Partial oxidation reformer-reforming exchanger arrangement for hydrogen production

Abstract

A method for retrofitting a syngas process entails converting a first hydrocarbon stream to a first reactor effluent through partial oxidation; cooling the first reactor effluent and producing steam with recovered heat; and receiving the cooled reactor effluent and producing a product syngas of enhanced hydrogen content. The downstream processing entails cooling the first reactor effluent to a temperature from about 650 to about 1000 degrees C. The first reactor effluent is diverted to a reforming exchanger. A second hydrocarbon portion with steam is passed through a catalyst zone in the reforming exchanger forming a second reactor effluent. The second reactor effluent is discharged from the catalyst zone forming an admixture with the first reactor effluent. The admixture is passed across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone. The cooled admixture is supplied back to the reforming exchanger.

1 ) A method for retrofitting a syngas process comprising
 a partial oxidation reaction step for converting a first hydrocarbon stream to a first reactor effluent through partial oxidation;   a heat recovery step for cooling the first reactor effluent and producing steam with recovered heat; and   a downstream processing step for receiving the cooled reactor effluent and producing a product syngas of enhanced hydrogen content, wherein the downstream processing step comprises:
 cooling the first reactor effluent to a temperature from about 650 degrees C. to about 1000 degrees C.; 
 diverting the first reactor effluent to a reforming exchanger; 
 passing a second hydrocarbon portion with steam through a catalyst zone in the reforming exchanger to form a second reactor effluent; 
 discharging the second reactor effluent from the catalyst zone to form an admixture with the first reactor effluent; 
 passing the admixture across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone; 
 supplying the cooled admixture from the reforming exchanger to the heat recovery step. 
   
   
   
       2 ) The method of  claim 1 , further comprising introducing water into the first reactor effluent as a quench fluid. 
   
   
       3 ) The method of  claim 1 , further comprising cooling the first reactor effluent by indirect heat exchange.  
   
   
       4 ) The method of  claim 1 , further comprising heating the second hydrocarbon portion by indirect heat exchange before supplying the second hydrocarbon portion to the reforming exchanger. 
   
   
       5 ) The method of  claim 1 , further comprising introducing the second hydrocarbon portion to a tube side inlet of the reforming exchanger. 
   
   
       6 ) The method of  claim 1 , further comprising supplying the first reactor effluent to a shell side inlet of the reforming exchanger. 
   
   
       7 ) The method of  claim 6 , wherein the shell side inlet is adjacent an outlet end of the catalyst tubes. 
   
   
       8 ) The method of  claim 1 , wherein the catalyst zone comprises catalyst tubes. 
   
   
       9 ) The method of  claim 1 , wherein the indirect heat exchange comprises heating the second hydrocarbon portion in a cross exchange. 
   
   
       10 ) The method of  claim 1  further comprising supplying the first and second hydrocarbon portions in a weight ratio of ranging from about 40:60 to about 95:5. 
   
   
       11 ) The method of  claim 1 , further comprising supplying the first and second hydrocarbon portions in a weight ratio of ranging from about 40:60 to about 60:40. 
   
   
       12 ) The method of  claim 1 , further comprising supplying the first and second hydrocarbon portions in a weight ratio of ranging from about 95:5 to about 80:20. 
   
   
       13 ) A method for retrofitting a syngas process comprising
 cooling the first reactor effluent to a temperature from about 650 degrees C. to about 1000 degrees C.;   diverting the first reactor effluent to a reforming exchanger;   passing a second hydrocarbon portion with steam through a catalyst zone in the reforming exchanger to form a second reactor effluent;   discharging the second reactor effluent from the catalyst zone to form an admixture  with the first reactor effluent;   passing the admixture across the catalyst zone in indirect heat exchange therewith to cool the admixture and heat the catalyst zone; and   supplying the cooled admixture from the reforming exchanger for cooling the first reactor effluent and producing steam with recovered heat.