# US 2014/0196875 A1 · Feed ratio control for hter

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- Number: US 2014/0196875 A1
- Document ID: US20140196875A1
- Status: Published application
- Kind: A1
- Application number: 14/151,435
- Filed: 2014-01-09
- Published: 2014-07-17
- Earliest claimed: 2013-01-14
- Assignees: Haldor TopsøE A/S
- Applicants: Haldor Topsøe A/S
- Inventors: Martin Frahm Jensen; Claus Fallesen Hansen
- Web page: https://patentgrep.com/patent/US20140196875A1

## CPC

- B01J 8/008: {Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction (B01J8/0285, B01J8/067, B01J8/087, B01J8/1836 take precedence)}
- B01J 8/025: {in a cylindrical shaped bed}
- B01J 8/0257: {in a cylindrical annular shaped bed}
- B01J 8/0278: {Feeding reactive fluids (for solid material B01J8/0015)}
- B01J 8/0285: {Heating or cooling the reactor (for tubular reactors in furnaces B01J8/062)}
- B01J 8/062: {being installed in a furnace}
- B01J 8/067: {Heating or cooling the reactor (B01J8/062 takes precedence)}
- C01B 3/382: Processes with two or more reaction steps, of which at least one is catalytic, e.g. steam reforming and partial oxidation
- B01J 2208/00212: Plates; Jackets; Cylinders
- B01J 2219/00006: Large-scale industrial plants
- B01J 2219/00038: Processes in parallel
- B01J 2219/0004: Processes in series
- C01B 2203/0233: the reforming step being a steam reforming step
- C01B 2203/0244: the reforming step being an autothermal reforming step, e.g. secondary reforming processes
- C01B 2203/0283: containing a CO-shift step, i.e. a water gas shift step
- C01B 2203/043: Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
- C01B 2203/0805: Methods of heating the process for making hydrogen or synthesis gas
- C01B 2203/0816: Heating by flames
- C01B 2203/0844: the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
- C01B 2203/1241: Natural gas or methane
- C01B 2203/1247: Higher hydrocarbons
- C01B 2203/1258: Pre-treatment of the feed
- C01B 2203/141: At least two reforming, decomposition or partial oxidation steps in parallel
- C01B 2203/142: At least two reforming, decomposition or partial oxidation steps in series
- C01B 2203/143: Three or more reforming, decomposition or partial oxidation steps in series
- Y02P 20/52: using catalysts, e.g. selective catalysts
- Y10T 29/4935: Heat exchanger or boiler making
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method for designing the construction of a Heat Exchange Reformer (HER) to minimise metal dusting, and a method for improved thermal control in a Heat Exchange Reformer (HER). By analysis of various parameters related to a Main Reforming Unit (MRU) and a Heat Exchange Reformer (HER), improved thermal control and reduced metal dusting is achieved.

## Claims

### Claim 1

A method for designing the construction of a Heat Exchange Reformer (HER) to minimise metal dusting, said HER being part of a synthesis gas production unit, said synthesis gas production unit comprising a Main Reforming Unit (MRU) and a Heat Exchange Reformer (HER), wherein the effluent from the MRU is arranged so as to provide heat to the HER, and wherein a hydrocarbon feedstock is arranged so as to pass in parallel through both the MRU and the HER, thus providing:
a. an MRU hydrocarbon feed having an MRU steam-to-carbon ratio (MRUS/C), an effluent outlet temperature (TMRU) and a MRU hydrocarbon flow rate (FMRU) and
b. an HER hydrocarbon feed having an HER steam-to-carbon ratio (HERS/C) and an HER hydrocarbon flow rate (FHER), said method comprising;
determining how the temperature profile within the HER varies with the distance from the inlet of the HER as a function of the ratio of FHER/FMRU, the MRU outlet temperature (TMRU), the MRU steam-to-carbon ratio (MRUS/C), the HER steam-to-carbon ratio (HERS/C) and the total hydrocarbon flow rate (FMRU+FHER);
from said temperature profile, determining a distance (A) from the inlet of the HER at which metal dusting is not significant;
at a distance greater than said distance (A) from the inlet of the HER, constructing the HER from a first metal has a higher resistance to metal dusting; and
at a distance less than said distance (A) from the inlet of the HER, constructing the HER from a second metal which has a lower resistance to metal dusting than said first metal.

### Claim at position 2

2-5. (canceled)

### Claim 6 (depends on 1)

The method according to claim 1, wherein the HER is a bayonet-type HER or a double-tube type HER.

### Claim 7 (depends on 1)

A method according to claim 1, wherein said method comprises decreasing the ratio of FHER/FMRU.

### Claim 8 (depends on 1)

A method according to claim 1, wherein the MRU provides synthesis gas to a hydrogen plant, ammonia plant, methanol plant and/or synfuel plant.

### Claim 9 (depends on 1)

A method according to claim 1, wherein the MSR is selected from a tubular reformer, an air-blown secondary reformer, an oxygen-blown secondary reformer and an autothermal reformer.

### Claim 10 (depends on 1)

A method according to claim 1, wherein the effluent from the MRU is arranged to flow co-current or counter-current with the HER hydrocarbon feed in the HER.

### Claim 11 (depends on 1)

A method according to claim 1, wherein the hydrocarbon feedstock comprises natural gas, LPG, naphtha, reformulated gasoline (RFG) or a mixture of LPG and naphtha.

### Claim 12 (depends on 1)

A method according to claim 1, wherein said synthesis gas production unit further includes a pre-reformer arranged upstream the MRU and/or the HER.

### Claim 13 (depends on 6)

Use of a method according to claim 6, for reduced metal dusting in the HER.