Catalytic Reforming Technology

Gerard B.
Hawkins
Managing Director, CEO
Cat al yt i c Ref or mi ng:
Cat al yst , Pr oc ess Technol ogy
and Oper at i ons Over vi ew
www.gbhenterprises.com
Fundamentals of Catalytic Reforming
Objective
Reaction Chemistry and Mechanisms
Desirable and Undesirable Reactions
Process Variables
Reactor Temperature
Reactor Pressure
Space Velocity
Hydrogen / Hydrocarbon Ratio
Feedstock
Yield Charts
Reforming Process Flow Sheets (PFDs)
Fixed Bed reforming
Semi Regenerative Reforming
(CCR) Continuous Catalytic Regenerative Reforming
Octanizing
Dualforming
RZ Platforming

Cont ent s
Reforming catalyst

Catalyst Types
Catalyst Poisons
Catalyst Distribution
Catalyst Sampling
Catalyst Regeneration

Catalytic Reforming Economics Comparison

Key Energy and Environmental Facts

Conclusions

Cont ent s, c ont
Fundament al s of Cat al yt i c Ref or mi ng
Basi c c at al yt i c r ef or mi ng scheme w i t h t hr ee heat er s,
t hr ee r eac t or s and r ecycl ed hydr ogen; t he exc ess H2 i s
l at er used i n ot her r ef i ni ng pl ant s.
Generalized Platforrming reaction scheme
Chemical Reactions
Major Reactions Occurring in the Reforming Unit
Desirable Reactions
Major Reactions Occurring in the Reforming Unit
Undesirable Reactions
Desirable reactions with hydrogen production
Adverse Reactions
Adverse Reactions
Adverse Reactions
Adverse Reactions
Adverse Reactions
Adverse Reactions
Adverse Reactions
Chemical Reactions
Processes Variables
Processes Variables
Process variables that may be adjusted by design or during
operation include:

Reactor temperature
Pressure
Space velocity
Hydrogen / hydrocarbon ratio
Feedstock characteristics

The relationships of the variables generally apply to both fixed-
bed reforming and continuous reforming.
Processes Variables
Processes Variables
Processes Variable: Pressure
Processes Variable: Pressure
Processes Variable: Temperature
Processes Variable: Space Velocity
Processes Variable: Hydrogen to Hydrocarbon ratio
Processes Variable: Hydrogen to Hydrocarbon ratio
Processes Variable: Feed Quality Chemical composition
Processes Variable: Feed quality Distillation range
Operating Parameters Summary
Processes Variables
Evolution of the relationship between liquid reformate
yield versus unleaded RON from the 1950s to the 1990s.
Reforming Process PFDs
Reforming Process PFDs
Catalytic Reformers Utilize Multiple Reactor Beds
Fixed bed reformer
Conventional Unit
Semi-Regenerative Catalytic Reformer Unit
Courtesy: UOP
Cycl i c Regener at i ve Ref or mi ng
CCR with stacked reactors
Courtesy: UOP
Stacked CCR Catalytic Reformer Unit
Courtesy: UOP
Stacked CCR Catalytic Reformer Unit
Side-by-Side Arrangement
Courtesy: Axens
CCR with side-by-side reactors
Courtesy: Axens
Courtesy: Axens
Courtesy: Axens
SR and CCR hybrid process
Courtesy: Axens
SR and CCR hybrid process
Courtesy: UOP
Compar i son of Semi -Regener at i on
Ref or mi ng Pr oc ess and CCR Pr oc ess
CCR Pl at f or r mi ng ver sus Fi xed-bed Pl at f or r mi ng
Advantages of CCR Continuous Reforming Technology
Courtesy: UOP
high utilization of feed due to low operating
pressure
on stream factor of more than 95%
flexibility to process a wide variety of feedstock
only two catalyst lifts for minimal catalyst attrition
Stacked reactors for economical design
optimized heat and compression integration for
every unit
liquid recovery optimized on every unit.
Disadvantages of CCR Continuous Reforming
Technology
Courtesy: UOP
CCR process shows disadvantages of complicated process
flow and more investment as an additional continuous
catalyst regeneration system is provided.

Note: However, it can contribute to high octane product, high
product yield, long unit operation cycle and flexible operation.
Compar i son of CCR Pr oc ess and Semi -
Regener at i on Ref or mi ng Pr oc ess
Courtesy: UOP
Basis: Same Feedstock processed.
Courtesy: UOP
Dualforming
RZ Platforrming
RZ Platforrming
Aromatics yields from raffinate
RZ Platforrming
Hydrogen yield from raffinate.
Reforming Catalyst
Catalyst
Reforming Basics Bi-Functional Catalysts
Catalysis Mechanism
Catalyst
Objectives Path to Breakthrough Catalysts
Catalyst
Catalyst
Catalyst
State-of-the-Art Catalysts
WHICH METAL COMBINATION TO CHOOSE
SUMMARY - EFFECT OF SECOND METAL
Stability
SELECTIVITY
New Generation of Catalyst
Catalysts Poisons
Catalysts Contaminants
Catalysts Contaminants (Contd)
Catalysts Distribution
Catalyst Distribution
Temperatures and Compositions inside Reactors
Chemical Reactions
Catalyst Sampler
Catalyst Regeneration
Objectives of Regeneration Section
Regenerator Section: RegenC-2
Regen C
RegenC Catalyst Regenerator
Reactor Types
Typical Radial CCR Reactor
CCR Reactor Metallurgy
Typical Axial Fixed-Bed Reactors
Typical Radial Fixed-Bed Reactor
Catalytic Reforming Economics Comparison
Economics Reforming Comparison
Key Energy and Environmental FactsCatalytic
Reforming
Summary of Inputs and Outputs of Catalytic
Reforming
Estimated Energy Use in Catalytic Reforming
Conclusions

Catalytic Reforming Technology

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Catalytic Reforming Technology

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Gerard B.

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