As global demand for hydrogen, ammonia and fertilisers increases, LAND is empowering steam methane reformer (SMR) operators to unlock efficiency gains at existing plants to meet ambitious production targets while also safely decarbonising.
LAND specialists recommend accurate tube wall temperature (TWT) monitoring for SMR efficiency and combustion safety to overcome the yield output and environmental challenges presented by the industrial energy transition and agricultural market growth.
With SMRs positioned as the backbone of today’s hydrogen and ammonia production, LAND technology supports operators with thermal imaging solutions for continuous TWT measurements, delivering the data certainty and critical visibility needed to ensure tube integrity and to optimise flue gas temperatures.
The temperature data collected using LAND’s infrared pyrometers, thermal imaging borescopes and the Gold Cup reference probe can be analysed to enhance a plant’s balance, efficiency and combustion safety. With new insight from accurate thermal imaging of TWTs operators can ensure there are no hot spots in the catalyst-containing tubes to enable operation near to capacity without compromising asset integrity or safety – therefore optimising the production of blue ammonia.
The TWT monitoring, alongside measurement of flue gas and combustibles, supports combustion optimisation, facilitating the reduction of excess oxygen levels in the flue gas to a safe setpoint that drives lower fuel consumption and fewer emissions without increasing TWT and shortening tube lifespan.
James Cross, head of industry management at LAND, said: “SMRs, widely used in hydrocarbon processing applications, are the predominant hydrogen production route for ammonia synthesis. The process requires combustion to heat the reaction tubes, converting methane and steam via a catalyst into hydrogen. However, much of this installed base of SMRs is looking to reduce its CO2 footprint and optimise its processes for near-term emission targets.”
“At LAND, we understand the challenges facing operators of reducing combustion emissions safely while increasing product yield to meet the growing global demand. With our thermal imaging solutions to accurately monitor tube wall temperatures, we can support plants to achieve safety and efficiency to meet production targets as well as environmental and decarbonisation goals.”
Accurate thermal imaging of TWTs is achieved using LAND products, including a thermal imager, developed both as fixed automated solutions and as portables. The corrected data from thermal images, supported by LAND’s industry standard Gold Cup reference measurement solution and portable pyrometer information, can then be used to create a thermal profile of the fired heater.
TWT measurement to find a balanced temperature is critical to safe operation and controlling the reforming reaction. Exceeding the operating window temperature will shorten tube lifespan, while falling below this range will lead to a loss of production. This continuous and accurate monitoring solution delivers more data certainty, helping to identify the hottest and coldest tubes and allowing operators to improve balance and efficiency, reduce methane slip and lower the risk of tube failure.
By implementing thermal imaging with their SMRs, operators have the visibility to extend tube life safely and optimise flue gas temperatures, even at lower excess oxygen levels, resulting in new capabilities to optimise operation and safety, maximise infrastructure assets and uptime, and minimise unwanted emissions.
Cross added: “Combustion remains critical to the reforming process despite global efforts to reduce carbon emissions. We believe that increasing the efficiency of both new and existing SMRs is an essential consideration in decarbonisation. This is why monitoring TWT is so important for operators looking to maximise the level of catalyst tube life to ensure energy efficiency and productivity.”
For more information contact AMETEK Land,
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