Automated operation of

Topsøe steam reformers

S-01838 / KSIN

S-01838,MRPL

Automated operation of Topsøe steam

reformers

Topics:

Areas of application

Features and benefits

Working principles

Human machine interface (HMI)

Implementation and references

22060 El & Instrument, Syngas

Areas of application

Topsøe system for automated operation of steam

reformers:
– Load and temperature management system (LTM)

Area of application for LTM:

– Steam reformers in hydrogen plants
– Reformer types: SMR, HTCR and TBR

Other Topsøe technologies, such as ammonia and

methanol plants may be fitted with similar applications

22060 El & Instrument, Syngas

1
LTM features (1)

Main operator input:

– Plant capacity

Operator tuning parameters:

– S/C-ratio
– Excess air ratio
– Process gas temperature outlet the tubular reformer

22060 El & Instrument, Syngas

LTM features (2)

System outputs are set points for:

– Feed flow
– Process steam flow
– Firing

Fuel

Combustion air
– Cutback firing if high gas temperature outlet reformer

All in the correct sequence, dependent on whether the plant load increases or decreases

22060 El & Instrument, Syngas

LTM diagram
VA PORIZ ED NA PHTHA PSA OF F GA S P ROCE SS GAS

HI C HIC HI C
034 036 035 FUEL GA S/ NG
LHV LHV LHV
HIC HIC HIC HI C HIC HI C HIC
016 017 024 E xcess air 038 037 039 040
Capaci ty S /C correct ion ai r dem and air demand air demand LHV
f actor

Load and Temperature Management System

SP SP SP
AIC T IC TIC
008 061 062
O2

STE AM

F IC F IC
017 020

FEE D

RE CY CLE HY DRO GEN

TI C
074
PROCES S GAS

F LUE GA S

HIGH SELE CTOR

P IC FY
SP 192 048 A

FI C FY
029 054
CO MB US TION AIR
LOW S ELE CT OR
FY
048 B
SP
FIC FIC FIC FI
037 048 055 T OTAL FIRE D DUT Y 046

PSA OFF GA S F UE L NA PHTHA

VA PORIZ ED NA PHTHA

FI HC FROM ROG
167 SE PARA TOR
FA- 32315
SP
FI C
HC FROM ROG
059
COM PRE SSO R
PROCES S GAS FI INTE R S TAGE
166
K .O. DRUM
F A-32327

FI
058

FUEL GAS /NG

22060 El & Instrument, Syngas

2
P&I Diagram with Feed and Process Steam

22060 El & Instrument, Syngas

LTM features (3)

Benefits
– Simple operator interface to complex flow adjustments of feed,
process steam, fuel and combustion air. Reduces requirements for
operator
– Adjusts the hydrogen plant capacity from an external demand
signal. Allows adjustment of capacity by 15-30% per hour
– Automatic and smooth adjustments make the plant more energy-
efficient and reduce its carbon footprint
– Manages capacity changes of up to 2% per minute

22060 El & Instrument, Syngas

LTM features (4)

Benefits cont.
– Adjustments of multiple reformer fuels: PSA off-gas, reformer fuel
gas, excess process gas
– Cutback in firing if over-firing is detected
– Specially useful for plants with mixed feed
– Prolongs the lifetime of tubular reformer tubes due to less
temperature fluctuations in the tubes
– Reduces risk of operation at too low S/C

22060 El & Instrument, Syngas

3
Working principles (1)

The concept is based on Topsøe’s experience with

steam reformer technology and catalyst

Calculations are based on first order principles, such as
heat and mass balances

Simple to implement in DCS compared to numerical

methods, such as model-based predictive control

22060 El & Instrument, Syngas

Working principles (2)

Basic formulas for calculation of controller set points

connected to the LTM:
– Feed flow = f(capacity)
– Process steam flow = f(capacity, S/C ratio)
– Fuel flow = f(capacity, capacity factor, LHV)
– Combustion air flow = f(capacity, fuel air demand, excess air
ratio)
– Temperature cutback = f(capacity)

22060 El & Instrument, Syngas

Working principles (3)

Basic formulas:

Lead and lag functions on:
– Feed
– Process steam
– Fuel gas
– Combustion air

Conditions for running the LTM:
– Plant capacity 50-110%
– Measurements within defined ranges

22060 El & Instrument, Syngas

4
Working principles (4)

Even if the LTM controllers are not in Cascade, the

calculated set points can be used by the operator in Auto
as manually adjusted controller set points. This is done,
for example before the LTM is enabled.

22060 El & Instrument, Syngas

LTM increase capacity

Capasity increase
ramp sequence

O perator setting

Capasity Ramp Max 2%/Min

Steam 10 S

10 S
Feed

Fuel

Time

22060 El & Instrument, Syngas

LTM decrease capacity

22060 El & Instrument, Syngas

5
LTM enable/disable

22060 El & Instrument, Syngas

Human Machine Interface (1)

LTM Primary Display
Manual Inputs Tag No Unit Value LTM Calculations Tag No Unit Value
Plant Capacity HIC-323016 % 100 Actual plant capacity - 100
Steam/Carbon ratio HIC-323017 - 2.5 Allow LTM Y/N Y
Excess air correction factor HIC-323024 - 1

LTM enabled by operator ON/OFF ON

LTM measurements Tag No Unit Reading Tag No Unit Reading

Process gas BA-32301 TE-323023-A °C 915 Oxygen in flue gas AI-323006 %O2 1.39
Process gas BA-32301 TE-323023-B °C 916 Oxygen in flue gas AI-323007 %O2 1.4
Process gas BA-32301 TE-323023-C °C 915
Flue gas TE-323058 °C 1055
Flue gas TE-323059 °C 1060
Flue gas TE-323060 °C 1065

Controllers LTM Deviation

Medium Tag No Unit STATUS CV open SP PV SP Abs. Rel.%
Process gas BA-32301 TIC-323074 °C AUTO 918 915
Flue gas TIC-323061 °C AUTO 1065 1060 1060 0
TIC-323062 °C CAS 1065 1060 1060 0
Process feed FIC-323017 kg/h AUTO 79 26700 26684 26700 16 0.06
Process steam FIC-323020 kg/h AUTO 82 72300 72821 72400 -421 -0.58
Total duty FIC-323055 Gcal/h AUTO 82 81.69 82.1 0.41 0.50
Combustion air FIC-323029 Nm3/h AUTO 76 178000 177326 178000 674 0.38
Oxygen in flue gas AIC-323008 %O2 CAS 1.39 1.38 1.4 0.02 1.42857

Notes:
If Abs. Or Rel.% Deviations are outside the limits defined on the limit setting display, values should go to alarm.

Colour Coding:

Background colour

Operators manual input

Control System values

LTM calculations

22060 El & Instrument, Syngas

Human Machine Interface (2)

LTM Feed and Fuel setting Display
Manual Inputs Tag No Unit Value Allow. Min Allow Max
Carbon Number 1.095 0.5 5

Fuel Naptha flow FI-323046 kg/h 5204 0 10400

Fuel Naptha LHV (Man.) HIC-323034 Kcal/Nm3 10663 9600 11800
Air demand Naptha/ Fuel Gas HIC-323038 Nm3/Nm3 44.35 10 60

PSA off gas flow FIC-323037 Nm3/h 52784 20000 63000

PSA off gas LHV HIC-323036 Kcal/Nm3 1374 1400 1700
PSA off gas Air demand HIC-323037 Nm3/Nm3 1.47 1 2

Process Gas flow FIC-323059 Nm3/h 33312 10000 34500

Process Gas LHV (Man.) HIC-323035 Kcal/Nm3 2174 2000 2500
Process Gas Air demand HIC-323039 Nm3/Nm3 2.16 2 3

Fuel Gas/ NG flow FI-323058 Nm3/h 6260 2000 9500

Fuel Gas/ NG LHV (Man.) HIC-323040 Kcal/Nm3 7272 6600 8000

Background colour

Operators manual input

Control System values

LTM calculations

22060 El & Instrument, Syngas

6
Human Machine Interface (3)
LTM Limit Setting Display
Manual Inputs Tag No Unit Value Min Max
Plant Capacity 19-HIC9208 % 50 110
Steam/Carbon ratio 19-HIC9214 mole/mole
Excess air correction factor 19-HIC9213 - 0.95 1.5

Plant capacity ramping 19-HIC9216 %/min 1 0 2

Plant capacity ramp on/off 19-HS9216 On/Off On
Plant capacity feed delay 19-HIC9201 min. 300
Plant capacity steam delay 19-HIC9202 s 10

S/C ratio ramping 19-HIC-9205 %/min 1 0 2

S/C ratio ramp on/off 19-HS-9205 On/Off On

Heat input increase ramping 19-HIC-9267A %/min 1 0 2

Heat input decrease ramping 19-HIC-9267B %/min 1 0 2
Heat input ramping on/off 19-HS-9267 On/Off

LTM disable limits Absolute values PV/SP deviation

Reading Min Max
Process feed 19-FIC9201 kg/h 14000 32000 +/- Rel. dev. % 5
Process steam 19-FIC9203 kg/h 40000 100000 +/- Rel. dev. % 5
Total duty 19-FIC9267 MW 85 200 +/- Rel. dev. % 5
Combustion air 19-FIC9221 Nm3/h 80,000 200000 +/- Rel. dev. % 5
Oxygen in flue gas 19-AIC9231 vol%O2 1.4 10 +/- Rel. dev. % 5
Flue gas 19-TIC9245A °C 0 1070 +/- Rel. dev. % 5

Note: Inputs in this display must be protected. They must only be accessible with "Engineering key".

22060 El & Instrument, Syngas

Implementation (1)

No extra instruments are required in plants with standard

Topsøe design

Implemented as formulas directly programmed in the
plant DCS

Formulas and basic engineering information supplied by
Topsøe
– Description of LTM, incl. the formulas
– Block diagrams for LTM
– Suggested graphics for LTM

22060 El & Instrument, Syngas

Implementation (2)

Implemented in the DCS by the integrator who is

responsible for the implementation and maintenance

Dedicated process graphics for display and operator
settings

Topsoe can participate in FAT and SAT

LTM references: 20+

22060 El & Instrument, Syngas

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DCS Graphic display of LTM Load Controller

22060 El & Instrument, Syngas

DCS Graphic display of LTM Setting Display

22060 El & Instrument, Syngas

Thank you for your attention

S-01838,MRPL