Steam reformer is one of the most critical unit in the hydrogen, ammonia and methanol plants. It is complex, energy intensive, very expensive and by nature its design is often aggressive, due to the need for harsh operating conditions and specialty materials.

Process performances and mechanical integrity of a steam reformer have a direct impact on the overall plant performances as well as a premature failure, which can be preventively avoided, typically has large financial implications.

Casale expertise and know-how on the Steam Reformer furnace, jointly with his extensive Licensor background, is the right solution to ensure optimal performance and profitability.

Based on his worldwide well-recognized unique revamping expertise, Casale can provide a complete technical assistance on any kind of steam reformer design.

As a technology Licensor with a deep knowledge in designing complete syngas generation processes (hydrogen, methanol, ammonia), we are highly qualified to assess the reformer in detail, looking at the steam reformer as a stand-alone unit and at the same time linked to rest of the plant.

Casale approach is to built-up a complete thermal model of the steam reformer able to reconciliate all field collected data. Our long experience, growth with many types of aged steam reformer units, gave us the possibility to fine tune very proven tools which in turns, with high accuracy grade, are able to solve all complex heat transfer phenomena involved.

Casale services involves a thorough analysis of:

  • Whole steam reformer process parameters
  • Radiant chamber
  • Combustion system
  • Flue gas and combustion air distribution system
  • Convection section
  • Air preheating system
  • FD/ID fans sections
  • Steam reformer control system

The aim is to highlight any underlying problem areas in order to develop the remedial strategies and in the meantime asses if further optimization of the steam reformer operation is possible.

Finally, the Steam Reformer Assessment/Optimization can help to:

  • Identify bottlenecks
  • Restore adequate design limits
  • Save energy or increase/stabilize throughput
  • Improve safety and reliability of the steam reformer
  • Increase tube and critical items lifetime
  • Optimize normal operations
  • Manage steam reformer upset