Gas Processes Handbook - 85

2019 GAS PROCESSES HANDBOOK
PROCESS CATEGORIES

COMPANY INDEX

HYDROGEN / SYNTHESIS GAS

Steam Methane Reforming (SMR)

Flue gas

HP steam

Application: Generation of syngas by steam reformation of methane-rich hydrocarbon.
Process steam

Feedstocks: LPG, naphtha, natural gas, refinery offgas.
Products: Hydrogen, carbon monoxide, syngas or a combination thereof.

Fuel gas

Heat
recovery
Flue gas
Tail gas

Coproducts: Steam, optionally carbon dioxide.
Capacity: Per SMR train:
* 15,000 Nm3/hr-200,000 Nm3/hr H₂ plant
* 3,500 Nm3/hr-40,000 Nm3/hr CO plant
* Up to 350,000 Nm3/hr syngas.
Description: Feedstocks are desulfurized, mixed with steam and preheated.
Optionally, a catalytic prereforming step may be foreseen to convert the feed/
steam mixture to a methane-rich gas to improve the efficiency of the SMR. The main
reforming reaction takes place in the proprietary top-fired steam reformer, in which
the feed/steam mixture is converted, while passing catalyst-filled and heated tubes
at temperatures of 800°C-940°C and pressures of 15 barg-45 barg. Reformed gas
leaving the reformer contains H₂, CO, CO₂ and unreacted components.
Efficiency of the process and composition of the reformed gas can be adjusted
via the process parameters of reforming pressure, temperature and steam-to-feed
ratio. If H₂ yield should be increased or maximized, then a catalytic shift reactor may
be added and fed with reformed gas to convert CO and steam to additional H₂ and
CO₂. If a high CO yield is targeted, then CO₂ may be separated from reformed gas and
recycled to the SMR. Additional import CO₂ may be added if available.
Suitable product purification technologies include: PSA and membrane for H₂,
amine wash (aMDEA) for CO₂ removal, and methane wash cold box for CO.
Advantages: Steam reforming is a mature technology, and several hundred units are in
operation worldwide. More than 50% of the work of the H2 production is generated via
steam reforming and, therefore, it represents the state-of-the-art production method.
Main features:
* Flexibility in process design to optimize for best efficiency, lowest CAPEX or
lowest total cost of ownership
* Optimized integration of refinery offgases for H₂ production and recovery

Natural gas

Syngas

Prereformer

H2

Hydrodesulfurization
pretreatment

Syngas
cooling

Reformer
Boiler
feedwater

* Best-in-class plant reliability and operability through operational feedback
from Air Liquide's own plants.

Economics:
OPEX for H₂ plants (based on natural gas feed and fuel):
* Steam co-export ratio: 0.4 kg/Nm3-1.1 kg/Nm3 H₂
* Feed plus fuel: 14.5 MJ/Nm3-15.3 MJ/Nm3 H₂.
OPEX for HyCO plants (based on natural gas feed and fuel):
* H₂/CO product ratio: 2.6-4.2
* Steam co-export ratio: 0.3 kg/Nm3-0.7 kg/Nm3 [H₂ + CO]
* Feed plus fuel: 14.2 MJ/Nm3-14.8 MJ/Nm3 [H₂ + CO].
CAPEX for H₂ and HyCO plants (including purification): $25 MM-$370 MM.

Utilities: The main utility consumption is the feed and fuel utilized by the process.
Consumption of other utilities, such as cooling water, boiler feedwater, instrument air,
nitrogen and/or electrical power, is required.
Continued 
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