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Corrosion Prevention

IP.com Disclosure Number: IPCOM000244734D
Publication Date: 2016-Jan-06
Document File: 10 page(s) / 47K

Publishing Venue

The IP.com Prior Art Database

Abstract

[0001] The present disclosure discloses a hydrogen production method and apparatus for producing a hydrogen-containing product from a hydrocarbon feedstock containing higher hydrocarbons. The hydrocarbon feedstock is reformed with steam in a plurality of catalyst-containing reformer tubes to form a reformate. The catalyst in the catalyst-containing tubes is an alkali-promoted reforming catalyst. Surfaces that contact the reformate in the process gas boiler, transfer lines, and intermediate equipment operatively disposed between the plurality of catalyst-containing reformer tubes and the shift reactor is maintained above the deliquescence temperature of the reformate.

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TITLE:

Hydrogen Production Process Using Higher Hydrocarbon Feedstocks

ABSTRACT

[0001]      The present disclosure discloses a hydrogen production method and apparatus for producing a hydrogen-containing product from a hydrocarbon feedstock containing higher hydrocarbons. The hydrocarbon feedstock is reformed with steam in a plurality of catalyst-containing reformer tubes to form a reformate. The catalyst in the catalyst-containing tubes is an alkali-promoted reforming catalyst. Surfaces that contact the reformate in the process gas boiler, transfer lines, and intermediate equipment operatively disposed between the plurality of catalyst-containing reformer tubes and the shift reactor is maintained above the deliquescence temperature of the reformate.

BACKGROUND

[0002]      The present disclosure relates to a process and apparatus for steam reforming a hydrocarbon feed containing higher hydrocarbons to produce a hydrogen-containing product, for example, industrial hydrogen or synthesis gas.

[0003]      Carbon formation and deposition of the carbon on the catalyst can be a problem when steam reforming hydrocarbon feeds containing hydrocarbons heavier than methane. For example, hydrocarbon feed containing a heavy natural gas (i.e. containing greater than 10 mole % C2 to C4 hydrocarbons) can more easily crack and form carbon that can deposit on the reforming catalyst.

[0004]      Industry has addressed the increased risk of carbon formation by increasing the ratio of steam used in the reforming reaction. However, using a higher steam-to-carbon molar ratio decreases the efficiency of the process.

[0005]      Industry has also addressed the increased risk of carbon formation by using a so-called prereformer, which is a reactor, often adiabatic, with a high-nickel content catalyst where steam and the hydrocarbon feed are reacted to a limited extent to form an intermediate product before introducing the intermediate product from the prereformer into the primary reformer. Employing a prereformer, obviously increases the complexity and capital cost of the process.

[0006]      Industry has also addressed the increased risk of carbon formation by employing reforming catalysts that are promoted with alkali metals, often potassium. However, the use of alkali-promoted catalysts, created a new problem. Corrosion of downstream equipment, particularly the process gas boiler, was observed to occur much more readily. Alkali components (mainly potassium) from the alkali-promoted reforming catalyst are extracted from the catalyst and migrate in the reformate stream to downstream equipment. Under certain conditions, an aqueous liquid solution forms on cold m...