Method and Apparatus for Producing a Hydrogen-Containing Product

A process for producing a hydrogen-containing product,

• wherein during a first time period, the process comprises:
• heating a first reactant gas mixture comprising steam and a first group of hydrocarbons;
• passing a first fraction or all of the first reactant gas mixture after heating to a heat exchanger thereby cooling the first fraction or all of the first reactant gas mixture in the heat exchanger, the first fraction or all of the first reactant gas mixture passed to the heat exchanger having a mass flow rate, M1,HX;
• passing a second fraction or none of the first reactant gas mixture after heating to a bypass conduit that bypasses the heat exchanger, the second fraction or none of the first reactant gas mixture having a mass flow rate, M1,BP, where M1,BP is zero when none of the first reactant gas mixture is passed to the bypass conduit;
• passing the first fraction or all of the first reactant gas mixture from the heat exchanger to the catalyst-containing reactor, introducing the first fraction or all of the first reactant gas mixture into the catalyst-containing reactor as at least a portion of a feed to the catalyst-containing reactor, the feed to the catalyst-containing reactor having a mass flow rate, M1,T, reacting the first fraction or all of the first reactant gas mixture in the catalyst-containing reactor, and withdrawing an effluent formed from at least the first fraction or all of the first reactant gas mixture from the catalyst-containing reactor;
• passing at least a portion of the effluent from the catalyst-containing reactor to a reformer furnace, introducing the at least a portion of the effluent into a plurality of catalyst-containing reformer tubes in the reformer furnace as a reformer feed gas mixture, reacting the reformer feed gas mixture in a reforming reaction under reaction conditions effective to form a reformate comprising H2, CO, CH4, and H2O, and withdrawing the reformate from the plurality of catalyst containing reformer tubes;
• combusting a first quantity of fuel with a first quantity of oxidant gas 99 in a combustion section of the reformer furnace external to the plurality of catalyst-containing reformer tubes under conditions effective to combust the fuel to form a first quantity of combustion product gas and generate heat to supply energy for reacting the reformer feed gas mixture inside the plurality of catalyst-containing reformer tubes, and withdrawing the first quantity of the combustion product gas from the combustion section;
• wherein during a second time period, the process comprises :
• heating a second reactant gas mixture comprising steam and a second group of hydrocarbons;
• passing a first fraction or all of the second reactant gas mixture after heating through the bypass conduit that bypasses the heat exchanger, the first fraction of the second reactant gas mixture having a mass flow rate, M2,BP;
• passing a second fraction or none of the second reactant gas mixture after heating to the heat exchanger, the second fraction or none of the second reactant gas mixture having a mass flow rate, M2,HX, where M2,HX, is zero when none of the second reactant gas mixture is passed to the heat exchanger, wherein the second fraction of the second reactant gas mixture is cooled in the heat exchanger if the second fraction is passed to the heat exchanger;
• passing the first fraction or all of the second reactant gas mixture from the bypass conduit to the catalyst-containing reactor, introducing the first fraction or all of the second reactant gas mixture into the catalyst-containing reactor as at least a portion of a feed to the catalyst-containing reactor, the feed to the catalyst-containing reactor having a mass flow rate, M2,T, reacting the first fraction or all of the second reactant gas mixture in the catalyst-containing reactor, and withdrawing an effluent formed from at least the first fraction or all of the second reactant gas mixture from the catalyst-containing reactor;
• passing at least a portion of the effluent from the catalyst-containing reactor to the reformer furnace, introducing the at least a portion of the effluent into a plurality of catalyst-containing reformer tubes in the reformer furnace as a reformer feed gas mixture, reacting the reformer feed gas mixture under reaction conditions effective to form a reformate comprising H2, CO, CH4, and H2O, and withdrawing the reformate from the plurality of catalyst containing reformer tubes;
• and
• combusting a second quantity of fuel with a second quantity of oxidant gas 99 in the combustion section of the reformer furnace external to the plurality of catalyst-containing reformer tubes under conditions effective to combust the second quantity of fuel to form a second quantity of combustion product gas and generate heat to supply energy for reacting the reformer feed gas mixture inside the plurality of catalyst-containing reformer tubes, and withdrawing the second quantity of the combustion product gas from the combustion section;
• wherein the first reactant gas mixture has a composition such that when reacted in the catalyst-containing reactor, the first reactant gas mixture reacts exothermically;
• wherein the second reactant gas mixture has a composition such that when reacted in the catalyst-containing reactor, the second reactant gas mixture reacts endothermically;
• and
• wherein
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