CH4 slip out R04203

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chinh
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CH4 slip out R04203

Post by chinh » Tue Nov 28, 2017 4:58 am

Hi everyone,
My plant have small problem at R04203 (secondary reformer)
During annual turn around of plant (August, 2017). We have implemented some of the following issues:
1. We have just replaced for new secondary reformer catalyst since 8/2017.
2. We have also replaced ball with new lump (the same time).
3. Distribution plate of Burner on top of secondary reformer is bended a little.
Is operating with current status:
- Steam/Carbon ration = 3.2
- Temperture outlet of Primary reformer is 760o C
- Temperture of Process air is 553 oC
- Temperature out let of Secondary reforemer is around 943 oC
- Pressure Drop Measurement of secondary reformer is normal (about 24kpa).
- Load 110%
CH4 slip outlet of Secondary reformer is so high. It is about 0.7% in normal operation.
We also reduced load to 103%, but CH4 slip outlet is still high.
Could you please give us some advices that will help us improve it?
Thank you!

rajneesh_jauhari
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Re: CH4 slip out R04203

Post by rajneesh_jauhari » Fri Dec 01, 2017 4:29 pm

Dear Chinh,
Have u attend Sec Ref burner as found bend?
It may contribute the air distribution problem (as poor mixing in mixing zone may contribute high approach and high methane slip).
Please check the following
1. Primary Reformer Process Data and lab analysis specially CH4 slip, inlet NG analysis and compare with earlier data.
2. After charging the Sec Ref Catalyst, hv u measure the distance between Burner Gun tip to Target Tiles. Whether matching with last charge?
3. Is Process Steam flow indication correct?
4. During startup any wrong operation?
Please check the above and share the outcome.
Regards
RJ

chinh
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Re: CH4 slip out R04203

Post by chinh » Mon Jan 15, 2018 8:16 am

Thank you Mr Rajneesh_Jauhari
1. We already checked all CH4 inlet/outlet PR and compare with before turnaround
2. We already measured the distance between Burner Gun tip to Target Tiles. It’s oke
3. The process steam flower was checked and it’s oke
4. We checked all step in startup. It isn’t problem
Now, we increase the S/C ratio, increase temp outlet PR and decrease G/A ratio. However, the CH4 slip is still high.

rajneesh_jauhari
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Re: CH4 slip out R04203

Post by rajneesh_jauhari » Mon Oct 15, 2018 6:46 pm

Sorry I could not check my email.
Now what is the condition of CH4 slip, still high or have u got anything?

chinh
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Re: CH4 slip out R04203

Post by chinh » Fri Oct 19, 2018 2:41 am

Hi Mr Rajneesh_Jauhari
In the last stop. We opened, checked and detected the distribution of burners, that was bent. We have rolled out. At present, CH4 slip has fallen much, but still higher than required a bit.

Thank you for your interest!

noralbam
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Re: CH4 slip out R04203

Post by noralbam » Tue Oct 30, 2018 2:11 pm

If the Sec ref is the Uhde type you must check for internal inlet tube as I have learnt from a plant that had the same problem and they had a leak from the feed gas to the exit gas at the bottom part

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