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7/27/2019 7 FW Optimise Oct12 Hydrogen SMR
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2012 Foster Wheeler. All rights reserved
H
ydrogen Steam Methane Reforming:The Workhorse for HydrogenProduction for Refineries
Foster Wheeler Seminar at Asia-Tech 2012, Bangkok
Luigi Bressan Director of Process & Technologies
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
The hydrogen production plant
The Foster Wheeler Terrace WallTM
steam reformer Hydrogen plant optimization design steps
Conclusions
Agenda
2
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2012 Foster Wheeler. All rights reserved
The Hydrogen Production Plant
Steam methane reforming (SMR) continues to be the leadingtechnology for hydrogen generation
Although SMR is a mature technology, incremental economicimprovements are being made by continuous development
The plants consist of four basic sections:
1. Treatment to remove sulphur traces and other contaminants
2. Steam methane reformer, which converts feedstock and steam tosyngas at high temperature and moderate pressure
3. CO shift reactor(s) to increase hydrogen yield
4. Hydrogen purification; modern plants use a pressure swing adsorption(PSA) unit to achieve final product purity
In addition to the core process sections, compression is oftenneeded to raise the feedstock and product hydrogen pressures.
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2012 Foster Wheeler. All rights reserved
The Hydrogen Production Plant
Make up water
PSA
Hydrogen
Steam
Natural gas
Comb. air
Steam drum
Deaerator
Hydrogenator
Shift reactor
Terrace WallTM
steam reformerDesulphuriser
Pre-reforming
Air preheating
CW
Waste heat boiler
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2012 Foster Wheeler. All rights reserved
The Hydrogen Production Plant
Refineries can use different feedstocks, subject to internal priceand availability:
Natural gas
Refinery gas
LPG
Light naphtha Heavy naphtha
. and even straight-run naphtha
Optimising hydrogen plant design and operating parametersdepends on the economic values attributed to the feedstock, fueland steam
The characteristics of the feedstock will define the processing
capabilities of the plant
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2012 Foster Wheeler. All rights reserved
The Hydrogen Production Plant
The optimum is achieved by minimising :(Feedstock (Gcal/h) + Fuel (Gcal/h) Steam (Gcal/h)) / H2 flowratewhere steam is the net export flow rate of steam from the plant
With the proposed scheme a net thermal efficiency of less than
3.0 Gcal per Nm3 of produced hydrogen can be achieved whenstarting from natural gas
The economic optimum is achieved by minimising:(Feedstock*CostFeedstock + Fuel*CostFuel Steam*ValueSteam) / H2 flow
Accurate pricing of feed, fuel and steam allows a fit-for-purpose
design for the hydrogen plant
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2012 Foster Wheeler. All rights reserved
Two FiringLevels for
UniformHeat Input
SlightlySloped
Walls
Upward
FiringBurners
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Side-fired heater with burners located along lateral walls with flamesvertically arranged.
Radiant section comprising a firebox with a single row of catalyst
tubes with two terraces on both sides of the tubes on which theburners are installed.
Catalyst tubes are flanged at the top to allow loading and unloadingof the catalyst.
Heat is supplied via ultra-low-NOX burners (forced- or natural-draft)
Terrace Wall TM main process features
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved
Temperature
Distance Down Tube
Temp vs Distance Down Tube
Process Fluid Terrace Wall TMT
Log. (Side Fired TMT) Radiant Fired TMTT
HeatFlux
Distance Down Tube
Heat Flux vs. Distance Down Tube
Terrace Wall Top Fired Radiant Wall Fired
Top Fired TMT
Terrace Wall TM main process features
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Outlet pigtails arranged vertically providing better access for easierwelding and nipping, removing need for a cold bottom flange forcatalyst removal
Vacuum-type catalyst removal systems allow removal of catalyst via
the tube inlet flange
Reduced number of burners by about 30% due to increasedcapacity, with new burners using staged fuel and air combustiontechniques for lower NOx emissions
Process gas boiler is natural circulation type, located at grade levelin the middle of the radiant cell, avoiding need for a transfer line.
Terrace Wall TM main process features
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved
Building Block Design
TWIN CELLHigh H2
production
Add auxilliary
burners formaximum steam
production
INCREASE CELLLENGTH
For larger units
SINGLE CELL
Low H2
production
Convection sectionsuited for any steam
production
The Foster Wheeler Terrace WallTM Steam Reformer
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Modules include all components from inlet
manifold to outlet manifold
Increase productivity
Improve quality & schedule
Shippable by truck
Minimize high alloy field welds
Reduce erection time & costs
Modular Design & Assembly
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved
Simple, Safe & Reliable Simplicity
Start up on natural draft
Easy and safe light-off ofall burners
Natural draft capability
Simple manifold system
Nipping in operation
Extend run length
Operations & maintenance
Clear outboard access to burners
Good visibility of catalyst tubes
Good visibility of burner flames
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved
.. in summary
Long tube and catalyst life
Natural draft capability
Low net power consumption Optimized radiant design
Reduced plot area
Extended modular construction
and we continue to develop our design to
deliver further performance enhancements
The Foster Wheeler Terrace WallTM Steam Reformer
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Evaluation of client design basis and specific requirements
Hydrogen quality
Feed quality, characteristics and cost
Fuel quality, characteristics and cost
Utilities characteristics, costs and availabilty
Site constraints
Layout limitations
Hydrogen plant optimization
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Selection of optimum plant configuration
Purification steps
Integration of pre-reforming
Selection of S/C ratio and shift technology
Selection of steam reformer outlet temperature
Pressure profile analysis
... The optimum plant configuration is the one that minimizes opex
with acceptable level of capex.
Hydrogen plant optimization
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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9100
9200
9300
9400
9500
9600
9700
9800
9900
10000
10100
10200
0.50 0.60 0.70 0.80 0.90 1.00
Operatingcosts($/h)
Fuel/Feed price
MTS
case 2
HTS+LTS
case 2
MTS
case 1
HTS+LTS
case 1
Case 1 = steam value 85% fuel costCase 2 = steam value 115% fuel cost
Hydrogen plant optimization
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Optimization of selected configuration
Detailed simulation with adequate software
Pinch analysis
Review of design alternatives with NPV
Optimization of plant pressure profile HSE review (safeguarding philosophy)
Control system definition
Evaluation of turndown cases for both plant and fired heater
performance perspective Regular contacts with catalyst vendors
Careful evaluation of PSA parameters and performances
.....each plant parameter is deeply analyzed and then selected
Hydrogen plant optimization
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Evaluation of H2 production costs & variations with economics parameters
Technical Parameters
Plant size 100,000 Nm3/h
Feed/Fuel type Natural gas
Plant configuration Prereformer, MTS, A/P @ 520 C, S/C=2.2
Economic Parameters
Plant Cost 114 MM$
IRR (full equity) 10
Plant life 15 years
Feed/Fuel cost 4/8/12 $/MMBTU
Steam credit 0.9 feed/fuel cost
Other Parameters Taxes= 20%, Inflation=2%
Hydrogen plant optimization
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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0
20
40
60
80
100
120
140
160
FEED 4 $/Mmbtu IRR 10 FEED 8 $/Mmbtu IRR 10 FEED 12 $/Mmbtu IRR 10
H2Cost
[Euro/1000Nm3]
CAPEX
FIXED COST
OPEX~ 60
~ 100 Euro/1000Nm3
~ 135 Euro/1000Nm3
Opex /Capex trend (plant life 15 years) Vs. Feed Cost
Hydrogen plant optimization
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2012 Foster Wheeler. All rights reserved 2012 Foster Wheeler. All rights reserved
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Conclusions
General considerations
There is not a single solution for designing a high performancehydrogen plant
Client-specific requirements may affect the final plant configuration
Feed, fuel and steam values are of paramount importance forselecting the best plant configuration
Electric power and cooling water can also be considered
The lowest net energy solution may not provide the lowest-cost
solution.
Foster Wheeler specially designs your hydrogen plant to ensure that
the highest performance, together with the most cost-effective
solution, are both achieved
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