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FURNACE DESIGN
Introduction
Direct-fired steam hydrocarbon reforming furnace is the work-horse of
gas production processes.
Steam reforming process is a well-established catalytic process that
convert natural gas or light hydrocarbons in a mixture containing a major
portion of Hydrogen. The Steam reforming process has gained more and
more importance with the increasing demand of various type of syngases
for the chemical and petrochemical industries. Its application are in the
production of:
-
Ammonia
Methanol
OXO Alcool
Hydrogen
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The upflowing hot flue gases exhaust naturally at the top of the firebox,
entering the heat recovery section where feed preheat, steam generation,
air preheat or post-combustion Nox reduction (SCRs) may be installed.
FIGURE 2
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FIGURE 3
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The burner arrangement on the Terrace Wall design (firing along the
refractory sidewalls) allows stable burning 100% of PSA off-gas once the
firebox is heated.
Top Fired (Downfired)
The down-fired design (Figure 4) locates from one to as many as ten or
more rows (or lanes) of catalyst tubes (in-line) in a single radiant firebox
enclosure, with rows of burners located in the roof (or arch) of the firebox
between the tube lanes. The burners fire downwards, parallel to the
hydrocarbon-steam mixture flow direction through the catalyst tubes.
Burner flame and hot gas radiation provide heat input to the tubes. The
combustion of low calorific value PSA gas produce long, lazy and
uncontrollable flame patterns which will be creating down-flowing as well
as side turning flames with impingement on catalyst tubes, since no hot
refractory lining is present to retain the flame away from the catalyst
tubes.
FIGURE 4
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The concentration of heat flux at catalyst tube inlet might result in local
overheating of both tubes and catalyst in particular when operating at
partial loads.
Each row of burners provides heat input affecting two rows of catalyst
tubes. The two lateral rows are subject in addition to flue gas radiation
also to the radiation of the hot unshielded wall facing the tubes. This fact
results in an overheating of one side of the lateral catalyst tube with
consequent heat maldistribution.
Flue gases are collected at the bottom of the firebox in refractory
tunnels, properly sized and arranged to maintain a uniform flow pattern
in the firebox. The flue gases exit the tunnels and are directed to the
heat recovery section for process coil heating, steam generation services,
and air preheating exchanger.
To assure negative pressure at the firebox, mechanical draft equipment
(induced draft fan) must be installed to overcome the draft gain in the
firebox and the pressure losses in the various heat recovery coils and/or
equipment.
Having firing only at one level, there is no possibility of control of the heat
input along the catalyst tubes, and the heat transfer mechanism more
dependent on burner spacing (not by uniformly heated sidewalls). The
catalyst tubes are spaced at a 2.0 to 2.5 ratio (center-to-center divided by
outside diameter) to minimize peak tube metal temperatures. (Using the
API RP-530 curve, the circumferential heat flux factor for calculating tube
temperature is 1.20 to 1.15 at this spacing).
Lane spacing (versus tube length) is established to assure proper heat
transfer.
Access for burner operating maintenance, is from the walkways located
between the tube lanes and burner rows at the firebox arch.
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FIGURE 5
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FIGURE 6
Mechanical Features
Proper installation and support systems for the catalyst tubes are critical
to the successful long-term operation of the reformer furnace. Much work
has been done over the years in learning the dos and donts of the
systems. Experience is the best teacher, and use of that experience in
todays reformer furnaces assures the most reliable product.
In the Terrace Wall design with outlet pigtails and hot outlet header
(Figure 6), the system provides full load top support (catalyst tube weight
plus catalyst weight) with expansion of the catalyst tube upwards through
the arch (typically 200 250 mm). Top support is provided with a simple,
positive counterweights system, which allows for the necessary variation
in expansion between adjacent tubes. (Figure 7).
The hot outlet header expands along the furnace length, pulling the
outlet pigtails and the catalyst tubes with practically no stress since all
the weight is supported from the top.
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Although a single row of tubes fired equally from both sides should have
little if any temperature difference from one side to the other, the
outlet pigtail does provide flexibility to reduce any bending stresses which
might develop due to tube bowing.
FIGURE 7
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Miscellaneous
Refractories
Radiant section linings are exposed to firebox temperatures of 1000C and
higher, and therefore necessitating high quality insulating refractory
materials to withstand the environment and reduce the heat loss (lower
the casing temperature).
Insulating firebricks backed by lightweight insulating blanket is used.
Convection sections are lined with insulating castable.
Assembly
Where shipping clearance is adequate, the Terrace Wall radiant section
design lends itself to full modularization (steel and linings, catalyst tubes
and outlet collectors, shop installed). (See figure 9). This feature is not
possible with the Downfired design.
Convection section is usually fully modularized with steel, linings and
coils shop installed.
FIGURE 9
Environmental
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Burner Nox levels can be effectively reduced using current low Nox burner
designs. The low calorific value of PSA gas and the staged air design
effectively reduces the Nox generated by the burner. This design is
possible in the Terrace Wall reformer since the shape of the flames is
controlled by the sloped wall design.
Conclusion
The steam-hydrocarbon reformer furnace can be designed to meet the
specific needs of a hydrogen plant. Optimal design configurations are
available; one will provide the best solution for a particular purpose.
Based on the consideration mentioned above it is clear the Terrace Wall
design has several advantages if compared with the Downfiring design for
what concerns safety, reliability and operability, along with design
experience and quality. These are important factors to be considered
when selecting this important component in a hydrogen plant.
Foster Wheeler Experience
The attached pages show Foster Wheeler experience in the steam
reformer heater design and the photos of some steam reformer heaters
are herewith attached.
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YEAR
CLIENT
CONTRACTOR
OWNER
COUNTRY
SIZE
(MMSCFD)
2-BE-0024A
WINTER 2005
AO MOZYR
AO MOZYR
BELARUS
22
2-BE-0023A
AUTUMN 2005
KBR/SNAM
EGTL
NIGERIA
27
2-BE-0022A
AUTUMN 2005
KOCH GLITSCH
PNCHZ
KAZAKHSTAN
15
2-BE-0020A
SUMMER 2005
AO MOZYR
AO MOZYR
BELARUS
22
2-BE-0013A
SPRING 2004
TECHNIP ITALY
ARAMCO
SAUDI ARABIA
20
NA
SUMMER 2003
PETROM
PETROM
ROMANIA
22
2-BE-0008A
SUMMER 2002
FWI/ESSO
ESSO
GERMANY
10
2-21-20070
SUMMER 2001
FW/BOC
HUNTSMAN
ENGLAND
37
2-BE-0002A
SPRING 2000
TECHNIP ITALY
REFINERIA ISLA
NETH. ANTILLES
22
NA
1997
FW
LAGOVEN
VENEZUELA
50
2-21-1830
WINTER 1996
CHIYODA
THAIOIL
THAILAND
35
2-21-1800
FALL 1996
CHIYODA
MRC
MALAYSIA
15
2-21-1780
SUMMER 1996
SNAMPROGETTI
PEMEX
MEXICO
85
2-21-1775
SUMMER 1995
ESSO
ESSO
SINGAPORE
15
2-21-20035
SPRING 1995
FWEL
PERTAMINA
INDONESIA
75
RAYTHEON
PETROTRIN
TRINIDAD
40
NA
5-16-1130
1994
FW
CENEX
MINNESOTA
12
5-16-1094
SPRING 1989
FW
NEWGRADE
ENERGY
CANADA
60
FW
NEWFOUNDLAND
CANADA
42
NA
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NOTES
COMPLETE
MODULE
TOP FIRED
2-21-1760
SUMMER 1996
SNAMPROGETTI
TUPRAS
TURKEY
52
2-21-1705
FALL 1993
SNAMPROGETTI
TUPRAS
TURKEY
44
2-21-1655
FALL 1993
JGC
NIOC
IRAN
50
2-21-1640
SUMMER 1996
SNAMPROGETTI
NIOC
IRAN
50
2-21-1585
SUMMER 1987
C.F. BRAUN
KNPC
KUWAIT
50
3 UNITS
ARAMCO
ARAMCO
SAUDI ARABIA
50
2 UNITS
5-16-1069
2-21-1570
SUMMER 1985
SNAMPROGETTI
ADNOC
ABU DHABI
65
5-16-1049
SUMMER 1984
FW
UNOCAL
ILLINOIS
14
FW
PETROSAR
CANADA
5-16-1034
5-16-1033
FALL 1984
PBS
SHELL
CANADA
35
2 UNITS - TOP
FIRED
2-21-1565
SUMMER 1984
JGC
KNPC (FUC)
KUWAIT
42
2 UNITS
5-16-1030
SPRING 1984
FE
SNC / SUNCOR
CANADA
41
2-21-1540
SUMMER 1983
JGC
KNPC (RMP)
KUWAIT
42
5-16-1026
FALL 1983
BECHTEL
PETROCANADA
CANADA
36
5-16-1020
SPRING 1983
FLUOR
PHILLIPS
TEXAS
60
5-16-1010
FALL 1982
FLUOR
POWERINE OIL
CALIFORNIA
19
5-16-1003 (GTE)
SUMMER 1983
FW
CHEVRON
MINNESOTA
95
2-21-1455
WINTER 1980
CHIYODA
ARAMCO
SAUDI ARABIA
66
2-21-1405
SUMMER 1980
SNIA
TECHMASHIMPOR
T
RUSSIA
8,5
5-16-964
WINTER 1979
FW
KIPCO
KOREA
17,7
5-16-956
WINTER 1979
FW
PGW
PENNSILVANIA
CONFID.
2-21-1385
SUMMER 1978
SNAMPROGETTI
NIOC
IRAN
34
5-16-940
SUMMER 1977
PROCON
AMOCO
ALABAMA
16
5-16-935
SUMMER 1978
KNPC
KNPC
KUWAIT
70
Page 17
2 UNITS
2 UNITS
5-16-926
1978
FW
PETROCANADA
CANADA
17
5-16-903
FW
MOBIL
NEW JERSEY
21
5-16-886
FLUOR
TUCSON O & G
ARIZONA
5-16-883
FLUOR
BP
OHIO
42
NEVER
ERECTED
5-16-863
FW
CHEVRON
NEW JERSEY
NEVER
ERECTED
2-21-60107
1976
FWL
BP
ENGLAND
48
PRH 2940
1976
FWF
RHONE POULENC
FRANCE
7,6
5-16-853
SUMMER 1976
MCKEE
VENEZUELA
29
2-21-1370
1975
FWI
SIR
ITALY
34
2-21-60095
1975
FWEL
NIOC
IRAN
32
5-16-851
WINTER 1975
PROCON
AMOCO
TEXAS
FLUOR
OREGON
BADGER
BORCO
BAHAMAS
35
FLUOR
TRANSCO
PENNSILVANYA
10,5
9,5
5-16-847
5-16-824
SUMMER 1975
5-16-818
5-16-802
SPRING 1975
FW
PUBLIC SERVICE
G&E
NEW JERSEY
2-21-1320
SPRING 1975
FWI
ISAB
ITALY
2-21-1275
SUMMER 1973
SNAMPROGETTI
NIOC
IRAN
17
2-21-60052
1973
FWL
IRVING OIL
CANADA
40
PRH 1805
SUMMER 1973
FWF
BP LAVERA
FRANCE
29
5-16-801
SPRING 1973
FW
PUBLIC SERVICE
G&E
NEW JERSEY
2-21-60030
1972
FWL
NIOC
IRAN
30
5-16-779
FALL 1972
IHI
TOKAI DENKA
JAPAN
1,9
2-21-1295
FALL 1972
FLOUR
ESSO CREOLE
VENEZUELA
5-16-762
SPRING 1972
IHI
SHOWA
YOKKAICHI
JAPAN
Page 18
NEVER
ERECTED
2 UNITS
ESSO DESIGN
ESSO DESIGN
31,1
5-16-751
SUMMER 1972
LUMMUS
CANADA
PETROFINA
CANADA
45,8
5-16-705
SPRING 1971
FW
PENNZOIL
PENSYLVANYA
1,65
5-16-672 (GTE)
SPRING 1971
BECHTEL
CHEVRON
MINNESOTA
80
5-16-670
SUMMER 1972
BECHTEL
PEMEX
MEXICO
52,5
5-16-648
SPRING 1972
IDEMITSU-KOSAN
IDEMITSU-KOSAN
JAPAN
17
5-16-645
SPRING 1971
KELLOGG
SHELL
TEXAS
CONFIDENTIAL
2-21-10273
1970
FWL
SAO PAULO
BRAZIL
5-16-625
WINTER 1970
BECHTEL
MARATHON
ILLINOIS
26,5
5-16-622
1967
NOHON KIHATSUYU
NOHON
KIHATSUYU
JAPAN
28
5-16-611
FALL 1970
PROCON
SHELL
CANADA
35
5-16-608
SUMMER 1969
PRITCHARD
MOBIL
LOUISIANA
26
5-16-604
FALL 1968
DAIKYOWA
DAIKYOWA
JAPAN
12
5-16-555
FALL 1968
JGC
KNPC
KUWAIT
39
5-16-535
SPRING 1969
FW
MOBIL
TEXAS
60
2-21-10253
1968
FWL
NATREF
SOUTH AFRICA
22
2-21-10239
1968
FWL
PETROBRAS
BRAZIL
220
2-21-10238
1968
FWL
BP
ENGLAND
80
5-16-501
WINTER 1970
AG MCKEE
SHELL
ILLINOIS
55
5-16-488
SUMMER 1968
FLUOR
KNPC
KUWAIT
70
5-16-479
SUMMER 1968
FLUOR
NIOC
IRAN
33
2-21-1075
SPRING 1968
FWI
MONTESUD
ITALY
2,2
2-21-10212
1967
FWL
NTGB
ENGLAND
50
5-16-451
SPRING 1967
FLUOR
ATLANTIC
REFINING
PENNSYLVANYA
50
2-21-10197
1966
FWL
GULF OIL
WALES
12
Page 19
3 UNITS
2 UNITS
2-21-10186
1966
FWL
NIOC
IRAN
30
5-16-444
WINTER 1966
PARSONS
MOBIL
CALIFORNIA
50
5-16-437
FALL 1966
PARSONS
ARCO
CALIFORNIA
55
5-16-397
SUMMER 1966
FLUOR
BP
OHIO
26,9
5-16-388
WINTER 1965
FW
CHEVRON
CALIFORNIA
67,5
5-16-328
WINTER 1964
FW
KETONA
CHEMICAL
ALABAMA
2,3
5-16-315
SPRING 1964
FW
AMERICAN
CYNAMID
NEW JERSEY
FWL
ESSO FAWLEY
ENGLAND
1,6
5-16-290
5-16-248
WINTER 1963
PARSONS
LINDE NASA
CALIFORNIA
26
5-16-242
WINTER 1962
FWL
BRITISH
AMERICAN
CANADA
11
WINTER 1962
FLUOR
CHEVRON
MINNESOTA
20
Page 20
2 UNITS
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