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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    2012 Foster Wheeler. All rights reserved

    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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    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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    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]