Reformer heater Baton Rouge Louisiana

Top-fired reformers

Top-fired steam reformer designs commonly used in hydrogen, ammonia and synthesis gas plants around the world. We can design and supply top-fired reformers based on our own design or third-party designs. Reformer heater Baton Rouge Louisiana.

These units are noted for a number of alternating rows or lanes of tubes and burners located within a rectangular firebox. The burners are mounted on the arch level and their flames are ‘drafted’ downward by large power-consuming forced-draft and induced-draft (ID) fans. Loss of power to either fan requires immediate shutdown of the reformer as it cannot be operated in natural-draft mode. Reformer heater Baton Rouge Louisiana.

All the tube support systems, burners, burner piping and inlet manifolds/pigtails are located on top of the radiant box in a ‘penthouse’. Special designs are required to maintain ventilation and man safe conditions in the penthouse. Reformer heater Baton Rouge Louisiana.As the flues gases are drawn downward by the ID fans a plug flow effect has to be maintained for proper operation. The flues gases are collected at the bottom brick tunnels, often called ‘coffins’, and exit to a grade-mounted convection section. Reformer heater Baton Rouge Louisiana.

The top-fired radiant box is more compact compared with single-row designs when it comes to large-scale units. Reformer heater Baton Rouge Louisiana. However, this advantage will be diminished or even eliminated by the large amount of additional plot space required for the convection section with air preheater, fans, and stack, as they cannot be mounted on top of the reformer box. Reformer heater Baton Rouge Louisiana.

Primary steam reformers are used for the production of hydrogen. A hydrocarbon feedstock such as natural gas is mixed with steam and heated in the presence of a catalyst to produce crude hydrogen which is then purified. Reformer heater Baton Rouge Louisiana.

Steam reforming takes place in a steam reformer furnace. The furnace is usually a large refractory lined box with gas burners heating many catalyst filled tubes that carry the feed (natural gas) and steam. Reformer heater Baton Rouge Louisiana. Depending on the design, the reformer’s firebox or cell may contain only a single row of tubes or may contain multiple rows making it more difficult to obtain accurate temperature data. Reformer heater Baton Rouge Louisiana.

Apart from the primary steam reformer, there are also several other critical types of furnaces in a chemical and petrochemical plant that require accurate tube temperature measurement. One such furnace is the ethane cracker furnace. Reformer heater Baton Rouge Louisiana.

Both the primary steam reformer and ethane cracker furnace carry out a basic function in which they use a catalytic reaction to convert feedstock into a desired hydrocarbon fluid. Reformer heater Baton Rouge Louisiana.

Another similarity is in the tube material used for these furnaces. Because of the elevated temperatures that usually are beyond that of a standard borne heater or reboiler, special alloy metals (HK-40, HP-MA, Et45-Micro) must be used in order to minimize the effect of creep damage and failure. Reformer heater Baton Rouge Louisiana.Tube wall temperatures ranging from 700°C to 1200°C (1292°F to 2192°F) are common for these types of furnaces. Reformer heater Baton Rouge Louisiana.

The temperature limits of these tubes are based primarily on the tube’s metallurgy (high Ni and Cr content) and the process. Reformer heater Baton Rouge Louisiana. If the temperature is too high, then there is a real danger of creep damage and failure and the chances of coking increases, resulting in further tube metallurgical damage and process flow restriction. If the temperature is too low, then production output is decreased resulting in loss of profit in a highly competitive market. Reformer heater Baton Rouge Louisiana.

If a plant is to get the most life out of their tubes while maximizing production, these tubes must be operated and fired as close to maximum operating temperature as possible. Reformer heater Baton Rouge Louisiana.However, there is a real risk of exceeding this maximum operating temperature if accurate tube wall temperatures are not known. Industry rule of thumb states that a 20C° increase in temperature above its maximum allowable will halve the tube life and can result in costly and dangerous mistakes in tube temperature operation. Reformer heater Baton Rouge Louisiana.

Temperature measurement of tubes is imperative for all reformers and critical heaters. Accuracy is critical but is it attainable? Plants may think they are accurate in their measurements but are they? How confident are they with their measured temperatures? Temperature accuracy is often disputed between departments (Operations, Production, Condition Monitoring, etc.); this is because it is very common to have all of these departments measuring the same tubes and acquiring different temperatures. Which temperatures are correct? Which are the most accurate? What safety margin should the plant use? Reformer heater Baton Rouge Louisiana.

Current Commonly Used Tube! Temperature Methods

In order to answer all the above concerns and questions, we must first understand the tools at our disposal to acquire temperature. Reformer heater Baton Rouge Louisiana. Each tool or means of measuring tube wall temperature has limitations and error sources. Reformer heater Baton Rouge Louisiana. Choosing the correct temperature measurement solution for any furnace will be dependent on these limitations, error sources and practicality. Reformer heater Baton Rouge Louisiana.

The following are the two most commonly used methods for acquiring tube wall temperatures. We will discuss their basic principle along with the benefits and limitations:

Single Point Radiometer (Spot IR Pyrometer):

Single Point (Spot) Infrared Pyrometers are non-contact infrared measuring devices. They measure the amount of infrared energy that is emitted and reflected from the tube wall. Reformer heater Baton Rouge Louisiana. The amount of infrared energy the instrument receives is then converted into a temperature reading. These units only measure a specific spot or area and do not provide imagery. Reformer heater Baton Rouge Louisiana.

Operators

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Benefits:

Cost Effective
Fast
Simple to Use
Repeatable Results
Temperature Trending

Limitations:

Frequently Used Improperly
Spot Temperatures Only
Spot Size (90:1 or 180:1). The Result is Increased Error Due to Distance
No Diagnostics Ability
No Reflected Temperature Input
Accurate Tube Wall Temperature is Difficult
Hot, Laborious Work

Although the Spot IR Pyrometer has many limitations, due to the simple use and repeatable temperature capabilities, this monitoring mode is well suited for the plant operator. Reformer heater Baton Rouge Louisiana.Training on proper usage is important as these instruments in the hands of an untrained user will yield unacceptable inconsistencies and errors. Reformer heater Baton Rouge Louisiana.

Thermal Imager / IR Camera (Portable):

Portable Thermal Imagers (Infrared Cameras) are also non-contact infrared measuring devices and work under the same theory and physics as the Spot IR Pyrometers. Reformer heater Baton Rouge Louisiana. However, Portable Thermal Imagers provide the advantage of imagery instead of only a spot. The added benefit of imagery allows everything in the field of view to be measured and the image can be saved for further computer analysis and historical data. Reformer heater Baton Rouge Louisiana.

Benefits:

Fast Reformer heater Baton Rouge Louisiana

Identify Maximum Tube Wall Temperature Area
Imagery of Tube Wall Temperature Profile
Repeatable Results
Temperature Trending
Databasing of Imagery (Permanent Record)
Problem Diagnostics Ability
Most Adaptable to Tube Wall Temperature Accuracy

Limitations:

High Cost
Requires Advanced Skills
Requires Proper Training in the Application
Analysis and Reporting Takes Time and Skill
Accurate Tube Wall Temperature is Difficult

Although Portable IR Imagery equipment or service is an expensive option, the data and diagnostics advantages exceeds all other forms of monitoring and makes it ideal for any furnace design. Training on infrared and the application is crucial. Reformer heater Baton Rouge Louisiana. Having dedicated in-house personnel or qualified service providers is required. High degrees of skill and knowledge are required for this application to be of any use. Reformer heater Baton Rouge Louisiana.

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