Innovative ZoneFlow Technology for Advanced Solutions in Steam Reforming based Syngas Generation

Transcription

1 ZoneFlow Reactor Technologies, LLC Innovative ZoneFlow Technology for Advanced Solutions in Steam Reforming based Syngas Generation Sanjiv Ratan & Prof. Juray de Wilde Global Syngas Technology Conference Colarado Springs, CO October

2 Presentation Outline Introduction Steam reforming pellet catalyst - Status quo ZoneFlow TM (ZF) structured catalytic reactor technology - an innovative breakthrough ZF development update and validation programs Application of ZF reactor technology suite for hydrogen-syngas steam methane reformers (SMR) 2

3 Steam Reformer: Heart of a Syngas Plant Flue gas 15 Typical Overview Fuel 180 Values are relaive energy for H2 SMR Steam Reforming duty C C Steam Air BFW C 340 C Syngas Excess steam 10 (Desul.) Feed 3

4 Steam Reforming Catalyst - Status Quo State-of-the-art steam reforming catalysts have till lately stayed in pellets form and so have the inherent deficiencies in terms of : Random (non-uniform) packing and settling high pressure drop (strength limited voidage) limited heat transfer (sporadic catalyst-to-wall contact) very low catalyst effectiveness (intrinsically diffusion limited) catalyst attrition / breakage from thermal cycling flow / temperature non-uniformity Various attempts for structured catalyst made over the years but weren t successful due to few core challenges till lately 4

5 ZoneFlow TM Structured Catalysts an Innovative Breakthrough Advanced high-performance structured catalyst overcoming most of the Pellet catalyst deficiencies : robust but flexible engineered metal foil high-voidage casing coated with proprietary catalysts annular casing design ensuring wall proximity in cold as well as hot conditions, also creating near-wall flow turbulence against stagnant layer higher heat transfer (up to 80% including internal radiative transfer) step reduction in pressure drop (up to 40%) more than 10 times higher catalyst effectiveness no attrition from thermal cycling; stable dp uniformity of flow over its entire operating life uniquely befitting for Recuperative reforming

6 Rigorous CFD Modeling and FEA Pellets reference dp v/s HTC Temp Profiles FE Analysis 6

7 ZF s Commercial Demonstration InstallaIon OperaIon ExtracIon Up to 80o C lower TMT compared to adjacent tubes Up to 24% lower pressure drop No hot spots ZF structure intact in original form amer >15,000 hrs operaoon and with 5 thermal cycles 7

8 HTC-dP Test Rigs and Kinetics Lab 8

9 HTC-dP Test Rig Results Pressure drop, mbar ZFRT CT-2 Packed bed Furnace exit temp, o C Packed bed ZFRT 10 CT Flow rate, Nm3/h Flow rate, Nm 3 /h 9

10 DP - HTC Mapping HTC Improvement over Pellets ~ 50 % for 30 % lower dp ~ 70% for the same dp (excluding internal radiaive contribuion of ~ 10% ) 10

11 Pilot Plant Installation At Université Catholique de Louvain (UCL), Belgium Fully equipped and instrumen for rigorous tesong under commercial condioons In collaboraoon with Prof. Froment and Prof. de Wilde OperaOonal 1Q

12 ZF s Core Merits and Benefits ZF s lower dp, higher HTC and higher catalyst effectiveness allow the following underlying advantages, especially for retrofits : higher throughput without increasing pressure drop increased SMR outlet temp without increasing maximum tube skin temperature (TSM) higher heat flux (average and peak) with minimized increase in bridge-wall temperature and thus related firing and flue gas higher reforming severity and lower approach to equilibrium Exploitation of ZF s annular structure supports recuperating reforming 12

13 ZF Advanced Solutions for SMRs ZF-Single pass (ZF-SP) De-stressing and/or debottlenecking of existing SMRs (upto 15%) Higher-flux, cost-effective and more reliable new SMRs ZF-Bayonet (ZF-B) Uniquely applicable for recuperative reforming in new SMRs, overcoming current challenges ZF-Convective pre-reforming (ZF-CPR) (Under development) Unmatched in-situ retrofit for additional capacity in existing SMRs without major modifications Efficient and cost-effective applications in new SMRs 13

14 ZF-SP for SMR Debottlenecking De-stressing Upgrading Max. current capacity, % Post ZF retrofit capacity, % S/C Ratio Outlet temp, C Approach to equilibrium C CH4 slip, vol % dry Catalyst pressure drop (design 2.8 bar ), bar < Relative Radiant duty % Avg heat flux kw/m Bridgwall temp, C Max. Tube Skin Temp (design 940 C) C <

15 ZF-Bayonet Configurations 15

16 ZF-Bayonet : Drivers and Benefits Direct exploitation of ZF s inherent annular design Overcomes innate limitations of the pellet catalyst against crushing from differential expansion / thermal cycling SMR size reduction up to 20% based on high grade heat recovery for reforming Allows Zero export steam hydrogen plants for : remote, stand-alone or distributed hydrogen plants wothout a steam host export steam with low or no credit compared to fuel Allows lowering of carbon-footprint from reduced firing per unit H2 Applicable in various SMR configurations and designs 16

17 Conclusions Steam Reforming has been the predominant technology for Syngas generation SMR performance, tube life and operational reliability are governed to a large extent by its catalyst Current pellet catalysts have inherent deficiencies, thus limiting the extent of possible improvements. ZoneFlow Reactor Technologies (ZFRT) has developed breakthrough and innovative structured catalyst reactors for steam reforming ZoneFlow TM (ZF) suite of catalysts offer exceptional and advanced solutions for revamping as well as new SMRs, providing Opex and Capex benefits. From successful demo and test results to the upcoming world class pilot plant will further allow extensive testing under commercial / clientspecific conditions for validating and establishing ZF s merits. 17

18 ZoneFlow Reactor Technologies, LLC Thank You! For addioonal informaoon, contact: Sanjiv Ratan Director of MarkeOng and Prod Dev