Fuel 4

FUEL TECHNOLOGY-4
Reforming and Isomerization
Mrs M Mambanda
Introduction
The catalytic cracking involves enhancing the octane
number of the product
 Heavy naphthas are used are typical feed stocks
The reaction is carried out on a catalyst
Reforming reaction produces hydrogen as a by product

which is used elsewhere in the refinery
 Usually Platinum supported on porous alumina is used

as a catalyst
Catalyst activity enhanced using chloride

Cracking Chemistry
Paraffin isomerisation takes place
Naphthene isomerisation also takes place to produce

cycloalkanes
 Cyclo alkanes undergo dehydrogenation to generate aromatics
Dehydrocyclization takes places to convert side chained alkanes

to cyclo alkanes and hydrogen
In summary lower octane number feeds are converted to high

octane products
The reformate thus produced has high octane and aromatics

(benzene, toluene and xylene) content.
Process technology
The feed is mixed with recycled hydrogen
Subsequently, it is heated before sending to reactor
Since the reactions are highly endothermic, several

combinations of reactor + heaters are used.
The products from the final reactor are cooled. Often this is
carried out with heat recovery principle in which heat is
recovered using the fresh feed to the first reactor.
After this, the product mixture enters a phase separator which

separates the hydrogen gas stream from the liquid stream.
The liquid stream from the phase separator is sent
to a debutanizer distillation column that separates
butanes and lower alkanes from the reformate
product.
 The hydrogen produced in the phase separator is
compressed and sent back to the first reactor.
Excess hydrogen generated in the reactions is
taken out as a bleed stream

Catalyst regeneration (not shown in the flow sheet)
needs to be carried out to regain catalyst activity.
This can be in different modes of operation namely
cyclic, semi-regenerative or continuous.
When continuous mode of catalyst regeneration is
carried out (as in UOP continuous catalytic reforming
process), the moving bed designs are used for the
reforming reactor.
Additional complexity in the moving bed reactors
is to enable process intensification to club the
sequence of three reactors + heaters into one
single unit.
Process parameters
 Reactor pressure: 4 – 24 barg
Reactor temperature: 500 – 525 oC
H2/Hydrocarbon molar ratio: 2 – 3

Introduction
The basic principle of Isomerization is to straight chain
alkanes to side chain paraffins. This enhances the octane
number substantially
For instance, n-pentane has an octane number of 61.7
where asiso-pentane has an octane number of 92.3
Usually light naphtha is used as a feed stock

Catalyst
 Platinum base catalysts are used
 AlCl3 is used as a promoter for the catalyst
During reaction, part of the AlCl3 gets converted to HCl
Therefore, completely dry conditions shall be maintained to
avoid catalyst deactivation and corrosion.
Catalytic reaction takes place in the presence of hydrogen
to suppress coke formation

Process technology
Light naphtha and hydrogen (make up) are totally dried
and sent to an isomerisation reactor after pre-heating the
feed mixture in a heat exchanger
Reaction operating conditions: 150 – 200 oC and 17 –
28 barg
Typical conversions: 75 – 80 % for pentanes.

After reaction, AlCl3 is recovered from the product
using condensation or distillation
The basic principle for AlCl3 recovery is that at the
reactor operating conditions, the AlCl3 is in volatile
conditions and is soluble in hydrocarbons
After AlCl3 is recovered from the product, it is sent back

to the reactor along with the make- up AlCl3
Eventually, the product enters a flash drum where bulkly
light ends along with little quantities of HCl are separated
from the liquid product.
The light ends recovered from the flash drum are sent to
an HCl absorber where HCl is absorbed into caustic
solution to generate the light end gases. The light end
gases can be further used for other processes in the
refinery.
The bottom product then enters an HCl stripper where
most of the HCl is stripped from the isomerisation product
rich stream.
The HCl is recycled back to the reactor to ensure good
catalyst activity.
Make-up HCl is added to account for losses

Subsequently, caustic wash is carried out to
remove any trace quantities of HCl
The isomerized product rich stream is then sent
to a fractionators that separates the isomerized
product from the unreacted feed.
The unreacted feed from the fractionators is
sent back to the reactor.

Thank you- 4.2

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FUEL TECHNOLOGY-4

Reforming and Isomerization

 Heavy naphthas are used are typical feed stocks

The reaction is carried out on a catalyst

Reforming reaction produces hydrogen as a by product

 Usually Platinum supported on porous alumina is used

Catalyst activity enhanced using chloride

Naphthene isomerisation also takes place to produce

 Cyclo alkanes undergo dehydrogenation to generate aromatics

Dehydrocyclization takes places to convert side chained alkanes

In summary lower octane number feeds are converted to high

The reformate thus produced has high octane and aromatics

The feed is mixed with recycled hydrogen

Subsequently, it is heated before sending to reactor

Since the reactions are highly endothermic, several

After this, the product mixture enters a phase separator which

to a debutanizer distillation column that separates

butanes and lower alkanes from the reformate

 The hydrogen produced in the phase separator is

compressed and sent back to the first reactor.

Excess hydrogen generated in the reactions is

taken out as a bleed stream

needs to be carried out to regain catalyst activity.

This can be in different modes of operation namely

cyclic, semi-regenerative or continuous.

When continuous mode of catalyst regeneration is

carried out (as in UOP continuous catalytic reforming

process), the moving bed designs are used for the

is to enable process intensification to club the

sequence of three reactors + heaters into one

 Reactor pressure: 4 – 24 barg

Reactor temperature: 500 – 525 oC

H2/Hydrocarbon molar ratio: 2 – 3

The basic principle of Isomerization is to straight chain

alkanes to side chain paraffins. This enhances the octane

For instance, n-pentane has an octane number of 61.7

where asiso-pentane has an octane number of 92.3

Usually light naphtha is used as a feed stock

 Platinum base catalysts are used

 AlCl3 is used as a promoter for the catalyst

During reaction, part of the AlCl3 gets converted to HCl

Therefore, completely dry conditions shall be maintained to

avoid catalyst deactivation and corrosion.

Catalytic reaction takes place in the presence of hydrogen

to suppress coke formation

Light naphtha and hydrogen (make up) are totally dried

and sent to an isomerisation reactor after pre-heating the

feed mixture in a heat exchanger

Reaction operating conditions: 150 – 200 oC and 17 –

Typical conversions: 75 – 80 % for pentanes.

using condensation or distillation

The basic principle for AlCl3 recovery is that at the

reactor operating conditions, the AlCl3 is in volatile

conditions and is soluble in hydrocarbons

After AlCl3 is recovered from the product, it is sent back

light ends along with little quantities of HCl are separated

from the liquid product.

an HCl absorber where HCl is absorbed into caustic

solution to generate the light end gases. The light end