Medium-sized hydrogen plants based
on convection reforming
Erik Broman and Jack Heseler Carstensen Haldor Topsøe
T
opsoe offers clients flexible and tailor-made
solutions for hydrogen production by inte-
grating catalyst and technology. The
integrated approach ensures a fundamental
understanding of the hydrogen process, backed
up by decades of industrial experience.
Topsøe has designed more than 250 hydrogen
plants with maximum capacity exceeding
200 000 Nm3/h. For medium-scale hydrogen
production (5–30 000 Nm3/h, 5–27 MM SCFD),
Haldor Topsøe recommends a technology based
on the Haldor Topsøe convection reformer
(HTCR), which is a high-efficiency, compact heat
exchange reformer. The HTCR technology was
developed in the 1980s and has been in large-
scale industrial operation since 1997. This paper
describes this technology and the industrial
Figure 1 Convection reformer
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experience with designs up to 30 000 Nm3/h (27
MMSCFD)
HTCR
The convection reformer as shown in Figure 1 is
the key equipment in a HTCR plant. The HTCR
reactor consists of a vertical, refractory lined
vessel containing the tube bundle with several
bayonet tubes. Below the vertical section is a
horizontal combustion chamber containing a
single burner. In a HTCR, the heat is transferred
mainly by convection, and the improved utilisa-
tion of the heat input provides a design with low
consumption figures and no steam export.
Feedstock can range from natural gas to naph-
tha. A typical feed and fuel consumption figure
is 3.4 Gcal/1000 Nm3 hydrogen (362 BTU/SCF),
which will lead to very substantial savings in
operating costs and furthermore reduces CO2
emissions. Depending on the process layout, the
energy consumption can be further decreased
towards 3.3 Gcal/1000 Nm3 H2 (351 BTU/SCF)
for a HTCR plant.
Figure 2 HTCR reformer tube principle
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 Figure 3 30 000 Nm3/h (27 MMSCFD) hydrogen plant layout based on HTCR reformers

HTCR reformer tube • Convective reforming in two parallel HTCR

Each tube assembly consists of three tubes. reformers
Outermost is the flue gas tube, where the heat • High-temperature shift conversion
flux is adjusted by a proprietary flue gas control • Purification by pressure swing adsorption
device. As the flue gas flows upwards through the (PSA).
flue gas annulus, heat is transferred to the catalyst For smaller capacities, a single HTCR reformer
by convection. The catalyst is placed in the annuli is used.
between the reformer tube and the centre tube.
The centre tube through which reformed gas Energy consumption
leaves the reformer is inside the catalyst tube. The convection principle of a HTCR hydrogen
Hereby, the reformed gas is cooled on its way out, plant leads to a low energy consumption. Table 1
and the heat is passed on to the catalyst. shows the consumption of feed and fuel in a
HTCR plant compared with a traditional hydro-
HTCR process layout gen plant. It is seen that the performance of the
A simplified process flow diagram for a 30 000 HTCR is quite attractive compared to the tradi-
Nm3/h (27 MMSCFD) HTCR hydrogen plant is tional process, with a yearly cost saving
shown in Figure 2. The process comprises the of $3.1 million (natural gas price of €25/Gcal
same main steps as a traditional hydrogen plant: ($8/MMBTU)).
• Desulphurisation of feedstock
• Pre-reforming in an adiabatic reactor Plot plan area
The convection principle allows for the
Energy consumption and cost design of compact reformers, and a
HTCR hydrogen plant can be supplied
HTCR Traditional as a very compact unit, with part of the
process process
equipment supplied skid-mounted.
Feed, Gcal/1000 Nm3 H2 (BTU/SCF) 3.32 (354) 3.30 (352)
Fuel, Gcal/1000 Nm3 H2 (BTU/SCF) 0.10 (11) 0.50 (53) Typical plot plan area for a 30 000
Feed + fuel Gcal/1000 Nm3 H2 (BTU/SCF) 3.42 (365) 3.80 (405) Nm3/h (27 MMSCFD) plant is 50 x
Cost of feed + fuel, MM USD/year 27.9 31.0 40m (164 x 131ft) and can be adjusted
according to conditions at client’s site.
Table 1 The required plot plan area for a HTCR

2 October 2011 www.digitalrefining.com/article/1000061

Figure 4 30 000 Nm3/h (37 MMSCFD) HTCR hydrogen
plant – plot plan area
Figure 6 Transportation of HTCR skid
unit is approximately 30% less than a conven-
tional hydrogen unit with a box-type reformer
(SMR). Figure 4 shows the plant layout for a 30
000 Nm3/h (27 MMSCFD) plant currently under
construction.
Scope of supply
In connection with HTCR hydrogen plant
projects, Haldor Topsøe’s typical scope of supply
is:
• Licence
• Basic and detailed engineering
• Full plant documentation
• Supply of all materials and equipment within
battery limits
• On-site supervision (for assembly, pre-commis-
sioning, startup, test run)
• Training of operators.
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Figure 5 Assembly of HTCR skids in workshop
Figure 7 Site installation
Workshop skid assembly
Due to the compact layout, a large part of a
HTCR plant can be pre-assembled in skids in a
workshop outside the client’s plant site.
Depending on plant capacity, the skids are
assembled in the workshop with vessels, heat
exchangers, reactors, valves instrumentation,
piping, etc (see Figure 5).
For transport reasons, the skids are subse-
quently separated by cutting the interconnecting
piping (see Figure 6).
Site Installation
The use of pre-assembled skids minimises instal-
lation time and erection costs compared to a
traditional plant. Typically, the site installation
can be completed in three months and, where
the site installation work for a traditional steam
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 Figure 8 Installation of HTCR tube bundle
reformer plant often amounts to 30–35% of the
investment cost, an estimate of only 15–20% can
be applied for a skid-mounted HTCR unit.
Operating experience
HTCR designs include plants with capacities up
to 30 000 Nm3/h (27 MMSCFD), and with 32
reformers and more than 10 years’ operating
experience a HTCR plant provides a well-proven,
efficient and reliable concept for hydrogen
production. Operating data from HTCR plants
meet or outperform the flow sheet figures and
confirm the high energy efficiency of the HTCR
technology. The operating principles for an
HTCR and traditional hydrogen plant are the
same, but the HTCR concept with only one
burner makes startup, shutdown and operation
of an HTCR plant extremely easy, with very fast
responses to changes in load requirements. The
load and temperature management (LTM)
system ensures that the capacity can be increased
fully automatically from 30–100% in approxi-
mately one hour. Startup is furthermore
facilitated by the fact that no import of steam is
required at any time. A hot restart of the plant
can be done in two to three hours; a procedure
that typically takes 15–20 hours in a conven-
tional hydrogen plant.
The easy operation of an HTCR hydrogen plant
implies that only a minimum of operator attend-
ance is required. Operators who have operating
experience from both a HTCR plant and a
conventional hydrogen plant confirm the superi-
ority of the HTCR technology and expressed
their full satisfaction with their HTCR hydrogen
plant. One HTCR reference has been able to
4 October 2011
Figure 9 Plant in operation
maintain the existing number of operators after
starting up its HTCR plant and now each shift
two operators operate both the existing hydrogen
plant and the new HTCR hydrogen plant. At
another HTCR facility in Western Europe there
are no operators present during normal opera-
tion. In case of an alarm, the operator on call
will be alerted via his mobile phone and will then
log into the operator station at his home to
determine whether any action is required.
Conclusions
Industrial experience with 32 HTCR hydrogen
units designed has demonstrated:
• Low feed plus fuel consumption
• Proven design up to 30 000 Nm3/h (27
MMSCFD)
• Compact flexible design that can be adapted to
actual plot area
• Skid assembly in external workshop ensures
minimum construction work and time on site
• Low investment
• Short implementation time
• Minimum manpower requirement and easy
operation.
References
1 S W, P Rudbeck, P Gauthier, D Cieutat, Advanced Reforming
Technologies for Synthesis Gas Production, International
Symposium on Large Chemical Plants 10, Antwerp, 1998.
2 I Dybkjær, S W Madsen, Advanced Reforming Technologies for
Hydrogen Production, Int. J. Hydcar. Eng., 3(1), 1997/98, 56.
3] T Rostrup-Nielsen, The High Flux Solution, Hydcar. Eng., 7 (8),
2002, 51.
4 S W Madsen, I Dybkjær, Novel Revamp Solutions for Increased
www.digitalrefining.com/article/1000061
Hydrogen Demands, ERTC, London, 17–19 Nov 2003.
5 I Dybkjær, S W Madsen, N Udengaard, Revamp Options to Links
Increase Hydrogen Production, PTQ, Spring 2000, 93.
6 I Dybkjær, J N Gøl, D Cieutat, R Eyguessier, Medium Size More articles from the following categories:
Hydrogen Supply Using the Topsoe Convection Reformer, NPRA Hydrogen Management Reforming
AM, San Antonio, US, AM-97-18, 16–18 March 1997.
7 US 5429809 to Haldor Topsøe.

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