3rd Middle East Fertilizer Symposium at the Middle East Chemical Week, 10-13 October 010, !

ahrai"

Material Selection for Primary Reformer Adding value to your asset

Sha"kar #e"katarama" $ !e""o %a"ser

S+C : Heart of petrochemical industry

Crude Oil
Naphtha NGL Ethane Propane Butane Steam cracker Ethylene Propylene Butadiene Aromatics

Natural gas

FURNACE TUBES
Steam reforming

Ammonia Methanol Hydrogen

Methane

Steam Methane Reforming Most widely used with mature te hnologies Syngas unit is a!ital intensi"e #$% &$ ' of total in"estment (rimary reformer is a riti al unit Reformer !erforman e lin)ed to )ey om!onents Catalyst tu*es

Steam Methane Reforming- A Primer #!$ % !&' (((((((() CO + &H# Factors affecting syngas conversion Temperature Pressure Steam to car on ratio !ydrocar on feedstock Syngas Production re"uires high T and p

Schematic Reformer tu e
Bul) ,as Flow Tem!erature Reformer Furna e -all
.$$$ /C 0.1&# /F2

Fluegas
3$$ /C 0.45# /F2

1$$ /C 0.67# /F2

Catalyst Bed

7$$ /C 0.#3# /F2

Reformer tu e material re!uirements

Cree! resistan e A*ility to withstand high tem!erature deformation Resistan e to thermal stresses Caused due to startu!8shutdown O9idation resistan e Flue gas on outside and steam ar*on mi9ture inside A*ility to withstand hoo! stresses Created due to internal !ressure

*eformer tu e material development

H@ 6$ >N 5.3 Ni:N* #5 Cr: #$ Ni #6 Cr: #6 Ni: N* Centralloy; , 6155< Centralloy; , 6161<
Ti:=r

H( N* #5 Cr: &5 Ni: N* Centralloy; , 615#<

Ti: =r

H@ 6$ MA #5 Cr: #$ Ni: N*: Ti: =r Centralloy; , 6161 M>CRO<

H( N* MA #5 Cr: &5 Ni: N*: Ti: =r Centralloy; , 615# M>CRO< < S+C trade mar) alloys

H( N* MA O!timi?ed Mi roalloys

Centralloy , 615# M>CRO R<

*eformer tu e material development

High ar*on tu*es made *y entrifugal asting

Cree! Strength

Bow Car*on Stainless steel -rought !i!es

H@ 6$ #5 Cr 8#$ Ni

>N 5.3 #6 Cr 8#6 Ni

H( MOC #5 Cr 8&5 Ni 8 . N*

H( MOC MA #5 Cr 8&5 Ni 8 . N* + Ti: =r

O(T>M>=EC H( MOC MA CENTRABBOA; , 615# M>CRO R

.34$

.376

.371

.334

#$$4

Aear

+aterial development philosophy at S%#

>m!ro"ed tu*e metallurgy shall reate *enefit for user

Centralloy; , 615# M>CRO R O!timi?ation of om!osition Nano ar*ide !re i!itates im!ro"es strength Su*stantial im!ro"ement in ree! resistan e >m!ro"ised melting and asting te hniDues Mat hing filler metal de"elo!ed and a!!ro"ed
&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+ (' .uber, &' (akobi, /itro0e" 1 Sy"0as 30- 2 0103 1-3

#entralloy, G $-.& +/#*' *

Se ondary M#&C4 (rimary ar*ides

500 nm

Se ondary M0C:N2

TEM mi rogra!h of ty!i al !re i!itates after a ree! test at 3$$/C

&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+

Benefits for syngas producers .E Can we fire tu*es harder F #E Could we !rodu e more syngas F a2 Based on same tu*e dimensions *2 Based on hange in tu*e dimensions &E Can we im!ro"e thermal effi ien y F 6E Can we de rease the thermal stress on tu*e F 5E Can we get more "alue for our in"estment F

0 1 #an 2e fire our tu es harder 3

Syngas reformer for Ammonia G TG 3&$ /C : ( G &4 *ar: OCG .5#E. mm: >CG .#4E7 mm: MS-G ..E3 mm Cesign lifeG .$$ $$$ hr as !er A(>%5&$

Aes: M>CRO R allows higher tu*e metal tem!erature

Alloy , 615# M>CRO , 615# M>CRO R

Temperature ( C) 3&$ 35#

Higher tem!erature resistan e More o!erational fle9i*ility

&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+ (' .uber, &' (akobi, /itro0e" 1 Sy"0as 30- 2 0103 1-3

0 1 #an 2e fire our tu es harder 3

Aes: M>CRO R allows higher tem!erature without im!a ting life
120000

Time to rupture,

100000 80000 60000 40000 20000 0 920

&esi0"

3&$

940

35$

960

970

980

990

1000

Temperature, C

& a 1 #an 2e produce more syngas ased on same dimensions 3

Aes: M>CRO R allows higher tu*e metal tem!erature

SU(ER>OR HEAT RES>STANCE

TEM(ERATURE 0/ C2

34$

35# H C 3&$ H C

365

3&$

3.5

3$$ , 615# M>CRO , 615# M>CRO R

ABBOA

>n reasing Tem!erature *y #$ / C # ' in rease in syngas !rodu tion

&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+ (' .uber, &' (akobi, /itro0e" 1 Sy"0as 30- 2 0103 1-3

& 1 #an 2e produce more syngas ased on change in tu e dimensions 3

Syngas reformer for Ammonia G TG 3&$ /C : ( G &4 *ar: Cesign lifeG .$$ $$$ hr as !er A(>%5&$

Higher Cree! resistant M>CRO R allows thinner wall

Alloy , 615# M>CRO , 615# M>CRO R (" (mm) .5#E. .5#E. !" (mm) .#4E7 .#3E1 #$% (mm) ..E3 .$E6 Cataly&t 'olume Base + 6E7 '

@ee!ing the OC onstant in rease in >C allows more atalyst Signifi ant in rease in syngas a!a ity
&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+ (' .uber, &' (akobi, /itro0e" 1 Sy"0as 30- 2 0103 1-3

4 1 #an 2e improve thermal efficency 3

Higher Cree! resistant M>CRO R allows thinner wall
-ABB TH>C@NESS RECUCT>ON
-all thi )ness 0 mm 2
.#

..E3
.. .$ 3 1 , 615# M>CRO , 615# M>CRO R

.$E6

Alloy

>m!ro"ed heat transfer due to thinner wall Bess fuel gas onsum!tion for same syngas "olume
&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+ (' .uber, &' (akobi, /itro0e" 1 Sy"0as 30- 2 0103 1-3

$ 1 #an 2e decrease the stresses on tu e 3

Thinner wall leads to redu ed stresses "e)rea&e* ri&+ o, lon-itu*inal )reep &tre&&e& .o/er t ermal &tre&& *ue to unplanne*0planne* outa-e Thinner wall leads to lower thermal gradients !n)rea&e* t ermal & o)+ re&i&tan)e .on-er li,e 1uel &a2in-& ,or &pe)i,i) )a&e&
&' (akobi et al' )mmo"ia *ech"ical Ma"ual 010, +,--+ (' .uber, &' (akobi, /itro0e" 1 Sy"0as 30- 2 0103 1-3

. 1 #an 2e get more value for our investment 3

Syngas reformer for Ammonia G TG 3&$ /C : ( G &4 *ar: OCG .5#E. mm: >CG .#7 mm: MS-G ..E3 mm Cesign life< as !er A(>%5&$

Bife time is su*stantially longer

Alloy , 615# M>CRO , 615# M>CRO R Bife time 0h2 .$$$$$< &.5$$$<

(ra ti ally dou*les the tu*e life !n )a&e o, un) an-e* *imen&ion& Con"ert a ommodity to an in"estment
4 )ssumes co"sta"t "o"-stop operatio" as per desi0"' E55ects o5 i"terruptio"s "ot co"sidered

. 1 #an 2e get more value for our investment 3 E9em!lary (lant Cata
$yn-a& re,ormer in 1000 #T3" 456 plant 1ee*&to)+7 4atural -a& 4um8er o, tu8e&7 200 "imen&ion&7 (" 15291 mm, #$% 1199 mm Temperature7 960 C 3re&&ure7 66 8ar 3ro)e&& -a& )on&umption7 4700 ##:T;0 r 1uel -a& )on&umption7 480 ##:T;0 r 456 pri)e7 600 <0tonne 3lant li,e7 60 year&

Economics *elated to Primary *eformer

E5emplary Tu e Specific Life #ycle #ost
Co&t ,or tu8e repla)ement 2 #illion < Cataly&t )o&t& ( in)lu*in- loa*in- ) 0 (n)e in e2ery 6 year& 095 #illion < !n&pe)tion )o&t& *urin- )ataly&t ) an-e 091 #illion < #an our )o&t& *urin- tu8e ) an-eo2er 1 #illion < 3ro*u)tion lo&& ,or 21 *ay& 696 #illion < 3ro*u)tion lo&& ,or 5 *ay& 195 #illion < $a2in-& in ,ee* an* ,uel *urin- turnaroun* ,or 21 *ay& 199 #illion < $a2in-& in ,ee* an* ,uel *urin- turnaroun* ,or 5 *ay& 095 #illion < C an-eo2er time ,or tu8e& 21 *ay& C an-eo2er time ,or )ataly&t only 5 *ay&

*eformer Turnaround #osts 6Tu e Specific1

Tu*e re!la ement 0 >n Million I 2 No tu*e re!la ement 0 >n Million I 2

Co&t o, =e,ormer tu8e& Cataly&t ) an-e (e2ery 6 year&) 3ro*u)tion .o&& #an our )o&t& !n&pe)tion )o&t& $a2in-& in ,ee*&to)+ an* ,uel Tu8e $pe)i,i) )o&t&

# $E5 4E& . $E. %.E3 1

% $E5 .E5 % $E. %$E5 .E4

. 1 #an 2e get more value for our investment 3

>n"estment 0 in Million I 2
##E7 Standard +icroalloy

9ES7 9': #AN ;

3E3

0&7- +illion 8
#entralloy, G $-.& +/#*' *

(lant life 0 years 2

.#

.1

#6

&$

Summary
%e optimi>e* our Centralloy? mi)roalloy& re&ultin- in an &uperior material Centralloy? @ 4852 #!C=( = %e )oul* *emon&trate pro)e&& 8ene,it& ,or &pe)i,i) )a&e&9 $uperior tu8e metallur-y allo/& tu8e li,e time eAten&ion up to entire li,e time o, plant9

U!grade tu*e metallurgy and add "alue to your asset

HA((A REFORM>N,