In 2018 FEC completed the mechanical design of two novel high-temperature reactor systems for the conversion of iron-ore and natural gas into hydrogen and synthetic graphite.
Working with our client’s specialist chemical engineers, FEC progressed from a P&ID to a complete mechanical design (piping, vessels and structure). The reaction takes place inside the vessel at temperatures above 800°C and requires the use of exotic nickel alloys in the vessel construction.
Across the two reactor projects, key deliverables included:
- Creep design for reactor and piping components
- Complete stress analysis of the system
- CFD simulations for forced cooling
- Transient thermal simulation for prediction of component design temperature
- Tolerancing, machining and construction sequencing
- Complete detailed fabrication drawings
- Mechanical design of drive system including rotary seal, bearings, motor, gearbox and associated articulation system.
Both reactors have been constructed and are in a testing phase by the respective clients.