Reforming retrofits

Pre-Keformer A pre-reformer is based on the concept of shifting reforming duty away from the direct-fired reformer, thereby reducing the duty of the latter. The pre-reformer usually occurs at about 500°C inlet over an adiabatic fixed bed of special reforming catalyst, such as sulfated nickel, and uses heat recovered from the convection section of the reformer. The process may be attractive in case of plant retrofits to increase reforming capacity or in cases where the feedsock contains heavier components. 

Methanol would allow a transitional phase where some fuel cell vehicles use methanol, which is relatively simple to reform and would not present too big a change from our current system. However, methanol is toxic and very corrosive. Gas stations would need to be retrofitted to operate with it (new fuel tanks and fuel lines.) But, many gas station tanks are already methanol- compliant. 

Today, different processes (steam reforming, autothermal reforming, partial oxidation, gasification) are available and commercially mature for hydrogen production from natural gas or coal. These processes would have to be combined with technologies for C02 capture and storage (CCS), to keep the emissions profile low. A power plant that combines electricity and hydrogen production can be more efficient than retrofitted C02 separation systems for conventional power plants. 

P. W. Farnell, Pre-Reforming — a Retrofit Case Study, ICI Catalco Tech. Paper, 291W/025/0/ IMTOF. 

Some common challenges specific to refinery applications are relatively low furnace operating temperature, significant variation in fuels, and retrofitting existing equipment to utilize modem low or ultra-low emission burners. Relative to reforming and petrochemical applications, most refinery heaters operate at relatively low... 

Combined reforming has been successfully applied in grass roots applications, but it may find its best application in the potential retrofit of ammonia plants to methanol manufacturing. Use of combined reforming in a retrofit enables the ammonia producer to convert to methanol production and maximize production while achieving an acceptable return on investment (pretax, internal rate of return, IRR, of more than 20%). 

Combined reforming can be an attractive option for retrofitting an existing ammonia plant to methanol production. 

Combined reforming seems particularly attractive for maximizing production when retrofitting an existing ammonia plant for methanol production. 

Another key feature of this new process is the patented KBR Reforming Exchanger System (KRES), which eliminates the need for the directly fired primary reformer furnace (fig. 6.11). This reduces capital costs by 5-8%, and emissions of NO and CO2 by 70-75%. The first KAAP process was installed for the Ocelot Ammonia Company s (now Pacific Ammonia Inc.) retrofit of its plant in Kitimat, British Columbia, in 1992 and when the first two new KAAP plants (for Farmland Misschem and PCS Nitrogen) were completed at Point Lisas, Trinidad, in July 1998, they became the world s largest ammonia facilities (each at 1,850 t/day) to date. ... 

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