(19)

*EP003160632B1*
(11) EP 3 160 632 B1
(12) EUROPEAN PATENT SPECIFICATION

(45) Date of publication and mention (51) International Patent Classification (IPC):
of the grant of the patent: B01J 8/06 (2006.01) C01B 3/38 (2006.01)
28.06.2023 Bulletin 2023/26
(52) Cooperative Patent Classification (CPC):
(21) Application number: 15811966.9 C01B 3/384; B01J 8/062; B01J 2208/00176;
B01J 2208/00495; B01J 2208/00504;
(22) Date of filing: 19.06.2015 B01J 2208/0053; C01B 2203/0233;
C01B 2203/0238; C01B 2203/043;
C01B 2203/0827; C01B 2203/0833;
C01B 2203/0883; C01B 2203/0894;
C01B 2203/1235; Y02P 20/10; (Cont.)

(86) International application number:

PCT/US2015/036680

(87) International publication number:

WO 2015/200128 (30.12.2015 Gazette 2015/52)

(54) STEAM METHANE REFORMER SYSTEM AND METHOD OF PERFORMING A STEAM METHANE
REFORMING PROCESS
DAMPF-METHANREFORMERSYSTEM UND VERFAHREN ZUR DURCHFÜHRUNG EINES
VERFAHRENS ZUR DAMPF-METHANREFORMIERUNG
SYSTÈME REFORMEUR DE MÉTHANE À LA VAPEUR ET MÉTHODE DE RÉALISATION D’UN
PROCÉDÉ DE REFORMAGE DE MÉTHANE À LA VAPEUR

(84) Designated Contracting States: (74) Representative: Petersen, Frank

AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Patentanwalt
GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO Mannheimer Strasse 46
PL PT RO RS SE SI SK SM TR 76131 Karlsruhe (DE)

(30) Priority: 25.06.2014 US 201414314679 (56) References cited:

EP-A2- 0 437 059 US-A- 4 180 128
(43) Date of publication of application: US-A- 4 985 231 US-A1- 2003 101 651
03.05.2017 Bulletin 2017/18 US-A1- 2003 113 257 US-A1- 2003 131 533
US-A1- 2007 264 186 US-A1- 2009 180 949
(73) Proprietor: Zoneflow Reactor Technologies, LLC US-A1- 2009 255 181 US-A1- 2011 042 620
Windsor, Connecticut 06095 (US) US-A1- 2012 022 299 US-A1- 2012 326 090
US-A1- 2013 156 686 US-B1- 8 496 908
(72) Inventors:
• RALSTON, Michael P.
Jenks, Oklahoma 74037 (US)
• FEINSTEIN, Jonathan Jay
Sandisfield, Massachusetts 01255 (US)
EP 3 160 632 B1

Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent
Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the
Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been
paid. (Art. 99(1) European Patent Convention).

Processed by Luminess, 75001 PARIS (FR) (Cont. next page)

 EP 3 160 632 B1

(52) Cooperative Patent Classification (CPC): (Cont.)

Y02P 20/141

2
 1 EP 3 160 632 B1
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to the field of
chemical plant apparatus and methods, and more spe-
cifically to steam methane reformer systems and meth-
ods of performing a steam methane reforming process
according to the introductory part of appended claims 1
or 9 respectively.
BACKGROUND
[0002] Steam methane reforming is a process that may
be used to produce synthesis gas and hydrogen. A hy-
drocarbon and at least one of steam and carbon dioxide
are reacted or reformed in the presence of a catalyst to
produce hydrogen mixed with oxides of carbon, called
synthesis gas or syngas. Known devices are e.g. dis-
closed in US2009/0180949 A1, US 2003/0131533 A1,
US 2012/0022299 A1, US 2011/0042620 A1, US
4,985,231, US 2012/0326090, EP 0 437 059 A2 or US
2003 /113257 A1.The reforming reaction is often per-
formed within the radiant zone of a furnace heated by
combustion of a fuel and an oxidant such as air.
[0003] Prior to entering the furnace the hydrocarbon is
preheated, the steam, for example, is vaporized and su-
perheated, the hydrocarbon and steam are combined in-
to a common stream, and the resulting mixed feed is
preheated against the flue gas to as high a temperature
as possible to lower the firing requirements of the furnace
and recover heat from the flue gas without causing the
hydrocarbon to crack or precipitate solid carbon deposits.
The desirably high temperature for the mixed feed to en-
ter the furnace is normally in the range of 500 ° to 650
°C, more often being about 650 °C.
[0004] It is advantageous to recover heat from the re-
sulting hot syngas and products of combustion or flue
gas. Heat is normally recovered from the syngas in a first
or syngas heat recovery section and from the flue gas in
a second heat recovery section called a convective sec-
tion.
[0005] Heat recovered from the syngas is utilized in
what is called a process gas boiler to preheat the hydro-
carbon feedstock and to vaporize steam.
[0006] The flue gas commonly performs diverse heat-
ing duties in the convective section. One duty is to va-
porize and superheat steam. Another duty sometimes
practiced is to preheat the air combusted in the furnace.
An additional duty is to preheat the mixed feed of super-
heated steam and a preheated hydrocarbon feedstock
to as high a temperature as possible without incurring
carbon deposition.
[0007] Where efficient heat recovery is practiced, such
as in a large steam methane reformer ("SMR"), the total
amount of steam vaporized in the first and second heat
recovery sections greatly exceeds the amount of steam
required for the steam reforming process. The excess
2
steam must be exported to another process unit in a
chemical or power generation complex or refinery. Steam
export typically reduces the net energy consumption of
the SMR process by about 10 %, which is substantial,
5 but makes the SMR dependent on an external demand
for the excess steam.
[0008] It is generally less expensive to build chemical
plant equipment in a fabrication facility than in the field.
Up to a very limited production capacity SMR furnaces
10 can be built and assembled within a fabrication facility.
For larger SMR furnace capacities it is necessary to build
and assemble furnaces in the field. Although multiple
modular furnaces may have lower installed costs than a
single field assembled furnace, linking more than two fur-
15 naces to a common large flue gas heat recovery section
is difficult. The difficulty in linking more than one furnace
and especially more than two furnaces to a common con-
vective section is that the flow of fluids for the combination
of heat duties of steam raising and superheating together
20 with hydrocarbon or mixed feed preheating can become
imbalanced between a single, common convective zone
and two or more reforming furnaces. For example, if one
furnace is in a startup or turn down cycle it may not proc-
ess a hydrocarbon or mixed feed while other furnaces
25 do process hydrocarbons and/or mixed feed. Hence the
preheating of hydrocarbons and mixed feed must be per-
formed in conjunction with the operation of individual fur-
naces. Otherwise all furnaces must be started up and
turned down in unison. Multiple small convective sections
30 have higher combined installed costs than a common,
large convective section.
[0009] Fig. 1 illustrates an exemplary conventional
bayonet reformer tube system 100. A bayonet reformer
tube 101 is disposed within a furnace 102. The tube con-
35 sists of an outer tube 103 and an inner tube 104. An
annulus between the inner and outer tubes contains a
reforming catalyst 105 (shown in Fig. 1 by cross-hatch-
ing). Gas enters the tube from an inlet header 106, flows
downward through the annulus containing the catalyst,
40 transfers to the inner tube 104 near a tip 107 of the tube,
where the volumes of the annulus and inner tube are in
communication with each other. The gas then flows up-
ward from the tip 107 via the inner tube 104, and exits
the tube to flow into an outlet header 108. Gas is heated
45 and reformed in the annulus against combustion heating
from the furnace and against the resulting heated syngas
flowing through inner tube 104. Syngas flowing through
inner tube 104 is cooled against the gas flowing through
the annulus. Patent application WO2001012310 A1 is an
50 example of the prior art shown in Fig. 1.
[0010] Fig. 2 illustrates a conventional SMR 200 and
flow schematic. A hydrocarbon feedstock 281 enters
SMR 200 via a line 202 and is conveyed to a heat ex-
changer 203 wherein the feedstock is heated against hot
55 syngas. The preheated feedstock is conveyed by a line
204 to a desulfurization unit 205 wherein it is desulfurized
and is then conveyed by a line 206 to be mixed with su-
perheated steam, together forming mixed feed.
3
 3 EP 3 160 632 B1
[0011] Boiler feed water ("BFW") 282 enters SMR 200
via a line 207 which conveys the BFW to a heat exchanger
208 wherein the BFW is heated against hot syngas. The
preheated BFW is conveyed by a line 209 to a heat ex-
changer 210 wherein it is vaporized against flue gas. The
resulting steam is then conveyed by a line 211 to a heat
exchanger 212 wherein it is superheated against flue
gas. A portion of the superheated steam 283 in excess
of the reformer requirements is exported from SMR 100
via a line 213. The balance of the superheated steam is
conveyed via a line 214 wherein it is mixed with the feed-
stock, forming mixed feed, and to a heat exchanger 215,
wherein the mixed feed is preheated to the inlet temper-
ature of the reformer furnace. The preheated mixed feed
is conveyed via a line 216 to a reformer tube 217 within
a reformer furnace 218, wherein the mixed feed is heated
and reformed against heat from the furnace. The result-
ing reformed hot syngas exits the furnace and is con-
veyed via a line 219 to heat exchanger 208 (which may
be a process gas boiler, for example) wherein it is cooled
against BFW, is conveyed via a line 220 to a water gas
shift reactor 221 wherein some of the steam and carbon
monoxide contained in the syngas react to form addition-
al hydrogen and carbon dioxide, is conveyed via a line
222 to heat exchanger 203 wherein it is cooled against
feedstock 281, is conveyed via a line 223 to a fin fan (or
heat exchanger) 224 wherein it is cooled against ambient
air, is conveyed via a line 225 to a water knockout unit
226 wherein condensed steam is separated from the syn-
gas, and is conveyed via a line 227 to a pressure swing
adsorption or PSA unit 228 wherein most of the hydrogen
is separated from the remainder of the syngas. Hydrogen
287 exits the PSA unit 228 as a hydrogen product via a
line 229, and the remainder of the syngas exits the PSA
unit 228 as a tail gas via a line 230 and is conveyed to
the furnace burners wherein the tail gas is combusted.
[0012] Combustion air 284 enters SMR 200 and is con-
veyed via a line 231 to a heat exchanger 232 wherein it
is preheated against flue gas. The preheated combustion
air is conveyed via a line 233 to the furnace burners
wherein the air is combusted with tail gas and supple-
mental fuel to heat the furnace. Supplemental fuel 286
enters SMR 200 and is conveyed via a line 234 to the
furnace burners wherein it is combusted to heat the fur-
nace. Combustion products exit the furnace as flue gas
285 via a convection section 236 and are progressively
cooled as they sequentially pass through heat exchang-
ers 215, 212, 210, and 232. The flue gas 285 then exits
SMR 200.
SUMMARY
[0013] In accordance with an embodiment, an appa-
ratus includes at least two furnaces, each having at least
one bayonet reforming tube. Each furnace is adapted to
receive a gas including a hydrocarbon and at least one
of steam and carbon dioxide via the bayonet reforming
tube, heat and catalytically react the gas to form syngas
4
at a first temperature, cool the syngas to a second tem-
perature lower than the first temperature, and eject the
syngas from the bayonet reforming tube. Each of the at
least two furnaces has a flue gas effluent stream including
5 flue gas and a second effluent stream including syngas.
The apparatus also includes a first heat recovery section
adapted to transfer heat from the first effluent stream to
a first heat load including one of air, water, and steam,
and a second heat recovery section adapted to transfer
10 heat from the second effluent stream to a second heat
load.
[0014] In one embodiment, the second heat load in-
cludes one of water, carbon dioxide, a hydrocarbon, and
mixtures thereof.
15 [0015] In another embodiment the second heat load
contains at least one of a hydrocarbon and mixed feed.
[0016] In another embodiment, the apparatus includes
a heat recovery section including one or more burners
adapted to perform further heating of a load.
20 [0017] In another embodiment, the apparatus includes
a first heat recovery section adapted to transfer heat from
the first effluent stream to a first heat load including only
one of air, water, steam, and a combination of air, water,
and steam.
25 [0018] In an embodiment of the invention, the appara-
tus includes at least two furnaces and a single common
first heat recovery section.
[0019] In another embodiment, the apparatus includes
at least three furnaces and a single common first heat
30 recovery section.
[0020] In another embodiment, the second tempera-
ture is less than 500 °C.
[0021] In accordance with the invention, an apparatus
for the production of syngas is provided. The apparatus
35 includes at least two furnaces, each having at least one
bayonet reforming tube. Each furnace is adapted to re-
ceive a gas including a hydrocarbon and at least one of
steam and carbon dioxide via the tube, heat and catalyt-
ically react the gas to form syngas at a first temperature,
40 cool the syngas to a second temperature lower than the
first temperature, wherein the second temperature is less
than 500 °C, and eject the syngas from the tube.
[0022] In another embodiment, the second tempera-
ture is less than 450 °C.
45 [0023] In another embodiment, the second tempera-
ture is less than 400 °C.
[0024] In another embodiment, the first temperature is
greater than 700 °C.
[0025] In accordance with another embodiment, an ap-
50 paratus for the production of syngas is provided. The
apparatus includes a furnace and at least one bayonet
reforming tube including a first part disposed within the
furnace and a second part disposed outside the furnace.
The bayonet reforming tube further includes an outlet at
55 a first end and a tip at a second end. The bayonet re-
forming tube has a total length from the outlet to the tip,
wherein a portion of the total length that is outside the
furnace is at least 10 % of the total length. The bayonet
4
 5 EP 3 160 632 B1
reforming tube is adapted to receive a gas including a
hydrocarbon and at least one of steam and carbon diox-
ide, heat and catalytically react the gas to form syngas
at a first temperature, cool the syngas to a second tem-
perature lower than the first temperature, and eject the
syngas.
[0026] In another embodiment, the portion of the total
length that is outside the furnace is at least 25 % of the
total length.
[0027] In accordance with another embodiment, a sys-
tem for the production of syngas is provided. The system
includes a furnace and at least one bayonet reforming
tube including an inner tube, an outer tube, and an an-
nulus between the inner tube and the outer tube. The
bayonet tube is disposed only partly within the furnace.
The bayonet reforming tube is adapted to receive a gas
including a hydrocarbon and at least one of steam and
carbon dioxide, heat and catalytically react the gas within
the annulus to form syngas at a first temperature, cool
the syngas within the inner tube to a second temperature
lower than the first temperature, and eject the syngas.
At least 5 % of the heat transferred to the gas in the
annulus is transferred to the gas in a portion of the an-
nulus located outside the furnace.
[0028] In another embodiment, at least 15 % of the
heat transferred to the gas in the annulus is transferred
to the gas in the portion of the annulus located outside
the furnace.
[0029] In accordance with another embodiment, a
method of producing syngas is provided. A gas including
a hydrocarbon and at least one of steam and carbon di-
oxide is received into a furnace, via a bayonet reforming
tube located at least partially within the furnace. The gas
is heated and catalytically reacted to form syngas at a
first temperature. The syngas is cooled to a second tem-
perature lower than the first temperature, and the syngas
is ejected from the tube. Heat from a first effluent stream
including flue gas is transferred, at a first heat recovery
section, to a first heat load including one of air, water,
and steam. Heat from a second effluent stream including
syngas is transferred, at a second heat recovery section,
to a second heat load.
[0030] In another embodiment, the second heat load
includes one of water, carbon dioxide, a hydrocarbon,
and mixtures thereof.
[0031] In another embodiment the second heat load
contains at least one of a hydrocarbon and mixed feed.
[0032] In another embodiment, the second tempera-
ture is less than 500 °C.
[0033] In another embodiment, the second tempera-
ture is less than 450 °C.
[0034] In another embodiment, the second tempera-
ture is less than 400 °C.
[0035] In another embodiment, heat from a first effluent
stream including flue gas is transferred, at a first heat
recovery section, to a first heat load that includes only
one of air, water, steam, and a combination of air, water,
and steam.
6
[0036] These and other advantages of the present dis-
closure will be apparent to those of ordinary skill in the
art by reference to the following Detailed Description and
the accompanying drawings.
5
BRIEF DESCRIPTION OF THE DRAWINGS
[0037]
10 Figure 1 shows an exemplary conventional bayonet
reformer tube;
Figure 2 shows an exemplary conventional steam
methane reformer and flow schematic;
Figure 3 shows a steam methane reformer and flow
15 schematic in accordance with an embodiment; and
Figure 4 is a flowchart of a method of producing syn-
gas in accordance with an embodiment.
DETAILED DESCRIPTION
20
[0038] Objectives of the present invention include at
least partial, and preferably complete elimination of the
process gas boiler, at least partial and preferably com-
plete elimination of mixed feed preheating in the convec-
25 tive section, at least partial and preferably complete elim-
ination of steam export in a steam methane reformer
("SMR") practicing efficient heat recovery, and significant
reduction of the heat duty and hence the equipment
costs, flue gas heat losses and emissions associated with
30 the furnace and convective sections of an SMR. Another
objective is to permit multiple modular reforming furnac-
es, such as two or three or more furnaces, to be linked
to a single, common convective zone. Other objects of
the present invention will be observed in the reading of
35 this disclosure by one reasonably skilled in the art.
[0039] Fig. 3 shows a steam methane reformer
("SMR") 300 and flow schematic in accordance with an
embodiment. A hydrocarbon feedstock 381 enters SMR
300 via a line 302 and is conveyed to a heat exchanger
40 303 wherein the feedstock is heated against hot syngas.
The preheated feedstock is conveyed by a line 304 to a
desulfurization unit 305 wherein it is desulfurized and is
then conveyed by a line 306 to be mixed with superheated
steam, together forming mixed feed.
45 [0040] Boiler feed water ("BFW") 382 enters SMR 300
via a line 307 which conveys BFW 382 to a heat exchang-
er 308 wherein the BFW is heated against hot syngas.
The preheated BFW is conveyed by a line 309 to a heat
exchanger 310 wherein it is vaporized against flue gas.
50 The resulting steam is then conveyed by a line 311 to a
heat exchanger 312 wherein it is superheated against
flue gas. A portion of the superheated steam 387 in ex-
cess of the reformer requirements is exported from the
SMR 300 via a line 313. The balance of the superheated
55 steam is conveyed via a line 314 to be mixed with the
feedstock, forming mixed feed. The mixed feed is con-
veyed to a bayonet reformer tube 315 within a reformer
furnace 316, wherein the mixed feed is heated and re-
5
 7 EP 3 160 632 B1
formed against heat from the furnace 316. The furnace
contains an insulation 340 (shown as a dotted region),
the insulation 340 having a hot interior surface or hot face
341 forming a wall bounding a furnace volume within
which furnace volume heat transfer occurs between the
combustion gases and the heat load of gases within the
tube.
[0041] The bayonet reforming tube 315 includes an
outlet 371 at a first end and a tip 372 at a second end,
wherein the bayonet reforming tube 315 has a total length
from the outlet to the tip. In one embodiment, a portion
of the total length that is outside the furnace is at least
10 % of the total length. In another embodiment, a portion
of the total length that is outside the furnace is at least
25 % of the total length.
[0042] The mixed feed is heated and reacted to form
a syngas in the bayonet tube (e.g., heated to a first tem-
perature). The resulting reformed hot syngas, is cooled
and exits the furnace 316 and exits the bayonet tube 315
at the outlet 371 of the bayonet tube (e.g., cooled to a
second temperature) and is conveyed via a line 317 to a
water gas shift reactor 318 wherein some of the steam
and carbon monoxide contained in the syngas react to
form additional hydrogen and carbon dioxide. Some of
the syngas in line 317 is diverted via a line 319 to pass
through heat exchanger 303 wherein it is cooled against
inlet feedstock and returned to line 317. Valve 320, for
example, may control the amount of syngas so diverted.
The syngas is conveyed from water gas shift reactor 318
via a line 321 to heat exchanger 308 wherein it is cooled
against BFW, is further conveyed via a line 322 to a fin
fan (or heat exchanger) 323 wherein it is cooled against
ambient air, is conveyed via a line 324 to a water knockout
unit 325 wherein condensed steam is separated from the
syngas, and is conveyed via a line 326 to a PSA unit 327
wherein most of the hydrogen is separated from the re-
mainder of the syngas. A purified hydrogen stream 383
exits the PSA unit 327 as a hydrogen product via a line
328, and the remainder of the syngas exits the PSA unit
327 as a tail gas via a line 329 and is conveyed to the
furnace burners wherein the tail gas is combusted.
[0043] Combustion air 386 enters the SMR 300 and is
conveyed via a line 330 to a heat exchanger 331 wherein
it is preheated against flue gas. The preheated combus-
tion air is conveyed via a line 332 to the furnace burners
wherein the air is combusted with tail gas and supple-
mental fuel to heat the furnace.
[0044] Supplemental fuel 384 enters the SMR 300 and
is conveyed via a line 333 to the furnace burners wherein
it is combusted to heat the furnace. Combustion products
exit the furnace as flue gas 385 via a convection section
336 and are progressively cooled as they sequentially
pass through heat exchangers 312, 310, and 331. The
flue gas 385 then exits the SMR 300.
[0045] In one embodiment, all hydrocarbon and mix-
tures containing the hydrocarbon are substantially heat-
ed in heat recovery sections other than the first heat re-
covery section. In the illustrative embodiment of Fig. 3,
8
convection section 336 and heat exchangers 310, 312,
and 331 contained therein constitute a first heat recovery
section in which steam, boiler feed water, and air are
exclusively heated against hot flue gas 385. Heat ex-
5 changers 303 and 308 in which syngas is progressively
cooled against at least hydrocarbon feedstock 381 con-
stitutes a second heat recovery section.
[0046] In one embodiment, at least 5 % of the heat
transferred to the gas in the annulus of bayonet reforming
10 tube 315 is transferred to the gas in a portion of the an-
nulus located outside of furnace 316. In another embod-
iment, at least 15 % of the heat transferred to the gas in
the annulus is transferred to the gas in the portion of the
annulus located outside the furnace.
15 [0047] In another embodiment, a method of producing
syngas is provided. Figure 4 is a flowchart of a method
of producing syngas in accordance with an embodiment.
At step 410, a gas including a hydrocarbon and at least
one of steam and carbon dioxide is received into a fur-
20 nace, via a bayonet reforming tube located at least par-
tially within the furnace. At step 420, the gas is heated
and catalytically reacted to form syngas at a first temper-
ature. At step 430, the syngas is cooled to a second tem-
perature lower than the first temperature. At step 440,
25 the syngas is ejected from the tube. At step 450, heat
from a first effluent stream including flue gas is trans-
ferred, at a first heat recovery section, to a first heat load
including one of air, water, and steam. At step 460, heat
from a second effluent stream including syngas is trans-
30 ferred, at a second heat recovery section, to a second
heat load.
[0048] Thus, in accordance with one embodiment, an
apparatus includes a furnace having at least one bayonet
reforming tube. The furnace is adapted to receive a gas
35 including a hydrocarbon and at least one of steam and
carbon dioxide via the bayonet reforming tube, heat and
catalytically react the gas to form syngas at a first tem-
perature, cool the syngas to a second temperature lower
than the first temperature, and eject the syngas from the
40 tube. The furnace has a first effluent stream including
flue gas and a second effluent stream including syngas.
The apparatus also includes a first heat recovery section
adapted to transfer heat from the first effluent stream to
a first heat load including one of air, water, and steam,
45 and a second heat recovery section adapted to transfer
heat from the second effluent stream to a second heat
load.
[0049] In one embodiment, the second heat load in-
cludes one of water, carbon dioxide, a hydrocarbon, and
50 mixtures thereof.
[0050] In another embodiment the second heat load
contains at least one of a hydrocarbon and mixed feed.
[0051] In another embodiment, the apparatus includes
a heat recovery section including one or more burners
55 adapted to perform further heating of a load.
[0052] In another embodiment, the apparatus includes
a first heat recovery section adapted to transfer heat from
the first effluent stream to a first heat load including only
6
 9 EP 3 160 632 B1
one of air, water, steam, and a combination of air, water,
and steam.
[0053] In another embodiment, the apparatus includes
at least three furnaces and a single common first heat
recovery section.
[0054] In another embodiment, the apparatus includes
at least two furnaces and a single common first heat re-
covery section.
[0055] In another embodiment, the second tempera-
ture is less than 500° C.
[0056] In accordance with another embodiment, an ap-
paratus for the production of syngas is provided. The
apparatus includes a furnace that has at least one bay-
onet reforming tube. The furnace is adapted to receive
a gas including a hydrocarbon and at least one of steam
and carbon dioxide via the tube, heat and catalytically
react the gas to form syngas at a first temperature, cool
the syngas to a second temperature lower than the first
temperature, wherein the second temperature is less
than 500 °C, and eject the syngas from the tube.
[0057] In another embodiment, the second tempera-
ture is less than 450 °C.
[0058] In another embodiment, the second tempera-
ture is less than 400 °C.
[0059] In another embodiment, the first temperature is
greater than 700 °C.
[0060] In accordance with another embodiment, an ap-
paratus for the production of syngas is provided. The
apparatus includes a furnace and at least one bayonet
reforming tube including a first part disposed within the
furnace and a second part disposed outside the furnace.
The bayonet reforming tube further includes an outlet at
a first end and a tip at a second end. The bayonet re-
forming tube has a total length from the outlet to the tip,
wherein a portion of the total length that is outside the
furnace is at least 10 % of the total length. The bayonet
reforming tube is adapted to receive a gas including a
hydrocarbon and at least one of steam and carbon diox-
ide, heat and catalytically react the gas to form syngas
at a first temperature, cool the syngas to a second tem-
perature lower than the first temperature, and eject the
syngas.
[0061] In another embodiment, the portion of the total
length that is outside the furnace is at least 25 % of the
total length.
[0062] In accordance with another embodiment, a sys-
tem for the production of syngas is provided. The system
includes a furnace and at least one bayonet reforming
tube including an inner tube, an outer tube, and an an-
nulus between the inner tube and the outer tube. The
bayonet tube is disposed only partly within the furnace.
The bayonet reforming tube is adapted to receive a gas
including a hydrocarbon and at least one of steam and
carbon dioxide, heat and catalytically react the gas within
the annulus to form syngas at a first temperature, cool
the syngas within the inner tube to a second temperature
lower than the first temperature, and eject the syngas.
At least 5 % of the heat transferred to the gas in the
10
annulus is transferred to the gas in a portion of the an-
nulus located outside the furnace.
[0063] In another embodiment, at least 15 % of the
heat transferred to the gas in the annulus is transferred
5 to the gas in the portion of the annulus located outside
the furnace.
[0064] In accordance with another embodiment, a
method of producing syngas is provided. A gas including
a hydrocarbon and at least one of steam and carbon di-
10 oxide is received, into a furnace, via a bayonet reforming
tube located at least partially within the furnace. The gas
is heated and catalytically reacted to form syngas at a
first temperature. The syngas is cooled to a second tem-
perature lower than the first temperature, and the syngas
15 is ejected from the tube. Heat from a first effluent stream
including flue gas is transferred, at a first heat recovery
section, to a first heat load including one of air, water,
and steam. Heat from a second effluent stream including
syngas is transferred, at a second heat recovery section,
20 to a second heat load.
[0065] In another embodiment, the second heat load
includes one of water, carbon dioxide, a hydrocarbon,
and mixtures thereof.
[0066] In another embodiment the second heat load
25 contains at least one of a hydrocarbon and mixed feed.
[0067] In another embodiment, the second tempera-
ture is less than 500 °C.
[0068] In another embodiment, the second tempera-
ture is less than 450 °C.
30 [0069] In another embodiment, the second tempera-
ture is less than 400 °C.
[0070] In another embodiment, heat from a first effluent
stream including flue gas is transferred, at a first heat
recovery section, to a first heat load that includes only
35 one of air, water, steam, and a combination of air, water,
and steam.
Claims
40
1. An apparatus for producing syngas comprising:
at least two furnaces (316), each comprising at
least one bayonet reforming tube (315), each
45 furnace (316) being adapted to:
receive a gas comprising a hydrocarbon
and at least one of steam and carbon diox-
ide via the bayonet reforming tube (315);
50 heat and catalytically react the gas to form
syngas at a first temperature;
cool the syngas to a second temperature
lower than the first temperature; and
eject the syngas from the bayonet reforming
55 tube (315);
wherein each of the at least two furnaces
(316) has a flue gas effluent stream (385)
and a syngas effluent stream (317);
7
 11 EP 3 160 632 B1
a single common first heat recovery section
(336; 310, 312, 331) operably connected to each
of the at least two furnaces (316), wherein the
flue gas effluent streams (385) of each of the at
least two furnaces (316) are in thermal commu-
nication with a heat load within the first common
heat recovery section (336; 310, 312, 331) and
a second heat recovery section (303) being
adapted to transfer heat from a syngas effluent
stream to hydrocarbon feedstock (381) of each
of the at least two furnaces (316) before the hy-
drocarbon feedstock together with at least one
of steam or carbon dioxide is received by a re-
spective bayonet reforming tube (315) of each
of the at least two furnaces (316).
2. The apparatus of claim 1, wherein the heat load com-
prises only one of water, steam, air, and a combina-
tion of air, water, and steam.
3. The apparatus of claim 1
wherein the single common first heat recovery sec-
tion comprises one or more burners adapted to per-
form further heating of a load.
4. The apparatus of claim 1, further comprising at least
three furnaces (316) the single common first heat
recovery section (336; 310, 312, 331) operably con-
nected to each of the at least three furnaces (316),
wherein the flue gas effluent streams (385) of each
of the at least three furnaces (316) are in thermal
communication with a heat load within the single first
common heat recovery section (336).
5. The apparatus of claim 1 configured such that the
second temperature is less than 500 °C.
6. The apparatus of claim 1 configured such that the
second temperature is less than 450 °C.
7. The apparatus of claim 1 configured such that the
second temperature is less than 400 °C.
8. The apparatus of claim 1, wherein the single com-
mon first heat recovery section (336) for the heat
load comprises:
a first heat exchanger (312) configured to ex-
change heat between the common flue gas ef-
fluent stream (385) and steam;
a second heat exchanger (310) configured to
exchange heat between the common flue gas
effluent stream (385) and boiler feed water; and
a third heat exchanger (331) configured to ex-
change heat between the common flue gas ef-
fluent stream (385) and air.
9. A method of producing syngas, the method compris-
12
ing:
receiving, into at least two furnaces (316), via a
bayonet reforming tube (315) located at least
5 partially within each furnace (316) of the at least
two furnaces (316), a gas comprising a hydro-
carbon and at least one of steam and carbon
dioxide;
heating and catalytically reacting said gas to
10 form syngas at a first temperature;
cooling the syngas to a second temperature low-
er than the first temperature;
ejecting the syngas from the reforming tube
(315); and,
15 within a single common first heat recovery sec-
tion (336; 310, 312, 331), transferring heat from
a flue gas effluent stream (385) of each of the
at least two furnaces (316) to a heat load and,
within a second heat recovery section (303),
20 transferring heat from said syngas effluent
stream (317) to hydrocarbon feedstock (381) of
each of the at least two furnaces (316)
before the hydrocarbon feedstock together with
at least one of steam or carbon dioxide is re-
25 ceived by a respective bayonet reforming tube
(315) of the at least two furnaces (316).
10. The method of claim 9, wherein the second heat load
comprises one of water, carbon dioxide, a hydrocar-
30 bon, and mixtures thereof.
11. The method of claim 9, wherein the second temper-
ature is less than 500 °C.
35 12. The method of claim 9, wherein the second temper-
ature is less than 450 °C.
13. The method of claim 10 or 11, wherein the second
temperature is less than 400 °C.
40
14. The method of claim 9, wherein transferring heat at
the single common first heat recovery section (336)
includes transferring heat from the flue gas effluent
stream (385) of each of the at least two furnaces
45 (316) to steam, using a first heat exchanger (312),
boiler feed water, using a second heat exchanger
(310), and air, using a third heat exchanger (331).
50 Patentansprüche
1. Vorrichtung zur Erzeugung von Synthesegas, um-
fassend:
55 mindestens zwei Feuerungen (316), die jeweils
mindestens ein Bajonett-Reformierungsrohr
(315) umfassen, wobei jede Feuerung (316) an-
gepasst ist um:
8
 13 EP 3 160 632 B1
über das Bajonett-Reformierungsrohr (315)
ein Gas aufzunehmen, das einen Kohlen-
wasserstoff und mindestens eines von
Dampf und Kohlendioxid enthält;
das Gas zu erhitzen und katalytisch zu re-
agieren, um bei einer ersten Temperatur
Synthesegas zu bilden;
das Synthesegases auf eine zweite Tem-
peratur zu kühlen, die niedriger ist als die
erste Temperatur; und
das Synthesegas aus dem Bajonett-Refor-
mierungsrohr (315) auszustoßen;
wobei jede der mindestens zwei Feuerun-
gen (316) einen Abgasabflussstrom (385)
und einen Synthesegasabflussstrom (317)
aufweist;
einen einzelnen gemeinsamen ersten Wärme-
rückgewinnungsabschnitt (336; 310, 312, 331),
der betriebsmäßig mit jeder der mindestens
zwei Feuerungen (316) verbunden ist, wobei die
Abgasabflussströme (385) von jeder der min-
destens zwei Feuerungen (316) in thermischer
Verbindung mit einer Wärmelast innerhalb des
ersten gemeinsamen Wärmerückgewinnungs-
abschnitts (336; 310, 312, 331) stehen und
einen zweiten Wärmerückgewinnungsabschnitt
(303), der angepasst ist, um Wärme von einem
Synthesegasabflussstrom auf Kohlenwasser-
stoffeinsatzmaterial (381) von jedem der min-
destens zwei Feuerungen (316) zu übertragen,
bevor das Kohlenwasserstoffeinsatzmaterial
zusammen mit mindestens einem von Dampf
oder Kohlendioxid aufgenommen wird von ei-
nem jeweiligen Bajonett-Reformierrohr (315)
von jedem der mindestens zwei Feuerungen
(316).
2. Vorrichtung nach Anspruch 1,
wobei die Wärmelast nur entweder Wasser, Dampf
oder Luft oder eine Kombination aus Luft, Wasser
und Dampf enthält.
3. Vorrichtung nach Anspruch 1
wobei der einzelne gemeinsame erste Wärmerück-
gewinnungsabschnitt einen oder mehrere Brenner
umfasst, die angepasst sind, um eine weitere Erwär-
mung einer Last durchzuführen.
4. Vorrichtung nach Anspruch 1,
ferner umfassend mindestens drei Feuerungen
(316), wobei der einzelne gemeinsame erste Wär-
merückgewinnungsabschnitt (336; 310, 312, 331)
betriebsmäßig mit jedem der mindestens drei Feu-
erungen (316) verbunden ist, wobei die Abgasab-
flussströme (385) von jedem der mindestens drei
Feuerungen (316) in thermischer Verbindung mit ei-
ner Wärmelast innerhalb des einzelnen ersten ge-
14
meinsamen Wärmerückgewinnungsabschnitts
(336) stehen.
5. Vorrichtung nach Anspruch 1,
5 die so konfiguriert ist, dass die zweite Temperatur
geringer ist als 500 °C.
6. Vorrichtung nach Anspruch 1,
die so konfiguriert ist, dass die zweite Temperatur
10 geringer ist als 450 °C.
7. Vorrichtung nach Anspruch 1,
die so konfiguriert ist, dass die zweite Temperatur
geringer ist als 400 °C.
15
8. Vorrichtung nach Anspruch 1,
wobei der einzelne gemeinsame erste Wärmerück-
gewinnungsabschnitt (336) für die Wärmelast um-
fasst:
20
einen ersten Wärmetauscher (312), der so kon-
figuriert ist, dass er Wärme zwischen dem ge-
meinsamen Abgasabflussstrom (385) und
Dampf austauscht;
25 einen zweiten Wärmetauscher (310), der so
konfiguriert ist, dass er Wärme zwischen dem
gemeinsamen Abgasabflussstrom (385) und
Kesselspeisewasser austauscht; und
einen dritten Wärmetauscher (331), der so kon-
30 figuriert ist, dass er Wärme zwischen dem ge-
meinsamen Abgasabflussstrom (385) und Luft
austauscht.
9. Verfahren zur Herstellung von Synthesegas, wobei
35 das Verfahren Folgendes umfasst:
in mindestens zwei Feuerungen (316) über ein
Bajonett-Reformierungsrohr (315), das mindes-
tens teilweise in jeder Feuerung (316) der min-
40 destens zwei Feuerungen (316) angeordnet ist,
ein Gas empfangen, das einen Kohlenwasser-
stoff umfasst und mindestens einen von Dampf
und Kohlendioxid;
Erhitzen und katalytisches Reagieren des Ga-
45 ses zur Bildung von Synthesegas bei einer ers-
ten Temperatur;
Abkühlen des Synthesegases auf eine zweite
Temperatur, die niedriger ist als die erste Tem-
peratur;
50 Ausstoßen des Synthesegases aus dem Refor-
mierrohr (315); und
innerhalb eines einzigen gemeinsamen ersten
Wärmerückgewinnungsabschnitts (336; 310,
312, 331) Wärme aus einem Abgasabfluss-
55 strom (385) von jeder der mindestens zwei Feu-
erungen (316) zu einer Wärmelast übertragen
und
innerhalb eines zweiten Wärmerückgewin-
9
 15 EP 3 160 632 B1
nungsabschnitts (303) Wärme aus dem ge-
nannten Synthesegasabflussstrom (317) auf
Kohlenwasserstoffeinsatzmaterial (381) von je-
dem der mindestens zwei Feuerungen (316)
übertragen,
bevor das Kohlenwasserstoffeinsatzmaterial
zusammen mit mindestens einem von Dampf
oder Kohlendioxid von einem jeweiligen Bajo-
nett-Reformierungsrohr (315) der mindestens
zwei Feuerungen (316) aufgenommen wird.
10. Verfahren nach Anspruch 9,
wobei die zweite Wärmelast eines enthält von Was-
ser, Kohlendioxid, einem Kohlenwasserstoff und Mi-
schungen davon.
11. Verfahren nach Anspruch 9,
wobei die zweite Temperatur geringer ist als 500 °C.
12. Verfahren nach Anspruch 9,
wobei die zweite Temperatur geringer ist als 450 °C.
13. Verfahren nach Anspruch 10 oder 11,
wobei die zweite Temperatur geringer ist als 400 °C.
14. Verfahren nach Anspruch 9,
wobei das Übertragen von Wärme an dem einzelnen
gemeinsamen ersten Wärmerückgewinnungsab-
schnitt (336) das Übertragen von Wärme umfasst
aus dem Abgasausflussstrom (385) von jedem der
mindestens zwei Feuerungen (316) auf Dampf unter
Verwendung von einem ersten Wärmetauscher
(312), auf Kesselspeisewasser unter Verwendung
eines zweiten Wärmetauschers (310) und auf Luft
unter Verwendung eines dritten Wärmetauschers
(331).
Revendications
1. Appareil destiné à produire du gaz de synthèse com-
prenant:
au moins deux fours (316), chacun comprenant
au moins un tube de reformage de type baïon-
nette (315), chaque four (316) étant adapté
pour:
recevoir un gaz comprenant un hydrocar-
bure et au moins un élément parmi de la
vapeur et du dioxyde de carbone par le biais
du tube de reformage de type baïonnette
(315);
chauffer et faire réagir catalytiquement le
gaz pour former du gaz de synthèse à une
première température;
refroidir le gaz de synthèse jusqu’à une
deuxième température plus basse que la
16
première température; et
éjecter le gaz de synthèse du tube de refor-
mage de type baïonnette (315);
chacun des au moins deux fours (316) ayant
5 un courant d’effluent de gaz de combustion
(385) et un courant d’effluent de gaz de syn-
thèse (317) ;
une unique première section de récupération de
10 chaleur commune (336 ; 310, 312, 331) fonc-
tionnellement raccordée à chacun des au moins
deux fours (316), les courants d’effluent de gaz
de combustion (385) de chacun des au moins
deux fours (316) étant en communication ther-
15 mique avec une charge thermique à l’intérieur
de la première section de récupération de cha-
leur commune (336 ; 310, 312, 331); et
une deuxième section de récupération de cha-
leur (303) adaptée pour transférer de la chaleur
20 depuis un courant d’effluent de gaz de synthèse
à une charge d’hydrocarbure (381) de chacun
des au moins deux fours (316) avant que la char-
ge d’hydrogène conjointement avec au moins
un élément parmi de la vapeur et du dioxyde de
25 carbone soit reçue par un tube de reformage de
type baïonnette respectif (315) de chacun des
au moins deux fours (316).
2. Appareil de la revendication 1,
30 dans lequel la charge thermique comprend un seul
élément parmi de l’eau, de la vapeur, de l’air, et une
combinaison d’air, d’eau et de vapeur.
3. Appareil de la revendication 1,
35 dans lequel l’unique première section de récupéra-
tion de chaleur commune comprend un ou plusieurs
brûleurs adaptés pour effectuer un chauffage sup-
plémentaire d’une charge.
40 4. Appareil de la revendication 1,
comprenant en outre au moins trois fours (316), l’uni-
que première section de récupération de chaleur
commune (336 ; 310, 312, 331) fonctionnellement
raccordée à chacun des au moins trois fours (316),
45 dans lequel les courants d’effluent de gaz de com-
bustion (385) de chacun des au moins trois fours
(316) sont en communication thermique avec une
charge thermique à l’intérieur de l’unique première
section de récupération de chaleur commune (336).
50
5. Appareil de la revendication 1
configuré de telle sorte que la deuxième température
est inférieure à 500 °C.
55 6. Appareil de la revendication 1
configuré de telle sorte que la deuxième température
est inférieure à 450 °C.
10
 17 EP 3 160 632 B1 18

7. Appareil de la revendication 1 dans lequel la deuxième charge thermique com-

configuré de telle sorte que la deuxième température prend un élément parmi de l’eau, du dioxyde de car-
est inférieure à 400 °C. bone, un hydrocarbure, et un mélange de ceux-ci.

8. Appareil de la revendication 1, 5 11. Procédé de la revendication 9,

dans lequel l’unique première section de récupéra- dans lequel la deuxième température est inférieure
tion de chaleur commune (336) pour la charge ther- à 500 °C.
mique comprend:
12. Procédé de la revendication 9,
un premier échangeur de chaleur (312) configu- 10 dans lequel la deuxième température est inférieure
ré pour échanger de la chaleur entre le courant à 450 °C.
d’effluent de gaz de combustion commun (385)
et de la vapeur; 13. Procédé de la revendication 10 ou 11,
un deuxième échangeur de chaleur (310) con- dans lequel la deuxième température est inférieure
figuré pour échanger de la chaleur entre le cou- 15 à 400 °C.
rant d’effluent de gaz de combustion commun
(385) et de l’eau d’alimentation de chaudière; et 14. Procédé de la revendication 9,
un troisième échangeur de chaleur (331) confi- dans lequel le transfert de chaleur au niveau de l’uni-
guré pour échanger de la chaleur entre le cou- que première section de récupération de chaleur
rant d’effluent de gaz de combustion commun 20 commune (336) comporte le transfert de chaleur de-
(385) et l’air. puis le courant d’effluent de gaz de combustion (385)
de chacun des au moins deux fours (316) à de la
9. Procédé de production de gaz de synthèse, le pro- vapeur au moyen d’un premier échangeur de chaleur
cédé comprenant : (312), de l’eau d’alimentation de chaudière au
25 moyen d’un deuxième échangeur de chaleur (310),
la réception, à l’intérieur d’au moins deux fours et l’air au moyen d’un troisième échangeur de cha-
(316), par le biais d’un tube de reformage de leur (331).
type baïonnette (315) situé au moins partielle-
ment à l’intérieur de chaque four (316) des au
moins deux fours (316), d’un gaz comprenant 30
un hydrocarbure et au moins un élément parmi
de la vapeur et du dioxyde de carbone;
le chauffage et la réaction catalytique dudit gaz
pour former du gaz de synthèse à une première
température; 35
le refroidissement du gaz de synthèse jusqu’à
une deuxième température plus basse que la
première température;
l’éjection du gaz de synthèse du tube de refor-
mage (315) ; et, 40
à l’intérieur d’une unique première section de
récupération de chaleur commune (336 ; 310,
312, 331), le transfert de chaleur depuis un cou-
rant d’effluent de gaz de combustion (385) de
chacun des au moins deux fours (316) à une 45
charge thermique et,
à l’intérieur d’une deuxième section de récupé-
ration de chaleur (303), le transfert de chaleur
depuis ledit courant d’effluent de gaz de synthè-
se (317) à une charge d’hydrocarbure (381) de 50
chacun des au moins deux fours (316) avant
que la charge d’hydrocarbure conjointement
avec au moins un élément parmi de la vapeur
et du dioxyde de carbone soit reçue par un tube
de reformage de type baïonnette respectif (315) 55
des au moins deux fours (316).

10. Procédé de la revendication 9,

11
EP 3 160 632 B1

12
EP 3 160 632 B1

13
EP 3 160 632 B1

14
EP 3 160 632 B1

15
 EP 3 160 632 B1

REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the European
patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be
excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• US 20090180949 A1 [0002] • US 20120326090 A [0002]

• US 20030131533 A1 [0002] • EP 0437059 A2 [0002]
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• US 4985231 A [0002]

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