Hydrogen production by steam methane reforming
11591215 · 2023-02-28
Assignee
Inventors
- Peter Mølgaard Mortensen (Roskilde, DK)
- Kim Aasberg-Petersen (Alleroed, DK)
- Robert KLEIN (Roskilde, DK)
Cpc classification
B01J2219/00155
PERFORMING OPERATIONS; TRANSPORTING
C01B2203/1023
CHEMISTRY; METALLURGY
C01B2203/141
CHEMISTRY; METALLURGY
B01D53/228
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/00186
PERFORMING OPERATIONS; TRANSPORTING
B01J15/005
PERFORMING OPERATIONS; TRANSPORTING
B01J19/0013
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/2432
PERFORMING OPERATIONS; TRANSPORTING
C01B2203/0283
CHEMISTRY; METALLURGY
B01D53/265
PERFORMING OPERATIONS; TRANSPORTING
C01B2203/0233
CHEMISTRY; METALLURGY
B01J2219/0871
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/2443
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/2416
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/2428
PERFORMING OPERATIONS; TRANSPORTING
B01J12/007
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/00135
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01J19/00
PERFORMING OPERATIONS; TRANSPORTING
C01B3/50
CHEMISTRY; METALLURGY
B01J19/24
PERFORMING OPERATIONS; TRANSPORTING
B01J35/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A hydrogen plant for producing hydrogen, including: a reforming reactor system including a first catalyst bed including an electrically conductive material and a catalytically active material, a heat insulation layer between the first catalyst bed and the pressure shell, and at least two conductors electrically connected to the electrically conductive material and to an electrical power supply placed outside the pressure shell, wherein the electrical power supply is dimensioned to heat at least part of the first catalyst bed to a temperature of at least 500° C. by passing an electrical current through the electrically conductive material, where the pressure shell has a design pressure of between 5 and 200 bar; a water gas shift unit downstream the reforming reactor system; and a gas separation unit downstream the water gas shift unit. A process for producing hydrogen from a feed gas including hydrocarbons.
Claims
1. A hydrogen plant for producing hydrogen, said hydrogen plant comprising: a reforming reactor system comprising a first catalyst bed comprising an electrically conductive material and a catalytically active material, said catalytically active material being arranged for catalyzing steam reforming of a feed gas comprising hydrocarbons, a pressure shell housing said first catalyst bed, a heat insulation layer between said first catalyst bed and said pressure shell, and at least two conductors electrically connected to said electrically conductive material and to an electrical power supply placed outside said pressure shell, wherein said electrical power supply is dimensioned to heat at least part of said first catalyst bed to a temperature of at least 500° C. by passing an electrical current through said electrically conductive material, wherein said pressure shell has a design pressure of between 5 and 200 bar, a water gas shift unit downstream the reforming reactor system, and a gas separation unit downstream the water gas shift unit.
2. A hydrogen plant according to claim 1, wherein said first catalyst bed comprises a structured catalyst comprising a macroscopic structure of electrically conductive material, said macroscopic structure supporting a ceramic coating, wherein said ceramic coating supports a catalytically active material.
3. A hydrogen plant according to claim 2, wherein the first catalyst bed comprises an array of macroscopic structures.
4. A hydrogen plant according to claim 2, wherein said macroscopic structure has a plurality of parallel channels, a plurality of non-parallel channels and/or a plurality of labyrinthic channels.
5. A hydrogen plant according to claim 2, wherein said macroscopic structure is extruded and sintered structure(s).
6. A hydrogen plant according to claim 2, wherein said macroscopic structure is 3D printed and sintered structure(s).
7. A hydrogen plant according to claim 1, wherein the resistivity of the electrically conductive material is between 10.sup.−5 Ω.Math.m and 10.sup.−7 Ω.Math.m.
8. A hydrogen plant according to claim 2, wherein the material of the macroscopic structure is chosen as a material arranged to generate a heat flux of 500 to 50000 W/m.sup.2 by resistance heating.
9. A hydrogen plant according to claim 2, wherein the macroscopic structure and said at least two conductors are connect by a mechanical connection, a welded connection, a brazed connection or a combination thereof.
10. A hydrogen plant according to claim 2, wherein the macroscopic structure has at least one electrically insulating part arranged to increase a principal current path within the macroscopic structure, wherein the at least one electrically insulating part has a length arranged to ensure that a minimum current path between the conductors is larger than the largest dimension of the macroscopic structure.
11. A hydrogen plant according to claim 2, wherein the feed gas comprising hydrocarbon enters into the structured catalyst at a first end and wherein a product gas exits the structured catalyst at a second end, wherein said at least two conductors are connected to the structured catalyst at a position closer to said first end than to the second end.
12. A hydrogen plant according to claim 11, wherein said structured catalyst is constructed to direct an electrical current to run from one conductor to said second end of said structured catalyst and return to a second of the at least two conductors.
13. A hydrogen plant according to claim 1, wherein said pressure shell further comprises one or more inlets close to or in combination with at least one fitting in order to allow a cooling gas to flow over, around, close to, or inside at least one conductor within said pressure shell.
14. A hydrogen plant according to claim 1, wherein the electrically conductive material of the first catalyst bed comprises a resistor embedded in a catalyst material.
15. A hydrogen plant according to claim 14, wherein said embedded resistor supports a ceramic coating, wherein said ceramic coating supports said catalytically active material.
16. A hydrogen plant according to claim 1, wherein the reforming reactor system further comprises a second bed of a second catalyst material upstream said first catalyst bed and within said pressure shell.
17. A hydrogen plant according to claim 1, wherein said gas separation unit comprises one or more of the following units: a flash separation unit, a CO.sub.2 wash unit, a pressure swing adsorption unit, a membrane, and/or a cryogenic separation unit.
18. A hydrogen plant according to claim 1, wherein said hydrogen plant comprises two or more water gas shift units.
19. A hydrogen plant according to claim 1, further comprising a heater unit for heating the feed gas upstream said reforming reactor system.
20. A hydrogen plant according to claim 1, said hydrogen plant further comprising a gas purification unit and/or a prereforming unit upstream said reforming reactor system.
21. A hydrogen plant according to claim 1, wherein said reforming reactor system further comprises a control system arranged to control the electrical power supply to ensure that the temperature of the gas exiting the pressure shell of the reforming reactor system lies in a predetermined range and/or to ensure that the conversion of hydrocarbons in the feed gas lies in a predetermined range and/or to ensure the dry mole concentration of methane lies in a predetermined range and/or to ensure the approach to equilibrium of the steam reforming reaction lies in a predetermined range.
22. A process for producing hydrogen from a feed gas comprising hydrocarbons in a hydrogen plant, said hydrogen plant comprising a reforming reactor system with a pressure shell housing a first catalyst bed, said first catalyst bed comprising an electrically conductive material and a catalytically active material, said catalytically active material being arranged to catalyzing steam reforming of a feed gas comprising hydrocarbons, wherein said reforming reactor system is provided with heat insulation between said first catalyst bed and said pressure shell; said process comprising the following steps: pressurizing said feed gas to a pressure of between 5 and 200 bar, supplying said pressurized feed gas to the reforming reactor system, allowing said feed gas to undergo steam reforming reaction over the first catalyst bed and outletting a product gas from the reforming reactor system, heating said catalytically active material by supplying electrical power via electrical conductors connecting an electrical power supply placed outside said pressure shell to said electrically conductive material, allowing an electrical current to run through said electrically conductive material, thereby heating at least part of the first catalyst bed to a temperature of at least 500° C., letting the product gas into a water gas shift unit downstream the reforming reactor system in order to generate a water gas shifted product gas, condensing water in the water gas shifted product gas and separating this water in a flash separation step, thereby providing a dry water gas shifted product gas, and removing at least CO.sub.2 from the dry water gas shifted product gas in a gas separation unit downstream the water gas shift unit.
23. A process according to claim 22, wherein the feed gas is pressurized to between 80 and 180 bar upstream the reforming reactor system.
24. A process according to claim 22, wherein the process comprises heating the feed gas let into the reforming reactor system to a temperature of between 200° C. and 700° C.
25. A process according to claim 22, wherein the first catalyst bed comprises a structured catalyst comprising a macroscopic structure of electrically conductive material, said macroscopic structure supporting a ceramic coating, wherein said ceramic coating supports a catalytically active material, where the macroscopic structure is heated by leading an electrical current through the macroscopic structure, so that a maximum temperature of the macroscopic structure lies between 500° C. and 1300° C.
Description
SHORT DESCRIPTION OF THE FIGURES
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DETAILED DESCRIPTION OF THE FIGURES
(13) Throughout the Figures, like reference numbers denote like elements.
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(15) Hydrogen H.sub.2 is added to the compressed hydrocarbon gas 5 to obtain a first feed gas 8 comprising hydrocarbons and hydrogen. Typically, the added hydrogen is also compressed (not shown in
(16) The first feed gas 8 is pressurized to a pressure between 5 and 200 bar and has been heated (not shown in
(17) The steam H.sub.2O is also pressurized (not shown in
(18) In the prereforming unit 120, higher hydrocarbons in the second feed gas 9″ reacts with steam and are converted to a mixture of CH.sub.4, H.sub.2, CO, CO.sub.2 and H.sub.2O as an initial step in the process of producing high pressure hydrogen. The pressure of the prereformed gas 11 leaving the prereforming unit 120 is substantially equal to the pressure of the gas 9″ entering the prereforming unit 120. The prereformed gas 11 from the prereforming unit 120 is heated to a suitable process temperature by heat exchange in a heat exchanger 125, thereby rendering a third feed gas 11′ which is led into a reforming reactor system 100.
(19) The reforming reactor system 100 comprises (not shown in
(20) The first feed gas 8 is pressurized prior to letting it into the optional gas purification unit 110, and the gasses 9, 9′, 9″, 11, 11′, 12, 12′, 13, 13′, 14 and 14′, 15 and 16 are compressed to a pressure of substantially the same pressure as the first feed gas 8. However, it should be foreseen that a minor pressure loss will occur through the hydrogen plant 1000, such that the pressure of the high pressure hydrogen gas 16 is up to about 5% lower than the pressure of the first feed gas 8. Thus, if the pressure of the hydrogen gas 16 should be about 100 bar, the pressure of the first feed gas 8 should preferably be at about 105 bar.
(21) The hydrogen plant 1000 may furthermore comprise other heating means, such as further heat exchangers and/or a fired heater in order to heat the gasses within the hydrogen plant 1000. In order to provide a feed gas at a high pressure, one or more compressor may be present in the hydrogen plant upstream the reactor unit 100, preferably upstream the gas purification unit 110. Of such compressors, only the compressor 106 is shown in
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(23) In an embodiment, the electrical power supply supplies a voltage of 26V and a current of 1200 A. In another embodiment, the electrical power supply supplies a voltage of 5V and a current of 240 A. The current is led through electrical conductors 40, 40′ to conductor contact rails 41, and the current runs through the structured catalyst 10 from one conductor contact rail 41, e.g. from the conductor contact rail seen to the left in
(24) The macroscopic structures 5 are made of electrically conductive material. Especially preferred is the alloy kanthal consisting of aluminum, iron and chrome. The ceramic coating, e.g. an oxide, coated onto the structure catalysts 5 is impregnated with catalytically active material. The conductors 40, 40′ are made in materials like iron, aluminum, nickel, copper or alloys thereof.
(25) During operating, the third feed gas 11′ enters the reforming reactor system 100 from above as indicated by the upper arrow and the product gas 12 exits the reforming reactor system from the bottom thereof as indicated by the lower arrow.
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(27) In the reforming reactor system 100 shown in
(28) In the reforming reactor system 100 shown in
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(30) The reforming reactor system 100′ of
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(34) The walls 75 of the structured catalyst 10 are of extruded or 3D printed material coated with a ceramic coating, e.g. an oxide, which has been coated onto the macroscopic structure. In the Figures, the ceramic coating is not shown. The ceramic coating is impregnated with catalytically active material. The ceramic coating and thus the catalytically active material are present on every walls within the structured catalyst 10 over which the gas flow flows during operation and interacts with the heated surface of the structured catalyst and the catalytically active material.
(35) Thus, during use in a reforming reactor system 100 for steam reforming, a hydrocarbon feed gas flows through the channels 70 and interacts with the heated surface of the structured catalyst and with the catalytically active material supported by the ceramic coating.
(36) A slit 60 has been cut into the structured catalyst 10 shown in
(37) The channels 70 in the structured catalyst 5 are open in both ends. In use of the structured catalyst in a reforming reactor system, a hydrocarbon feed gas flows through the unit, in the direction shown by arrows 11′ and 12 in
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(41) It should be noted, that even though the structured catalysts shown in the figures are shown as having channels with a square cross section, as seen perpendicular to the z-axis, any appropriate shape of the cross sections of the channels is conceivable. Thus, the channels of the structured catalyst could alternatively be e.g. triangular, hexagonal, octagonal, or circular, where triangular, square, and hexagonal shapes are preferred.
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EXAMPLES
(49) While the invention has been illustrated by a description of various embodiments and examples while these embodiments and examples have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.
(50) The examples described below relate to hydrogen plants with a reforming reactor system comprising a structured catalyst. Such reforming reactor systems are compact reforming reactor systems since the compact macroscopic supports has a high thermal flux when powered by a power source. It is moreover to be noted, that the dimensions of the structured catalysts may be chosen relatively freely, so that the structured catalyst may be almost cubic in outer shape or it may be wider than its height.
(51) The examples all describe operation conditions with high pressure, ranging from 28 bar to 182 bar. Such high pressures within the hydrogen plant are made possible by the configuration of the reforming reactor system 100 since the structured catalyst within the reforming reactor system 100 has high thermal flux upon powering by a power source, is to some extent thermally insulated from the pressure shell, and the pressure drop through the reforming reactor system 100 is very low compared to an SMR. The macroscopic structure of electrically conductive material will obtain the highest temperature within the reforming reactor system 100, while the pressure shell will have a significantly lower temperature due to the thermal insulation between the structured catalyst and the pressure shell. Ideally, the temperature of the pressure shell will not exceed 500° C. When product gas with a high pressure is needed, such as 30 bar or above, the product gas exiting the reforming reactor system can in many cases be used directly, without the use of compressors. This is due to the possibility of pressurizing the feed gas upstream the reforming reactor system. Pressurizing the feed gas will require less energy than the product gas as the volume of the feed is lower than the volume of the product gas as the steam reforming reaction has a net production of molecules. Additionally, one of the feed gas constituents may be pumped which requires significantly less energy compared to gas compression.
(52) In all the examples described below, the feed gas enters the reforming reactor system and flows through the structured catalyst housed therein. When the heat insulation layer of the reforming reactor system is a heat insulating material, the heat insulating material typically makes up most of the space between the structured catalyst and the pressure shell along the walls of the pressure shell so that the feed gas is forced to flow along walls of the macroscopic structure on its way through the pressure shell.
(53) In the examples below, the structured catalysts described in these examples comprise one or more macroscopic structures. The one or more macroscopic structures of the examples below all support a ceramic coating supporting catalytically active material. Advantageously, substantially all the surface of the macroscopic structure supports the ceramic coating supporting the catalytically active material; however, at connections points, e.g. between two adjacent macroscopic structures or between a macroscopic structure and a conductor, the macroscopic structure may be free from ceramic coating in order to facilitate connection between a conductor and the macroscopic structure.
Example 1
(54) An example calculation of the process of the invention is given in Table 1 below. The composition of a third feed gas 11′ entering the reforming reactor system 100 is given in Table 1 below. The third feed gas 11′ entering the reforming reactor system 100 is a prereformed gas. It has been pressurized to a pressure of 28 bar, viz. 28 kg/cm.sup.2.Math.g, and has a temperature of 500° C.
(55) Inside the reforming reactor system 100, a structured catalyst comprising nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter. Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm. Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure is a zigzag path. A current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure in the reforming reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power supplied in the structured catalysts of 9899 kW. If preferred, the nine macroscopic structures can be parallel coupled in groups of three instead of serial coupling all nine, which will decrease the voltage to ca. 1.8 kV, or even parallel coupled as individual monoliths that would require a voltage of ca. 0.6 kV. This must be chosen according to most suitable configuration of associated power supply.
(56) The reforming reactor system 100 of the current configuration has an overall internal diameter of the reforming reactor system of 3.2 m and a total internal height of 5.5 m when the reforming reactor system 100 is made as a cylindrical reactor system with spherical heads. In this specific configuration, the macroscopic structures are placed in a square orientation having a diagonal length of 2.3 m. In all the examples described herein, except for the comparative example, inert material is placed around the structured catalyst to close the gap to the insulation material, adjacent to the pressure shell. The insulation material in example 1 has a cylindrical form with an internal diameter of 2.5 m and a thickness of 0.35 m.
(57) During the passage of the third feed gas 11′ through the reforming reactor system 100, the third feed gas 11′ is heated by the structured catalyst and undergoes steam reforming to a product gas 12 having an exit temperature of 963° C.
(58) TABLE-US-00001 TABLE 1 Size of macroscopic structure: Edge size [m] 0.53 Height [m] 2.3 Number of macroscopic structures 9 Total volume of structured catalyst [L] 5888 Structured catalyst height/diagonal length [—] 1.02 Feed gas Product gas T [° C.] 500 963 P [kg/cm.sup.2 g] 27.97 27.47 CO2 [Nm.sup.3/h] 168 727 N2 [Nm.sup.3/h] 26 26 CH4 [Nm.sup.3/h] 2630 164 H2 [Nm.sup.3/h] 590 8545 CO [Nm.sup.3/h] 1 1907 H2O [Nm.sup.3/h] 8046 5022 Total flow [Nm.sup.3/h] 11461 16391 ΔT.sub.app,SMR [° C.] 10 Power [kW] 9899 Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 1950
Example 2
(59) An example calculation of the process of the invention is given in Table 2 below. The composition of a third feed gas 11′ entering the reforming reactor system 100 is given in Table 2. The third feed gas 11′ entering the reforming reactor system 100 is a prereformed gas. It has been pressurized to a pressure of 28 bar, viz. 28 kg/cm.sup.2.Math.g, and has a temperature of 500° C.
(60) Inside the reforming reactor system 100, a structured catalyst comprising 1 macroscopic structure having a square cross section is placed which has a size of 0.4 times 0.4 times 0.35 meter. The macroscopic structure additionally has 10000 channels with a square cross section having a side or edge length of 0.32 cm. The macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure is a zigzag path. A current of 200 A and a voltage of ca. 500 V are applied to the macroscopic structure in the reforming reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 99 kW.
(61) The reforming reactor system 100 in the current configuration has an overall internal diameter of the reforming reactor system of 1.2 m and a total internal height of 1.5 m when the reforming reactor system is made as a cylindrical reactor system with spherical heads. In this specific configuration, the structured catalyst has a diagonal length of 0.6 m. Inert material is placed around the structured catalysts to close the gap to the insulation material which has an internal diameter of 0.6 m and a thickness of 0.3 m.
(62) During the passage of the third feed gas 11′ through the reforming reactor system 100, the third feed gas 11′ is heated by the structured catalyst and undergoes steam reforming to a product gas 12 having an exit temperature of 963° C.
(63) TABLE-US-00002 TABLE 2 Size of macroscopic structure: Edge size [m] 0.4 Height [m] 0.35 Number of macroscopic structures 1 Total volume of structured catalyst [L] 55.4 Structured catalyst height/diagonal length [—] 0.61 Feed gas Product gas T [° C.] 500 963 P [kg/cm.sup.2g] 27.97 27.47 CO2 [Nm.sup.3/h] 1.7 7.3 N2 [Nm.sup.3/h] 0.3 0.3 CH4 [Nm.sup.3/h] 26.3 1.6 H2 [Nm.sup.3/h] 5.9 85.4 CO [Nm.sup.3/h] 0 19.1 H2O [Nm.sup.3/h] 80.5 50.2 Total flow [Nm.sup.3/h] 114.7 163.9 ΔT.sub.app,SMR [° C.] 10 Power [kW] 99 Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 2071
Example 3
(64) An example calculation of the process within the reforming reactor system of the hydrogen plant is given in Table 3 below. The third feed gas 11′ entering the reforming reactor system 100 may be a prereformed gas. It has been pressurized to a pressure of 97 bar, viz. 97 kg/cm.sup.2.Math.g, and has a temperature of 500° C.
(65) Inside the reforming reactor system 100, a structured catalyst comprising nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter. Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm. Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends so that the current path through the macroscopic structure is a zigzag path. A current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure in the reforming reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW. If preferred, the nine macroscopic structures can be parallel coupled in groups of three instead of serial coupling all nine, which will decrease the voltage to ca. 1.8 kV, or even parallel coupled as individual monoliths which would require a voltage of ca. 0.6 kV. This must be chosen according to most suitable configuration of associated power supply.
(66) The reforming reactor system 100 of the current configuration could have an overall internal diameter of the reforming reactor system of 3.2 m and a total internal height of 5.5 m when the reforming reactor system 100 is made as a cylindrical reforming reactor system with spherical heads. In this specific configuration, the macroscopic structures 5 are placed in a square orientation having a diagonal length of 2.3 m. Inert material is placed around the structured catalyst to close the gap to the insulation material which has an internal diameter of 2.5 m and a thickness of 0.35 m.
(67) During the passage of the gas 11′ through the reforming reactor system 100, the gas 11′ is heated by the structured catalyst and undergoes steam reforming to a product gas 12 having an exit temperature of 1115° C.
(68) Since the product gas 12 exiting the reforming reactor system is pressurized to a pressure of 97 bar, no compressors will be needed downstream the reforming reactor system 100 when a high pressure product gas with a pressure of about 100 bar or lower is requested. This reduces the overall cost of a plant of the invention compared to a standard plant with compressors downstream the steam reforming unit.
(69) TABLE-US-00003 TABLE 3 Size of macroscopic structure: Edge size [m] 0.53 Height [m] 2.3 Number of macroscopic structures 9 Total volume of structured catalyst [L] 5888 Structured catalyst height/diagonal length [—] 1.01 Gas 11' Product gas 12 T [° C.] 500 1115 P [kg/cm.sup.2g] 96.97 96.47 CO2 [Nm.sup.3/h] 111 510 N2 [Nm.sup.3/h] 23 23 CH4 [Nm.sup.3/h] 2337 143 H2 [Nm.sup.3/h] 372 7354 CO [Nm.sup.3/h] 1 1796 H2O [Nm.sup.3/h] 7111 4518 Total flow [Nm.sup.3/h] 9955 14344 ΔT.sub.app,SMR [° C.] 10 Power [kW] 9899 Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 1691
Example 4
(70) An example calculation of the process within a reforming reactor system 100 of the hydrogen plant 1000 of the invention is given in Table 4 below. The gas 11′ entering the reforming reactor system 100 may be a prereformed gas. It has been pressurized to a pressure of 180.5 bar and has a temperature of 500° C.
(71) Inside the reforming reactor system 100, a structured catalyst 10 comprising nine macroscopic structures 5 having a square cross section are placed in an array and each macroscopic structure 5 has a size of 0.53 times 0.53 times 2.3 meter. Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm. Each macroscopic structure 5 has slits parallel to the longitudinal direction thereof, so that clusters of five times five channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure has a zigzag path. A current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure 5 in the reforming reactor system 100 of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW. If preferred, the nine macroscopic structures can be parallel coupled in groups of three instead of serial coupling all nine, which will decrease the voltage to ca. 1.8 kV, or even parallel coupled as individual monoliths which would require a voltage of ca. 0.6 kV. This must be chosen according to most suitable configuration of associated power supply.
(72) The reforming reactor system 100 in the current configuration could have an overall internal diameter of the reforming reactor system of 3.2 m and a total internal height of 5.5 m when the reforming reactor system 100 is made as a cylindrical reforming reactor system with spherical heads. In this specific configuration, the macroscopic structures are placed in a square orientation having a diagonal length of 2.3 m. Inert material is placed around the structured catalyst to close the gap to the insulation material which has an internal diameter of 2.5 m and a thickness of 0.35 m.
(73) During the passage of the gas 11′ through the reforming reactor system 100, the gas 11′ is heated by the structured catalyst and undergoes steam reforming to a product gas 12 having an exit temperature of 1236° C. The total flows of the gas 11′ and the product gas 12 are lower than the total flow of the gas in Example 3.
(74) Since the product gas 12 exiting the reforming reactor system is already pressurized to a pressure of 181 bar, it is suited for being input into e.g. a hydrotreater of a refinery plant without further pressurizing. Thus, no compressors will be needed between the reforming reactor system and the hydrotreater of the refinery plant. This reduces the overall cost of the plant with a reforming reactor system of the invention.
(75) TABLE-US-00004 TABLE 4 Size of macroscopic structure: Edge size [m] 0.53 Height [m] 2.3 Number of macroscopic structures 9 Total volume of structured catalyst [L] 5888 Structured catalyst height/diagonal length [—] 1.01 Gas 11' Product gas 12 T [° C.] 500 1236 P [kg/cm.sup.2g] 180.5 180 CO2 [Nm.sup.3/h] 86 395 N2 [Nm.sup.3/h] 21 21 CH4 [Nm.sup.3/h] 2116 95 H2 [Nm.sup.3/h] 279 6651 CO [Nm.sup.3/h] 0 1713 H2O [Nm.sup.3/h] 6424 4094 Total flow [Nm.sup.3/h] 8926 12969 ΔT.sub.app,SMR [° C.] 10 Power [kW] 9899 Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 1516
Example 5
(76) An example of a hydrogen plant is given in Table 5, which shows the gas composition at relevant places in the chemical plant. The calculation illustrates how the high pressure and temperature durability of the electrically heated reforming reactor system allows for a high reforming temperature and consequently a high methane conversion at the high pressure. Several unit operations are used in an addition to those shown in Table 5, including preheating, desulfurization, cooling, heat exchangers, and phase separations. A person skilled in the art of designing a reforming plant will be able to insert these as required. Table 5 below relates to a hydrogen plant 1000 with two water gas shift units 130a, 130b and cooling of the gas between the reforming reactor system 100 and the first water gas shift unit 130a.
(77) TABLE-US-00005 TABLE 5 Gas 11' Gas 12 Cooled Gas 13 to from gas 12 to Gas 14' reforming reforming to first second to gas First reactor reactor WGS WGS separation Product feed system system unit unit unit gas gas 8 10 10 130a 130b 150 16 T [° C.] 450 450 1088 340 238 40 40 P [kg/cm.sup.2g] 104 99.6 99.6 96.9 96.2 C.sub.2H.sub.6 238 0 0 0 0 0 0 [Nm.sup.3/h] CH.sub.4 [Nm.sup.3/h] 26319 25861 1721 1721 1721 1721 1720 CO [Nm.sup.3/h] 0 7 18657 18657 4741 877 877 CO.sub.2 [Nm.sup.3/h] 416 1425 6915 6915 20831 24694 21 H.sub.2 [Nm.sup.3/h] 621 4354 82264 82264 96180 100045 100000 N.sub.2 [Nm.sup.3/h] 193 193 193 193 193 193 193 H.sub.2O [Nm.sup.3/h] 94066 92043 62413 62413 48493 105 105