Challenges in the Life Management of Steam Methane Reformer (SMR) Components

Abstract

Abstract Steam methane reforming (SMR) is a process in which methane from natural gas is heated, with steam, usually with a catalyst, to produce a mixture of carbon monoxide and hydrogen used in organic synthesis and as a fuel. The steam-gas mixture enters the reformer from the inlet manifold. The reforming reaction is an endothermic reaction requiring a large amount of heat to be supplied to the system. Because of the high temperature and high heat input required for the reaction, it is carried out in directed fired, catalyst filled tubes keeping the temperature of the mixture > 1,500°F (815°C). At these temperatures, methane (CH4) reacts with steam (H2O) to produce hydrogen (H2) and carbon monoxide (CO). The presence of a catalyst helps this process react more quickly and to retain more hydrogen gas. The hydrogen-carbon monoxide mixture exits the reformer via the outlet manifold. In the energy sector, SMR is the most widely used process for the generation of hydrogen. This paper focuses on the impact of time-dependent damage (creep) on critical steam methane reformer components such as tubes, pigtails, and outlet headers. Specific challenges linked to material variability, well-pedigreed databases, damage development, and standard or feature testing will be addressed.