The present invention is an apparatus arranged to maximize heat
utilization for a hydrocarbon steam reforming process to produce
synthesis gas. The apparatus comprises a refractory lined vessel with
partition walls that divide the inside of the vessel into (1) a
combustion chamber(s) containing one or more burners, and (2) convection
chambers used as a means to remove combustion products from the
combustion chamber through one or more openings at the opposite end of
the burner end. The combustion chamber contains one or more reformer
tubes in which a mixed-feed of hydrocarbon and steam flow co-current with
combustion products and receive direct radiant heat from the combustion
flame through the tube wall. The convection chambers contain a
tube-in-tube device filled with catalyst in the annuli. The mixed-feed in
the annuli flows counter-current with combustion products and the hot
product synthesis gas, and thereby substantially lowers the temperature
of the combustion and product gases before the gases exit the furnace.
High emissivity materials or walls are used inside the convection
chambers to enhance the heat transfer from the flue gas to the reformer
tubes.