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Hydrogen Production Unit

3 days RAF/HMP-E
Level
Proficiency
Audience
  • Engineers, supervisors and staff interested or involved in the operation of a SMR unit.
Purpose
  • This course provides a deeper understanding of the operating and monitoring of steam reformers.
Learning Objectives
  • Upon completion of the course, the participants will be able to:
  • analyze the impact of operating parameters on the SMR unit efficiency through an analysis of the catalyst's performance,
  • know about the effect of various control parameters,
  • operate a steam reformer with proper safety measures.
Prerequisite
  • No prerequisites for this course.
Ways and means
  • Applications, case studies based on typical industrial situations.

PURPOSE OF STEAM REFORMING 0.25 day
  • Hydrogen in the oil industry: resources and consumption.
  • Main hydrogen manufacturing processes.
  • Objective of the successive steps: desulfurization, steam reforming, CO shift, hydrogen purification.
ANALYSIS OF SMR OPERATING CONDITIONS 1.5 days
  • Process flow scheme.
  • Material balance, conversion, yields at various steps.
  • Feedstock and product quality: natural gas, demineralized water, hydrogen quality.
  • Operating conditions and control loops.
  • Characteristics of the chemical reactions involved: thermodynamic and kinetic aspects, their consequences on the operation, side reactions and optimum operating conditions to limit their evolution.
  • Role and mechanism of a catalyst: chemical and physical characteristics, effect of poisoning and ageing.
  • Influence of operating conditions on hydrogen production and on downstream steps.
  • Hydrogen purification:
  • Adsorption (PSA) and methanation: comparison of performances.
  • Influence of operating parameters on hydrogen purity, CO2 absorption and amine regeneration.
  • PSA unit characteristics and operation.
STEAM REFORMER FURNACE OPERATION 0.5 day
  • Different types of furnaces: technology, furnace efficiency, operating parameters, control and safety loops.
  • Catalyst loading procedure.
  • Behavior of the tube bundle. Mechanical and thermal stress.
  • Routine operation and main operating constraints.
STEAM PRODUCTION 0.25 day
  • Water preparation: drawbacks arising from impurities in water, water quality measurement, characteristics of feed water, thermal degassing, chemical conditioning of water.
OPERATION & START-UP 0.25 day
  • Key operating parameters and overall process optimization, interactions between process steps, catalyst cycles management.
  • Principles of start-up procedure: preparation, ignition, temperature build-up, feed in.
DISTURBANCES & TROUBLESHOOTING 0.25 day
  • Disturbances: modification of the steam/HC ratio, decrease of feed flowrate, change in feed composition.
  • Incidents: pretreatment reactor runaway, tube rupture in the furnace, absorption section bypassing.