Abstract
Steam methane reforming processes represent the economically most competitive processes for the production of synthesis gas and hydrogen despite their high energy costs. Although there is a strong need for highly resource-efficient production, literature on the optimal design of reformers remains scarce due to the inherently high complexity of these processes. This contribution addresses design aspects of reformers for the case study of a side-fired reformer. Based on a two-dimensional furnace representation heat transfer and the optimal tube bundle arrangement for a fixed furnace chamber are investigated using simulation-based optimization with both a lean radiation-based model and a computational fluid dynamics model that enables the consideration of fuel efficiency. Radiative heat transfer prevails in the reformer on the furnace side and inter-tube distances of at least three diameters are optimal within the investigated design space. The line arrangement of reformer tubes is beneficial in terms of total heat transferred, fuel efficiency as well as the homogeneity of the tube surface temperatures. These findings pave the way for further studies such as three-dimensional design aspects.
Highlights
In order to mitigate global warming and provide services more sustainably, closing material cycles and pushing alternative energy sources are just as important as a significant increase in resource efficiency (IPC, 2018)
We considered the identification of optimal tube bundle heat exchangers for liquid flow and within a narrow temperature window as compared to the high temperature application of a tube bundle furnace where additional models such as radiative heat transfer need to be considered
The prevalence of radiative heat transfer is analyzed for the proposed furnace design space and the applicability of the radiation-based furnace model for quick comparative decision-making is illustrated
Summary
In order to mitigate global warming and provide services more sustainably, closing material cycles and pushing alternative energy sources are just as important as a significant increase in resource efficiency (IPC, 2018). Many sources indicate that radiation is responsible for 95% of total heat transfer (Yu et al, 2006; Olivieri and Vegliò, 2008; Tran et al, 2017) It was shown recently, that this assumption does not hold under any circumstances and that convection may play a significant role at reduced furnace temperatures and in high convection zones of the furnace (Liesche and Sundmacher, 2019). That this assumption does not hold under any circumstances and that convection may play a significant role at reduced furnace temperatures and in high convection zones of the furnace (Liesche and Sundmacher, 2019) Both the analysis of heat transfer and the identification of optimal tube bundle configurations in a steam reforming furnace are the objectives of this study. All findings are summarized and conclusions are drawn in the last Section 4
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