Process lay-out 

Topsoe's oxygen-fired Autothermal Reformer (ATR) offers a simple straight-forward process lay-out, where plot area and construction costs are reduced due to the compact design. Autothermal reforming typically operates on pre-reformed hydrocarbon feedstock.

The autothermal reforming process

The Topsoe ATR consists of a fixed bed reactor in which the reforming process takes place. The feedstock is mixed with oxygen and steam in a mixer/burner. In the combustion chamber, partial combustion reactions take place, followed by methane steam reforming reaction and shift conversion to equilibrium over the catalyst bed.

The overall reaction is exothermic, resulting in high outlet temperatures, typically 950-1100°C (1750-2000ºF). The pressure may be high, up to 100 bar. Soot-free operation is achieved through optimised burner design and by catalytic conversion of soot precursors over the catalyst bed.

The ATR reactor system

The ATR reactor system includes the following main elements:

Vessel and refractory
Topsoe uses a very stable multi-layer refractory lining to protect the pressure vessel from the hot gases reacting in the reformer. Topsoe has more than 60 refractory-lined reformer references worldwide.

CTS burner
The burner is the key element for the oxygen-fired reformer. The burner mixes the hydrocarbon and oxygen feedstocks. Careful design of the burner nozzles ensures a flow pattern with efficient mixing that protects the refractory and burner from the hot flame core. This advanced proprietary burner was introduced to the industry in 1992. The operating quality of the CTS burner has been demonstrated in more than 35 units.

Catalysts
For oxygen-fired autothermal reformers, the thermal stability of the catalyst is of great importance. For this application, Topsoe has developed the RKS-2-7H catalyst with high thermal resistance and stable activity.