Steam Methane Reformer Services — Maintenance, Revamp and Technical Support
Specific technical parameters, inspection methods and performance benchmarks to be confirmed by Howe Baker engineering before publication.
Key Takeaway
Steam methane reformers are capital-intensive, safety-critical assets that require specialist engineering and maintenance support throughout their operating life. Services include reformer tube inspection and assessment, catalyst management, performance monitoring, and engineering for revamp or capacity increase. Howe Baker provides technical services for operating SMR plants in refinery and dedicated hydrogen production service.
Steam Methane Reformer Overview
A steam methane reformer is a fired furnace in which natural gas (or other light hydrocarbons) reacts with steam at high temperature over a catalyst to produce synthesis gas — a mixture of hydrogen, CO, CO₂ and steam. The reformer is the central piece of equipment in an SMR-based hydrogen production plant.
The reformer consists of a firebox containing reformer tubes packed with catalyst, a burner system, and a waste heat recovery section that recovers heat from the hot flue gas. The process gas leaving the reformer tubes passes to a shift reactor, heat exchangers and a PSA purification system.
Reformer Tube Inspection and Assessment
Reformer tubes operate at high temperature and under internal pressure, and are subject to creep damage over time. Tube failure can lead to serious safety incidents. Planned inspection of reformer tubes is an important element of SMR plant maintenance and integrity management.
Tube inspection methods include visual inspection, dimensional measurement (to detect creep bulging), optical pyrometry (to detect hot spots or burner misalignment) and non-destructive testing of tube material where access allows. The results of tube inspection are used to assess remaining tube life and inform decisions about tube replacement.
Specific inspection methods, acceptance criteria and tube life assessment approaches used by Howe Baker to be confirmed by Howe Baker engineering before publication.
Catalyst Management
The reformer catalyst — typically a nickel-based material supported on a refractory carrier — deactivates over time due to sintering, poisoning, carbon deposition and physical damage. Catalyst performance affects reformer outlet composition and therefore hydrogen plant capacity and efficiency.
Catalyst management services include performance monitoring (tracking reformer outlet composition and temperature approach to equilibrium), assessment of catalyst condition, and planning of catalyst change-out procedures.
Desulphurisation of the natural gas feed is critical to protecting reformer catalyst from sulphur poisoning. Assessment of the desulphurisation system — zinc oxide beds and, where applicable, upstream hydrodesulphurisation — is an important part of an SMR plant review.
SMR Performance Optimisation
SMR plant performance can deteriorate over time due to catalyst deactivation, tube fouling, burner degradation and changes in operating conditions. Performance optimisation involves assessment of the current operating conditions against the design basis and identification of measures to improve hydrogen production, energy efficiency or reliability.
Integrated performance of the SMR and downstream PSA system should be considered together — changes in reformer outlet composition affect PSA feed conditions and can influence PSA hydrogen recovery and purity.
SMR Revamp and Capacity Increase
SMR plants can be debottlenecked or revamped to increase hydrogen production capacity. Revamp options include increasing feed gas flow rates (subject to reformer and downstream equipment hydraulic limits), improving catalyst performance, modifying the firing system, and adding or modifying downstream shift and PSA systems.
A revamp study assesses the current plant against the capacity target and identifies the limiting constraints. Engineering options to address each constraint are evaluated on technical and economic grounds to identify the preferred revamp scheme.
Howe Baker SMR Services
Howe Baker provides technical services for operating SMR plants including engineering assessments, performance reviews, catalyst management support, and revamp engineering. The company's SMR service capability covers both Howe Baker-designed plants and SMRs designed by others.
Common Questions
Speak to a Howe Baker Engineer
Our engineering team can assess your requirements and advise on the most appropriate solution, technology or delivery model for your project.