Key Considerations for a Reforming Unit Revamp

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GBHE Technical Bulletin CTB #54
Catalytic Reforming
Key Considerations for a Reforming
Unit Revamp
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be accurate and correct at time of going to press, and is given in good faith, but it is for
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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

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

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

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

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

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

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

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?

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

Key Considerations for a Reforming Unit Revamp

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