MTPD NH3 Conventional Plant
LAC Plant
Desulphurisation
24.8 m3
28.0 m3
Primary Reformer
36.0 m3
37.0 m3
Secondary Reformer
35,1 m3
--
HT Shift
70.5 m3
--
LT Shift
96.5 m3
52.0 m3
Methanation
27.0 m3
--
Ammonia Synthesis
92.3 m3
83.9 m3
382.2 m3
200.9 m3
Total
Linde 12-Bed PSA System Top View 110.000 Nm3/h H2
Linde Air Separation Plant Conventional Cryogenic Process coldbox GAN
GOX low pressurecolumn
heatexchanger molecularsieve adsorber
expansionsturbine with boostercompressor evaporator/ condenser
Impure GAN direct-contact cooler
evaporation cooler pressurecolumn
air compressor filter
AIR
air compression
air purification
cold generation
heat exchange
rectification
General Overview LAC-Plant for the production of 1350 MTPD NH3
Section View Reformer + Isothermal Shift
Linde Ammonia Concept 1350 mtd Ammonia Plant, GSFC. India
Ammonia Synthesis Vadodara / Indien
Thank you for your attention Linde’s HyCO offerings BOO / Over the Fence Supply
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Agenda
1. BOCI 2. Typical commercial model for BOO / over-the-fence gas supply 3. Over the Fence (BOO) supply advantages 4. Linde Gas HyCO Experience 5. Linde’s Operational Excellence 6. Overall value that Linde can bring to IOCL/BP
Linde Hydrogen Technology
LINDE IS ONE OF THE FEW COMPANY IN THE WORLD THAT
DESIGNS
BUILDS
OPERATES
ASU, HYDROGEN, SYNGAS & CO FACILITIES USING THEIR OWN „IN-HOUSE TECHNOLOGY“
Plant Operation
LINDE ENGINEERING DESIGNS & BUILDS
LINDE GAS OPERATES AND MAINTAINS
EXPERIENCE
Hydrogen and Synthesis Gas technologies of the Linde Engineering Division
Hydrogen Plants Gas Removal Processes
H2/CO Plants
Product Line Hydrogen & Synthesis Gas CO-Plants
Gas Separation Processes
Methanol Plants
Syngas Plants Ammonia Plants
The Best in the Business Trust Us
Linde Gas - Worldwide market share and position 1
#2 Europe 32%
#3 North America 15%
#2 South America
#1 Africa
24%
1 Total market share subject to potential disposals 2 Includes all of Asia and Australia, including captive market China Source: Annual Reports, Broker Reports, Spiritus Consulting, Linde Analysis
42%
#1 Asia/Pacific 2 19%
Linde Group in India - BOC India Limited
BOC India Limited (A member of The Linde Group), is India’s leading Industrial Gas Company which is established over 75 years in India with headquarters in Kolkata.
BOCI has around 700 employees in India
Linde Gas On-site / BOO Plants Worldwide
In total Linde is operating more than 1000 plants producing industrial gases in all continents with strong focus in Asia HYCO Tonnage
Air Tonnage
ECOVAR® (standard plants)
H2, CO, CO2, Synthesis gas
O2, N2, Ar, Kr, Xe
O2, N2, H2
100 – 200.000 Nm3/h
3.000 – 50.000 Nm3/h
50 – 3.000 Nm3/h
> 65 plants
> 300 plants
> 800 plants
Overview of the major syngas (H2/ CO) production facilities owned and operated by the Linde Group
Salt Lake
Lemont Toledo
Teesside Leuna
Lima
La Porte Clear Lake
Daesan
Milazzo
Caojing Paraguana
Map Tha Phut Singapore
Bulwer MurrinMurrin
Concon
Concepcion
H2-plant H2/CO-plant POX-plant
Aurangabad
BOO or On-site Supply – Typical Commercial Model
Fixed Fee for Capital Recovery and Fixed Operational Cost Unit Charge for molecules (adjusted with actual price of Feedstock & Utilities) 15 year contract
Feedstock/Air & Utilities HYCO – Plant Or ASU
Supply of H2, CO, Syngas, CO2 ,O2, N2 molecules
Customer Production
Summary of Benefits of over the fence supply scheme – Improved Gas Economics Obvious
—
Project development costs such as initial capital, utilities etc
Less obvious
—
Future major equipment repair capital
—
Ownership costs such as overheads, insurance, debt impact, & labor legacy
IMPROVED ALIGNMENT FINANCIAL
SHIFT OF RISKS
• Capital Avoidance.
• Capital Accuracy
• Payments only begin when gas is delivered.
• Construction
• Level and predictable gas costs. Turnaround peaks avoided. No major $MM surprises
• Maint. & Operations Accuracy Volatility
• 15+ Year, not 2 – 3 as for LSTK Low gas cost, not cheap equipment
• Alignment of gas delivery / need schedule. Mechanical completion inappropriate target.
• On-Stream Reliability
• Collaborate on cost/benefit analysis decisions.
• Labor Relations, Cost, & Legacy.
• Continuous innovation
• Changing Safety & Maint. Standards & Policies.
Maintain Competitiveness Improve Reliability Improved Safety Practice
H2 for Refinery Toledo, USA Steam Reformer supplying H2 to 2 Refineries H2: 144,000 Nm3/h
2 x Top-fired Selas Reformer Trains
Steam: 67.8 t/h
12 bed Linde PSA
Feed: Natural Gas / ROG / RFG Fuel: Natural Gas / ROG / RFG
Average Reliability of each train >>99,5%
Thank you for your attention
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