Gas Processes Handbook - 192

2019 GAS PROCESSES HANDBOOK
PROCESS CATEGORIES

COMPANY INDEX

SYNTHESIS GAS

Syngas, autothermal reforming (ATR)

Sulfur removal

Application: Produce CO-rich synthesis gas.

CO2 rich gas

Products: Pure carbon monoxide (CO) and hydrogen (H2 ) or synthesis gas
for methanol, synthetic fuels, oxo-synthesis or ammonia. Very large-scale production
of synthesis gas for GTL plants.

Hydrocarbon feed

Description: The process combines partial oxidation and adiabatic steam
reforming using a fixed catalyst bed (nickel catalyst). Soot-free operation is secured
by a proprietary burner design. The unit consists of a feed preheater (1); feed
desulfurization (2); prereforming (optional) (3); an autothermal reformer reactor
with a burner, a combustion chamber and catalyst bed (4); a heat recovery section (5);
and, when required, a gas purification section [e.g., CO2 removal (not shown)].
The autothermal reformer burner features low metal temperatures and high
resistance to mechanical wear, thus ensuring a long burner lifetime. The burner is
manufactured in commercially available, high-temperature alloys without cooling
circuits.
The hydrocarbon feedstock can be natural gas, LPG or naphtha. The oxygen feed
can be pure oxygen, air or enriched air. CO2 recycle or CO2 import can be applied
to adjust synthesis gas composition.
Operating conditions: Typically, CO-rich synthesis gas is obtained at feed ratios of
H2O:CH4 = 0.2 to 1.5, and CO2:CH4 = 0 to 2, resulting in synthesis gas ratios H2:CO with
0.8 to 2.5 at reactor exit temperatures of 950°C-1,050°C. Reactor pressure ranges are
between 20 bar and 70 bar.
Installations: Since 1958, 26 complete installations have been licensed. A new burner
technology with an improved lifetime was introduced in 1992 and is in operation
in 20 autothermal reforming plants, of which six lines are GTL plants with up to
17,000 bpd of capacity per line. ATR installations for GTL projects are in operation
in South Africa and Qatar.

Prereforming

Fired heater
Process steam

Autothermal
reformer

Steam production
Steam export

Hydrogen

2

3
1

Oxygen

4
5

Synthesis gas

Boiler feedwater

References:
1. Christensen, T. S. et al., "Syngas preparation by autothermal reforming
for conversion of natural gas-to-liquid products (GTL)," Monetizing
Stranded Gas Reserves Conference, San Francisco, California, 1998.
2. Christensen, T. S. et al., "Burners for secondary and autothermal reforming-
design and industrial performance," Ammonia Plant Safety, Vol. 35, 1994.
Licensor: Haldor Topsoe A/S

Copyright © 2019 Gulf Energy Information. All rights reserved.



https://www.hydrocarbonprocessing.com/

Gas Processes Handbook

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