A section of furnace reaction
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The process consists of one stage and two subsequent stages. Currently, the exit temperature of the first stage is too high, at 750 degrees, while it should be below 700 degrees. The methane content at the exit of this stage is around 40%, whereas it should be below 30%. The high temperature is due to some methane not undergoing reaction, thus no heat is absorbed. It’s not clear yet what the cause of this problem is; possible reasons include blockages in the reaction tubes or the tail pipes, or incomplete reduction of the catalyst. However, the catalyst was just replaced, and this issue existed even before the replacement. I also want to know what the reaction temperature is for methane and water vapor in the absence of a catalyst
It is possible that carbon deposition has occurred, and the catalyst’s activity has not been fully restored. It is recommended to reduce the load, increase the water-to-carbon ratio appropriately, and analyze the methane content at the outlet from time to time. The superheat at the furnace outlet is quite severe