Professional Documents
Culture Documents
Technical Design and Requirements
Technical Design and Requirements
assumptions related to the technical aspects and requirements needed for the
design of the steam methane reforming plant. Standards were used to come
DESIGN OPTION 1
capture from the syngas stream. The heat required in the reactor is delivered
by a furnace burning the process tail gas as well as additional natural gas if
needed.
B. Design Specification of each Equipment
methane prior to the main reforming reactor. The pre-reforming reactor usually
steam reforming unit. The temperature is normally in the range from 350– 550
°C. There are several benefits to pre-reforming, but most important is the
(SMR) are the temperature range and the method of heat transfer. Where the
reactor tubes and burners, the GHR works as a heat exchanger, absorbing
Efficiency 100%
the use of steam methane reforming (SMR). The reaction is endothermic and
converts steam and methane into H2 and CO. The reaction is a catalytic
efficient and have sufficient activity. When more activity is needed, a more
noble catalyst can be used. Nobel catalysts provide higher activities and faster
reactions but are very expensive. The reactor consists of several reactor
tubes filled with reforming catalysts and kept in a furnace that provides the
Efficiency 100%
After the reforming process, the syngas undergoes a water gas shift,
controlled by equilibrium.
done in two steps, a high temperature shift (HTS) and a low temperature shift
(LTS). In the HTS, the mole fraction of CO is reduced from typically 10-13% to
lower limit is set due to the water dew point of the gas. Condensation
Efficiency 100%
Efficiency 100%
CO2 ABSORPER
After the WGS, hydrogen and CO2 are produced and have to be
separated and purified. Concepts for CO2 separation are presented in this
commonly used to remove CO2 from NG [8]. The liquid solvent can be
solvents react with CO2 and require heat to activate the reaction. Chemical
solvents offer fast reaction rates which results in smaller plant size. Physical
solvents do not react but dissolve CO2 and require less heat than chemical
compared to physical solvents and are therefore preferred at low CO2 partial
pressures. The chemical solvents will begin to saturate with increasing CO2
partial pressures and physical solvents are therefore preferred at high CO2
partial pressures. The CO2 recovery and purity will depend on the syngas
composition and various solvents may be optimal for CO2 separation. Studies
have shown that MDEA can capture as much as 95% of the CO2 with a purity
of above 99%.
hydrogen while adsorbing CO2 and other impurities. The pressure inside the
Hydrogen is purified with a pressure drop between 1-2 bar. The off-gas exits
COMPRESSOR
blades and stationary vanes. At the end of the compressor, before reaching
temperature by compression.
specifications.
Type Centrifugal
WATER PUMP
The pumps are installed for the circulation of water for steam
generation.
Motor 60 Hz
GAS EXPANDER
required heat by burning NG and the tail gas with air. The required air is
while the NG and tail gas is heated to a temperature of 500°C before entering
the furnace. Post combustion, the flue gas leaves the furnace at a
S + NG = M1
Steam= 2,722 kg/hr
Steam
GHR M1 100%
NG NG= 9,903 kg/hr
M1 + Steam = M2
M1 M1=12,625 kg/hr
SMR M2 100% Steam= 26,818 kg/hr
Steam M2=39,443 kg/hr
M2 = M3 + H20
M2=39,443 kg/hr
M2 M3
WGS 100% M3=29,908 kg/hr
H20= 9,535 kg/hr
H20
M3 M4 M3 + CO2 = M4
CO2 M3=29,908 kg/hr
100%
Absorber CO2=23,450 kg/hr
CO2 M4= 6,458 kg/hr
M4 = H2 + M5
M4 M5 M4=6,458 kg/hr
PSA 100% H2=3,848 kg/hr
M5= 2,610 kg/hr
H2
M5 + A + NG = FG + W
M5 M5= 2,610 kg/hr
Air
Flue Gas Air=60,957 kg/hr
NG
Furnace 100% NG=2,199 kg/hr
Waste
Flue Gas= 65,766 kg/hr
Waste = 0 kg/hr
T2NG = 773.15 K
Tcombustion = 1273.15 K
DESIGN OPTION 2
In order to further reduce the carbon emissions, the natural gas feed to
the furnace is replaced by produced hydrogen. Thus, the CO2 emissions per
carbon-lean solution.
achieve higher energy efficiencies with SMR+, but that would result in
methane prior to the main reforming reactor. The pre-reforming reactor usually
steam reforming unit. The temperature is normally in the range from 350– 550
°C. There are several benefits to pre-reforming, but most important is the
(SMR) are the temperature range and the method of heat transfer. Where the
reactor tubes and burners, the GHR works as a heat exchanger, absorbing
Efficiency 100%
the use of steam methane reforming (SMR). The reaction is endothermic and
converts steam and methane into H2 and CO. The reaction is a catalytic
efficient and have sufficient activity. When more activity is needed, a more
noble catalyst can be used. Nobel catalysts provide higher activities and faster
reactions but are very expensive. The reactor consists of several reactor
tubes filled with reforming catalysts and kept in a furnace that provides the
Efficiency 100%
After the reforming process, the syngas undergoes a water gas shift,
controlled by equilibrium.
done in two steps, a high temperature shift (HTS) and a low temperature shift
(LTS). In the HTS, the mole fraction of CO is reduced from typically 10-13% to
lower limit is set due to the water dew point of the gas. Condensation
Efficiency 100%
Efficiency 100%
CO2 ABSORPER
After the WGS, hydrogen and CO2 are produced and have to be
separated and purified. Concepts for CO2 separation are presented in this
commonly used to remove CO2 from NG [8]. The liquid solvent can be
solvents react with CO2 and require heat to activate the reaction. Chemical
solvents offer fast reaction rates which results in smaller plant size. Physical
solvents do not react but dissolve CO2 and require less heat than chemical
compared to physical solvents and are therefore preferred at low CO2 partial
pressures. The chemical solvents will begin to saturate with increasing CO2
partial pressures and physical solvents are therefore preferred at high CO2
partial pressures. The CO2 recovery and purity will depend on the syngas
composition and various solvents may be optimal for CO2 separation. Studies
have shown that MDEA can capture as much as 95% of the CO2 with a purity
of above 99%.
hydrogen while adsorbing CO2 and other impurities. The pressure inside the
Hydrogen is purified with a pressure drop between 1-2 bar. The off-gas exits
COMPRESSOR
blades and stationary vanes. At the end of the compressor, before reaching
temperature by compression.
specifications.
Type Centrifugal
WATER PUMP
The pumps are installed for the circulation of water for steam
generation.
Motor 60 Hz
GAS EXPANDER
FURNACE
The furnace is as mentioned supplying the SMR with the
required heat by burning NG and the tail gas with air. The required air is
while the NG and tail gas is heated to a temperature of 500°C before entering
the furnace. Post combustion, the flue gas leaves the furnace at a
M1 + Steam = M2
M1 M1=16,217 kg/hr
SMR M2 100% Steam= 34,444 kg/hr
Steam M2=50,661 kg/hr
M2 = M3 + H20
M2=50,661 kg/hr
M2 M3
WGS 100% M3=37,316 kg/hr
H20= 13,345 kg/hr
H20
M3 M4 M3 + CO2 = M4
CO2 M3=37,316 kg/hr
100%
Absorber CO2=30,115 kg/hr
CO2 M4= 7,201 kg/hr
M4 = H2 + M5
M4 M5 M4=7,201kg/hr
PSA 100% H2=3,848 kg/hr
M5= 3,353 kg/hr
H2
M5 + A + NG = FG + W
M5 M5= 3,353kg/hr
Air
Flue Gas Air=71,231kg/hr
H2
Furnace 100% H2=1,094 kg/hr
Waste
Flue Gas= 75678 kg/hr
Waste = 0 kg/hr
Table 3.11 Energy Balance Calculations for Design Option 2
T2NG = 773.15 K
Tcombustion = 1273.15 K
both the POX and the SMR reactions are active simultaneously. This concept
also need pure oxygen input as well as a catalyst bed in the steam reforming
section of the reactor. The core benefits of this system is that the heat
reaction.
methane prior to the main reforming reactor. The pre-reforming reactor usually
steam reforming unit. The temperature is normally in the range from 350– 550
°C. There are several benefits to pre-reforming, but most important is the
(SMR) are the temperature range and the method of heat transfer. Where the
reactor tubes and burners, the GHR works as a heat exchanger, absorbing
Efficiency 100%
The ATR reactors usually operate at temperatures between 900-1150 °C, with
pressure levels in the range 1 to 80 bar existing today. Figure below shows
the principles of the ATR reactor, with the different inputs and reaction zones.
No specific range was found for the typical energy efficiency of ATR, but it
Efficiency 100%
controlled by equilibrium.
done in two steps, a high temperature shift (HTS) and a low temperature shift
(LTS). In the HTS, the mole fraction of CO is reduced from typically 10-13% to
lower limit is set due to the water dew point of the gas. Condensation
Efficiency 100%
Efficiency 100%
CO2 ABSORPER
After the WGS, hydrogen and CO2 are produced and have to be
separated and purified. Concepts for CO2 separation are presented in this
commonly used to remove CO2 from NG [8]. The liquid solvent can be
solvents react with CO2 and require heat to activate the reaction. Chemical
solvents offer fast reaction rates which results in smaller plant size. Physical
solvents do not react but dissolve CO2 and require less heat than chemical
compared to physical solvents and are therefore preferred at low CO2 partial
pressures. The chemical solvents will begin to saturate with increasing CO2
partial pressures and physical solvents are therefore preferred at high CO2
partial pressures. The CO2 recovery and purity will depend on the syngas
composition and various solvents may be optimal for CO2 separation. Studies
have shown that MDEA can capture as much as 95% of the CO2 with a purity
of above 99%.
hydrogen while adsorbing CO2 and other impurities. The pressure inside the
Hydrogen is purified with a pressure drop between 1-2 bar. The off-gas exits
H2 Purity 99.999%
COMPRESSOR
blades and stationary vanes. At the end of the compressor, before reaching
temperature by compression.
The H-Series serves the requirements of many industries, from air
specifications.
Type Centrifugal
WATER PUMP
The pumps are installed for the circulation of water for steam
generation.
Figure 3.7 Water Pump
Motor 60 Hz
GAS EXPANDER
heat by burning NG and the tail gas with air. The required air is heated and
supplied at a temperature of 335°C and a pressure of 1.2 bar while the NG and
tail gas is heated to a temperature of 500°C before entering the furnace. Post
combustion, the flue gas leaves the furnace at a temperature of 1000°C and at
atmospheric pressure. The flue gas is cooled down to 100°C supplying heat to
S + NG = M1
Steam
Steam= 3,241 kg/hr
GHR M1 100%
NG NG= 11,787 kg/hr
M1= 15,028 kg/hr
M1 + Steam + O2 = M2
M1=15,028 kg/hr
M1 O2=11,822 kg/hr
ATR O2 M2 100%
Steam Steam= 15,449 kg/hr
M2= 42,299 kg/hr
M2 + Steam = M3 + H20
Steam
Steam=1,159 kg/hr
M2 M3 M2=42,299 kg/hr
WGS 100%
M3=37,768 kg/hr
H20 H20= 5,690 kg/hr
M3 M4 M3 = M4 + CO2
CO2 M3=37,768 kg/hr
100%
Absorber CO2=31,816 kg/hr
CO2 M4=5,952 kg/hr
M4 = H2 + M5
M4 M5 M4=5,952 kg/hr
PSA1 100% H2=3,498 kg/hr
M5= 2,454 kg/hr
H2
M5 = H2 + M6
M5 M6 M5=2,454 kg/hr
PSA2 100% H2=350 kg/hr
M6= 2,104 kg/hr
H2
M6 + A = FG + W
M6
M6= 2,104kg/hr
Flue Gas
Air Air=4830/hr
Furnace 100%
Flue Gas= 6934 kg/hr
Waste Waste = 0 kg/hr
T2NG = 773.15 K
Tcombustion = 1273.15 K