Hydrogen Production - Technical Analysis of Autothermal Reforming (ATR) Plant with CO2 Capture - Energy and Mass Balance Diagram
🟦 1) ATR Hydrogen Production Process Description
1.1. Prereformed gas enters an ATR (refractory lined vessel) with an oxidation section and a catalytic reforming section.
1.2. The feed gas is mixed with oxygen from the air separation unit (ASU) and partially oxidized:
CH4+ 1/2 O2↔ CO+ 2H2. Δ𝐻°rxn= −36.0 kJ/mol
1.3. This exothermic reaction is used to produce heat to drive the below endothermic methane reforming reaction:
CH4+ H2O↔ CO+ 3H2. Δ𝐻°rxn= 205.8 kJ/mol
1.4. The autothermal reformer unit combines heat-generating reactions and methane-reforming reactions within a single system, unlike the SMR configuration, where reaction heat is generated outside of the catalyst tubes.
1.5. The process uses a molar steam-to-carbon ratio of 1.57 and oxygen-to-carbon ratio of 1.29 entering the reactor.
1.6. Syngas exits the ATR at a temperature of 1,090 °C (2,000 °F) and a pressure of 2.8 MPa (411 psia).
1.7. Syngas pass through a syngas cooler, leaving ATR, which is used to generate LP steam before being fed into the series of WGS reactors.
🟦 2) Acid Gas Removal: The ATR plant with capture uses an MDEA unit for pre-combustion capture, and there is no need for a post-combustion Cansolv system. High levels of CO2 capture are achieved through the separation of CO2 from the high-pressure syngas.
🟦 3) Fired Heater: In autothermal reforming, waste heat is recovered using a fired heater. The off-gas from the PSA is combined with air and combusted to generate hot flue gas. This gas is then used to improve plant efficiency by providing heat to various plant sections, generating steam, and preheating feedwater and natural gas.
🟦 4) An air separation unit producing a 95% by volume O2 product at 3.3 MPa has been considered. The ASU power requirement is 420 kWh/ton-O2. The amount of O2 supplied to the ATR depends on the heating value of the fuel gas, with residual N2 being vented.
🟦 5) Major Equipment list in study
5.1. Primary Reformer (ATR fixed bed, catalytic):
Syngas Production: 429,000 kg/hr @ 2.8 MPa, 1093 °C
5.2. Sulfur Guard Bed (Fixed Bed, catalytic (ZnO))
Inlet: 107,000 kg/hr @ 3.0 MPa, 370 °C
5.3. Prereformer (Fixed Bed, catalytic)
NG In: 107,000 kg/hr @ 2.9 MPa, 500 °C
Steam In: 181,000 kg/hr @ 3.1 MPa, 399 °C
5.4. Syngas Coolers (STHE)
Syngas Cooler: 845 GJ/hr
LP Steam Generator 1: 120 GJ/hr
LP Steam Generator 2: 18 GJ/hr
LT Heat Recovery Exchanger: 141 GJ/hr
AGR Precooler: 240 GJ/hr
5.5. ASU Main Air Compressor (Centrifugal, multi-stage)
8,000 m3 /min @ 1.6 MPa
5.6. Cold Box (Vendor design)
3,400 tonne/day of 95% purity oxygen
5.7. Oxygen Pump (Centrifugal, multi-stage)
2,000 m3 /min
Suction – 1.0 MPa
Discharge – 3.3 MPa
✅ Source: see attached image
✅ My posts reflect my personal knowledge, experience, and advice.
👇 Can ATR + CCS help transition to cost-effective green hydrogen production?