Steam Reformers

SELAS-LINDE GmbH
The Furnace Company

Furnace Technology Meet
Steam Reformers
Tuesday, 23 April 2013 Mumbai
Thursday, 25 April 2013 New Delhi
SL _ PS / Dziurdza 2 19
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to 20
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October 2010
General
Process Design
Mechanical Design
Control and Safety Philosophy
References
Competing Reformer Technologies
Linde Reformer Technology
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to 20
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October 2010
Gas Generation by Steam Reforming
is applied for the production of
Hydrogen
Carbon Monoxide
Synthesis Gas
Reducing Gas
Ammonia
Methanol
Hydrocarbons
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to 20
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October 2010
Basic Chemistry:
C
n
H
m
+ mH
2
O
CH
4
+ H
2
O
CO + H
2
O
nCO + (n+m/2) H
2
CO + 3 H
2

CO
2
+ H
2

endothermic
endothermic
exothermic
Internal Heat Supply
by partial combustion of feedstock
External Heat Supply
Overall endothermic
Reformer Design Application
- Fundamental Reforming Chemistry
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to 20
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October 2010
Top-Fired
Reformer
Side-Fired
Reformer
Terraced-Wall
Reformer
Bottom-Fired
Reformer
Tubular Reformer Types
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to 20
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October 2010
General
Process Design
Mechanical Design
References
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to 20
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October 2010

Steam/ Carbon Ratio
Pressure
Tube Exit Temperature
Tube Inlet Temperature
Air Preheat Temperature
Excess Air
Process Design Variables

Heat Flux
Tube Inner Diameter
Heated Tube Length
Tube Material
Overall Arrangement
Mechanical Design Variables

Unit Cost of Feed/Fuel/Power
Export Steam Flow Rate
Desired Payback
Owner Design Criteria
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to 20
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October 2010
feedstock
catalyst type
demand of downstream units
downstream process units (e.g. PSA)
feed supply pressure
tube material
Reformer application
tube material
type of feedstock
material limits
export steam demand
NO
x
limitations
forced or induced draught
fuel type
quality of distribution
export steam demand
Steam / Carbon Ratio
Pressure
Tube Exit Temperature
Tube Inlet Temperature
Air Preheat Temperature
Excess Air
Process Design Variables
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October 2010
Low Steam / Carbon Ratio
High Pressure
High Tube Exit Temperature
High Tube Inlet Temperature
High Air Preheat Temperature
Low Excess Air
High Heat Flux
To cope with the more stringent request on the process variables like
Design limits are approached
Design margins have to be reduced
More sophisticated design tools have to be used
Environmental limits have to be considered
Challenges in Reformer Design
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October 2010
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
Top Fired Reformer Principle
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October 2010
Radiation from two sides Radiation from one side
T
T
DT
Circumference Temperature Distribution
D
i
r
e
c
t
i
o
n

o
f

m
a
x
i
m
u
m

F
l
u
x
D
i
r
e
c
t
i
o
n

o
f

m
a
x
i
m
u
m

F
l
u
x
D
i
r
e
c
t
i
o
n

o
f

m
a
x
i
m
u
m

F
l
u
x

T
u
b
e

P
i
t
c
h

Catalyst Tube Design
DT
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October 2010
Tubewall Temperature Profiles
770
780
790
800
810
820
830
840
850
860
870
880
0,0 2,0 4,0 6,0 8,0 10,0 12,0
Heated Tube Length <m>
T
e
m
p
e
r
a
t
u
r
e

<
C
>

Calc.average TWT
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to 20
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October 2010
Tubewall Temperature Profiles
820
840
860
880
900
920
940
960
0,0 2,0 4,0 6,0 8,0 10,0 12,0
Heated Tube Length <m>
T
e
m
p
e
r
a
t
u
r
e

<
C
>

Calc.average TWT
Calc. max TWT
Calc.max TWT with maldistribution allowance
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to 20
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October 2010
General
Process Design
Mechanical Design
References
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to 20
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October 2010
Typical Basic Dimensions:

Spacing row to row: 2100 - 2300 mm
Spacing wall to row: 1600 - 1800 mm
Spacing tube to tube: 260 - 300 mm

Tube inside diameter: 4 - 4.5 inch
Ratio Tube spacing: 1.8 - 2.0

max. tubes/burner 4 - 5
max. No. of tubes/row 54
Mechanical Design Variables
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October 2010
Top Fired Reformer - General Arrangement
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October 2010
Inlet Section
Radiant Section
Outlet Section
Radiant Box Sectional View
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to 20
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October 2010
Inlet Main Header
Inlet Sub Header
Inlet Pigtail
Reformer Tube
Outlet Pigtail
Hot outlet Header
Cold outlet Header
Feed Line
Hot System
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to 20
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October 2010
Fuel and Combustion Air
Distribution System
Feed Distribution System
Penthouse Ventilation
Tube Suspension System
Key Design Elements
Top Fired Reformer - Inlet Section
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to 20
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October 2010
Tube Suspension System
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to 20
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October 2010
Catalyst Tubes
Burners
Insulation
Key Design Elements
Top Fired Reformer - Radiant Section
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October 2010
Row Wise Modular Burner Design
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October 2010
Row Wise Modular Burner Design
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October 2010
Row Wise Modular Burner Design Concept
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October 2010
Burners
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October 2010
Harped Catalyst Tube Design
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to 20
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October 2010
Installed Catalyst Tube Harps
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to 20
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October 2010
Cold Collecting System
Fluegas Collecting System
Hot Collecting System
Key Design Elements
Top Fired Reformer - Outlet Section
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October 2010
Cold Collecting System
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to 20
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October 2010
Completely Insulated/Painted
Modular Components
Integrated SCR Design
Key Design Elements
Waste Heat Recovery Unit Modular Design
SL _ PS / Dziurdza
Overview of technologies: DeNOx System
Nitrogen compounds
NOx

DeNOx
+ High NOx reduction rates
+ Lower operating temperature
- High investment costs
- Catalyst has to be replaced
- Sensitivity of catalyst

Selective Catalytic Reduction (SCR)
+ Low investment costs
+ Easy maintenance
+ No major replacement parts
- Lower reduction rates
- Higher operating temperature
- Potential problems with WHR
Selective Non-Catalytic Reduction (SNCR)
SL _ PS / Dziurdza
Overview of technologies: DeNOx - Chemistry
Organic Nitrogen compounds in waste streams
NOx-formation

Injection of NH
3
or urea solution:
CO(NH
2
)
2
+ 2 NO + O
2
=> 2 N
2
+ CO
2
+ 2 H
2
O
4 NH
3
+ 4 NO + O
2
=> 4 N
2
+ 6 H
2
O

Injection controlled by downstream NOx-analyser
Minimisation of ammonia slip
DeNOx
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October 2010
Waste Heat Recovery Unit Modular Design
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October 2010
General
Process Design
Mechanical Design
References
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October 2010
TRIP
Reformer Fuel
Pressure
LOW
Combustion
Air Flow
LOW
Reformer
Furnace
Pressure
HIGH
Fluegas Fan
TRIP
Combustion
Air Fan
TRIP
Steam/
Carbon Ratio
LOW
Steam Drum
Level
LOW
Process
Feed Flow
LOW
Local and
Panel Hand
TRIPS
Reformer exit
temperature
HIGH
Furnace
Flame
Detector
FAILURE
Instrument Air Failure
Power Failure
Closes Process
Steam to a
minimum stop
Stops PSA
Program
Isolates Process
Feed to Reformer
Opens Vent
between Fuel
Valves
Isolates Reformer
Fuel
Stops Hydrogen
Compressor
Closes Valve inlet
PSA
Emergency Shut-Down System
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to 20
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October 2010
General
Process Design
Mechanical Design
References
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to 20
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October 2010
Application Ranges of Top Fired Reformers and Lindes Experience
1000
No. of Catalyst Tubes
436
No. of Tube Rows
16
9
Pressure (bar)
45
41
Exit Temperature (C)
1000
945
Application Ranges
SL _ PS / Dziurdza
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/m 84495
Selected Number of Tubes - 768
Number of Rows - 16
Tubes per Row - 48
Distance Tube/Tube (Center) mm 290
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
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 %
Burner Capacity (60%) MW 1.83 + 10 %
Total Burner Capacity MW 592.80
Combustion Air Excess 10%
Combustion Air Temperature C 360
SL _ PS / Dziurdza
Reformer Plot Plan Side View
SL _ PS / Dziurdza
Reformer Plot Plan Top View
SL _ PS / Dziurdza
SMR Process Flow Scheme
SL _ PS / Dziurdza
Reformer Section View
SL _ PS / Dziurdza
Reformer Side View
SL _ PS / Dziurdza
Reformer penthouse insight
SL _ PS / Dziurdza
Reformer Process Gas Piping

SL _ PS / Dziurdza
Feed Distribution System
SL _ PS / Dziurdza
Linde Catalyst tube design
Gas inlet through
Top Flange
Thermal Plug
Catalyst Grid
Catalyst Tube
Material: 2535 CrNiNbTi Microalloy R
Inner diameter: 4 to 4.5 inches
Heated Length: 12 to 14 metres
Top Flange
Outlet Pigtail
Material: Incoloy 800H
Inner diameter: 30 mm
Length: 600 to 800 mm
SL _ PS / Dziurdza
Linde Catalyst tube design
SL _ PS / Dziurdza
Burner Design
204 forced draft Low-NOx arch burners in total
Callidus, Zeeco, Bloom
17 rows 12 burners
15 rows with 100% burners 3.05MW
2 rows with 60% burners 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 1060C
Staged combustion air headers
SL _ PS / Dziurdza 50
Computational Fluid Dynamics
Fluid dynamics optimization
Software: FLUENT
SL is equipped with 4 Workstations

Radiant Zone Optimization - optional
SL _ PS / Dziurdza
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

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October 2010
Top Fired Reformer in Italy - 4 rows -
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to 20
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October 2010
Top-Fired Reformer in USA - 7 rows -
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October 2010
Top-Fired Reformer in India - 8 rows -
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to 20
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October 2010
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
Summary
COST EFFECTIVE,
RELIABLE AND MECHANICALLY ADVANCED DESIGN
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to 20
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October 2010

General
Process Design
Mechanical Design
References
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to 20
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October 2010
Top-Fired
Reformer
Side-Fired
Reformer
Terraced-Wall
Reformer
SIDE FIRED STEAM REFORMER
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October 2010
Top Fired Side-/Terraced Fired
Shape Rectangular Box Long & Narrow Box
No. of Cells Single Single or Multiple
Tube
Arrangement
Several Parallel Rows One Row per Cell
Process Flow Down Down
Flue Gas Flow Co-Current Counter-Current
Convection
Section
Horizontal at grade
Vertical along side box
Elevated above Radiant
Vertical Down
Draft Balanced or induced
Balanced, Induced or
Natural
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October 2010
Top Side Terraced
Maintenance Cost
Control Complexity
No. of Burners
Burner Access
Piping mass
Surface Area (box)
Natural Draft Operation
Heat input Control along tube
Investment Cost
Ease of expansion
high low
no
yes yes
no
yes yes
Reformer Design Application
SMR Configuration Comparisons
SL _ PS / Dziurdza
61
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
STEAM REFORMER
Key Data:

- No. 396 tubes
- No. 9 rows of tubes
- inner tube id. 127mm
- Heated tube length
11,5m
- tube spacing 290 mm
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
Ammonia
Product
Atmospheric
Air
Hydrocarbon
Feed
H2 Unit
with
PSA Purification
N2 Unit
Ammonia
Synthesis
Loop
Possible valuable By-Products
H2 Unit
with
PSA Purification
N2 Unit
Ammonia
Synthesis
Loop
Hydrocarbon
Feed
Atmospheric
Air
Ammonia
Product
CO2 CO H2
N2 O2 Ar
Rare
Gases
Methanol
CO Recovery
MEOH Unit
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
Comparison of LAC process with conventional scheme
Desulfu-
rization
Feed
Air
Primary
Reformer
Inertgas
Unit
Primary
Reformer
Desulfu-
rization
Feed
Air
Nitrogen
Unit
Secondary
Reformer
HT
Shift
Isothermal
Shift
LT
Shift
CO2
Removal
Metha-
nation
PSA
Ammonia
Synthesis
Ammonia
Synthesis
Purgegas
Separation
NH3
CO2
NH3
Conventional Ammonia Plant
H2 - Unit
Comparison of LAC process with conventional scheme
Desulfu-
rization
Desulfu-
rization
Primary
Reformer
Isotherma
l
Shift
Conventional Ammonia Plant
HT
Shift
LT
Shift
CO2
Removal
Methan-
nation
Ammonia
Synthesis
Purgegas
Separation
Feed
Air
Primary
Reformer
PSA
Nitrogen
Unit
Ammonia
Synthesis
NH3
CO2
NH3
Feed
Air
Secondary
Reformer
Downstream this point
the flowrate of a conventional
plant is 30 to 80% higher
compared to the LAC-process
0
Purgegas Separation
Cost related facts:
number of temperature changes
temperture levels
flowrate
number of equipment and catalyst

Efficiency related facts:
heat exchange losses
pressure drops
LAC-Process
Conventional Plant
Figure 1
Linde Isothermal Reactor
Figure 4
Steam
Circulating
Water
Boiler Feed Water
Gas Entry
Gas
Exit
Circulating
Water
Comparision of Equipment Items
Exchangers
Vessels
Columns
Reactors
Big Machines
(Compressors,Turbines
Generator)
Pumps
Other Machines
Air Separation Unit
Inert Gas Unit
Purge gas separator
PSA Unit

Totals
Conventional
Plant
LAC
Plant
60
25
8
8
6

35
11
-
1
1
-

155
34
19
4
5
4

25
12
1
-
-
1

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
Comparision of Catalyst volumes 1350 MTPD NH3
Conventional
Plant
LAC
Plant
Desulphurisation
Primary Reformer
Secondary Reformer
HT Shift
LT Shift
Methanation
Ammonia Synthesis
24.8 m3 28.0 m3
36.0 m3
35,1 m3
70.5 m3
96.5 m3
27.0 m3
92.3 m3
37.0 m3
--
--
52.0 m3
--
83.9 m3
Total 382.2 m3 200.9 m3
Linde 12-Bed PSA System Top View
110.000 Nm3/h H2
Linde Air Separation Plant
Conventional Cryogenic Process
cold generation air compression air purification heat exchange rectification
AIR
GAN
GOX
filter
air compressor
expansions-
turbine with
booster-
compressor
heat-
exchanger
pressure-
column
low pressure-
column
evaporator/
condenser
direct-contact
cooler
evaporation
cooler
molecularsieve
adsorber
Impure GAN
coldbox
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
SL _ PS / Dziurdza
Thank you
for your attention
Klicken Sie, um das Format des
Untertitelmasters zu bearbeiten
Lindes HyCO offerings
BOO / Over the Fence Supply
SL _ PS / Dziurdza
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. Lindes Operational Excellence
6. Overall value that Linde can bring to IOCL/BP

SL _ PS / Dziurdza
DESIGNS
BUILDS
OPERATES
LINDE IS ONE OF THE FEW COMPANY IN THE WORLD THAT
ASU, HYDROGEN, SYNGAS & CO FACILITIES
USING THEIR OWN IN-HOUSE TECHNOLOGY
Linde Hydrogen Technology
SL _ PS / Dziurdza
LINDE GAS
OPERATES AND MAINTAINS
LINDE ENGINEERING
DESIGNS & BUILDS
EXPERIENCE
Plant Operation
SL _ PS / Dziurdza
Hydrogen and Synthesis Gas technologies of the
Linde Engineering Division
Product Line
Hydrogen & Synthesis
Gas
Hydrogen Plants
H2/CO Plants
CO-Plants
Syngas Plants
Ammonia Plants
Methanol Plants
Gas Removal Processes
Gas Separation Processes
SL _ PS / Dziurdza
The Best in the Business Trust Us
SL _ PS / Dziurdza
Linde Gas - Worldwide market share and position
1
#3 North America
15%
#2 Europe
32%
#2 South America
24%
#1 Africa
42%
#1 Asia/Pacific
2
19%
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
SL _ PS / Dziurdza
Linde Group in India
- BOC India Limited
BOC India Limited (A member of The Linde Group), is Indias leading Industrial
Gas Company which is established over 75 years in India with headquarters in
Kolkata.
BOCI has around 700 employees in India
SL _ PS / Dziurdza
Linde Gas On-site / BOO Plants Worldwide
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
In total Linde is operating more than 1000 plants producing
industrial gases in all continents with strong focus in Asia

SL _ PS / Dziurdza
Overview of the major syngas (H2/ CO) production facilities
owned and operated by the Linde Group
La Porte
Concon
Singapore
Caojing
Leuna
Milazzo
H2/CO-plant
H2-plant
POX-plant
Toledo
Lima
Lemont
Salt Lake
Bulwer
Clear Lake
Paraguana
Concepcion
Daesan
Murrin-
Murrin
Teesside
Map Tha Phut
Aurangabad
SL _ PS / Dziurdza
BOO or On-site Supply Typical Commercial Model
Feedstock/Air &
Utilities
Customer Production
Fixed Fee for Capital
Recovery and Fixed
Operational Cost
Unit Charge for
molecules (adjusted
with actual price of
Feedstock & Utilities)
15 year contract
Supply of H2,
CO, Syngas, CO2
,O2, N2
molecules
HYCO Plant
Or ASU
HYCO Plant
Or ASU
SL _ PS / Dziurdza
Summary of Benefits of over the fence supply scheme
Improved Gas Economics
FINANCIAL
Capital Avoidance.
Payments only begin when
gas is delivered.
Level and predictable gas
costs.
Turnaround peaks avoided.
No major $MM surprises
SHIFT OF RISKS
Capital Accuracy
Construction
Maint. & Operations
Accuracy
Volatility
On-Stream Reliability
Labor Relations, Cost, &
Legacy.
Changing Safety & Maint.
Standards & Policies.
IMPROVED ALIGNMENT
15+ Year, not 2 3 as for LSTK
Low gas cost, not cheap equipment
Alignment of gas delivery / need
schedule.
Mechanical completion inappropriate
target.
Collaborate on cost/benefit
analysis decisions.
Continuous innovation
Maintain Competitiveness
Improve Reliability
Improved Safety Practice
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
SL _ PS / Dziurdza
H2 for Refinery Toledo, USA
Steam Reformer supplying H2 to 2 Refineries

H2: 144,000 Nm3/h
Steam: 67.8 t/h
Feed: Natural Gas / ROG / RFG
Fuel: Natural Gas / ROG / RFG

Average Reliability of each train
>>99,5%

2 x Top-fired Selas Reformer Trains
12 bed Linde PSA
SL _ PS / Dziurdza
Thank you
for your attention
Klicken Sie, um das Format des
Untertitelmasters zu bearbeiten
Hans Dziurdza
Manager Sales and Marketing

SELAS-LINDE GmbH
Wolfratshauser Str. 138
82049 Pullach
Phone +49 89 7447 47 12
Fax +49 89 7447 47 81
hans.dziurdza@linde-le.com
www.selas-linde.com

Thank you for your attention.

Steam Reformers

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The Furnace Company

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