Kellogg Brown + Root LLC

Shashi Prakash Singh

Avinash Malhotra

David P Mann

Robert Burlingame

Kamal Gursahani

Tim Weeks

Jim Gosnell

Anant Pisut

Stephen Allen Noe

Akhil Jain Nahar

Xueqian Lin

Arthur Joseph Price

Yue Jing

Keith King

Methods and systems for making ammonia are provided. The method can include heating a first compressed syngas to produce a heated first syngas. The heated first syngas and a second compressed syngas can be combined to produce a combined syngas. The combined syngas can be reacted within a first ammonia converter and a second ammonia converter to produce an ammonia product. Heat from the ammonia product can be transferred to a first heat transfer medium to produce a first cooled product and a second heat transfer medium. Heat from the first cooled product can be transferred to a third heat transfer medium to produce a second cooled product. Heat from the second cooled product can be transferred to the combined syngas to produce a third cooled product. The third cooled product can be separated to produce a purified ammonia product and a recycle gas.

Methods and systems for making ammonia in a double ammonia converter system

Methods and systems for making ammonia are provided. The method can include converting carbon monoxide in a first syngas to carbon dioxide to produce a shifted syngas. At least a portion of the carbon dioxide can be separated from the shifted syngas to produce a carbon dioxide-lean syngas. Carbon monoxide and/or carbon dioxide in the carbon dioxide-lean syngas can be converted to methane to produce a methanated first syngas. A second syngas can be separated to produce a purified second syngas and a waste gas. The methanated first syngas and the purified second syngas can be combined to produce an ammonia feedstock. The ammonia feedstock can have a hydrogen to nitrogen molar ratio of about 3.5:1 to about 2.5:1. At least a portion of the hydrogen and nitrogen in the ammonia feedstock can be reacted to produce an ammonia product.

Methods and systems for producing and processing syngas in a pressure swing adsorption unit and making ammonia therefrom

Systems and methods for producing syngas and ammonia are provided. The method can include reforming a hydrocarbon in a first reaction zone in the presence of one or more first catalysts and steam at conditions sufficient to produce an effluent comprising a portion of the hydrocarbon, carbon monoxide, carbon dioxide, and hydrogen. The effluent can be reformed in a second reaction zone in the presence of one or more second catalysts and nitrogen at conditions sufficient to produce a syngas comprising methane, hydrogen, nitrogen, carbon monoxide, and carbon dioxide, or any combination thereof. At least a portion of the nitrogen and hydrogen in the syngas can be converted to ammonia to produce an ammonia effluent. The ammonia effluent can be separated to produce an ammonia product and a purge gas comprising nitrogen. At least a portion of the purge gas can be recycled to the hydrocarbon, the effluent, or a combination thereof.

Systems and methods for producing syngas and products therefrom

Apparatus, systems, and processes for reforming hydrocarbons are provided. The process can include reforming a first hydrocarbon in the presence of steam and one or more first catalysts in a first reformer to produce a first reformed hydrocarbon. The process can also include reforming the first reformed hydrocarbon in the presence of one or more second catalysts in a second reformer to produce a second reformed hydrocarbon. The process can also include reforming a second hydrocarbon in the presence of steam and one or more third catalysts in a third reformer to produce a third reformed hydrocarbon, where heat from the second reformed hydrocarbon is transferred to the second hydrocarbon to support reforming of the second hydrocarbon.

Apparatus, systems, and processes for producing syngas and products therefrom

Reforming exchangers for syngas production are provided. The reforming exchangers can have a shell-and-tube configuration and include a shift catalyst on the shell side of the exchanger to reduce a carbon monoxide concentration in a shell side product gas mixture. Processes for forming syngas using the reforming exchangers are also provided.

Reforming exchanger with integrated shift conversion

A method can include combusting an expanded turbine exhaust and a first fuel within a first reformer to produce a first exhaust. A hydrocarbon can be reformed in the first reformer to produce a reformed hydrocarbon and heat can be transferred from the first exhaust to a first medium. A refrigeration unit can be powered with thermal energy from the heated first medium and can cool a second medium. Heat can be transferred from one or more oxidants to the cooled second medium to produce cooled first and second oxidants. The cooled first oxidant and a second fuel can be introduced to a gas turbine unit to produce the expanded turbine exhaust and mechanical power. The cooled second oxidant can be compressed in a compressor powered with the mechanical power and the compressed second oxidant and the reformed hydrocarbon can be introduced to a second reformer to produce a syngas.

A reforming exchanger system for syngas production is provided. The reforming exchanger system can have a first and a second reforming exchanger, each with a shell-and-tube configuration, and a shift reactor located intermediate to the first and second reforming exchangers to reduce carbon monoxide concentration in the outlet gas. Processes for forming syngas using the reforming exchanger systems described herein are also provided.

Reforming exchanger system with intermediate shift conversion

Systems and methods for producing ammonia. The system can include a first shell having two or more discrete catalyst beds disposed therein, a second shell disposed about the first shell, a first heat exchanger disposed external to the first shell and in fluid communication therewith, a second heat exchanger disposed external to the second shell and in fluid communication therewith, and a flow path disposed within the first shell. A first portion can be reacted in the presence of the catalyst to provide an ammonia effluent. The heat of reaction from the ammonia effluent can be exchanged within the first heat exchanger and the second heat exchanger. The heated second portion of the feed gas can be introduced to the first shell and can be reacted in the presence of the catalyst.

Efficiency of ammonia processes

An ammonia converter and method are disclosed. The reactor can alter the conversion of ammonia by controlling the reaction temperature of the exothermic reaction along the length of the reactor to parallel the equilibrium curve for the desired product. The reactorcan comprise a shelland internal catalyst tubes. The feed gas stream enters the reactor, flows through the shell, and is heated by indirect heat exchange with the catalyst tubes. The catalyst tubescomprise reactive zoneshaving catalyst and reaction limited zonesthat can comprise inert devices that function to both separate the reactive zones, increase heat transfer area, and reduce the temperature of the reaction mixture as the effluent passes through the catalyst tube

Maximum reaction rate converter process for exothermic reactions

An ammonia converter is disclosed. The converter can alter the conversion of ammonia by controlling the reaction temperature of the exothermic reaction along the length of the reactor to parallel the equilibrium curve for the desired product. The converter can comprise a shelland internal catalyst tubes. The feed gas stream enters the reactor, flows through the shell, and is heated by indirect heat exchange with the catalyst tubes. The catalyst tubescomprise reactive zoneshaving catalyst and reaction limited zonesthat can comprise inert devices that function to both separate the reactive zones, increase heat transfer area, and reduce the temperature of the reaction mixture as the effluent passes through the catalyst tube

Maximum reaction rate converter for exothermic reactions

An ammonia converter system and method are disclosed. The reactor can alter the conversion of ammonia by controlling the reaction temperature of the exothermic reaction along the length of the reactor to parallel the equilibrium curve for the desired product. The reactorcan comprise a shelland internal catalyst tubes. The feed gas stream enters the reactor, flows through the shell, and is heated by indirect heat exchange with the catalyst tubes. The catalyst tubescomprise reactive zoneshaving catalyst and reaction limited zonesthat can comprise inert devices that function to both separate the reactive zones, increase heat transfer area, and reduce the temperature of the reaction mixture as the effluent passes through the catalyst tube

Maximum reaction rate converter system for exothermic reactions

Recycling a portion of autothermal reformer effluent into the steam-hydrocarbon feed stream with a thermo-compressor ejector is disclosed, using the preheated feed mixture as motive fluid. Syngas recycle-motive fluid molar ratios are 0.2-1.0, selected to optimize the overall configuration. The recycle introduces hydrogen and steam into the feed, and elevates the feed temperature, for operating the reformer in a soot-free regime. There is some pressure drop between the raw feed steam-natural gas mixture and the reformer feed, which requires the raw feed mixture to be supplied at a higher pressure, but this is offset by the lower pressure drop in the process heater and other upstream and downstream equipment due to lower quantities of steam. The feed pre-heater can have a lower duty, and the upstream and downstream equipment can be reduced in size, while the size of the autothermal reformer is about the same compared to the size needed for operation without effluent recycle.

Growing community of inventors

Missouri City, TX, United States of America

Shashi Prakash Singh