Catalytic Reforming: Catalyst, Process Technology and Operations Overview

Gerard B. Hawkins
Managing Director, CEO
Catalytic Reforming:
Catalyst, Process Technology
and Operations Overview

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
Contents

Reforming catalyst
Catalyst Types
Catalyst Poisons
Catalyst Distribution
Catalyst Sampling
Catalyst Regeneration
Catalytic Reforming Economics Comparison
Key Energy and Environmental Facts
Conclusions
Contents, con’t

Fundamentals of Catalytic Reforming

Basic catalytic reforming scheme with three heaters,
three reactors and recycled hydrogen; the excess H2 is
later used in other refining plants.

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

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 Variable: Pressure

Processes Variable: Temperature

Processes Variable: Space Velocity

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

Cyclic Regenerative Reforming

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

www.gbhenterprises.comCourtesy: Axens
CCR with side-by-side reactors

SR and CCR hybrid process
Courtesy: Axens

SR and CCR hybrid process
Courtesy: UOP

Comparison of Semi-Regeneration
Reforming Process and CCR Process

CCR Platforrming versus Fixed-bed Platforrming

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.

Comparison of CCR Process and Semi-
Regeneration Reforming Process
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

Objectives Path to Breakthrough Catalysts

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

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 Facts—Catalytic
Reforming

Summary of Inputs and Outputs of Catalytic
Reforming

Estimated Energy Use in Catalytic Reforming

Conclusions

Catalytic Reforming: Catalyst, Process Technology and Operations Overview

Catalytic Reforming: Catalyst, Process Technology and Operations Overview

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