7 fw optimise oct12 hydrogen smr

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

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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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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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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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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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Two FiringLevels for

UniformHeat Input

SlightlySloped

Walls

Upward

FiringBurners

The Foster Wheeler Terrace WallTM Steam Reformer


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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



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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




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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.




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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



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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



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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



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.. 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



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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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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.



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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



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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



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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%



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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



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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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Thank youwww.fwc.com

[email protected]

7 fw optimise oct12 hydrogen smr

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