Catalytic Reforming

Catalytic Reforming
Catalytic Reforming
Under Supervision of
Under Supervision of
Dr. El-Shazly Salem
Dr. El-Shazly Salem
Eng. Hossam Hosny Mohamed El-Ghareeb
Eng. Hossam Hosny Mohamed El-Ghareeb
Eng. Mohamed Mohamed Refaat Ibrahiem
Eng. Mohamed Mohamed Refaat Ibrahiem
Eng. Mahmoud Ibrahiem Mohamed Mohamed
Eng. Mahmoud Ibrahiem Mohamed Mohamed
Eng. Mustafa Mahmoud Abd-ALLAH
Eng. Mustafa Mahmoud Abd-ALLAH
Eng. Mohamed Saied Abu Basha
Eng. Mohamed Saied Abu Basha
Antiknock Quality Problem
Antiknock Quality Problem

Low Octane Rating of Gasoline vs. Demand
Low Octane Rating of Gasoline vs. Demand

Noise and Loss in Energy
Noise and Loss in Energy

Solutions to the Problem
Solutions to the Problem

Addition of High O.N. Compounds
Addition of High O.N. Compounds


Tetra Ethyl Lead (TEL)
Tetra Ethyl Lead (TEL)

Oxygenates (MTBE & TAME)
Oxygenates (MTBE & TAME)

Alteration of the Chemical Composition
Alteration of the Chemical Composition

Thermal Reforming
Thermal Reforming

Catalytic Reforming
Catalytic Reforming
Catalytic vs. Thermal Reforming
Catalytic vs. Thermal Reforming
Catalytic
Catalytic

Higher Octane
Higher Octane
Number: 90 to 100
Number: 90 to 100

Lower Temp. ≈ 500°C
Lower Temp. ≈ 500°C

Higher H
Higher H
2

2
Production
Production

Trace Olefins Contents
Trace Olefins Contents

Pt/Alumina Catalyst
Pt/Alumina Catalyst
Thermal
Thermal

Lower Octane
Lower Octane
Number: 65 to 80
Number: 65 to 80

Higher Temp. ≈ 600°C
Higher Temp. ≈ 600°C

Lower H
Lower H
2
2
Production
Production

High Olefins Contents
High Olefins Contents


Without Catalyst
Without Catalyst
Feed Treatment By Hydrogen
Feed Treatment By Hydrogen

Removal of:
Removal of:

Nitrogen as Ammonia
Nitrogen as Ammonia

Sulfur as H
Sulfur as H
2
2
S
S

Oxygen as Water
Oxygen as Water

Saturation of Olefins Present in Special
Saturation of Olefins Present in Special
Feeds
Feeds
The Catalytic Reforming Process
The Catalytic Reforming Process

Aims of Process:
Aims of Process:


Max. ON
Max. ON
…………
…………
By Conversion
By Conversion

Min. Capacity to form Gums
Min. Capacity to form Gums
……
……
By Saturation
By Saturation

Production of Hydrogen for other Processes
Production of Hydrogen for other Processes

Production of BTX for the Petrochemical Industry
Production of BTX for the Petrochemical Industry
Feed To Catalytic Reforming
Feed To Catalytic Reforming

Sources of Feed:
Sources of Feed:

HSR Naphtha (90°C to 160°C)
HSR Naphtha (90°C to 160°C)

Not LSR

Not LSR
……………
……………
Why?
Why?

Not Heavier
Not Heavier
……………
……………
Why?
Why?

Visbreaking & Coking Gasolines
Visbreaking & Coking Gasolines

Hydrocracking
Hydrocracking
Two Typical Feeds Composition
Two Typical Feeds Composition
Paraffinic
(Arabian Light)
Naphthenic
(Nigeria)
RON 50 66
Av. Mw. 114 119
S
(weight ppm)
500 350
Paraffins 66.8 29.3

Naphthenes 21.8 61.85
Aromatics 11.4 8.85
Total Change to The Feed
Total Change to The Feed
Catalytic Reforming Product
Catalytic Reforming Product

Relation between ON and Reformate Yield
Relation between ON and Reformate Yield
Reformate Composition
Reformate Composition
Number
of carbon
atoms
nP iP P O N A Total
4
5
6
7
8
9
10
11
Total
0.57
1.51
1.69
2.5
1.16
0.26

0.07
0
7.76
2.37
1.97
8.42
4.91
1.04
0.28
0.02
21.01
0.57
3.88
5.66
10.92
6.07
1.3
0.35
0.02
28.77
0.1
0.16
0.35
0.44
0.08
0
0
1.13
0
0.19

0.4
0.34
0
0
0
0.93
2.34
14.16
26.28
21.08
4.76
0.55
69.17
3.98
8.35
25.83
33.13
22.46
5.11
0.57
100
nP: normal paraffins. iP: branched paraffins. P: total paraffins.
O: olefins. N: naphthenes. A: aromatics
Reformate Composition
Reformate Composition
Reformate Composition
Reformate Composition
Catalytic Reforming Technology
Catalytic Reforming Technology


Fixed-Bed Technology
Fixed-Bed Technology

Non-Regenerative
Non-Regenerative
……
……
Replacement (months)
Replacement (months)

Semi-Regenerative
Semi-Regenerative
……
……
Shutdown (years)
Shutdown (years)

Regenerative (Cyclic)
Regenerative (Cyclic)
……
……
Switching (days)
Switching (days)

Moving-Bed Technology
Moving-Bed Technology

Fluid-Bed Technology
Fluid-Bed Technology
Fixed-Bed Technology

Fixed-Bed Technology

Type of Reactors
Type of Reactors
Fixed-Bed Technology
Fixed-Bed Technology

Reactor Configuration
Reactor Configuration
Fixed-Bed Technology
Fixed-Bed Technology

Temperature Variation in Reactors
Temperature Variation in Reactors
Fixed-Bed Technology
Fixed-Bed Technology

Variation in Effluent Composition
Variation in Effluent Composition
Fixed-Bed Technology
Fixed-Bed Technology

Non-Regenerative Technique
Non-Regenerative Technique

The First Technique to be used (used by UOP)
The First Technique to be used (used by UOP)

High Pressures (above 35 bars)
High Pressures (above 35 bars)


Catalyst Life of 10 months
Catalyst Life of 10 months

Catalyst is replaced & Regenerated off-site
Catalyst is replaced & Regenerated off-site

Low Severity & High Pressures
Low Severity & High Pressures
……
……
led to switching
led to switching
to the (semi-regenerative) Technique
to the (semi-regenerative) Technique
Fixed-Bed Technology
Fixed-Bed Technology

Semi-Regenerative (SR) Technique
Semi-Regenerative (SR) Technique

Catalyst life of 7-10 years
Catalyst life of 7-10 years

Regeneration causes the Total Shutdown of System
Regeneration causes the Total Shutdown of System

Regeneration is carried out inside the system
Regeneration is carried out inside the system
Fixed-Bed Technology

Fixed-Bed Technology

Semi-Regenerative (SR) Technique
Semi-Regenerative (SR) Technique
Fixed-Bed Technology
Fixed-Bed Technology

Regenerative (Cyclic) Technique
Regenerative (Cyclic) Technique

Shutting Down is avoided by an Extra Reactor
Shutting Down is avoided by an Extra Reactor

Complex Valve System, Reactor Central Position
Complex Valve System, Reactor Central Position

Modes of Run: (Cyclic) or (Swing)
Modes of Run: (Cyclic) or (Swing)

Catalyst Life of about 5-15 days
Catalyst Life of about 5-15 days

Higher ON for the same Yield, and vice versa
Higher ON for the same Yield, and vice versa

5 Units higher ON than Semi-Regenerative
5 Units higher ON than Semi-Regenerative

“
“

Ultraforming
Ultraforming
”
”
and EXXON
and EXXON
“
“
Powerforming
Powerforming
”
”
Fixed-Bed Technology
Fixed-Bed Technology

EXXON Powerformer
EXXON Powerformer
Moving-Bed Technology
Moving-Bed Technology

Moving-Bed Advantages:
Moving-Bed Advantages:

Higher ON even from difficult feeds
Higher ON even from difficult feeds

All-year run, producing the H
All-year run, producing the H
2
2

that refineries need
that refineries need

Catalysts are less stable over time but more selective
Catalysts are less stable over time but more selective
making it possible to improve yields
making it possible to improve yields

Lower recycle rates, which improve yields and reduce
Lower recycle rates, which improve yields and reduce
operating costs
operating costs

Lower operating pressures which favors reformate
Lower operating pressures which favors reformate
yields and hydrogen production
yields and hydrogen production
Moving-Bed Technology
Moving-Bed Technology

Reactor Configuration:
Reactor Configuration:

“
“
One on the top of the other
One on the top of the other
”
”
, which is carried out by

, which is carried out by
UOP
UOP

“
“
Side by Side
Side by Side
”
”
, which is carried out by IFP
, which is carried out by IFP

UOP regeneration is
UOP regeneration is
“
“
Continuous
Continuous
”
”

IFP can be either
IFP can be either
“
“
Continuous
Continuous
”
”

or
or
“
“
Batch
Batch
”
”
Moving-Bed Technology
Moving-Bed Technology

UOP:
UOP:
“
“
CCR Platformer
CCR Platformer
®”
®”