SMR PRE-REFORMER DESIGN: Case Study

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SMR PRE-REFORMER DESIGN
Case Study #0618416GB/H
Contents

1. SMR Pre-Reformer Design
2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation

Technical Review and Commentary on Proposed Design

APPENDIX
A. Operating / Mechanical Data
B. Materials Specifications
C. Fabrication and Inspection Requirements
D. Weights
E. Nozzle Data
F. Instrument Connections
G. Manholes

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SMR PRE-REFORMER DESIGN: Case Study

  1. 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com GBH Enterprises, Ltd. SMR PRE-REFORMER DESIGN Case Study #0618416GB/H Process Information Disclaimer Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the Product for its own particular purpose. GBHE gives no warranty as to the fitness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability for loss, damage or personnel injury caused or resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.
  2. 2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com SMR Pre-Reformer Design: Case study Objective: Evaluation of a proposed SMR Pre-Reformer design. Background Pre-Reformers  React hydrocarbon feed with steam to give a methane rich product suitable for further downstream reforming.  Pre-reforming works as an adiabatic steam reforming step over a Ni based catalyst.  The basis for the reforming may be considered as the reaction between a hydrocarbon and steam • steam / methane reaction • water / gas shift reaction Typical Pre-Reformer Installation:
  3. 3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com SMR Pre-Reformer Design: Case Study #0618416GB/H Contents 1. SMR Pre-Reformer Design 2. Inlet Baffle Design 3. Outlet Collector 4. Hold Down Grating 5. Floating Hold Down Screen 6. Catalyst Drop Out Nozzle 7. Thermowell Detail 8. Technical Performance requirements 9. SMR Pre-Reformer Isolation Technical Review and Commentary on Proposed Design APPENDIX A. Operating / Mechanical Data B. Materials Specifications C. Fabrication and Inspection Requirements D. Weights E. Nozzle Data F. Instrument Connections G. Manholes
  4. 4. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com SMR Pre-Reformer
  5. 5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Inlet Baffle INLET BAFFLE NOTE: 1. Number, size and placement of support vanes by EPC contractor minimum 4 vanes required. 2. Final design and details by EPC contractor.
  6. 6. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Outlet Collector Table of Dimensions Nozzle Specifications: A, o C: 198 B, mm: 25 Open Area, m2 : 0.56 ΔP, bar: 2.86 C, mm: 25 D, o C: 250 Notes: 1. Uniformly perforate elliptical head with (“A”) “B” Dia. Holes pitch may be square or triangular. 2. Collector must withstand tabulated DP plus bed weight. 3. Open area tabulated is effective (i.e., hole area x wire screen open area) 4. Final design and details by EPC Contractor. Supplied by vessel vendor.
  7. 7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Hold Down Grating Notes: 1. Vessel vendor to install (2) sets of continuous rings at indicated elevations shown on sheet 6 to accommodate catalyst bed heights depending on which catalyst supplier is used. The continuous rings above hold down grating from overturning while allowing up and down movement. Rings to be welded to the shell. 2. Minimum open area is 70%. 3. Final design and details by EPC contractor.
  8. 8. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Floating Hold down Screen Note: 1. Wire Screen to be 6 x 6 x 1.19 mm Diameter wire. 2. Vessel vendor shall supply sufficient 1.0 mm diameter wire for field use to lace screen sections together along the overlaps. 3. Match mark sections for field installation. Screen sections and ring segments must pass through vessel manhole. 4. Final design and details by EPC Contractor.
  9. 9. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Catalyst Dropout Nozzle
  10. 10. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Thermowell Design Details
  11. 11. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com SMR Pre-Reformer Isolation
  12. 12. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Technical Review and Commentary on Proposed Design Bed Temperature Measurement: Bed temperature measurement is provided via a single thermo-well. There is no indication of the number of measurement points this will contain. For a vessel of this diameter a single thermo-well does not provide adequate coverage through the vessel. Pre-reforming catalysts should not be allowed to come into contact with liquid water. The proposed temperature control arrangement (both upstream and downstream of the reactor) provides a potential source of water to enter the system. In any future statement with respect to pre-reformer performance it will be assumed that water injected upstream of the pre-reformer feed pre-heater will be fully vaporized before coming into contact with the catalyst bed. Should this be found to not be the case in ultimate operation of the plant this will invalidate any performance guarantees that may be offered at the time of catalyst purchase. Note: Without additional information we are unable to comment on the suitability or otherwise of the proposed temperature control arrangement. Inlet Gas distributor: GBHE has no experience on this type of design and cannot comment on its performance. The inlet pipe does not meet the GBHE’s ‘straight length’ requirement and hence even more importance is placed on the good performance of the distributor itself. Good distribution is essential to ensure even flow through the bed. Hold Down Grid: It is proposed to place a hold down grid on top of the bed together with a wire mesh. Use of a wire mesh can lead to the potential risk of a partial blockage resulting in mal-distribution in flow. The use of wire mesh screens in the reactor is unacceptable.
  13. 13. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Outlet Collector: The outlet collector is, shown as covered by a wire cloth. As mentioned above the use of wire mesh is unacceptable in the reactor. Isolation system: The sketch shown indicates that on an emergency shutdown the pre-reformer is automatically bypassed and the reactor isolated. Apparently it is intended that the bypass be used to maintain production during catalyst change out, or perhaps it is a feature in the proposed start-up or shut down sequence? Without more knowledge of the overall operating philosophy to be used GBHE is unable to provide any detailed comment on adequacy of the proposed arrangement. Flaw List: The list provided makes reference to the possible presence of BTX in the feed but does not state how much. Pre-Reforming catalyst can tolerate aromatic compounds and will successfully operate in the presence of such components. The levels present may impact on life of the catalyst and this can only be evaluated at the time of the catalyst enquiry when performance/guarantee levels are being considered. Inert Ballast: Three types of inert materials are recommended. GBHE experience suggests that only material of the following specification is acceptable; Al2O3 99.0 wt% (min) SiO2 0.2 wt% (max) TiO2 0.5 wt % (max)
  14. 14. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX A. Operating Data Working temperature 515 0 C Working Pressure 27.5 bar ga Design temperature, upper / lower 535 / 4 0 C Design pressure 33 bar ga Vapor 79.08 kg/s Molecular Weight 17.8 Density at working temperature 7.81 kg/m3 Mechanical Data Diameter of Shell ID 3500 mm Length between Tangent Lines 2500 mm Height of skirt to bottom tangent line 7300 mm Type of Heads Hemispherical Wall Thickness Shell 110 mm Top Head 56 mm Bottom Head 56 mm Corrosion allowance 3 mm Insulation thickness 200 mm (Hot) Catalyst Volume 25.5 m3
  15. 15. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com B. Materials Specifications Shell EN 10028-2 10CrMo9-10 Downcomers Cladding/lining of Shell N/A Baffles Heads EN 10028-2 10CrMo9-10 Internal Pipe Fittings Cladding/lining of Heads N/A Stud Bolts External Reinforcing rings N/A Nuts External Skirt (Top 2000mm) EN 10028-2 10CrMo9-10 Bolts Internal Skirt Balance ASTM A516 – Gr.70 Nuts Internal Jacket N/A Gaskets Internal Shell flanges N/A Gaskets Internal Nozzels prEN 10216-2 10cRmO9-10 “ (DN 350 and smaller) Nozzles prEN 10216-2 10cRmO9-10 “ (DN 400 and larger) Flanges (ASME) EN 10222-2 11CrMo9-10 Internal Wire Screen Flanges (Non-ASME) EN 10222-2 11CrMo9-10 Hold Down Grating Welding fittings prEN 10216-2 10cRmO9-10 Floating Hold Down rings Stiffening rings N/A Insulation Support Rings As Shell Cleats for platforms, etc. As Shell Internal Parts As Shell
  16. 16. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com C. Fabrication and Inspection Requirements Inspection Authority Client Third Party, including design review Stress relieving Yes, per code Special heat treatment Yes, EPC Contractor Radiography Per Code Other Non-destructive Testing Per Code Chemical Analysis See GBHE D. Weights Erection weight (shipping weight) 58,000 kg Total weight operating 105,000 kg Total Weight Full of Water 124,000 kg Max O/T Moment at Base 500 kNm Max Base Shear 70 kN E. Nozzle Data Vapor In DN 750 CL 900 # RFLWN Vapor Out DN 750 CL 900 # RFLWN Drain DN 80 CL 900 # RFLWN Utility Connection DN 50 CL 900 # RFLWN Catalyst Unloading Connection DN 200 CL 900 # RFLWN F. Instrument Connections Diff Press Indicator DN 50 CL 900 # RFWN Thermowell DN 80 CL 900 # RFWN PG DN 50 CL 900 # RFWN G. Manholes 600 I.D. CL 900# RFLWN
  17. 17. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

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