Scribd Logo
Upload

Welcome to Scribd!

  • 255 views

    Catalytic Reforming Process

    Uploaded by

    Siddesh Patil
    Catalytic reforming is a process that converts low octane petroleum naphthas into high octane liquid reformates. It involves reactions like dehydrogenation, isomerization, and dehydrocyclization over platinum catalysts. The Platforming process is a commercial catalytic reforming technology developed by UOP. It uses platinum-based catalysts to promote reactions at high temperatures and pressures. The Continuous Catalyst Regeneration version of Platforming overcomes issues like rapid catalyst deactivation through continuous regeneration of the catalyst externally.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Catalytic Reforming Process

    Uploaded by

    Siddesh Patil
    255 views28 pages
    Catalytic reforming is a process that converts low octane petroleum naphthas into high octane liquid reformates. It involves reactions like dehydrogenation, isomerization, and dehydrocyclization over platinum catalysts. The Platforming process is a commercial catalytic reforming technology developed by UOP. It uses platinum-based catalysts to promote reactions at high temperatures and pressures. The Continuous Catalyst Regeneration version of Platforming overcomes issues like rapid catalyst deactivation through continuous regeneration of the catalyst externally.

    Original Title

    Catalytic Reforming Process (1)

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Catalytic reforming is a process that converts low octane petroleum naphthas into high octane liquid reformates. It involves reactions like dehydrogenation, isomerization, and dehydrocyclization over platinum catalysts. The Platforming process is a commercial catalytic reforming technology developed by UOP. It uses platinum-based catalysts to promote reactions at high temperatures and pressures. The Continuous Catalyst Regeneration version of Platforming overcomes issues like rapid catalyst deactivation through continuous regeneration of the catalyst externally.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    255 views28 pages

    Catalytic Reforming Process

    Uploaded by

    Siddesh Patil
    Catalytic reforming is a process that converts low octane petroleum naphthas into high octane liquid reformates. It involves reactions like dehydrogenation, isomerization, and dehydrocyclization over platinum catalysts. The Platforming process is a commercial catalytic reforming technology developed by UOP. It uses platinum-based catalysts to promote reactions at high temperatures and pressures. The Continuous Catalyst Regeneration version of Platforming overcomes issues like rapid catalyst deactivation through continuous regeneration of the catalyst externally.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 28

    Catalytic Reforming Process

    Introduction

    ● Catalytic reforming is a chemical process used to convert petroleum refinery naphthas distilled
    from crude oil (typically having low octane ratings) into high-octane liquid products called
    reformates which are premium blending stocks for high-octane gasoline.

    ● The process converts low-octane linear hydrocarbons (paraffins) into branched alkanes
    (isoparaffins) and cyclic naphthenes, which are then partially dehydrogenated to produce high-
    octane aromatic
    Catalytic Reforming Unit
    Catalytic Reforming Unit
    Reforming Reactions
    ● Dehydrogenation
    ● Isomerization
    ● Hydrogenation of un-saturates
    ● Paraffin de-hydrocyclisation
    ● Naphthene isomerisation and dehydrogenation
    ● Cracking
    ● Hydrodesulfurization
    ● Denitrogenation
    ● Deoxidation
    Reforming Reactions
    The four major catalytic reforming reactions are:
    1. The dehydrogenation of naphthenes to convert them into aromatics as exemplified in the conversion
    methylcyclohexane (a naphthene) to toluene (an aromatic)

    2. The isomerization of normal paraffins to isoparaffins as exemplified in the conversion of normal octane to 2,5-
    Dimethylhexane (an isoparaffin)
    Reforming reactions
    3. The dehydrogenation and aromatization of paraffins to aromatics (commonly called dehydrocyclization) as
    exemplified in the conversion of normal heptane to toluene:

    4. The hydrocracking of paraffins into smaller molecules as exemplified by the cracking of normal heptane into
    isopentane and ethane,
    Purpose of Catalytic Reforming

    Purpose of reforming process is to produce:


    ● high octane reformate, which is a main component of motor fuel,aviation gasoline blending or
    aromatic rich feedstock.
    ● Hydrogen rich gas
    ● Due to the nature of reactions, reforming process produces also
    ○ LPG-FG-600 psig steam with waste heat reboilers.
    Feed

    Reformer feed:
    ● Low quality straight run naphtha.
    ● Or cracked naphtha, generally mixed with straight run naphtha.
    ● Feed should be free from impurities like sulfur, nitrogen and oxygen compounds
    ● For Pt based catalysts, sulfur and nitrogen content < 5 ppm.
    Reaction conditions
    Process Variables:
    ● Reactor Temperature
    ● Pressure
    ● Space Velocity
    ● Hydrogen/Hydrocarbon ratio
    ● Feedstock characteristics

    Typical operating parameters (from economic operation):


    • Low pressure (10 – 50 atm)
    • High temperature ( 450 – 500 C)
    • High H2 recirculation (H2/HC ratio)
    • High catalyst to feed ratio (effects on space velocity)
    Catalyst

    ● The catalyst affects reaction rates through its two different functions/type of sites:
    ○ Metallic
    ○ Acidic

    ● Different types of reactions are promoted by these sites as:


    Catalyst

    Some examples of catalysts used:


    ● ZSM – 5 (Zeolite Socony Mobil – 5)
    ● R-132 (UOP) (Pt based)
    ● Cr oxide and Mb oxide on alumina
    ● Bauxite and clay catalysts were used in earlier days
    ● Pt combination with other metals are also being used
    Catalytic reforming technologies

    Different commercial catalytic reforming processes:

    ● Platforming (UOP) – 1949


    ● Rheinforming (Chevron)
    ● Powerforming (Exxon)
    ● Ultraforming (Amoco)
    ● Catalytic reforming (Engelhard)
    Platforming process

    1)In the Platforming process, light petroleum distillates (naphtha) is contacted with a platinum-containing catalyst at
    elevated temperatures and hydrogen pressures ranging from 345 to 3450 kPa.

    2)Originally developed to upgrade low-octane-number straight-run naphtha to high-octane motor fuels

    3)The process has since been applied to the production of LPG and high purity aromatics.

    4)The first Platforming units were designed as semi regenerative (SR),Semi Regenerative Platforming units are periodically
    shut down to regenerate the catalyst. This regeneration includes burning off catalyst coke and reconditioning the catalyst’s
    active metals.

    .
    Platforming process
    Platforming process
    Uniqueness and specificness -

    1. Reactions- dehydrogenation,isomerization,dehydrocyclization, and cracking.

    The reactions are promoted by two kinds of active sites on the catalyst, acidic and metallic.
    Platforming Process

    2. Heat of reactions
    Platforming process
    3. Catalyst -
    I) Platforming catalysts are heterogeneous and composed of a base support material (usually Al2O3) on which catalytically
    active metals are placed. The first Platforming catalysts were monometallic and used platinum as the sole metal.

    II) UOP introduced bimetallic catalysts in 1968. These catalysts contained platinum and a second metal, rhenium, to meet
    increasing severity requirements. Catalyst metals are typically added at levels of less than 1 wt % of the catalyst

    III) To develop the acid functionality of the catalyst, a promoter such as chloride or fluoride is added. Most catalyst
    development for SR Platforming has followed the path of maximizing the efficiency and balance of the metal and acid
    functionalities of the catalyst system.
    CONTINUOUS PLATFORMING PROCESS
    ● Improvements in the catalyst and process could not keep up, and the need to regenerate catalyst at shorter and
    shorter intervals became a serious limitation of the SR Platforming units. UOP developed the CCR Platforming
    process to overcome this limitation.
    ● In the CCR Platforming unit, partially coked catalyst in the reactors is continuously replaced with catalyst that has
    been freshly regenerated in an external regenerator (CCR section) to maintain a low average coke for the reactor
    catalyst.
    CONTINUOUS PLATFORMING PROCESS
    CONTINUOUS PLATFORMING PROCESS
    CONTINUOUS PLATFORMING PROCESS
    Advantages of CCR Platforming-

    1)The CCR Platforming unit has the highest possible yields because it is capable of the lowest possible pressure operation.
    If operated at the same conditions, the SR Platforming catalyst is completely deactivated after only a few days of operation.

    2)CCR Platforming units have higher on-stream efficiency and are able to handle upset scenarios without long-term
    shutdown or significant decline in performance.

    3)Since the catalyst is not regenerated in situ, the reactor section operates only in its primary function of providing the
    catalytic environment for the reforming reactions.
    CONTINUOUS PLATFORMING PROCESS
    Rheinforming (Semi regenerative process)
    Challenges
    Platforming
    CHALLENGES FACED:
    1)Lots of fire heaters required as most of the reactions which occur are endothermic

    2) The increased coking of the catalyst at the higher severity limits the operating run length and the ability to further reduce
    pressure.
    3) Fixed- bed catalyst stability was an issue in the first process due to coking of the catalyst.
    4) The sensitivity of catalytic reforming to contamination by sulfur and nitrogen.
    5) The platformate has a much higher content of benzene than is permissible by the current regulations in many countries.
    Challenges
    SOLUTIONS:

    1)Heat Integration- Effluent from the last reactor exchanges heat with the feed for maximum heat recovery.
    2) Catalyst development alone could not solve these problems; process innovations were needed. In the 1960s, cyclic
    reforming was developed to sidestep this barrier. Cyclic reforming employs fixed-bed reforming, but the reactors can be
    individually taken off-line, regenerated, and then put back into service without shutting down the unit and losing production.
    3) The inception of CCR Platforming ( Continuous Catalyst Regeneration) was done in 1971. The process employs
    continuous catalyst regeneration in which catalyst is continuously removed from the last reactor, regenerated in a
    controlled environment, and then transferred back to the first reactor. With continuous regeneration, coke laydown is no
    longer an issue because the coke is continuously burned off and the catalyst is reconditioned to its original performance.
    The CCR Platforming process has enabled ultra low-pressure operations at 345 kPa (50 lb/in2 gage) and produced product
    octane levels as high as 108.
    Challenges
    SOLUTIONS:

    4) Hydrotreating the naphtha before it enters the reformer, adding to the cost and complexity of the
    process.
    5) The reformate should either be further processed in an aromatics extraction unit, or blended with
    appropriate hydrocarbon streams with low content of aromatics.

    You might also like