CA2413388A1 - Improved system for hydrogen generation through steam reforming of hydrocarbons and integrated chemical reactor for hydrogen production from hydrocarbons - Google Patents

Improved system for hydrogen generation through steam reforming of hydrocarbons and integrated chemical reactor for hydrogen production from hydrocarbons Download PDF

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Publication number
CA2413388A1
CA2413388A1 CA002413388A CA2413388A CA2413388A1 CA 2413388 A1 CA2413388 A1 CA 2413388A1 CA 002413388 A CA002413388 A CA 002413388A CA 2413388 A CA2413388 A CA 2413388A CA 2413388 A1 CA2413388 A1 CA 2413388A1
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Prior art keywords
reactor
section
shell assembly
water gas
gas shift
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CA002413388A
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French (fr)
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CA2413388C (en
Inventor
Franklin Delano Lomax Jr.
John P. Reardon
Jason P. Barbour
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Air Liquide Process and Construction Inc
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Individual
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Priority claimed from US09/642,008 external-priority patent/US6497856B1/en
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    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
    • C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
    • C01B3/384—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts the catalyst being continuously externally heated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/0005—Catalytic processes under superatmospheric pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/008—Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J8/06—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds in tube reactors; the solid particles being arranged in tubes
    • B01J8/062—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds in tube reactors; the solid particles being arranged in tubes being installed in a furnace
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/323—Catalytic reaction of gaseous or liquid organic compounds other than hydrocarbons with gasifying agents
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    • C01B3/48—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents followed by reaction of water vapour with carbon monoxide
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    • B01J2208/023—Details
    • B01J2208/024—Particulate material
    • B01J2208/025—Two or more types of catalyst
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    • B01J2219/00761—Details of the reactor
    • B01J2219/00763—Baffles
    • B01J2219/00765—Baffles attached to the reactor wall
    • B01J2219/00777—Baffles attached to the reactor wall horizontal
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    • B01J2219/194—Details relating to the geometry of the reactor round
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    • C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
    • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
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    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/12—Feeding the process for making hydrogen or synthesis gas
    • C01B2203/1288—Evaporation of one or more of the different feed components
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/14—Details of the flowsheet
    • C01B2203/142—At least two reforming, decomposition or partial oxidation steps in series
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/14—Details of the flowsheet
    • C01B2203/146—At least two purification steps in series
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1604—Starting up the process
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1609—Shutting down the process
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1614—Controlling the temperature
    • C01B2203/1619—Measuring the temperature
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1642—Controlling the product
    • C01B2203/1647—Controlling the amount of the product
    • C01B2203/1652—Measuring the amount of product
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1642—Controlling the product
    • C01B2203/1647—Controlling the amount of the product
    • C01B2203/1652—Measuring the amount of product
    • C01B2203/1661—Measuring the amount of product the product being carbon monoxide
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1642—Controlling the product
    • C01B2203/1671—Controlling the composition of the product
    • C01B2203/1676—Measuring the composition of the product
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1685—Control based on demand of downstream process
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/16—Controlling the process
    • C01B2203/1695—Adjusting the feed of the combustion
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/80—Aspect of integrated processes for the production of hydrogen or synthesis gas not covered by groups C01B2203/02 - C01B2203/1695
    • C01B2203/82—Several process steps of C01B2203/02 - C01B2203/08 integrated into a single apparatus

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
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  • General Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Inorganic Chemistry (AREA)
  • Hydrogen, Water And Hydrids (AREA)
  • Separation Of Gases By Adsorption (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)

Abstract

The present invention provides a reactor, which includes: a unitary shell assembly (10) having an inlet (1) and an outlet (8); a flow path extending within the shell assembly (10) from the inlet (1) to the outlet (8), the flo w path having a steam reformer section with a first catalyst (5) and a water g as shift reactor section with a second catalyst (50), the steam reformer sectio n being located upstream of the water gas shift reactor section; a heating section within the shell assembly (10) and configured to heat the steam reformer section; and a cooling section within the shell assembly (10) and configured to cool the water gas shift reactor section. The present inventio n also provides a simplified hydrogen production system, which includes the catalytic steam reforming and subsequent high temperature water gas shift of low-sulfur (< 100ppm by mass) hydrocarbon fuels followed by hydrogen purification through the pressure swing adsorption (PSA).

Claims (43)

1. A reactor, comprising:
a unitary shell assembly having an inlet and an outlet;
a flow path extending within said shell assembly from said inlet to said outlet, said flow path having a steam reformer section with a first catalyst and a water gas shift reactor section with a second catalyst, said steam reformer section being located upstream of said water gas shift reactor section;
a heating section within said shell assembly and configured to heat said steam reformer section; and a cooling section within said shell assembly and configured to cool said water gas shift reactor section.
2. The reactor of Claim 1, wherein said flow path includes a preheat section located upstream of said steam reformer section.
3. The reactor of Claim 2, wherein said preheat section includes a packing material.
4. The reactor of Claim 3, wherein said packing material is a sulfur absorbent bed.
5. The reactor of Claim 1, wherein said flow path includes an adiabatic water gas shift reactor section located downstream of said water gas shift reactor section.
6. The reactor of Claim 1, wherein:

said steam reformer section and said water gas shift reactor section are formed of an array of tubes;
said flow path includes an inlet tube header located upstream of said steam reformer section; and said flow path includes an outlet tube header located downstream of said water gas shift reactor section.
7. The reactor of Claim 6, wherein the interior of the tubes is provided with a catalyst in the form of at least one selected from the group consisting of a coating, a monolith, a loose packing of pellets, extrudates, and mixtures thereof.
8. The reactor of Claim 1, wherein said shell assembly includes:
a means of thermal expansion relief;
at least one inlet to said cooling section configured to receive a cooling medium; and at least one outlet for said cooling section.
9. The reactor of Claim 8, wherein said shell assembly includes:
at least one inlet to said heating section configured to receive a heating medium; and at least one outlet for said heating section.
10. The integral reactor of Claim 6, wherein said tubes in said array of tubes have an exterior surface configured to aid heat transfer between said heating section and said steam reformer section, and between said cooling section and said water gas shift reactor section.
11. The reactor of Claim 10, wherein said exterior surface of said tubes are configured with at least one configuration selected from the group consisting of twisted tubes, finned tubes, rifled tubes, plate fins, loose packing material, and combinations thereof.
12. The reactor of Claim 6, further comprising baffles within said shell assembly and provided exterior of said tubes, said baffles being configured to force a heat transfer medium flowing outside said tubes across the array of tubes in a direction substantially normal to a longitudinal axis of said tubes.
13. The reactor of Claim 12, wherein said baffles have a modified surface area.
14. The reactor of Claim 1, further comprising a catalytic burner configured to heat at least one of a heating medium provided within said heating section and a cooling medium provided within said cooling section.
15. The reactor of Claim 14, wherein said catalytic burner is provided within said shell assembly.
16. The reactor of Claim 14, wherein said catalytic burner includes at least one inlet for fuel delivery.
17. The reactor of Claim 14, Wherein said catalytic burner includes at least one selected from the group consisting of a means for mixing fuel and heated air, a means for preheating and/or igniting, at least one temperature sensor, and combinations thereof.
18. The reactor of Claim 1, wherein said first catalyst is substantially resistant to poisoning by sulfur and molecular oxygen.
19. The reactor of Claim 1, wherein said second catalyst is substantially resistant to poisoning by sulfur.
20. The reactor of Claim 1, further comprising:
an insulation assembly provided on at least a portion of an exterior of said shell assembly; and an outer housing provided on an exterior of said insulation assembly.
21. The reactor of Claim 1, further comprising a second flow path defined by said cooling section and said heating section, wherein said cooling section and said heating section axe fluidly connected.
22. The reactor of Claim 1, wherein said unitary shell assembly is a pressurized shell assembly.
23. The reactor of Claim 1, wherein said unitary shell assembly is a gas-tight shell assembly.
24. The reactor of Claim 1, wherein said shell assembly further comprises an insulating layer.
25. The reactor of Claim 24, wherein said insulating layer is contiguous or non-contiguous.
26. The reactor of Claim 1, wherein said first and second catalysts are the same or different.
27. The reactor of Claim 1, wherein said first catalyst is in admixture with said second catalyst.
28. The reactor of Claim 1, wherein said second catalyst is in admixture with said first catalyst.
29. The reactor of Claim 1, wherein said shell assembly comprises a plurality of inlets.
30. The reactor of Claim 1, wherein said shell assembly comprises a plurality of outlets.
31. The reactor of Claim 1, wherein said shell assembly comprises a tube side and a shell side.
32. The reactor of Claim 31, wherein said tube side forms a continuous pressure vessel.
33. A reactor for the production of hydrogen from at least one selected from the group consisting of natural gas, propane, liquefied petroleum gas, alcohols, naphtha, hydrocarbon fuels and mixtures thereof, said reactor comprising:

a unitary shell assembly having an inlet and an outlet;

a flow path extending within said shell assembly from said inlet to said outlet, said flow path including a convectively-heated catalytic steam reformer and a convectively-cooled water gas shift reactor.
34. A method for producing hydrogen, comprising the step of:
feeding at least one fuel selected from the group consisting of natural gas, propane, liquefied petroleum gas, alcohols, naphtha, hydrocarbon fuels and mixtures thereof, into a reactor comprising a unitary shell assembly having an inlet and an outlet, and a flow path extending within the shell assembly from the inlet to the outlet, the flow path comprising a convectively-heated catalytic steam reformer and a convectively-cooled water gas shift reactor, whereby hydrogen is produced.
35. A method for producing hydrogen from at least one fuel selected from the group consisting of hydrocarbon fuel, natural gas, propane, naphtha, hydrocarbons with < 100 ppm sulfur by mass, and mixtures thereof, comprising:

producing hydrogen by steam reforming said fuel; and substantially purifying said hydrogen with a pressure swing adsorption (PSA) system;

wherein prior to said producing, no pretreatment of said fuel to remove at least one impurity selected from the group consisting of sulfur and molecular oxygen and mixtures therof is carried out.
36. The method of Claim 35, wherein said steam reforming comprises a steam reforming catalyst, and wherein said steam reforming catalyst is insensitive to sulfur and molecular oxygen.
37. The method of Claim 36, wherein said steam reforming catalyst comprises a catalytically active metal selected from the group consisting of group VIIIB
metals, ruthenium, iridium, rhodium, platinum, palladium and mixtures thereof supported upon a ceramic support.
38. The method of Claim 35, which is carried out at a pressure of between 4 and 18 atmospheres.
39. The method of Claim 35, further comprising a feedback control loop for delivering said fuel or air or both to said steam reforming and for controlling a temperature of said fuel or air or both.
40. The method of Claim 35, which does not comprise a low temperature water gas shift reaction.
41. The method of Claim 40, further comprising, prior to said purifying and subsequent to said steam reforming, a high temperature water gas shift reaction, and wherein an exit temperature of a product exiting said high temperature water gas shift reaction is above 200°C.
42. The method of Claim 35, wherein said reforming produces carbon monoxide or at least one impurity or both, and wherein said method further comprises a feedback control loop for controlling a concentration of said carbon monoxide or said impurity or both.
43. The method of Claim 35, wherein said pretreatment is at least one selected from the group consisting of partial oxidation, hydrodesulfurization, adsorption, absorption, and combinations thereof.
CA002413388A 2000-06-29 2001-06-29 Improved system for hydrogen generation through steam reforming of hydrocarbons and integrated chemical reactor for hydrogen production from hydrocarbons Expired - Lifetime CA2413388C (en)

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US21473700P 2000-06-29 2000-06-29
US60/214,737 2000-06-29
US09/642,008 2000-08-21
US09/642,008 US6497856B1 (en) 2000-08-21 2000-08-21 System for hydrogen generation through steam reforming of hydrocarbons and integrated chemical reactor for hydrogen production from hydrocarbons
PCT/US2001/016513 WO2002002220A1 (en) 2000-06-29 2001-06-29 Improved system and integrated chemical reactor for hydrogen production through steam reforming of hydrocarbons

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EP1294477A1 (en) 2003-03-26

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