Improve syngas production using autothermal reforming

Synthesis gas or syngas, i.e., mixtures of CO and H[sub 2], is a major route from hydrocarbons to many important bulk chemicals ranging from acetic acid to ammonia. Syngas conversion uses hydrocarbon feedstocks, steam, O[sub 2] and CO[sub 2], either separately or in combinations. Autothermal reforming (ATR) is a low-investment process using a simple reactor design. The process is soot-free due to burner design and fixed-bed catalyst. Developed in the late '50s, ATR's main application was for ammonia and methanol syntheses. In ammonia plants, hydrogen production was maximized by operating at high H[sub 2]O/C ratios ranging from 2.5 to 3.5 mole/mole. In methanol units, CO[sub 2] recycle adjusted the syngas composition. ATR is also used to co-produce CO and H[sub 2] as separate streams at H[sub 2]O/C ratios of 1.4 to 2.0 mole/mole. recent developments and optimizations allow cost-effective operation at very low H[sub 2]O/C feed ratios to produce CO-rich syngas. The paper describes the process, including feedstocks and reactor design, the chemical reactions, development and improvements to the process, test results, soot formation, burner design, burner testing, applications, thermodynamic calculations, industrial application, noncatalytic and catalytic partial oxidation, and future uses.