3rd Reformer from a complete Methanol facility (IPP stock #600993)
Started up in 2009 and is capable of producing enough syngas for 250 mt/day of methanol production (currently limited by oxygen supply). This unit has the hydro-desulfurization section for removing trace amounts of sulfur in the natural gas feed. The natural gas is then mixed with hydrogen and steam at 550°C before combining with oxygen in the ATR.
This latest third, synthesis gas generation unit, sec. 10,000, designed, engineered and built in 2007 and 2008, with startup in 2009 employs a different flowsheet from the first two steam reforming based syngas unit, secs.100 and 1000 at the methanol Plant. The main flowsheet starts as before with a hydrodesulphurization section but then the sulfur free natural gas with some hydrogen plus process steam is preheated in a simple fired heater to about 550 C and fed to a high temperature autothermal reformer ( catalytic partial oxidation ) where together with oxygen the process natural gas is subjected to non catalytic partial oxidation in the upper section of the reactor and then reforming is completed in the lower single catalyst bed of the same reactor to produce a low residual CH4 content sub-stoichiometric syngas. The subsequent syngas cooling and heat recovery train is rather similar to that of the other two syngas units, starting with a WHB for generation of 64 bar steam, followed by a steam superheater to superheat this steam to about 480 C, then an economizer etc. This sub-stoichiometric syngas when mixed with the hydrogen rich super-stoichiometric syngas from either or both of the steam reforming units, sec. 100 and / or sec. 1000, results in an almost or slightly more than stoichiometric syngas going to the make-up syngas compressors, effectively increasing slightly their capacity in terms of H2 + CO and CO2 for methanol production. The ATR syngas unit maximum capacity (limited by the available O2 capacity ) is equivalent to about 240 mt/day of methanol.
The incoming natural gas is first routed through two hydro-desulfurization reactors. Steam, CO2, and recycle/purge gases are then combined with the natural gas prior to feeding the auto-thermal reformer. The reformed syngas is then routed to the waste heat boilers.
The syngas pressure and temperature after heat recovery and final refrigerant cooling is about 17 bar and 9°C. Steam generated in the raw gas waste-heat boiler and the reformer is at about 64 bar and is superheated in the reformer´s convection section to about 480°C.
The syngas production for the ATR unit is listed as 16,000 kg/hr with the following composition (mole %); 74% hydrogen, 16% CO, 6.7% CO2, 2.9% methane, and the remainder as nitrogen and water.
GET IN TOUCH
Call us at +1 609 586 8004 or CONTACT US