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Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
Key Considerations for a Reforming Unit Revamp
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Key Considerations for a Reforming Unit Revamp

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Revamp objectives …

Revamp objectives
Revamp Philosophy
Revamp options
Semi-Regenerative Reforming Unit
Typical Flow Scheme
Continuous Reforming Unit
Typical Flow Scheme
Revamp to Hybrid Operation
What may be achieved?
Typical C5+ Yield at Decreasing Pressure
Changes Required for Full Conversion
Typical Benefits of Full Conversion
Revamping of Existing Continuous Reforming Units
Fired Heaters Revamp
Burners
Reactor Options
Regeneration Section
Summary

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  • 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com GBHE Technical Bulletin CTB #54 Catalytic Reforming Key Considerations for a Reforming Unit Revamp Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.
  • 2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Table of Contents Revamp objectives Revamp Philosophy Revamp options Semi-Regenerative Reforming Unit Typical Flow Scheme Continuous Reforming Unit Typical Flow Scheme Revamp to Hybrid Operation What may be achieved? Typical C5+ Yield at Decreasing Pressure Changes Required for Full Conversion Typical Benefits of Full Conversion Revamping of Existing Continuous Reforming Units Fired Heaters Revamp Burners Reactor Options Regeneration Section Summary
  • 3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Typical Revamp Objectives - Increase capacity - Increase octane - Increase cycle length - Increase H2 Production - Limit downtime for implementation - Fit within available plot space Revamp Philosophy: Bring the Project into Focus!! One Licensor’s Approach
  • 4. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Common Semi-regen Revamp Options Replace smallest reactor with new large reactor – Increase cycle life by 50% for same severity – Or allow increased severity with same cycle life Replace combined feed exchanger – Unloads charge heater and product condenser simultaneously – Reduces reactor circuit pressure drop and allows increased recycle gas
  • 5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Lower operating pressure – Increase liquid and hydrogen yields Revamp heaters – Keep up with increased duty required by increased throughput or increased yield Recycle gas compressor is rarely replaced
  • 6. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Revamp to Hybrid Operation Hybrid Operations Falls between semi-regen and full continuous reforming operation – New last reactor added with a catalyst regeneration section on the last reactor only. – The operating pressure usually decreased within constraints of existing net gas pressure requirements. Advantages over semi-regenerative units: – Yield benefit of decreased pressure and fresh catalyst in last reactor – Long cycle length at high severity possible • >2 year cycle at 100 RONC becomes practical – Less capital than full conversion to a continuous reforming unit Advantages not realized versus full conversion to continuous reforming – Full yield advantage of fresh catalyst vs semi-regenerative catalyst – Maximize on-stream time
  • 7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com What is typically achieved with revamp to Hybrid Operations? – Maintain unit throughput – Marginal decrease in operating pressure – Increase product RONC • 100 RONC or more – Increase cycle length • Minimum 2 year cycle life is a typical goal Typical C5+ Yield at Decreasing Pressure
  • 8. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Changes Required for Full Conversion Typical Benefits of Full Conversion - Maintain unit throughput - Reduce unit operating pressure – Increase in liquid and hydrogen yields - Increase product octane - Increased on-stream time Revamping of Existing Continuous Reforming Units - Increased heater capacity - Debottleneck reactors - Increase regeneration section coke burning and catalyst circulation capacity Fired Heaters Revamp - Add burners - Add surface area - Increase number of passes
  • 9. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Burners - Change burner tips - Change burners Reactor Options - Increase catalyst activity – Change to more active catalyst – Add reactor as last resort - Decrease coke make – Change to lower coke make catalyst Regeneration Section - Increased coke burning required – Increase oxygen delivery – Increase catalyst circulation rate What may be economical to achieve with a maximum capacity revamp?
  • 10. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Summary - Semi-Regenerative Reforming Unit Revamp - Maintain fixed-bed mode of operation o Increase throughput or cycle length - Convert to hybrid mode of operation o Maintain throughput o Increase RONC and cycle length - Convert to full continuous reforming operation o Increase yields and throughput o Increase on-stream factor - Continuous Reforming Unit Revamp - Capacity increase of >50% may be economically achieve
  • 11. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

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