Steam generation apparatus and method

1. A process for generating steam comprising:

(i) supplying a first stream to a retrofitted steam reformer,

wherein the first stream consists essentially of water;

has a temperature of about 185° C. or greater;

a pressure of about 1150 kPa or greater; and

at least about 50 wt % of the first stream is in the form of steam;

wherein the retrofitted steam reformer comprises a reformer inlet in fluid communication with a reformer outlet, and at least one tube arranged between, and in fluid communication with the reformer inlet and the reformer outlet;

wherein the at least one tube is in thermal communication with a furnace of the retrofitted steam reformer; and

wherein the at least one tube is a reformer section of the retrofitted steam reformer in which prior to being retrofitted, a feed stock of the steam reformer, being operated on to produce synthesis gas, would have been contacted with a catalyst in the presence of heat to effect a reformation process such that the feed stock would have been converted into a product of the steam reformer;

(ii) heating at least a portion of said first stream within said at least one tube to produce a second stream consisting essentially of steam at a temperature of about 760° C. or greater and at a pressure of 1150 kPa or greater such that the molecular composition of the first stream is identical to the molecular composition of second stream; and

(iii) removing said second stream from said outlet of said retrofitted steam reformer,

wherein the only process which takes place within the retrofitted steam reformer is the increase in temperature and/or phase change of the first stream from liquid water to steam.

2. The process of claim 1 wherein the at least one tube comprises a heat resistant alloy.

3. The process of claim 1 , wherein the at least one tube comprises a plurality of tubes.

4. The process of claim 1 , wherein an packing material is dimensioned and arranged with the at least one tube to provide a turbulent flow within the first stream.

5. The process of claim 4 , wherein the packing material includes conventional reformer catalyst.

6. The process of claim 4 , wherein the packing material comprises particles of an inert material.

7. The process of claim 4 , wherein the packing material comprises ceramic balls, cylinders, saddles, pellets, or a combination thereof.

8. The process of claim 4 , wherein the packing material comprises balls or pellets having a diameters of about 8 mm to about 50 mm.

9. The process of claim 4 , wherein the packing material comprises natural stones, gravel, or a combination thereof.

10. The process of claim 1 , wherein the first stream comprises from about 0 wt % to about 20 wt. % free water carried by steam at a temperature of about 185° C. or greater of about 230° C. and a pressure of 1150 kPa to about 2170 kPa.

11. The process of claim 1 , wherein the first stream comprises from about 20 wt. % or less free water.

12. The process of claim 11 , wherein the first stream comprises about 5 to 15 wt % free water.

13. The process of claim 12 , wherein the first stream comprises about 5 to about 10 wt % free water.

14. The process of claim 1 , wherein the first stream is at a temperature of about 185° C. to about 550° C.

15. The process of claim 1 , wherein the first stream is a temperature of about 450° C. to about 550° C.

16. The process of claim 1 wherein the first stream is at a pressure of about 1150 kPa to about 4600 kPa.

17. The process of claim 1 wherein the first stream is at a pressure of about 1150 kPa to about 2170 kPa.

18. The process of claim 1 wherein the second stream consists essentially of superheated steam.

19. The process of claim 1 wherein the second stream is at a temperature of about 760° C. to about 900° C. and a pressure of 1150 kPa to about 4600 kPa.

20. The process of claim 1 wherein the first stream is heated using an exhaust gas from the retrofitted steam reformer furnace prior to providing the first stream to the retrofitted steam reformer.

21. The process of claim 1 wherein the first stream is heated in the retrofitted steam reformer to produce the second stream at an efficiency of at least 80%.

22. The process of claim 1 further comprising the step of cooling the second stream in a thermal heat exchanger to a temperature of about 200° C. to about 320° C. following removal of the second stream from the retrofitted steam reformer.

23. The process of claim 22 wherein the second stream is cooled in the thermal heat exchanger with boiler feed water.

24. A process for generating steam comprising:

(i) supplying a first stream to a retrofitted steam reformer,

wherein the first stream consists essentially of water;

has a temperature of about 450° C. to about 550° C.;

a pressure of about 1150 kPa to about 4600 kPa; and

at least about 80 wt % of the first stream is in the form of steam;

wherein the retrofitted steam reformer comprises a reformer inlet in fluid communication with a reformer'outlet, and a plurality of tubes are arranged between, and in fluid communication with the reformer inlet and the reformer outlet;

wherein an inert packing material is dimensioned and arranged with each of the plurality of tubes to provide a turbulent flow within the first stream, the packing material comprising ceramic balls, cylinders, saddles, pellets, natural stones, natural gravel, or a combination thereof having a diameters of about 8 mm to about 50 mm; and wherein the tubes are in thermal communication with a furnace of the retrofitted steam reformer;

wherein the plurality of tubes are a reformer section of the retrofitted steam reformer in which prior to being retrofitted, a feed stock of the steam reformer, being operated on the produce synthesis gas, would have been contacted with a catalyst in the presence of heat to effect a reformation process such that the feed stock would have been converted into a product of the steam reformer;

(ii) heating at least a portion of said first stream within said plurality of tubes to produce a second stream consisting essentially of superheated steam at a temperature of about 760° C. or greater and at a pressure of 1150 kPa or greater such that the molecular composition of the first stream is identical to the molecular composition of second stream; and

(iii) removing said second stream from said outlet of said retrofitted steam reformer,

wherein the only process which takes place within the retrofitted steam reformer is the increase in temperature and/or phase change of the first stream from liquid water to steam.