Typical Steam Reformed Natural Gas Reformate

A typical steam reformed natural gas reformate is presented in Table 9-2. 

Table 9-2 Typical Steam Reformed Natural Gas Reformate...

Typical feedstock is natural gas, mainly CH4, although oil, coal and biomass can be used. The main route for synthesis gas formation is through steam reforming ... 

A typical steam reforming schematic is given in Figure 17 [18]. Note the relative simplicity of this process. A light feed gas is simply preheated, desulfurized, mixed with steam, and then reformed and cooled before being compressed as feed to a methanol synthesis reaction loop. The process steps utilized in the steam reforming of a natural gas feedstock are described in somewhat more detail in Section 3.4. 

Hot flue gases are typically used to heat mixed streams of steam and natural gas feed to the reformer, steam only, fuel gas, boiler feedwater, and combustion air. 

High temperature steam reforming of natural gas accounts for 97% of the hydrogen used for ammonia synthesis in the United States. Hydrogen requirement for ammonia synthesis is about 336 m /t of ammonia produced for a typical 1000 t/d ammonia plant. The near-term demand for ammonia remains stagnant. Methanol production requires 560 m of hydrogen for each ton produced, based on a 2500-t/d methanol plant. Methanol demand is expected to increase in response to an increased use of the fuel—oxygenate methyl /-butyl ether (MTBE). 

Na.tura.1 Ga.s Reforma.tion. In the United States, most hydrogen is presently produced by natural gas reformation or methane—steam reforming. In this process, methane mixed with steam is typically passed over a nickel oxide catalyst at an elevated temperature. The reforming reaction is... 

Steam-Reforming Natural Gas. Natural gas is the single most common raw material for the manufacture of ammonia. A typical flow sheet for a high capacity single-train ammonia plant is iadicated ia Figure 12. The important process steps are feedstock purification, primary and secondary reforming, shift conversion, carbon dioxide removal, synthesis gas purification, ammonia synthesis, and recovery. 

In a typical PAFC system, methane passes through a reformer with steam from the coolant loop of the water-cooled fuel cell. Heat for the reforming reaction is generated by combusting the depleted fuel. The reformed natural gas contains typically 60 percent H9, 20 percent CO, and 20 percent H9O. Because the platinum catalyst in the PAFC can tolerate only about 0.5 percent CO, this fuel mixture is passed through a water gas shift reactor before being fed to the fuel cell. 

Natural gas consists mainly of methane together with some higher hydrocarbons (Tab. 8.1). Sulfur, if present, must be removed to a level of about 0.2 ppm prior to the steam reforming process as it poisons the catalyst. This is typically done by cata-lytically converting the sulfur present as thiols, thiophenes or COS into H2S, which is then adsorbed stochiometrically by ZnO, at 400 °C, upstream of the reactor. 

Fuel Hydrogen for PAFC power plants will typically be produced from conversion of a wide variety of primary fuels such as CH4 (e.g., natural gas), petroleum products (e.g., naphtha), coal liquids (e.g., CH3OH) or coal gases. Besides H2, CO and CO2 are also produced during conversion of these fuels (unreacted hydrocarbons are also present). These reformed fuels contain low levels of CO (after steam reforming and shift conversion reactions in the fuel processor) which cause anode poisoning in PAFCs. The CO2 and unreacted hydrocarbons (e.g., CH4) are electrochemically inert and act as diluents. Because the anode reaction is nearly reversible, the fuel... 

In addition to natural gas, steam reformers can be used on light hydrocarbons such as butane and propane and on naphtha with a special catalyst. Steam reforming reactions are highly endothermic and need a significant heat source. Often the residual fuel exiting the fuel cell is burned to supply this requirement. Fuels are typically reformed at temperatures of 760 to 980°C (1,400 to 1,800°F). 

Natural gas is reacted with steam on an Ni-based catalyst in a primary reformer to produce syngas at a residence time of several seconds, with an H2 CO ratio of 3 according to reaction (9.1). Reformed gas is obtained at about 930 °C and pressures of 15-30 bar. The CH4 conversion is typically 90-92% and the composition of the primary reformer outlet stream approaches that predicted by thermodynamic equilibrium for a CH4 H20 = 1 3 feed. A secondary autothermal reformer is placed just at the exit of the primary reformer in which the unconverted CH4 is reacted with O2 at the top of a refractory lined tube. The mixture is then equilibrated on an Ni catalyst located below the oxidation zone [21]. The main limit of the SR reaction is thermodynamics, which determines very high conversions only at temperatures above 900 °C. The catalyst activity is important but not decisive, with the heat transfer coefficient of the internal tube wall being the rate-limiting parameter [19, 20]. 

HyL Process. This batch-cyclic process reduces rich lump-iron ores by Mowing a reducing gas in a lixed-bed reactor. Die reducing gas may be prepared by steam reforming of natural gas or other hydrocarbons. A typical reducing gas may contain 74 hydrogen, 13 k carbon mnnoxide. 

A simplified flowsheet for an ammonia plant that processes natural gas via steam reforming is shown in Figure 6.7. A block diagram of this same plant is shown in Figure 6.8. This diagram lists typical stream compositions, typical operating conditions, catalyst types (recommended by Synetix) and catalyst volumes82. 

Without a doubt, a complete picture of the dynamics of dissociative chemisorption and the relevant parameters which govern these mechanisms would be incredibly useful in studying and improving industrially relevant catalysis and surface reaction processes. For example, the dissociation of methane on a supported metal catalyst surface is the rate limiting step in the steam reforming of natural gas, an initial step in the production of many different industrial chemicals [1]. Precursor-mediated dissociation has been shown to play a dominant role in epitaxial silicon growth from disilane, a process employed to produce transistors and various microelectronic devices [2]. An examination of the Boltzmann distribution of kinetic energies for a gas at typical industrial catalytic reactor conditions (T 1000 K)... 

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