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15 - CHM - Chemical and Process Engineering

CHM 130 - Ammonia Plant: Hydrogen Production Unit, Steam Reforming

Code Start Date Duration Venue
CHM 130 12 June 2023 5 Days Istanbul Registration Form Link
CHM 130 21 August 2023 5 Days Istanbul Registration Form Link
CHM 130 16 October 2023 5 Days Istanbul Registration Form Link
CHM 130 11 December 2023 5 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

This 5 day course is planned to provide participants with latest know how of the safe operation of the steam reforming unit. This course provides a deeper understanding of the operating and monitoring of steam reformers. The use of hydrogen for petrochemicals, fertilizers and as energy carrier in connection with renewable energy production will increase substantially in the future as even more stringent environmental legislation is enforced. Hydrogen will be required by fertilizers, refineries and specialty chemical manufacturers to meet the global need for cleaner products. The growing fuel cell market will be dependent on hydrogen as a primary fuel source. Hydrogen requirements vary widely. In spite of efforts to produce hydrogen by processes involving solar energy, wind energy, nuclear energy and biofuels, fossil fuels remain the most feasible feedstock in the near term, and for commercial scale production of pure hydrogen, steam reforming remains the most economic and efficient.

Course Objectives

  • Gaining a solid understanding of the key elements associated with the design, operation and control of steam reformers. 
  • Realizing the impact of feed quality, catalyst, operation conditions and unit design on the steam reforming unit. 
  • Gaining valuable insight into how to optimize the steam reforming unit
  • Recognizing how to effectively debottleneck the steam reforming unit 
  • Recognizing how to effectively troubleshoot the steam reforming unit 
  • Comprehending the process safety management systems and their functions
  • Performing safe and successful operations of the steam reforming unit with proper safety measures.
  • Analysing the impact of operating parameters on the HPU efficiency through an analysis of the catalyst's performance,
  • Identifying the effect of various control parameters

Who Should Attend?

  • 1st Line Operation and Production personnel.
  • Process and Operational Engineers and Supervisors
  • Mechanical and Maintenance Engineers and Supervisors 
  • Reliability Engineers and Supervisors
  • Inspection Engineers and Supervisors
  • Instrumentation and Process Control Engineers and Supervisors
  • Safety Engineers and Supervisors  
  • Others involved in the design, operation,  modification or maintenance of Ammonia and Urea process plants

Course Details/Schedule

Day 1

  • Analysis of SMR operating conditions
  • Main hydrogen manufacturing processes
  • Objective of the successive steps
  • Desulfurization
  • Steam reforming (primary and secondary reformer)
  • CO shift conversion
  • Process flow scheme
  • Material balance, conversion, yields at various steps
  • Feedstock and product quality

Day 2

  • Operating conditions and control loops
  • Characteristics of the chemical reactions involved
  • Thermodynamic and kinetic aspects
  • Their consequences on the operation
  • Side reactions and optimum operating conditions to limit their evolution
  • Role and mechanism of a catalyst
  • Chemical and physical characteristics
  • Effect of poisoning and ageing
  • Influence of operating conditions on downstream steps and ammonia production 
  • Methanation
  • Influence of operating parameters on synthesis gas purity, CO2 absorption and amine regeneration

Day 3

  • Steam reformer furnace operation
  • Different types of furnaces
  • Technology
  • Furnace efficiency
  • Operating parameters
  • Control and safety loops
  • Catalyst loading procedure
  • Routine operation and main operating constraints
  • Water preparation
  • Steam production
  • Drawbacks arising from impurities in water
  • Water quality measurement
  • Characteristics of feed water
  • Thermal degassing
  • Chemical conditioning of water
  • Demineralized water “DW” treatment (deaerator, chemical control) 
  • Effect of “BFW” properties on steam generation and relevant equipment

Day 4

  • Operation & start- up- disturbances & troubleshooting
  • Key operating parameters and overall process optimization
  • Interactions between process steps
  • Catalyst cycles management
  • Principles of start- up procedure
  • Preparation
  • Ignition
  • Temperature build- up
  • Feed in
  • Disturbances
  • Modification of the steam/ HC ratio
  • Decrease of feed flowrate
  • Change in feed composition
  • Incidents
  • Tube rupture in the furnace
  • Case Study

Day 5

  • Process Safety and Control System Management
  • Cold Start- Up Guidelines
  • Steam Introduction Procedure
  • Feed Gas Introduction Procedure
  • Normal Shutdown Guidelines
  • Emergency shutdown Procedure
  • Incidents and Troubleshooting
  • Case Study