Kellogg Brown + Root LLC

Bd Energy Systems, LLC

Daniel Joseph Barnett

Richard B Strait

Gregory B Cargle

Venancz Laszlo Patrovics

Gregory Bryan Cargle

Daniel Ryan Znidersic

Shashi Prakash Singh

Methods and apparatus for improved efficiency and flue gas scrubbing in a fired heater using a condensing convection section. The method preheats a hydrocarbon or hydrocarbon/water process feed stream in a coil in the convection section of a fired heater, collects condensate from the flue gas, and scrubs the flue gas with the recirculated condensate. The apparatus has a heat transfer coil disposed in the convection section, to preheat a process stream and form condensate from the flue gas, and a condensate recirculation loop to collect the condensate from the convection section and scrub the flue gas with the condensate.

Method and apparatus for improved efficiency and flue gas scrubbing in a fired heater using a condensing convection section

Processes and apparatus for low-CO2 emissions methanol production using a high efficiency (>90%) reformer fired with a low-carbon fuel (C:H<0.03) to produce syngas. CO2 is removed from the syngas, and the CO2-lean syngas is fed to a methanol synthesis loop. A purge stream from the methanol synthesis loop is processed to recover a hydrogen-rich stream and a tail gas stream. The hydrogen-rich stream is supplied as fuel to fire the reformer, along with a portion (<10%) of the tail gas, to produce a CO2-lean flue gas (<3 vol %, dry basis). The flue gas is optionally cooled below a dew point to form condensate, which can be collected and removed. The methanol production can have a carbon efficiency of 97% or more, and a CO2 emissions reduction (compared to natural gas firing) of 88% or more.

Low CO2 emissions methanol process and production apparatus

A reformer suitable for micro-scale design has horizontal catalyst tube(s) passing through a baffled radiant section for convective and radiant heat transfer to the tube(s). To reduce the footprint and/or to facilitate field assembly a combustion chamber and convection section can be oriented transversely with respect to the radiant section; the tube(s) can be horizontal and/or include structured catalyst; and/or the combustion chamber provides flameless combustion or produces a flame without impinging on the tubes. Also, a skid frame-mountable version of the reformer; and a process for transporting, assembling, and/or operating the steam methane reformer.

Micro reformer

Flue gas entry into the tunnel(s) of a furnace is controlled by varying the flow conductivity or size of the individual or groups of openings through the entry ports. The openings can be provided either as gaps between adjacent blocks, or through bores of varying diameter, or as inserts having orifices of varying diameter and a profile matching the ports in which they are placed. Matching the flow conductivity (or cross-sectional flow area) and pressure drop through the individual ports to the desired mass flow, the flue gas flow can be distributed evenly, or as otherwise desired, into different ports, intervals, and/or regions of the tunnel.

Furnace tunnels and assembly system

Ammonia is produced in a reactor in which pseudoisothermal conditions can be approached by convective cooling of a reaction zone of the reactor by positioning at least a portion of the reaction zone in indirect contact with a flow of hot gas such as exhaust gas or preheated air. The hot gas may be supplied from a fired heater, a boiler, a reformer, a process air preheat furnace, a gas turbine, or the like. The reactor converts a feed stream of a purge gas or syngas to ammonia. The method may be implemented in a primary synthesis loop or in a purge gas loop of a new ammonia plant, or by retrofitting an existing ammonia plant. Cooperatively installed with a primary ammonia synthesis loop, the reactor increases total ammonia production.

Pseudoisothermal ammonia process

Ammonia is produced in a reactoror, in which pseudoisothermal conditions can be approached by convective cooling of a reaction zone of the reactor by positioning at least a portion of the reaction zone in indirect contact with a flow of hot gas such as exhaust gasor preheated air. The hot gasmay be supplied from a fired heater, a boiler, a reformer, a process air preheat furnace, a gas turbine, or the like. The reactor converts a feed stream of a purge gasor syngas to ammonia. The method may be implemented in a primary synthesis loop (as at) or in a purge gas loopof a new ammonia plant, or by retrofitting an existing ammonia plant. Cooperatively installed with a primary ammonia synthesis loop, the reactor increases total ammonia production.

A steam/hydrocarbon reformer employing a convection-heated pre-reformer is disclosed. The pre-reformer comprises catalyst-filled tubes disposed in the transition section between the radiant and convection sections. The pre-reformer tubes are transverse to the flow of flue gas from the radiant section. The pre-reformer achieves 10-20% of the total reforming load, and can be installed as a module or modules between the radiant and convection sections without increasing the size of the reformer.

Steam-methane reformer furnace with convection-heated pre-reformer

Refinery process furnaces are disclosed that have horizontal-helical radiant coils and/or improved ladder-type supports for the horizontal tubes. The coils have a tubeside fluid flow path from an inlet pipe section through an alternating series of straight horizontal pipe sections and wide sweep return bends to an outlet pipe section. The horizontal pipe sections are arranged in at least two vertical banks that are parallel and horizontally spaced apart. The bent pipe sweep return bends are arranged in vertical banks at either end of the straight pipe banks. Each bend connects a pair of straight pipe sections in adjacent vertical banks, and each return bend is sloped between horizontal and vertical so that one of the straight pipe sections in the connected pair thereof is elevated with respect to the other. The ladder supports have two opposing columns with a number of vertically spaced support members each having a generally horizontal upper engagement surface. The horizontal tubes in the furnace are supported on cradles formed in transverse crosspieces that have opposite ends engaged by the support members, each end of the crosspiece having a generally horizontal lower engagement surface supported on the upper engagement surface, which allows for horizontal, upward or angled movement of the transverse crosspiece with respect to the support members that can occur due to thermal expansion thereof or shifting of the vertical columns with respect to each other.

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Katy, TX, United States of America

Daniel Joseph Barnett