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Comment Processing & Handling

Making CO-rich syngas while avoiding carbon formation

By Gerald Ondrey |

Haldor Topsoe A/S (Lyngby, Denmark; www.topsoe.com) has developed a new technology, called ReShift, that can utilize a significant amount of CO2 for making synthesis gas (syngas; H2 + CO) without the traditional challenge of carbon formation. “CO2 addition in HyCO plants typically required a high steam-to-carbon (S/C) ratio to prevent carbon formation in the reformer,” says Peter Mølgaard Mortensen, principal scientist. “However, operating with a high S/C ratio is neither optimal for production of CO-rich syngas, nor energy efficient,” he says.

With ReShift technology (flowsheet), the CO2 is added downstream of the steam methane reformer (SMR), enabling the reformer to operate at lower S/C ratios. The CO2 is heated (above 600°C) and added to the hot reformer effluent before entering an Adiabatic Post Converter (APOC). There, the mixed syngas and CO2 are converted over a nickel-based catalyst (R-100 ReShift) into a CO-rich gas. For example, a syngas with a H2-to-CO ratio of 2.5 leaving a SMR can be shifted to 1.0 after the APOC. Practically any H2-to-CO ratio can be produced with this approach.

For new plants, ReShift technology can be included in the design, which leads to a 30% reduction in the size of the primary reformer. ReShift can also be used to boost CO production capacity in existing plants, while lowering the carbon footprint of the plant. ReShift technology can be applied downstream an SMR or an autothermal reformer (ATR).

The process is based on known process and catalyst systems and the catalyst has been tested in laboratory at ReShift conditions. The elements of the APOC reactor are similar to Haldor Topsoe’s proven ATR reactor systems. The technology has been released for sale for first commercial unit.

syngas

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