Using Improved Catalyst Designs for Secondary Reforming

Similarly to the catalysts in primary reformers, the use of high surface secondary reformer catalysts will result in improved activity. The reaction in the secondary reformer is adiabatic and therefore, improved heat transfer is not required. In the past years, the increase in Geometric Surface Area (GSA) has resulted in significant increases in space velocities. The outcome was up to 50% shorter loading catalyst volumes and a bigger area above the catalyst bed in which the combustion can take place (Beyer et al., 2005 p.5). The use of lower catalyst volumes has allowed the construction of smaller secondary reformers and a decrease in pressure drop (Beyer et al., 2005 p.10).

To avoid increase in pressure drop, the secondary reformer catalyst will need to have good thermal stability to withstand the high operating temperatures at the secondary reformer, and improved physical strength (Beyer et al., 2005 p.4).

Indian flag Decreasing the catalyste volume in secondary reformer can also provide other benefits. In an Indian plant, the top layer of the catalyst was fused, forming lumps that were difficult to revove, due to poor mixing of process air and proces gas. By reducing the catalyst volume by 14% with the use of more active catalyst, better mixing was obtained and catalyst fusion was avoided (Patel and Mehta, unknown date). 

Development Status Products
Commercial
Ammonia

Using Improved Catalyst Designs for Secondary ReformingCosts & Benefits

Parent Process: Steam Reforming
Energy Savings Potential
CO2 Emission Reduction Potential
Costs

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Assessment to Action (A2A) Toolkit

Developed by IIP, in collaboration with energy expertsat ICF Marbek, members of the IFA and experts in China, the A2A (Assessment to Action) Toolkit is a free suite of resources on energy management and technology best practices created for ammonia companies. The A2A Toolkit provides a first-order, high-level assessment to identify and prioritize energy efficiency opportunities. It does so by drawing on various assessment modules on technical best practices, management best practices (based on ISO 50001 standard) and productivity improvements. 

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