Our Terrace Wall™ reformer has a number of advantages ranging from lower fuel costs to longer tube/catalyst life. These add up to lower life cycle costs for the operator.
Lower fuel costs
The ability to adjust the location of the upper terrace reduces the bridge wall temperature for a fixed average flux rate and radiant duty. This results in less residual heat to recover in the convection section. The overall reformer firing is reduced and less air and flue gas is used. Since the Terrace Wall can be easily configured with air preheat systems, all this can be achieved at high fuel efficiency as well. The net effect is less fuel for product produced.
Life cycle costs
The upward firing of the burners and ability to adjust the heat flux as the catalyst ages allows a more predictable and uniform flux profile on the tube with no intense peak fluxes. This has been demonstrated on units of all hydrogen services, methanol and ammonia to extend not only the catalyst tube life but the catalyst life as well. Some hydrogen reformers have had their original tubes for close to 20 years.
In addition, the close-coupled process gas boiler that eliminates the high maintenance transfer line, along with vertical outlet pigtails, simple counterweight systems and other standard features of the Terrace Wall reformer reduce maintenance costs compared to top-fired units.
Natural draft capability
The upward flow of flue gases from the radiant to convection section then to the stack is a standard feature in our Terrace Wall reformer. The reformer can be designed to switch over to natural draft mode allowing natural draft performance even when the air preheat system is not used. This feature eliminates the need for redundant fans required for high reliability on top-fired units, not only saving on the cost of fans but also the associated infrastructure of a motor control center, wiring and installation costs.
Another benefit of upward firing is that the fan horsepower is significantly less than comparable top-fired units; usually half the power is required. On large-scale units this can offer significant operational cost savings compared to top-fired designs.
Highly modularised design
Our Terrace Wall module significantly reduces the total installed costs for the reformer in high-labor cost or labor-constrained construction situations. It also provides a better quality product in the field since the high-alloy welding is performed and tested in a shop environment, reducing rework.