Abstract
In this paper, the effect of catalyst shape and characteristics has been investigated where five types of a catalyst were examined under the same operation conditions, where catalysts are similar in the chemical properties (Ni/MgOAl2O3) but it's different in their physical properties in the catalyst section of secondary reformer. The secondary reformer involves continuation of the methane reforming reaction that began in the primary reformer to produce Nitrogen and Hydrogen in the ammonia plant. In order to evaluate performance of various types of catalysts in the secondary reformer reactor, mathematical model have been created. The mathematical model covers all aspects of major chemical kinetics, heat and mass transfer phenomena in the secondary reformer in the ammonia plant at steady state conditions. It aims to optimize the best catalyst from five types of catalyst of the secondary reformer reactor in the State Company of Fertilizers South Region in the Basra/Iraq. The mathematical model allows calculating the axial variations of compositions, temperature and pressure of the gases inside two reactors in series by using the atomic molar balance and adiabatic flame temperature in the combustion section while, in the catalyst section, they are predicted by using a one-dimensional heterogeneous catalytic reaction model. The analysis evaluation performance of the catalyst (RKS-2-7H') have good results than other the catalyst types (RKS - 2, ICI 54 - 2, RKS-2-7H”, RKS-2-7H”’) in catalyst zone of the secondary reformer.
Highlights
In a traditional ammonia plant, the secondary reformer is rather used downstream of the primary reformer in order to reform the unreacted methane to produce Hydrogen and Nitrogen.The reactor consists of two sections, the combustion section is the empty space above the catalyst section is preferred to combust process gases with oxygen of the air to produce the Nitrogen while, the catalytic section is a fixed-bed reactor, in which the hydrocarbons are converted through heterogeneous catalytic reactions to produce the Hydrogen
The effect of catalyst shape and characteristics has been investigated where five types of a catalyst were examined under the same operation conditions, where catalysts are similar in the chemical properties (Ni/MgOAl2O3) but it's different in their physical properties in the catalyst section of secondary reformer
The mathematical model allows calculating the axial variations of compositions, temperature and pressure of the gases inside two reactors in series by using the atomic molar balance and adiabatic flame temperature in the combustion section while, in the catalyst section, they are predicted by using a one-dimensional heterogeneous catalytic reaction model
Summary
In a traditional ammonia plant, the secondary reformer is rather used downstream of the primary reformer in order to reform the unreacted methane to produce Hydrogen and Nitrogen. The reactor consists of two sections, the combustion section is the empty space above the catalyst section is preferred to combust process gases with oxygen of the air to produce the Nitrogen while, the catalytic section is a fixed-bed reactor, in which the hydrocarbons are converted through heterogeneous catalytic reactions to produce the Hydrogen. It is provided with Ni/MgOAl2O3 as a catalyst, the Reformat Gases leaves the secondary reformer, as shown in the Figure 1. The results of mathematical model such as mole fraction, temperature profile and pressure drop of the combustion and catalyst zones of secondary reformer reactor in the State Company of Fertilizers South Region in the Basra/Iraq will be studied and compared relative to five different types of Ni-catalyst
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