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China Petroleum Processing and Petrochemical Technology

Novel Technology 2013, Vol. 15, No. 4, pp 1-8 December 30, 2013

Development and Commercial Application of Ultra-Low


Pressure Naphtha Reforming Technology with
Continuous Catalyst Regeneration
Ma Aizeng1; Xu Youchun2; Yang Dong3; Zhang Xinkuan1; Wang Jieguang1
(1. Research Institute of Petroleum Processing, SINOPEC, Beijing 100083; 2. SINOPEC Luoyang
Petrochemical Engineering Company; 3. SINOPEC Guangzhou Company)

Abstract: The development history and major technological innovations of the ultra-low pressure naphtha reforming tech-
nology with continuous catalyst regeneration in China were introduced. This technology had been adopted by the 1.0 Mt/a
CCR unit at the Guangzhou Company. The appropriate catalyst was selected to meet the demand of the unit capacity, the
feedstock, and the product slate. The design parameters, including the reaction pressure, the octane number of C5+ liquid
product, the reaction temperature, the space velocity, the hydrogen/oil molar ratio, and the catalyst circulating rate, were
chosen based on the study of process conditions and parameters. The commercial test results showed that the research oc-
tane number of C5+ product reached 104 when the capacity of the CCR unit was 100% and 115% of the design value. The
other technical targets attained or exceeded the expected value.
Key words: ultra-low pressure; continuous catalytic reforming; catalyst; regeneration; aromatics; gasoline; process; naphtha

1 Introduction outline its development history, major technological in-


novations and commercial applications in a 1.0 Mt/a CCR
Naphtha catalytic reforming with continuous catalyst unit at SINOPEC Guangzhou Company refinery.
regeneration (CCR) is a process that can produce high-
octane gasoline components, aromatics and hydrogen. 2 Development History and Major Tech-
High-octane gasoline components can be blended into nological Innovations
gasoline pool to produce clean fuel. Aromatics are gener-
ally used as the raw material for manufacture of chemical Since the 1990s, SINOPEC Research Institute of Petro-
fiber, plastics and rubber products. Hydrogen is a primary leum Processing (RIPP) began to carry out the research
resource utilized by hydrogen-consuming units at refiner- and development of continuous catalytic reforming cata-
ies. Therefore, the CCR technology level can affect the lyst and related process technologies[1-15]. During this pe-
technical progress and competitive edge of China’s pe- riod, RIPP successfully developed the catalytic reforming
troleum and petrochemical industry. To exploit the self- reaction process model and the low-pressure combined
dependent CCR technology, SINOPEC organized two bed catalytic reforming process, and filed many patents
research projects, the low pressure combined bed (LPCB) associated with the catalytic reforming reaction, the re-
catalytic reforming technology and the continuous naph- generation process and the regenerator. SINOPEC Luoy-
tha catalytic reforming technology, which had been com- ang Petrochemical Engineering Company (LPEC) also
mercialized at the refineries of Changling Company and developed some patented technologies related to CCR
Luoyang Company. After the successful application of regeneration process and apparatus and automatic control
the above-mentioned CCR technology, SINOPEC con-
tinued to organize the research and development of ultra- Recieved date: 2013-06-09; Accepted date: 2013-06-27.
low pressure naphtha catalytic reforming technology with Corresponding Author: Dr. Ma Aizeng, E-mail: maaizeng.
continuous catalyst regeneration. This paper intends to ripp@sinopec.com.

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China Petroleum Processing and Petrochemical Technology 2013,15(4):1-8

techniques[16-20]. In the following years, LPEC and RIPP interlocking owing to low gas flowrate; (6) Developing
co-developed the low-pressure combined bed (LPCB) a new type of automatic control system for lock hopper
catalytic reforming process, which had been successfully to make catalyst circulation and transfer stable, safe and
commercialized at the SINOPEC Changling Company accurate; and (7) Exploiting patented sulfidation and de-
refinery [20]
. sulfidation technology, and preventing CCR units from
After application of LPCB, LPEC and RIPP soon co- coking without sulfur and poisoning by sulfur.
developed the continuous catalytic reforming technology
with independent intellectual property rights, which had
3 Investigation on Process Conditions of
Guangzhou CCR Unit
been successfully applied in revamping the 700 kt/a CCR
unit at the SINOPEC Luoyang Company refinery. How- 3.1 Unit capacity
ever, the reaction pressure of the revamped reforming
Before construction of the new CCR unit, the Guangzhou
unit is 0.68 MPa due to the constraints of existing equip-
Company refinery has a CCR unit with a capacity of
ment. Higher pressure does not favor catalytic reforming
400 kt/a. The refinery capacity was to be expanded
reaction, so the yields of C5+ product, aromatics and H2
to 13 Mt/a, the output of naphtha would additionally in-
delivered from the unit cannot reach the technical targets
crease to 1.0 Mt/a after completion of the revamp, leading
of ultra-low pressure continuous catalytic reforming
to a deluge of naphtha. Therefore, a new CCR unit with a
process. Out of this concern, LPEC and RIPP decided to
capacity of 1.0 Mt/a was planned for construction, which
develop the ultra-low pressure naphtha catalytic reform-
not only can process the surplus naphtha, but also opti-
ing process with continuous catalyst regeneration and
mize the production ratio of gasoline components coupled
finally succeeded .
with low-cost hydrogen.
Ultra-low pressure naphtha catalytic reforming process
with continuous catalyst regeneration possesses indepen- 3.2 Design feedstock and product target
dent intellectual property rights and its major technologi- According to the crude oil processing target envisaged
cal innovations cover the following items, viz.: (1) Pro- in the 13 Mt/a refinery revamping plan, the reformer
posing a design idea of maximizing target aromatic yield feedstock is designed to cope with two cases, including
for aromatic production unit and high octane-barrel for the lean feed case and the rich feed case. The lean feed
gasoline production unit through the investigation of cata- consists of 120 kt/a of hydrocracking heavy naphtha and
lytic reforming reaction laws; (2) Solving the problems a mixture composed of 30 m% of heavy naphtha, 30 m%
related with the manufacture, transportation, installation of medium naphtha and 40 m% of light naphtha derived
and maintenance of large-scale reactors, and alleviating from the Arabian crude. The rich feed is composed of 120
the difficulties in apparatus fabrication and installation by kt/a of hydrocracking heavy naphtha, 380 kt/a of Mangi
optimizing the configuration of reactors; (3) Avoiding the heavy naphtha and a mixture consisting of 30 m% of
damage of regenerator internals caused by heat stress heavy naphtha, 30 m% of medium naphtha and 40 m% of
through improving the design of its internal grids, mak- light naphtha derived from the Arabian crude. The com-
ing the installation and replacement of internals easier; positions of design feedstock are given in Table 1.
(4) Developing a reliable de-chlorination technology for In line with the overall process flow sheet of the refinery,
regeneration recycle gas, avoiding the chlorine and caus- the newly-built CCR unit at Guangzhou refinery not only
tic corrosion and pipeline scaling; (5) Optimizing the cir- can produce high-octane gasoline components, but also
cuit of gas discharged from the drying and oxychlorina- satisfy the hydrogen balance of the whole refinery. Fur-
tion zone for realizing low coke burning, and preventing thermore, after consideration of the surplus aromatics in
the electric heater for oxychlorination zone inlet gas from gasoline pool and the market demand for mixed xylenes,

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Ma Aizeng, et al. Development and Commercial Application of Ultra-Low Pressure Naphtha Reforming Technology with Continuous Catalyst Regeneration

Table 1 Compositions of design feedstock w, %


Lean feed Rich feed
Item Paraffins Naphthenes Aromatics Paraffins Naphthenes Aromatics
C6 3.55 2.41 0.40 2.45 3.41 0.36
C7 17.43 6.13 2.75 15.65 7.93 2.24
C8 18.97 7.34 5.56 17.35 11.14 3.69
C9 18.01 5.48 3.78 16.84 7.08 3.14
C10 6.67 1.42 0.01 5.69 3.02 0.01
Total 64.72 22.78 12.50 57.98 32.58 9.44

the product targets of the CCR unit are aimed at produc- Table 4 Composition and physical properties of some catalysts
tion of gasoline and aromatics. To meet the demand for Item PS-IV PS-V PS-VI PS-VII
w(Pt),% 0.35 0.28 0.28 0.35
hydrogen needed by the refinery, the hydrogen yield of
w(Sn),% 0.31 0.31 0.31 0.41
the CCR unit should exceed 3.61 m%.
w(M),% 0 0 a b
Bulk density, kg/m3 560 560 560 560
3.3 Selection of catalyst
Specific surface area, m2/g 200 200 195 195
As we all know, the product yield of CCR reforming unit
is dependent on the performance of catalyst. Therefore, Table 5 Comparison of catalyst performance
the selected catalyst should meet the requirements for the Item PS-IV PS-V PS-VI PS-VII
octane barrel, the aromatics yield and the hydrogen yield Aromatics yield, m% base-0.39 base-0.8 base base+0.31

provided by the newly-built CCR unit. It is necessary Octane barrel, m% base-1.05 base-1.23 base base-0.22

to compare the performance of catalysts developed by Coking rate, kg/h base×1.33 base×1.21 base base

RIPP. The catalyst evaluation tests were performed in a


It can be seen from Table 4 that the major metal elements
lab-scale apparatus equipped with a recycle gas compres-
of PS-IV and PS-V catalysts are Pt and Sn, and a new
sor. The properties of feedstock are listed in Table 2. The
auxiliary agent M is additionally introduced into PS-VI
evaluation test conditions are shown in Table 3. The com-
and PS-VII catalysts; the Pt content of PS-VI and PS-VII
position and physical properties of several catalysts are catalysts is 0.35 m%, while that of PS-V and PS-VI cata-
listed in Table 4, and the performance of catalyst is shown lysts is 0.28 m%. Table 5 indicates that the coking rate of
in Table 5. PS-IV and PS-V catalysts is by 33 m% and 21 m% higher
Table 2 Properties of feed used in lab-scale apparatus than that of PS-VI catalyst, while the aromatics yield
Item Value and octane barrel value decrease. Therefore, PS-IV and
Density (20 ℃), kg/m 3
736.2
PS-V catalysts are unsuitable for the newly-built CCR
unit. Compared to the PS-VI catalyst, the aromatics yield
Distillation (ASTM D86), ℃ 82—162
of PS-VII catalyst increases by 0.31 percentage points,
Composition, m%
Paraffins 52.96 and the octane barrel value decreases by 0.22 percentage
Naphthenes 43.43 points at a same coking rate.
Aromatics 3.71 The relationship between catalyst activity and C5+ liquid
Potential aromatic content, m% 44.23 yield is investigated in a lab-scale apparatus, using a feed
Table 3 Conditions of catalyst evaluation test given in Table 2. The evaluation test conditions cover a
Item Value reaction pressure of 0.35 MPa, a LHSV of 1.2 h-1, and a
Reaction pressure (gauge), MPa 0.69 hydrogen/hydrocarbon volume ratio of 1 300. The com-
LHSV, h-1 2.0 parison on activity and liquid yield between PS-VI and
H2 to hydrocarbon volume ratio 800 PS-VII catalysts are shown in Figures 1 and 2. It can be
WAIT, ℃ 530
seen from Figures 1 and 2 that the catalytic activity of PS-

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China Petroleum Processing and Petrochemical Technology 2013,15(4):1-8

VII catalyst is slightly lower than that of PS-VI catalyst forming will proceed along the direction of lower reac-
at lower reaction severity, and is slightly higher at higher tion pressure. Up to now, the reaction pressure of CCR
reaction severity. During the initial stage of catalyst op- unit has decreased to 0.35 MPa. If the reaction pressure
eration, the C5+ yield on PS-VII catalyst is slightly higher further decreases, the energy consumption and equipment
than that of PS-VI catalyst and then decreases gradually, investment of catalytic reforming unit would increase
but eventually reaches the similar level. sharply. After full consideration of positive and negative
factors related with lower operating pressure, the average
reaction pressure of the newly-built CCR unit is specified
at 0.35 MPa.
3.4.2 Reaction severity (RONC of C5+ product)
Figures 3—6 depict the effects of RONC of C5+ liquid
product on hydrogen yield, aromatics yield, coking rate
and octane barrel obtained during processing of lean
feed and rich feed in the presence of PS-VI catalyst at
a reaction pressure of 0.35 MPa, a LHSV of 1.2 h-1, and
Figure 1 Comparison of activity between PS-VI and PS-VII Catalysts a H2/hydrocarbon ratio of 2.5. Figure 3 indicates that the
hydrogen yield of rich feed is higher than that of lean feed
at the same RONC of C5+ product. The hydrogen yield of
lean feed and rich feed both increases with the increase in
RONC of C5+ product. For lean feed, the hydrogen yield
can reach 3.61 m% when RONC of C5+ product attains or
exceeds 102. For this reason, the bottom value of RONC
of C5+ product is designed as 102.

Figure 2 Comparison of liquid yield between PS-VI and


PS-VII catalysts

In summary, PS-VI and PS-VII catalysts can both meet


the requirements of the CCR unit. However, the Pt con-
tent of PS-VII catalyst is 25 m% higher than that of PS-
VI catalyst. Therefore, PS-VI catalyst is selected in an
Figure 3 Effect of RONC of C5+ product on H2 yield
attempt to reduce the initial investment cost.

3.4 Main reaction conditions Figures 4 and 5 show that the aromatics yield of rich feed
is higher than that of lean feed at the same RONC of C5+
The effects of main process parameters on product distri-
product, and increases with the increase in RONC of C5+
bution are investigated through using the catalytic reform-
product. The coking rate of rich feed is lower than that
ing reaction model developed by RIPP and the operating
of lean feed, and increases sharply with the increase in
data of commercial CCR units in China.
RONC of C5+ product. The coking rate of rich feed and
3.4.1 Reaction pressure lean feed increases by 86 m% and 59 m%, respectively,
Lower pressure can favor catalytic reforming reaction as the RONC of C5+ product increases to 105 from 102.
towards aromatics formation[12]. Therefore, catalytic re- The coking rate increases by 15 m%—28 m% on one

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Ma Aizeng, et al. Development and Commercial Application of Ultra-Low Pressure Naphtha Reforming Technology with Continuous Catalyst Regeneration

unit of RONC increase. hydrogen and aromatics yields slightly decrease with an
increase in hydrogen to hydrocarbon molar ratio, and
the coking rate also drops abruptly. The impact of H2 to
hydrocarbon molar ratio on reaction performance of rich
feed follows the same rules.

Table 6 Effect of H2 /HC molar ratio on catalyst performance


H2/hydrocarbon molar ratio 2.00 2.50 3.00
RONC of C5+ product 102 102 102
Octane barrel, m% base+0.31 base base-0.31
C liquid yield, m%
5+ base +0.30 base base-0.30

Figure 4 Relationship between aromatics yield and Aromatics yield, m% base+0.24 base base-0.24
RONC of C5+ product Pure H2 yield, m% base+0.03 base base-0.03
Coking rate, kg/h base×1.17 base base×0.85

With an increasing H2 to hydrocarbon ratio, the coking


rate declines so that the regeneration capacity can be
reduced, resulting in a decreased equipment investment
and energy consumption. However, the equipment cost
and energy consumption of recycle gas compressor in-
crease with the increase in the H2 to hydrocarbon molar
ratio[21-22]. Based on the above-mentioned facts, the H2 to
hydrocarbon molar ratio is set at 2.50.
Figure 5 Effect of RONC of C5+ liquid product on coking rate 3.4.4 Catalyst regeneration capacity

It can be seen from Figure 6 that the octane barrel of rich The CCR catalysts should be regenerated continuously
feed is higher than that of lean feed, and reaches a peak in order to restore their activity and selectivity. The re-
value when RONC of C5+ product is 104. So, the upper generation capacity is generally denoted by catalyst cir-
value of RONC of C5+ product is set at 104. culation rate. The higher the catalyst circulation rate is,
the greater the regeneration capacity would be. Catalyst
3.4.3 Hydrogen to hydrocarbon molar ratio
regeneration rate depends on the coking rate of catalyst
The influence of H2 to hydrocarbon molar ratio on reac- and the coke-burning process. The suitable coke content
tion performance of lean feed is given in Table 6. Table on spent catalyst is generally 3 m%—5 m% based on the
6 shows that the yield of C5+ liquid, the octane barrel, the characteristics of coke-burning process involved in the
ultra-low pressure naphtha catalytic reforming technology
with continuous catalyst regeneration.
Coke deposition on catalyst is associated with the com-
position and properties of feed, the reaction pressure, the
H2/hydrocarbon molar ratio, and RONC of C5+ product.
When the reaction pressure is 0.35 MPa, the H2/hydrocar-
bon molar ratio is 2.5, and the upper value of RONC of
C5+ product is 104, the coking rate is calculated by means
of the reforming reaction model for rich feed and lean
Figure 6 Effect of RONC of C liquid product on octane barrel
5
+ feed. The results show that the coking rate of rich feed

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China Petroleum Processing and Petrochemical Technology 2013,15(4):1-8

and lean feed is 44.7 kg/h and 56.75 kg/h, respectively. is plotted in Figure 8. Figure 8 depicts that the reaction
Upon designing the CCR regenerator, the maximum coke temperature for lean feed and rich feed both increases
content on spent catalyst is generally set at 5 m%. Based with an increasing LHSV, but the reaction temperature
on the value of coking rate and coke content, the calcu- for lean feed is higher than the case of rich feed at certain
lated circulation rate for the two cases is 885.4 kg/h and space velocities. When the WAIT is 530 ℃, the LHSV for
1 135 kg/h, respectively. Therefore, the maximum catalyst lean feed and rich feed is 1.2 h-1 and 1.4 h-1, respectively.
circulation rate is set at 1 135 kg/h. Hence, the design value of LHSV should be less than
3.4.5 Reaction temperature and space velocity 1.2 h-1 in order to ensure that WAIT can be maintained at

Nowadays the olefin content of reformate from CCR units below 530 ℃.
in China continues to increase, resulting in shorter service
life of clay used for removing the olefins. Thus, the clay
is replaced more frequently to shoot up the operating cost
and affect the safe and smooth operation of CCR units.
Much research shows that it is the ever increasing reac-
tion temperature that leads to the elevation of olefin con-
tent in reformate. Upon using the feedstock listed in Table
2, the relationship between the olefin content in reformate
and the reaction temperature is investigated at a lab-scale
apparatus, which operates at a reaction pressure of 0.35 Figure 8 Relationship between LHSV and WAIT
MPa, a LHSV of 1.2 h-1, and a H2/hydrocarbon volume ra-
tio of 1 300. The experimental results are shown in Figure 4 Commercial Test of the CCR Unit at
7. It can be seen from Figure 7 that the olefin content in Guangzhou Company
reformate increases sharply with the increase in reaction
temperature. This indicates that it is necessary to decrease The construction of the CCR unit was started on October
the reforming reaction temperature as far as possible in 26, 2007 and was completed on January 15, 2009. This
order to reduce the olefin content in reformate. After full unit was put into operation on April 12, 2009. The perfor-

consideration of the investment cost of equipment and mance evaluation of the CCR unit was carried out when

catalyst, the upper value of the designed WAIT is speci- the capacity reached 100% and 115% of the design target

fied at 530 ℃. in September, 2009 and May, 2010, respectively. The

At a reaction pressure of 0.35 MPa, a H2 to hydrocarbon feedstock for the performance evaluation is listed in Table

molar ratio of 2.5, and a RONC of C5+ product of 104, 7. The main reaction conditions and results are given in

the relationship between LHSV and reaction temperature Table 8.

Table 7 Properties and composition of CCR unit feedstock


Lean Rich Evaluation Evaluation
Item feed test 2
feed test 1
Density (20 ℃), kg/m3 725.5 735.0 732.1 735.0
Distillation (ASTM D-86), ℃
IBP 95 95 85 74.5
50% 110 133 116.1 118
FBP 160 163 161.8 166.3
Composition (w), %
Paraffins 64.72 57.98 63.78 54.45
Naphthenes 22.78 32.58 26.72 33.91
Aromatics 12.50 9.44 9.50 11.64
Figure 7 Effect of reaction temperature on olefin yield

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Ma Aizeng, et al. Development and Commercial Application of Ultra-Low Pressure Naphtha Reforming Technology with Continuous Catalyst Regeneration

Table 8 Main reaction parameters and results on value of rich feed, and the density is commensurate to the
evaluation of 1 Mt/a CCR unit design value. The RONC of C5+ liquid product reaches
Lean Evaluation Evaluation 104.1 at a WAIT value of 524 ℃. The corresponding C5+
Item Rich feed
feed test 1 test 2 liquid yield is 89.47 m%, which is 1.72 percentage points
Feed rate, kg/h 119 050 119 050 119 050 137 195
higher than the expected value. The aromatics yield is
WAIT, ℃ 530 525 522.4 524
73.71 m%, which is 1.21 percentage points higher than
WABT, ℃ 496 496.1 496.7 493.2
H2/HC molar ratio 2.5 2.5 2.5 2.2 the design value. The pure hydrogen yield is 3.96 m%,
LHSV, h-1 1.20 1.20 1.24 1.42 which is 0.27 percentage points higher than the target val-
Reaction pressure
0.35 0.35 0.35 0.35
ue. The octane barrel is 93.14 m%, which is 1.88 percent-
(gauge), MPa
age points higher than the design value. The coke content
Separator pressure
0.25 0.25 0.25 0.25 on spent catalyst is 3.51 m%, which can satisfy the needs
(gauge), MPa
Separator
40 40 40 40 of coke burning process. The consumption of catalyst is
temperature, ℃
4.8 kg/d, which is 3.4 kg/d less than the expected value.
RONC of C5+ product ≥104 ≥104 104.0 104.1
C5+ liquid yield, m% 87.06 87.75 87.58 89.47 In summary, the commercial tests of the 1.0 Mt/a CCR
Aromatics yield, m% 72.46 72.50 72.75 73.71 unit at Guangzhou Company, which utilizes the self-
Pure H2 yield, m% 3.61 3.69 3.90 3.96 developed ultra-low pressure naphtha reforming technol-
Octane barrel, m% 90.54 91.26 91.08 93.14
ogy with continuous catalyst regeneration, have shown
Catalyst circulation
rate, kg/h
1 135 1 135 1 135 1 135 that the research octane number of C5+ product reached
Coke content on spent 104 when the naphtha reforming capacity was 100% and
≯5 ≯5 3.83 3.51
catalyst, m%
115% of the design value. The other technical targets
Catalyst consumption,
kg/d
≯ 8.20 ≯ 8.20 1.5 4.8 have attained or exceeded the expected value.

It can be seen from Tables 7 and 8 that the distillation 5 Conclusions


range of evaluation feed 1 is in the range of from 85 ℃
(1) The ultra-low pressure naphtha reforming technology
to 161.8 ℃ and the mass fraction of naphthenes and aro- with continuous catalyst regeneration provided with inde-
matics is 36.22 m%, which is similar to the design value pendent intellectual property rights had been successfully
of lean feed. The RONC of C5+ liquid product reaches 104 developed after many years’ research efforts. The design
when the WAIT is 522.4 ℃, which is 7.6 ℃ lower than ideas for maximizing the target aromatic yield in line with
the expected temperature. The corresponding C5+ liquid the aromatics production mode or for boosting the octane
yield is 87.58 m%, which is 0.52 percentage points higher barrel in line with the gasoline production mode were put
than the expected value. The aromatics yield is 72.75 m%, forward. Many technological innovations were realized,
which is 0.29 percentage points higher than the design including the configuration of reactors, the structure of re-
generator’s internal grids, the technology for dechlorina-
value. The pure hydrogen yield is 3.90 m%, which is 0.29
tion of regenerator recycle flue gas, the process for burn-
percentage points higher than the target value. The octane
ing low coke content of catalyst, the automatic control
barrel is 91.08 m%, which is 0.54 percentage points higher
system of lock hopper, and the startup procedures.
than the design value. The coke content on spent catalyst is
(2) To meet the requirements of Guangzhou refinery, the
3.83 m%, which can satisfy the needs of coke burning pro-
capacity of CCR unit was set at 1.0 Mt/a, with the target
cess. The consumption of catalyst is 1.5 kg/h, which is products consisting of gasoline and aromatics. The PS-VI
6.7 kg/d lower than the expected value. Compared to the de- catalyst was selected for use in the CCR unit.
sign case of rich feed, the distillation range of the evaluation (3) Based on the investigations on process conditions and pa-
feed 2 is in the range of from 74.5 ℃ to 166.3 ℃ and the rameters, the design value of reaction pressure, the RONC of
mass fraction of naphthenes and aromatics is 45.55 m%, C5+ liquid product, the maximum reactor inlet temperature, the
which is 3.53 percentage points higher than the design LHSV, the H2 to hydrocarbon molar ratio, and the catalyst

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China Petroleum Processing and Petrochemical Technology 2013,15(4):1-8

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