Method to homogenize the tube temperatures between tubes during processes involving heating of gas flowing in the tubes

Abstract

The invention relates to a method for decreasing the spread of the tube temperatures between tubes in a process involving the heating of at least one fluid in a furnace that comprises at least one radiation chamber with radiant walls, at least one essentially vertical row of tubes inside of which circulate the at least one fluid to be heated, and being equipped with burners that heat the tubes, where the method comprises the steps of: determining, for each of the tubes the skin temperature of the tube, selecting the 50% tubes having the lowest temperatures determined, the process being stopped, realizing on each tube selected an operation that decreases the flow of the fluid distributed to said tube while keeping the total flow rate of the fluid unchanged.

Claims

1. A method to homogenize the tube temperatures between tubes in a process involving the heating of at least one fluid in a furnace that contains at least one radiation chamber with radiant walls, at least one essentially vertical row of tubes inside of which circulate the at least one fluid to be heated, and whereby said radiation chamber is equipped with burners that are used in the form of rows, whereby the at least one fluid to be heated is distributed uniformly to the tubes, and whereby the burners heat the tubes, the method comprising the steps of: a) determining the temperature of each tube; b) selecting the 50% tubes having the lowest temperatures as determined according to step a); c) realizing on each tube selected during step b) an operation that decreases the flow of the fluid distributed, entering in said tube; and d) keeping the total flow rate of the fluid unchanged, therefore distributing uniformly increased flow to the remaining tubes.

2. The method according to claim 1, wherein the temperatures of the tubes are determined by a simulation of the behavior of the furnace during said process involving the heating of at least one fluid.

3. The method according to claim 1, wherein the temperatures of the tubes are determined by measuring the skin temperature of the tubes by pyrometer measurement.

4. The method according to claim 1, wherein the operation realized on the tubes selected during step b) comprises increasing the pressure drop of said 50% tubes having the lowest tube temperatures.

5. The method according to claim 4, wherein the pressure drop is increased by installing elements in each of the individual tubes having the lowest temperature selected in step b), said elements that induces pressure drop being sized so that the flow distribution is the one required by step d) of the method.

6. The method according to claim 5, wherein the process uses tubes filled with catalyst.

7. The method according to claim 5, wherein said elements installed to increase the pressure drop are elements based on calibrated orifices that are installed at the inlet of the tube.

8. The method according to claim 6, wherein said elements installed in each of the individual tubes selected in step b) are individually adjusted catalyst packed bed inside the tubes, including additional catalyst bed height.

9. The method according to claim 8, wherein said elements installed in each of the individual tubes selected in step b) are individually filled catalyst packed bed inside the tubes with part of the catalyst packed bed height composed of a different kind of pellets with higher pressure drop characteristics relatively to the catalyst filled in the non selected tubes.

10. The method according to claim 1, wherein the process is a synthesis gas production process by steam methane reforming of a hydrocarbon feedstock using tubes filled with catalyst and where the at least one fluid distributed uniformly to the tubes is a mixture containing at least said hydrocarbon feedstock together with steam.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.

(2) FIG. 1 illustrates a typical SMR furnace of the prior art.

(3) FIG. 2 illustrates a typical SMR furnace of the prior art.

(4) FIGS. 3a and 3b provide simulated data for the SMR furnace shown in FIG. 2.

(5) FIG. 4 shows the measured and simulated temperatures of the tubes before applying the tuning according to the invention;

(6) FIG. 5 illustrates the hot tubes identification before applying the tuning according to the invention;

(7) FIG. 6 illustrates the temperature profiles of the tubes without tuning (i) and after tuning (ii) according to certain embodiments of the invention;

(8) FIG. 7 illustrates the temperature profiles of the synthesis gas without tuning and with tuning according to the invention;

(9) FIGS. 8 to 12 illustrate the upper part of the 50% of the tubes tuned according to the invention, in which:

(10) FIG. 8a, FIG. 8b FIG. 8c illustrate the pressure drop device implemented in the 50% tubes to be tuned according to the example;

(11) FIG. 9a and FIG. 9b illustrate a variant of a pressure drop device to be implemented in side fired furnaces;

(12) FIG. 10 illustrates another variant of a pressure drop device to be implemented in side fired furnaces;

(13) FIG. 11 illustrates the case of top fired furnace;

(14) FIG. 12a and FIG. 12b illustrate alternative solution suitable for side and top fired furnaces.

DETAILED DESCRIPTION

(15) The hereafter example refers to an industrial side fired reformer for a production of a synthesis gas for a final CO production. The furnace contains 32 tubes (two sections of 16 tubes); improving temperature distribution in a plant producing CO will allow either to increase operating temperature (5 to 10 C.) and thus to make CO production more efficient or to increase tubes life at same operating temperature. As a matter of fact, most of the time, the performances of CO plants are limited by the operating temperature.

(16) FIG. 4 shows the temperatures of the 32 tubes when the feedstock is evenly distributed in the tubes. For each tube, temperatures are presented which result from:

(17) (1): SMR3D computation at peephole level;

(18) (2): SMR3D computation max, which represents the maximum tube temperature for each tube (which takes also into account the perturbation induced by the peep hole)

(19) (3): measurements made using a pyrometer;

(20) The comparison between the values measured or calculated shows that despite some differences, comparable trends are observed.

(21) FIG. 5 shows the tube duty normalized profile, extracted from computation results before the implementation of the flow regulation devices. The 50% tubes (16 tubes) that receive higher duty are identified and selected to be cooled down (the 16 coldest tubes will receive a smaller process flow).

(22) This determination of the heat flux received by the tubes has been obtained by computation; as seen above on FIG. 4, by measuring the temperature of the tubes using a pyrometer during operations, the same hot and cold tubes could also have been identified

(23) According to the invention, these 50% tubes are cooled down by receiving a higher feed flow.

(24) As described previously, the recirculation effect due to flue gas convergence implies that the tubes between the burner columns are more heated than those in front of the burners. This is also clearly visible on FIG. 5 where the central horizontal line represents the normalized tube duty (i.e. tube duty divided by the averaged duty for the whole firebox), where the hottest tubes tend to be situated in the middle between two burners while the coldest ones are in front of the burners.

(25) The overall furnace is operated under the constraint of the hottest tube that should not exceed the design temperature.

(26) By applying the method of the invention, the distribution of the process gas flow in the tubes is adjusted in order to reduce temperature differences tube to tube while keeping the total flow unchanged: the feed gas flow rate is increased in the more heated tubes, and is decreased in the less heated ones.

(27) FIG. 6 shows temperature profiles obtained by performing SMR3D simulations: (i) without tuning (same flow rate in each tube), and (ii) applying the tuning according to the invention (adjusted flow rates). Hot spots are visibly reduced.

(28) Table 1 illustrates the homogenization of the tube temperatures.

(29) TABLE-US-00001 Tube temperatures Ref Tuned (Ref Tuned) Maximum temperature [ C.] 976 968 8 Diff Tmax-Tmin [ C.] 28 14 14

(30) FIG. 7 shows the syngas temperature profile obtained by performing SMR3D simulations (i) without tuning (same flow rate in each tube), and (ii) applying the tuning according to the invention (adjusted flow rates) which show that hot spots are reduced.

(31) Table 2 illustrates the homogenization of the syngas temperatures.

(32) TABLE-US-00002 Syngas temperatures Ref Tuned (Ref Tuned) Average syngas temperature [ C.] 925 925 0 Diff Tmax-Tmin [ C.] 29 21 8

(33) According to the simulation performed: maximum tube temperature Tmax is reduced by 8 C.; a good temperature homogenization is expected, temperature spread (TmaxTmin) is divided by two (28.fwdarw.14 C.); there is no impact on syngas production flow rate and not noticeable impact on syngas temperature (925 C.).

(34) This should allow increasing tube lifetime or running the furnace at higher temperature level, i.e. higher performances.

(35) In this example, the solution of the invention utilized for individually controlling the flow rate inside the tubes is the implementation of differential pressure drop elements in the 50% identified cold tubes. This implementation is advantageous as it allows being self-adaptable to the furnace load.

(36) A description of the solution that was chosen in the case of the example is provided below; various other technical solutions can be utilized to implement step c) of the invention, and several will also be briefly described later in the text.

(37) The furnace of the example is a usual side fired furnace with process tubes individually attached to the common feed system header by means of welded connection piping (hereafter called hairpins).

(38) In order to control the process gas flow rate distribution, calibrated orifices are installed in the 50% cold tubes in order to reach the desired pressure drop.

(39) As illustrated in FIG. 8a to FIG. 8c, the device 811 generating the pressure drop is placed in the feed stream 812 from the hairpin, and fixed to the flange 813; a calibrated orifice 814 realizes the desired pressure drop. The solution consists here in a modification of the metallic support of the existing insulation block 815, which is for the purpose of the invention, prolonged beyond the hairpin connection. The orifice support is then maintained using the fixation screw 816. The tightness is realized below the hairpin connection using ceramic fiber seal 817.

(40) The suitable additional pressure drop has been estimated using a simple fluid mechanics correlation to be 0.33 bar in present example case, which roughly corresponds to 0.33/2 additional pressure drop to the whole reformer system. This estimated value corresponds to the difference between the pressure drop induced by the tubes at high feed flow rate level and the tubes at low feed flow rate level.

(41) The diameter of the calibrated orifice 814 has been determined using classical pressure drop laws, and checked by means of CFD simulations.

(42) It will be understood that different types of devices are able to generate suitable pressure drop in the tubes.

(43) Beside the one described here above, various devices may be proposed; some of them are suitable for being implemented in side-fired design fireboxes, others in top-fired design fired-box, others in both top and side-fired fireboxes, and any other type of tubular reformers.

(44) As illustrated by FIG. 9a, according to a variant of the above device (suitable for side-fired firebox) where the desired pressure drop is also realized in front of the header by mean of a device placed in the feed stream from the hairpin and fixed to the flange, the calibrated orifice 914 is realized using a support 911 that is separated from the insulation support 915 and blocked between the flanges 913; the tightness is realized by using a ceramic fiber seal 917.

(45) According to another variant illustrated by FIG. 9b, the pressure drop device 921 may be placed inside the hairpin duct 922, at the connection level. The desired pressure drop is obtained through a calibrated orifice 924; the device 921 may be welded or mounted using a tight fit (e.g. immersed in liquid nitrogen before being placed in the hairpin connection)

(46) Alternatively, as illustrated in FIG. 10, the device generating the pressure drop may consist in a perforated plate 1011 with a determined number of calibrated orifices 1014 placed in the reforming tube stream; the plate may be suspended to the flange 1013 using the insulation fixation screw 1016, or using a specifically designed fixation to the flange, such as a welded metallic rod; at the orifice plate circumference, the tightness avoiding bypass around is obtained using a ceramic fiber fabric 1017 wrapped around the pressure drop device, constituting a seal.

(47) FIG. 11 illustrates a pressure drop device 1111 suitable to be implemented in top fired reformers, with an axial pigtail connection 1112 to the flange. The desirable pressure drop is obtained using calibrated orifice(s). This can be realized either by adjusting the diameter of the upper plate or by adjusting the diameter of the insulated block.

(48) Still another way of adjusting the flow rate in the tubes, suitable for any type of tubular reformer, is to induce a desired pressure drop in tubes by the friction of the process fluid flowing inside porous media placed in the reforming tubes. Different behaviors in terms of pressure drop between tubes may be obtained by: filling the tubes with two different catalyst beds, which will imply two different behaviors in term of pressure drop; the tubes that have been identified as receiving too much duty, therefore needing to be cooled down, may be filled with conventional catalyst, and the tubes which have been identified as receiving insufficient duty, therefore needing to be heated up, may be filled either with a single type of catalyst pellets inducing an increased pressure drop or alternatively with catalyst pellets with different pressure drop characteristics used on a part of the tube length so as to adapt the pressure drop to the desired value; one can also imagine a single catalyst with a new pellet shape to be designed so as to reach the pressure drop and flow distribution specifications, or in case of a single catalyst in tubes, one can imagine filling the tube with more or less catalyst packed bed depending on the desired pressure drop and relative flow rate distribution

(49) As illustrated by FIG. 12a and FIG. 12b, still another way of inducing different behaviors in terms of pressure drop between tubes so as to adjust the process flow rate in tubes may be to add some layers of smaller ceramic beads above the reforming catalyst 1220 in the tubes which request a lower flow rate, the other tubes may remain not completed, therefore implying two different behaviors in terms of pressure drop. The additional layers 1221 may be placed in the free space available above the reforming catalysts. The diameter of the additional beads may be adjusted so that the expected pressure drop is reached. In order to prevent the small diameter beads to fall down due to large interstitial remaining space between the reforming catalyst pellets, and/or to be entrained by the high velocity injection of the feed flow, and consequently undergo attrition, different options may be used. As an example, high pressure drop beads may be placed in between two layers 1222 of larger diameter ceramic balls, such as depicted in FIG. 12a, where the capping layer 1222 aims at avoiding small spheres entrainment by feed injection, the interface layer between small beads and catalyst pellets aims at limiting the particles to fall in the reforming catalyst bed, a stainless steel separation 1223 mesh may be also placed below the interface layer to ensure the small beads stays on top of catalysts. According to another option, the high pressure drop beads 1221 may be placed in a stainless steel grid basket 1224 such as illustrated in FIG. 12b so as to prevent the beads 1221 from falling down in the reforming catalyst bed 1220.

(50) Among the many advantages that ensue from the method of the invention are the following: the invention allows reducing maximum tubes temperature, and consequently increases their lifetime; the invention may also allow increasing the furnace efficiency; indeed, with a hotter furnace, better performances are obtained. As the fireboxes operation is limited by the hottest tube, once the temperature spread between tubes is reduced, the process may be operated at a higher average temperature; the invention is particularly advantageous in the case of steam methane reforming for CO production where the influence of temperature on efficiency is very important.

(51) While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. Furthermore, if there is language referring to order, such as first and second, it should be understood in an exemplary sense and not in a limiting sense. For example, it can be recognized by those skilled in the art that certain steps can be combined into a single step.

(52) The singular forms a, an and the include plural referents, unless the context clearly dictates otherwise.

(53) Comprising in a claim is an open transitional term which means the subsequently identified claim elements are a nonexclusive listing (i.e., anything else may be additionally included and remain within the scope of comprising). Comprising as used herein may be replaced by the more limited transitional terms consisting essentially of and consisting of unless otherwise indicated herein.

(54) Providing in a claim is defined to mean furnishing, supplying, making available, or preparing something. The step may be performed by any actor in the absence of express language in the claim to the contrary a range is expressed, it is to be understood that another embodiment is from the one.

(55) Optional or optionally means that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.

(56) Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such particular value and/or to the other particular value, along with all combinations within said range.

(57) All references identified herein are each hereby incorporated by reference into this application in their entireties, as well as for the specific information for which each is cited.