The M.w. Kellogg Company

Kellogg Brown + Root LLC

Pullman Incorporated

Larry Gene Hackemesser

Robert Burlingame

Lloyd Edward Cizmar

Thomas A Czuppon

Laura Beth Aguilar

William E Phillips

Jing M Lee

William C Petterson

William J Bracken

Robert Stevens Burlingame

Robert B Petru

Bradley L Lankford

Disclosed are a syngas production process and a reforming exchanger. The process involves passing a first portion of hydrocarbon feed mixed with steam and oxidant through an autothermal catalytic steam reforming zone to form a first reformed gas of reduced hydrocarbon content, passing a second portion of the hydrocarbon feed mixed with steam through an endothermic catalytic steam reforming zone to form a second reformed gas of reduced hydrocarbon content, and mixing the first and second reformed gases and passing the resulting gas mixture through a heat exchange zone for cooling the gas mixture and thereby supplying heat to the endothermic catalytic steam reforming zone. The endothermic catalytic steam reforming zone and the heat exchange zone are respectively disposed tube side and shell side within a shell-and-tube reforming exchanger. The reforming exchangercomprises a plurality of tubespacked with low pressure drop catalyst-bearing monolithic structureswherein an inside diameter of the tubesis less than 4 times a maximum edge dimension of the catalyst structures

Low pressure drop reforming exchanger

A syngas reforming reactor has a shell-and-tube configuration wherein the shell-side fluid flow path through the tube bundle has a longitudinal configuration. The reactor can include a shell-side inlet fluid distributor plate below the lower end of the tube bundle.

Low pressure drop reforming reactor

A syngas reforming reactor has a shell-and-tube configuration wherein the shell-side fluid flow path through the tube bundle has a longitudinal configuration. The reactor can include a shell-side inlet fluid distributor plate below the lower end of the tube bundle, and a flow sleeve in an enlarged-diameter discharge annulus at an upper end adjacent the tube sheet to prevent short-circuiting of the shell-side fluid into the shell-side fluid outlet. The tube bundle can include a plurality of ring baffles and lattice baffles. The longitudinal flow configuration can provide a lower shell-side pressure drop and lower cost compared to a conventional cross-flow reforming exchanger.

Syngas production process and reforming exchanger. The process involves passing a first portion of hydrocarbon feed mixed with steam and oxidant through an autothermal catalytic steam reforming zone to form a first reformed gas of reduced hydrocarbon content, passing a second portion of the hydrocarbon feed mixed with steam through an endothermic catalytic steam reforming zone to form a second reformed gas of reduced hydrocarbon content, and mixing the first and second reformed gases and passing the resulting gas mixture through a heat exchange zone for cooling the gas mixture and thereby supplying heat to the endothermic catalytic steam reforming zone. The endothermic catalytic steam reforming zone and the heat exchange zone are respectively disposed tube side and shell side within a shell-and-tube reforming exchanger. The reforming exchanger comprises a plurality of tubes packed with low pressure drop catalyst-bearing monolithic structures wherein an inside diameter of the tubes is less than 4 times a maximum edge dimension of the catalyst structures.

A thermal transition section for introducing a high temperature cracked process gas into a quench exchanger having an inlet end comprising inner and outer concentric pipes connected to a closure ring to define an annulus between the pipes and an interior exchanger surface having an inside diameter. The transition section has a metal outer wall extending from a downstream end connected to the closure ring to an upstream end connected to a metal transition cone. The transition cone is connected at an upstream end to a line for supplying the process gas. The downstream end of the inner sleeve has an outside diameter matching the inside diameter of the interior exchanger surface. A precast, pre-fired single-piece ceramic insert substantially fills the annulus between the outer wall and inner sleeve. By using the ceramic insert, particularly a relatively long insert, thermal stresses are reduced and coke formation in the annulus is inhibited.

Quench exchanger

An impingement distributor for a shell and tube heat exchanger and a method of recovering waste heat from a hot gas which minimizes adverse heat flux at the outermost banks of tubes for enhanced operational reliability. The impingement distributor has a cylindrical distribution plate having evenly arranged rows of longitudinal perforations and a plurality of impact bars longitudinally aligned with the perforations. The hot fluid impinges on the impact bars, and direct impingement on the tubes is avoided.

Shell and tube heat exchanger with impingement distributor

A process furnace and method of operating a furnace are disclosed. The furnace comprises a radiant heating chamber, a primary convection section leg, a secondary convection section leg with two or more parallel flow channels, convection burners to heat the primary and/or secondary convection sections and dampers to adjust flue gas flow and temperature through the parallel flow channels. Combustion air comprising a mixture of gas turbine exhaust and fresh air which has been preheated in one of the parallel flow channels s supplied to the burners. The split flue design facilitates greater control of the flue gas temperature for improved operating efficiency.

Process furnace with a split flue convection section

When steam cracking hydrocarbons to lower olefins in a tubular fired furnace having a convection section for preheating hydrocarbon feed, feedstock flexibility to process light feeds is provided by cooling mixed feed of steam and hydrocarbon followed by reheating to the desired mixed feed temperature.

Flexible feed pyrolysis process

Hydrocarbon feed to a steam cracking furnace is heated to near cracking temperature by indirect heat exchange with steam to permit use of a range of feedstocks.

An exchanger reactor including a shell assembly having a tube bundle assembly mounted in and separate from the shell assembly. Inlet and outlet means are provided to the tube bundle assembly which includes a tube inlet chamber, a tube outlet chamber, tubes extending between the tube inlet and outlet chambers and an expansion means positioned between the inlet means to the tube bundle assembly and the inlet chamber for providing relative movement between the shell assembly and the tube bundle assembly. The shell assembly includes a shell inlet chamber and a shell outlet chamber. A heating fluid inlet distributor is positioned between the shell inlet chamber and a main shell heating chamber for initially distributing heating fluid inwardly from the shell inlet chamber into the main heating chamber containing the tube bundle assembly and a fluid outlet distributor is positioned between the shell outlet chamber and the main shell heating chamber for distributing heating fluid radially outwardly from the shell main heating chamber into a shell outlet chamber.

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Houston, TX, United States of America

Larry Gene Hackemesser