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Novel Technology 2013, Vol. 15, No. 4, pp 1-8 December 30, 2013
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
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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
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
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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.
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.
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
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
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
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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.
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China Petroleum Processing and Petrochemical Technology 2013,15(4):1-8
circulation rate for the CCR unit is set at 0.35 MPa, 102—104, chemicals, 2002, 33(10): 1-5 (in Chinese)
530 ℃, 1.2 h-1, 2.5, and 1 135 kg/h, respectively. [12] Zhao Zhihai. Development of new regeneration process of
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ue. The other technical targets had attained or exceeded moisture content in regeneration recycle flue gas during
search Program(No.107025) is gratefully acknowledged. [14] Zhao Zhihai. Comparison and analysis of IFP and UOP
CCR regeneration coke burning process[J]. Petroleum Re-
finery Engineering, 2002, 32(1): 14-17 (in Chinese)
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