Systems and methods for improving ammonia synthesis efficiency

1. A method for producing syngas, comprising:

reforming a hydrocarbon in the presence of steam and one or more first catalysts in a first reaction zone to provide an effluent comprising a portion of the hydrocarbon, carbon monoxide, carbon dioxide, about 8% mol to about 12% mol methane, and hydrogen at a first temperature, wherein the first reaction zone comprises one or more catalyst-containing tubes, and wherein a ratio of steam to the hydrocarbon in the first reaction zone is 2.5 to 3.5;

indirectly heating the effluent from the first temperature to a second temperature;

reforming the effluent at the second temperature and at a pressure of about 4,000 kPa to about 5,500 kPa in the presence of one or more oxidants and one or more second catalysts at conditions sufficient to provide a syngas having a temperature of about 1,030° C. or more and comprising hydrogen, carbon monoxide, carbon dioxide, and less than 0.3% mol, dry basis, methane, wherein the syngas is used to indirectly heat the effluent from the first temperature to the second temperature;

converting at least a portion of the carbon monoxide in the syngas used to indirectly heat the effluent to provide a converted syngas comprising carbon dioxide and 1% mol dry basis or less carbon monoxide;

removing at least a portion of the carbon dioxide of the converted syngas to provide a lean syngas comprising 1% mol dry basis or less carbon dioxide and carbon monoxide;

converting at least a portion of any carbon dioxide, carbon monoxide, or both contained in the lean syngas to methane;

separating at least a portion of the water from the lean syngas;

separating at least a portion of nitrogen in the lean syngas to provide an ammonia syngas having a hydrogen to nitrogen ratio of about 2.9:1 to about 3.2:1; and

reacting at least a portion of the hydrogen and nitrogen in the ammonia syngas to provide an ammonia product.

2. The method of claim 1 , wherein the first temperature is about 700° C. or more.

3. The method of claim 1 , wherein the second temperature is about 850° C. or more.

4. The method of claim 1 , wherein the hydrocarbon comprises methane.

5. The method of claim 1 , wherein the temperature of the syngas after indirectly heating the effluent from the first temperature to the second temperature is about 880° C. or more.

6. The method of claim 1 , wherein heat is indirectly exchanged from the syngas after the syngas is used to indirectly heat the effluent to a condensate to provide high pressure steam.

7. The method of claim 1 , wherein reacting at least a portion of the hydrogen and nitrogen in the ammonia syngas to provide an ammonia product occurs in an ammonia converter, the ammonia converter comprising:

a first shell having two or more discrete catalyst beds disposed therein;

a second shell disposed about the first shell;

a first heat exchanger disposed external to the first shell and in fluid communication therewith;

a second heat exchanger disposed external to the second shell and in fluid communication therewith; and

a flow path disposed within the first shell, wherein the two or more discrete catalyst beds within the first shell are disposed about the flow path, wherein a first portion of the ammonia syngas is introduced to the first shell and a second portion of the ammonia syngas is introduced to the second shell.

8. The method of claim 1 , wherein the effluent comprises about 35% mol to about 39% mol hydrogen, about 4% mol to about 5% mol carbon monoxide, about 6% mol to about 8% mol carbon dioxide, about 8% mol to about 10% mol methane, and about 42% mol to about 47% mol steam.

9. The method of claim 1 , wherein the temperature of the hydrocarbon and steam is monotonically increased to the first temperature.

10. The method of claim 1 , wherein the syngas has a temperature of about 1,050° C. or more.

11. The method of claim 1 , wherein the syngas has a temperature from about 1,030° C. to about 1,050° C.

12. The method of claim 1 ,

wherein separating the at least a portion of the nitrogen in the lean syngas to provide the ammonia syngas comprises:

cooling the lean syngas in a cross-exchanger to obtain a cooled syngas;

introducing the cooled syngas to a distillation column;

expanding a liquid bottoms stream from the distillation column through a liquid expander to form a cooled waste fluid;

rectifying vapor in the distillation column to form an overhead having a reduced nitrogen content;

cooling the overhead vapor in indirect heat exchange with the cooled waste fluid to form the ammonia syngas.

13. A method for producing syngas, comprising:

reforming a hydrocarbon in the presence of steam and one or more first catalysts in a first reaction zone to provide an effluent comprising a portion of the hydrocarbon, carbon monoxide, carbon dioxide, about 8% mol to about 12% mol methane, and hydrogen at a first temperature, wherein the temperature of the hydrocarbon and steam is monotonically increased to the first temperature, and wherein a ratio of steam to the hydrocarbon in the first reaction zone is 2.5 to 3.5;

indirectly heating the effluent at the first temperature to provide an effluent at a second temperature; and

reforming the effluent at the second temperature and at a pressure of about 4,000 kPa to about 5,500 kPa in the presence of one or more oxidants and one or more second catalysts to provide a syngas, wherein the syngas has a temperature of about 1,030° C. or more and comprises hydrogen, carbon monoxide, carbon dioxide, nitrogen, less than 0.3% mol, dry basis, methane, and water, and wherein the syngas is used to indirectly heat the effluent at the first temperature to the second temperature;

converting at least a portion of the carbon monoxide in the syngas used to indirectly heat the effluent to provide a converted syngas comprising carbon dioxide and 1% mol dry basis or less carbon monoxide;

removing at least a portion of the carbon dioxide of the converted syngas to provide a lean syngas comprising 1% mol dry basis or less carbon dioxide and carbon monoxide;

converting at least a portion of any carbon dioxide, carbon monoxide, or both contained in the lean syngas to methane;

separating at least a portion of the water from the lean syngas;

separating at least a portion of the nitrogen in the lean syngas to provide an ammonia syngas having a hydrogen to nitrogen ratio of about 2.9:1 to about 3.2:1; and

reacting at least a portion of the hydrogen and nitrogen in the ammonia syngas to provide an ammonia product.

14. The method of claim 13 , wherein reacting at least a portion of the hydrogen and nitrogen in the ammonia syngas to provide an ammonia product occurs in an ammonia converter, the ammonia converter comprising:

a first shell having two or more discrete catalyst beds disposed therein;

a second shell disposed about the first shell;

a first heat exchanger disposed external to the first shell and in fluid communication therewith;

a second heat exchanger disposed external to the second shell and in fluid communication therewith; and

a flow path disposed within the first shell, wherein the two or more discrete catalyst beds within the first shell are disposed about the flow path, wherein a first portion of the ammonia syngas is introduced to the first shell and a second portion of the ammonia syngas is introduced to the second shell.

15. The method of claim 14 , wherein the effluent comprises about 35% mol to about 39% mol hydrogen, about 4% mol to about 5% mol carbon monoxide, about 6% mol to about 8% mol carbon dioxide, about 8% mol to about 10% mol methane, and about 42% mol to about 47% mol steam.

16. The method of claim 13 , wherein the first temperature is about 700° C. or more.

17. The method of claim 13 , wherein the second temperature is about 850° C. or more.

18. The method of claim 1 , wherein the temperature of the syngas after the syngas is used to indirectly heat the effluent is about 860° C. to about 900° C.

19. The method of claim 13 , wherein the temperature of the syngas after indirectly heating the effluent from the first temperature to the second temperature is about 880° C.

20. A method for producing syngas, comprising:

reforming a hydrocarbon in the presence of steam and one or more first catalysts comprising about 15 wt % to about 20 wt % nickel in a first reaction zone to provide an effluent comprising a portion of the hydrocarbon, carbon monoxide, carbon dioxide, about 8% mol to about 12% mol methane, and hydrogen at a first temperature, wherein the first reaction zone comprises a plurality of catalyst-containing tubes, each having an inside diameter of about 40 mm to about 115 mm, and wherein a ratio of steam to the hydrocarbon in the first reaction zone is 2.5 to 3.5;

indirectly heating the effluent from the first temperature to a second temperature; and

reforming the effluent at the second temperature and at a pressure of about 4,000 kPa to about 5,500 kPa in the presence of one or more oxidants and one or more second catalysts comprising about 10 wt % to about 15 wt % nickel in a second reaction zone at conditions sufficient to provide a syngas having a temperature greater of about 1,050° C. or more and comprising hydrogen, carbon monoxide, carbon dioxide, and less than 0.3% mol, dry basis, methane, wherein the syngas is used to indirectly heat the effluent from the first temperature to the second temperature;

indirectly exchanging heat from the syngas after the syngas is used to indirectly heat the effluent to a condensate to provide high pressure steam;

converting at least a portion of the carbon monoxide in the syngas used to indirectly heat the condensate to provide a converted syngas comprising carbon dioxide 1% mol dry basis or less carbon monoxide;

removing at least a portion of the carbon dioxide of the converted syngas to provide a lean syngas comprising 1% mol dry basis or less carbon dioxide and carbon monoxide;

converting at least a portion of any carbon dioxide, carbon monoxide, or both contained in the lean syngas to methane;

separating at least a portion of the water from the lean syngas;

separating at least a portion of nitrogen in the lean syngas to provide an ammonia syngas having a hydrogen to nitrogen ratio of about 2.9:1 to about 3.2:1; and

reacting at least a portion of the hydrogen and nitrogen in the ammonia syngas to provide an ammonia product.

21. The method of claim 20 , wherein the one or more second catalysts further comprises one or more noble metals.

22. The method of claim 20 , wherein the temperature of the syngas after the syngas is used to indirectly heat the effluent is about 880° C. to about 900° C.

23. The method of claim 20 , wherein the effluent comprises from about 35% mol to about 39% mol hydrogen, from about 4% mol to about 5% mol carbon monoxide, from about 6% mol to about 8% mol carbon dioxide, from about 8% mol to about 10% mol methane, and from about 42% mol to about 47% mol steam.