A Complete Analysis of Your Reformer

Bill Cotton and Barry Fisher Synetix Introduction

his paper details a rigorous technique for analyzing the performance of a primary reformer including both the radiant and convection sections, from both the process and mechanical engineering points of view. The technique is a development of the reformer survey technique that has been applied to over 80 reformers by Synetix in the last eight years. The primary reformer is at the heart of any synthesis gas generation plant and is the most costly item in the to system to purchase, maintain and operate. The primary reformer appears to be a simple box, however there are many processes occurring within this box, including, combustion, heat transfer, flow distribution and the kinetics. These complex processes mean that a primary reformer can not be treated as a simple black box. It has taken many years of study and application of science to generate mathematical models which represent the working of such a complex heater. Computational models such as this allow the designer to push the boundaries in terms of heater size from 1000 to 5000 tonnes per day of product in some cases. There are many problems that can commonly occur on a primary reformer leading to either a full plant shut down to effect repairs or to a loss of plant efficiency. The aim of a reformer survey is to detect problems that can occur on primary reformers and their associated equipment early on, such that the impact on the plant operability is minimised. Some typical examples include, but are not limited to,

Combustion imbalance both on the fuel / air side, Refractory damage in the box or outlet system, Air ingress, Instrument failures, Convection section failures, Poisoning of the catalyst, Damage to tunnels or tunnel removal, Maintenance changes, Poor design or operation/maintenance of burners, Combustion air mal-distribution, Leaks in Rotary Air Preheaters, Flame impingement, After burning, Premature tube failure due to general overheating or overheating in a specific area.

Initial Process
The process used in the audit of the reformer is a development of the reformer survey as detailed in references 1 and 2 and as noted in these, this includes the following work,

Carbon formation, Mal-distribution of flue gas,

Reformer tube wall temperature measurements, Collection of process data, Correction of the measured tube wall temperatures for background radiation,

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Modelling of the plant to check plant data consistency, Detailed modelling of the primary reformer using REFORM (a proprietary Synetix modelling program),

Temperature C 830
790 750
5
A B C D Ro E w

In addition, the following troubleshoot process is performed,

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Visual checks on the burners, refractory and tubes, Checks on the overall design philosophy of the reformer and convection section, Pressure measurements on the fuel headers, Pressure measurements on the combustion air headers (where applicable), Pressure measurements in the wind boxes of the burners, Oxygen analysis of the fluegas within both the radiant and convection sections, Thermal imaging scans of both the radiant and convection sections, this can be extended to the outlet system if defects are suspected. Flowsheeting of the convection section and associated steam system, and heat recovery coils.

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F G H 40

30 35

Data Rationalisation Synetix has a number of in house programs for accurate data rationalisation which have been specifically tailored to suit particular plants. These programs (CATPER for Ammonia/Hydrogen and PERFORM for Methanol plants) are used to check the consistency of the plant data and rationalise the data to eliminate any errors in the plant data. This ensures that all subsequent process analysis is using a set of data of known quality. REFORM Synetixs in house reformer simulation program, called REFORM, is capable of modelling a variety of reformers, including primary, secondary and pre reformers as well as Gas Heated Reformers. REFORM is based on a set of rigorous models that include,

Tube Wall Temperature Measurements This is a vital part of the data gathering since the Tube Wall Temperature measurements allow for an understanding of what is occurring within the primary reformer. By using the process outlined in reference 2, it is possible to gain an accurate measure of the tubewall temperatures within the primary reformer and to correct them for the effects of background radiation. This corrected measurement is then used in Synetixs simulation package, REFORM to give an accurate fix on the activity of the Primary Reformer catalyst. In order to check for possible problems areas in the primary reformer, the tube wall temperatures are plotted in a three dimensional graph as shown.

Combustion on the furnace side, Heat transfer by radiation and convection on the furnace side, Heat transfer through the tube wall and the catalyst, Reaction of methane, ethane, propane, butane and higher hydrocarbons including aromatics and cyclic compounds, Methane/steam and water gas shift equilibrium, Carbon formation prediction, Pressure drop calculation, Tube design calculations.

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Tu be

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This is best summarised in the following figure,

To cross check the performance of the reformer, a REFORM model is set up which includes the following information,

The process conditions (inlet and outlet temperatures and pressures), The feedstock details (feed composition and flow rate).

Furnace dimensions (width, length, fired height), Tube layout (lane spacing and tube pitch), Tube design (tube metallurgy, inside and outside tube diameters),
860 840 820 800 780 760 740 720 700 680 0 0.2 0.4 0.6

The model is then run and the corrected temperature measurements are then checked against the predicted REFORM temperature at the various peephole heights. The activity of the catalyst is varied to obtain a good fit between these temperatures as illustrated below,

Temperature (C)

Simulation Measured

0.8

Fractional Distance Down Tube

The results of the REFORM model coupled with the three dimensional plots and measured/corrected tube wall temperatures can highlight a number of potential 2002 problems that occur on primary reformers. In order to determine the cause of these problems, a more detailed analysis of the reformer are required.

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Troubleshooting Process
In order to determine the root cause of a problem, a second stage of analysis is required which looks in detail at the design and operation of the primary reformer. Visual Inspection of Reformer Whilst conducting the tube shoot, Synetix engineers will conduct a full visual examination of the primary reformer in order to check for problems associated with the burners, refractory and tubes. These observations can allow for detection of potential problems in the reformer for instance, the Fluegas Mal-distribution problem (see reference 3 for further details) was detected by observation of deviation of the burner flames from the vertical and the tube wall temperature profile. A case study 4 is presented below detailing the issues associated with fluegas mal-distribution and the cost to the operator. Two case studies are presented below which detail the value of a quality radiant box inspection. Checks on Design Philosophy Inspection of the reformer design, either using drawings or by walking around the furnace is useful in ensuring that the design of the reformer is acceptable and is not the root cause of operational problems. It should be noted that the reformer design should be as symmetrical as possible and any deviation can lead to a maldistribution (see case study 1 below). Clearly such an inspection is very important in determining the root cause of operational problems. In addition it is important to review the maintenance history, as most problems can be traced back to either lack of maintenance or changes that have been made over a number of years. Convection Section Convection sections are one of the most difficult areas to inspect for a variety of reasons, i.e: location of the tubes, tubes are generally finned for maximum efficiency and the space in which they are positioned is very tight. From a process point of view the convection section needs to be kept clean. Large primary reformers with ceramic fibre or refractory brick work linings shed small amounts of dust particles, these particles tend to block the finned sections of the tubes and reduce the heat transfer efficiency and increase pressure drop.

The measured values obtained on site can be compared with the design conditions and evaluation can be made, as to the impact of such fouling. Convection sections are notorious for air leakages due the large amounts of penetrations and the differential expansion between the tubes and the casing. Some convection designs address leakage well but in many cases this problem is not addressed and can lead to operational problems. Pressure Measurements on the Fuel Headers Using a standard pressure gauge, it is possible to check the pressures at both ends of all of the fuel headers and thereby gain an understanding of the fuel distribution across the furnace and along individual rows. This gives an understanding of the heat release pattern through out the furnace which can then be matched against the corrected tube wall temperature plots to determine if there are any systematic mal-distributions within the reformer. An example of this was found on a European Ammonia plant operating with a side fired furnace. A reformer survey identified that one end of the reformer was operating 100C cooler than the other end and the centre of the reformer. An inspection of the reformer coupled was performed and it was found that 30% of the burners at this end of the reformer were out of service. This reduction in heat input lead to the observed temperature drop; after re-commissioning of the burners, the temperatures at this end of the furnace rose to match the tube wall temperatures observed in the remainder of the furnace. A comparison to the visual inspection of the burners should also be made to determine if there are any local or general mal-distribution problems. Pressure Measurements on the Combustion Air Headers This is similar to measuring the pressure on the fuel headers, except that the checks are being made on the combustion air system. In this case, a set of manometers should be made up and then used to check the pressure at each end of the air ducts. Again the pressure readings can be matched against the tube wall temperature plots and the results of the visual inspection of the reformer.

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Pressure Measurements in the Wind Boxes This measurement allows for checks on whether an individual burner is operating correctly. Again such measurement should be compares to the temperature plots, the visual inspection of the reformer and also the combustion air duct pressure measurements. Oxygen Analysis of the Fluegas Air leakage into the radiant or convection section can cause major problems in terms of maximum plant rate and plant efficiency. This leakage can come from a number of sources such as,

plants. Typical areas of application for synthesis gas plants are for checking for hot spots on,

Radiant box casing, Convection section casing, Secondary reformers, Waste Heat Boilers, Outlet Header Systems

Leaks in rotary air pre heaters, Leaks through peephole doors, Radiant and convection section construction joints, Header box joints, Tube entry and exit point through the radiant box casing, Burner attachments to the reformer casing, Explosion protection plates. (these are not used in new designs)

The outcome from such a survey is not only valuable in terms of operation, but can also help with scheduling maintenance and ordering of materials, plus being able to put manpower on standby at the next overhaul. An example of this is from an Ammonia plant secondary reformer as illustrated in the figure below,

By testing the oxygen levels of the flue gas at various points within the radiant and convection sections, it is possible to determine the general location of such air leaks and thereby focus on this area for a more detailed examination of the equipment to locate the precise leakage point. This allows maintenance resources to be focussed during a shut down on the real problems areas. Excessive air leakage into the reformer is often highlighted by high box pressures with the flue gas (induced draft) fan operating at its maximum speed. The former can lead to a significant safety issue when working on the reformer and convection section since it is possible to have flames issuing from the peepholes. The latter can in some cases become a major plant rate limitation. One example of the effect of a leak in a rotary air pre heater is given in case study 3. Thermal Imaging Thermal imaging has been used in a number of areas on process plants to check for various problems such as leaking safety relief valves, leaks from process pipes etc. One area that Synetix has developed expertise in is around the use of thermal imaging on synthesis gas

The yellow zones indicate very high temperatures and if the temperature of these areas exceed the design temperature, can lead to premature failure of the line or vessel. Mal-Distribution Checks Flue gas mal-distribution can be checked for in two ways, the first is to inject dry powder from a fire extinguisher through either the peepholes or the burner ignition ports. The second method is to injection potassium bicarbonate through the burner ignition ports. The peephole tests allow for checks on up flow at the walls and in the centre of the furnace whilst the burner ignition port checks allow for tests on cross blow and flame shape. A combination of both of these tests allows for practical determination of the fluegas flow patterns within the radiant section. This combined with tube wall temperature measurements provides a powerful trouble

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shooting tool in analyzing problems in the primary reformer. An example of the use of these tools is given in case study 4. It is also possible to take CO/CO2 readings across the reformer using a long lance, this can also aid in the diagnosis of flue gas distribution and burner imbalances. Again these readings can be used in conjunction with the process calculations and the plant readings. Flowsheeting Front End of the Plant The final stage of the analysis of a reformer is to flow sheet the front end of the plant. Typically this includes the following areas,

Case Studies
Case Study 1 Combustion Air Mal-Distribution During a reformer survey on a Western European Ammonia plant, an unusual temperature distribution between two halves of the primary reformer was noted as highlighted in the figures below,

Radiant box, Convection section, Feed preheat coils, Steam raising and superheating coils, Boiler feed water preheating, Combustion air preheating, Secondary reformer, Waste heat boiler, High and Low Temperature Shifts, Reformer gas cooling.

Sufficient data is normally available such that there are a number of plant measurements that can be used as check variables within the flow sheet which allow for validation of the flow sheet. Using the rationalised plant data from CATPER or PERFORM the model is generated and then run. The results are then checked against the plant data to ensure accuracy and any deviations are noted and then discussed with the plant operator to determine whether the deviation is due to a poor measurement or in accurate modelling. The results of this modelling when compared to the plant data can highlight the following,

Poor measurement, Problems in heat recovery, Mal performance of catalyst beds, Operational issues.

Furthermore, this model can then be used as a basis for analyzing the effects of plant rate changes, plant operating parameter changes and revamps.

On site inspection of the layout of the reformer and feed/fuel and combustion air ducts coupled with detailed discussions with the plant engineers eliminated many of the causes of this temperature mal-distribution such as process feed variations, firing differences, inlet/outlet header asymmetry. The only possible cause left was that there were differential amounts of combustion air being feed to the two halves of the reformer; this was possible since each half of the reformer was fed from its own combustion air duct. During a subsequent plant shut down, inspection of the air dampers in each half of the duct found that one was wide open and the other was stuck. Repairs were conducted and after the plant start up, Synetix performed a further reformer survey from which the following temperature plots were generated. As can be seen the mal-distribution has been eliminated and the tube wall temperatures are very even through out the reformer. This problem has been shown to have cost the plant approximately US$ 500,000 per year.

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Case Study 2 - After Burning in Centre of Furnace During a routine reformer survey of a world scale Methanol customers primary reformer, it was noted that there was severe after burning was occurring in the centre of the radiant box. Afterburning is caused by incomplete combustion in the top of the furnace which allows fuel to move down until it mixes with oxygen, at which point the fuel combusts giving the classic observation of flames licking around the tubes in the bottom half of the furnace. It was noted that no after burning was seen in the outer lanes. It was noticed that the oxygen measurement exit the radiant box was at 1.5%; this was rechecked and confirmed by the plant operator. It was also noted that the fluegas fan was operating at its maximum speed and that the box pressure was close to being positive. Inspection of the combustion air duct showed that after the air was pre heated, the air was split into two ducts which passed along the side of the convection section and then to the mid point of the radiant section. At this point both ducts turned through 90 and ran vertically along side the radiant box until they reached the level of the penthouse. At this point both ducts were split and as shown in the figure below, ran along the side of the penthouse. At the ends of the penthouse all the sub ducts turned through 90 and passed along the ends of the penthouse. From here headers pass the combustion air along the burner rows and to each burner.

On inspection of this system it was clear that there was insufficient pressure differential between the duct and the box to force enough air through to the centre of the furnace. This caused there to be a lack of combustion air in the centre of the furnace, and hence there was incomplete combustion and fuel passed into the bottom half of the furnace. The outer lanes of burners had an excess of air, and therefore there was a high excess oxygen content in the fluegas. Some of this excess oxygen then mixed with the excess fuel in the centre of the furnace and this resulted in the after burning noted. This effect was costing the plant operator approximately US$ 383,000 per year in lost production. A further hidden cost was that the tubes affected by the after burning would be operating with high tube wall temperatures for short periods of time and therefore their overall life would be shortened. Case Study 3 Air Leaks in Rotary Air Pre Heaters A customer had noticed that the efficiency of his plant had been gradually reducing over the previous six months. Synetix conducted reformer survey covering both the radiant and convection sections. Detailed flowsheeting of the front end of the plant showed that the plant was generally operating as would be expected; however, there was a heat imbalance across the combustion air pre heater; it should be noted that the pre heater was of a rotary design. Further modelling of the combustion air pre heater indicated that there appeared to be a very large air leakage between the combustion air and the fluegas side. The plant checked the oxygen levels through out the

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convection section and the air pre heater and it was found that there was 16.3% oxygen in the fluegas exit the air pre heater compared to 2% inlet the air pre heater. This leak caused a plant inefficiency that is worth US$ 250,000 per year.

Case Study 4 Flue Gas Mal-distribution During a reformer survey on a large methanol plant, an unusual temperature mal-distribution was seen as highlighted in the following figure.

On site tests using dry powder from a fire extinguisher determined that there was a flue gas maldistribution pattern.

The picture below shows the result of injection of dry powder through a side peephole and highlights the up flow occurring at the walls,

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Dry powder injected through the burner ignition port shows that there is cross flow from the outer lanes through into the inner lanes as highlighted by the

movement of the dry powder from the burner towards the outer lane of tubes,

CFD modelling was conducted using the geometry of the furnace along with the process and fuel flows and this confirmed the results of the practical tests con-

ducted on the plant. The results of this modelling are illustrated below,

As can be seen the model predicts that there is up flow at the walls and there is cross flow from the outer lanes to the inner lanes at the top of the furnace. The root cause of the problem was a mismatch between the burner capacity, outer lane sizing and the outer coffin sizing.

From this an understanding of the costs of the problem to the operator can be determined which allows for a valued judgement as to whether a resolution is required in the short or long term.

References
Ref 1. Modern Techniques for Optimisation of Primary Reformer Operation P W Farnell Synetix Ref 2. Tube Wall Temperature Measurement in Steam Reformers B J Cromarty and S C Beedle Synetix Ref 3. Fluegas Mal-distribution W J Cotton IMTOF 1999 Synetix

Conclusions
The process defined above allows for a detailed examination of both the radiant and convection sections of an Ammonia, Methanol or Hydrogen plant. The tools detailed in this paper allow for,

Analysis of these areas of the plant, The detection of operational issues, The determination of the root cause of these problems.

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