CatalyticReformingfor

AromaticsProduction
TopsoeCatalysisForum
Munkerupgaard,DenmarkAugust2728,2015
GregMarshall
GAMEngineeringLLC

GAMEngineeringLLC 1
 REFINERYCONFIURATION
LPG

GASOLINE BLENDING
ISOMERISATION

NAPHTHA
HYDROTREATING MOTOR
CATALYTIC GASOLINE
REFORMING

ICN

ALKYLATION
CRUDE DISTILLATION (APS/VPS)

JET iC4= AROMATICS

AVIATION
HYDROTREATING FUEL SEPARATION BENZENE
EXTRACTION/ TOLUENE
XYLENES
FRACTIONATION

DISTILLATE BLENDING
DISTILLATE ADO
HYDROTREATING

LUBES
HEATING
OIL

VGO CATALYTIC
FCCU DISTILLATE
HYDROCRACKING/ CRACKING
HYDROTREATING
GOFINING (FCCU)

RESIDUUM FUEL OIL/

PROCESSING GAMEngineeringLLC ASPHALT 2
RoleofCatalyticReforming
MAINPROCESSFORUPGRADINGLOWOCTANENAPHTHASTOHIGHOCTANEGASOLINE
BLENDINGCOMPONENTSORCHEMICALSINTERMEDIATES(BENZENE/TOLUENE/XYLENES)
NUMBEROFIMPORTANTBYPRODUCTS
H2FORHYDROTREATING
C1C2 FORFUELGAS
C3C4 FORLPG
C4'S TOMOGASORALKYLATION(IC4=)
AROMATICSFORCHEMICALS
MODERNCATALYTICREFORMINGDEVELOPEDINTHEEARLY1950'SWITHDEMANDFOR
INCREASEDGASOLINEOCTANE
SIGNIFICANTIMPROVEMENTSOVERTHERMALREFORMING
HIGHEROCTANEANDYIELD
BETTERQUALITY(SULPHUR,DIOLEFINS)
GAMEngineeringLLC 3
ProcessDescription
Naphthafeedstock
TypicalC6toC10
FeedtailoredtothedesiredproductC6toC8isbetter
Fractionatedtoremoveheavyends
Hydrotreatedtoremove
Sulfur
Nitrogen
Olefins
Oxygenates
Metals
Paraffins,naphthenesandaromatics
Combinedwithhydrogenrichrecyclegas
Vaporizedinfeedeffluentheatexchangers
Necessarytobeallvaporbeforeheater
GAMEngineeringLLC 4
ProcessDescriptionContinued
Feedandrecyclegas
Heatedtoreactiontemperatureinfurnace
Introducedtofirstreactor
Desiredreactionsareendothermic
Strongendotherminfirstreactorreachingareactionquench
temperature
Followedby2to4additionalreactorheatercombinations
Entirereactiontraininvaporphase

GAMEngineeringLLC 5
SimplifiedSemiRegenReformer

GAMEngineeringLLC 6
CyclicReforming
TO/FROM
UPPER REACTION HEADER UPPER REGEN HEADER REGEN
CIRCUIT

REACTORS
A B C D A-S S

FIRST SECOND THIRD

REHEAT REHEAT REHEAT
FURNACE FURNACE FURNACE

PREHEAT TO EFFLUENT EXCHANGERS,

LOWER REACTION HEADER
FURNACE SEPARATOR DRUM, ETC.
LOWER REGEN HEADER
HYDROFINED
NAPHTHA
GAMEngineeringLLC 7
FEED
UOPCCRReformer
Regenerator

Cat Flow #1

#2

#3
Regenerated
Catalyst

Hydrogen

Spent Catalyst

Hydrotreated
Start
Naphtha Charge

GAMEngineeringLLC 8
UnitRevamps
Mostdonetostretchexistingunitcapacity
Heaterpreplacementduetocreep
Loweringpressuretoincreaseyields
Changingfeedeffluentexchangers
Purgefromcompressordischarge
Switchingfrommonometalliccatalysttobimetallic
catalyst

GAMEngineeringLLC 9
Catalyst
DualFunction
Acid:Aluminawithchloride
Metal:Ptwithorwithoutpromotermetals(Re,Ir,Sn)
ReprovidescokestabilityandadditionalrunlengthSulfiding required
Ir additionalactivitySulfiding required
Snpromotesyieldatlowcokelevelsnosulfiding required
Supportedongammaalumina
Highsurfacearea
200m2/gmfreshcatalyst
120m2/gmagedcatalyst
Surfaceareadeclinewithexposuretohightemperatureandsteam

Heartofreformingprocess
Promotesgoodreactions
GAMEngineeringLLC 10
Products
SAMEHYDROCARBONTYPESASFEEDBUTPRIMARILYAROMATIC
ANDC7 PARAFFINS
AROMATICSARETHEPRINCIPALSOURCEOFHIGHOCTANE
NAPHTHENESANDC8+PARAFFINSESSENTIALLYABSENTAT98+ RON
LIGHTERPARAFFINSAREMOREBRANCHEDTHANINFEEDBUTARESTILL
PREDOMINATELYSINGLEMETHYLSUBSTITUTEDWITHLOWRON

100 %AromaticsVsRON
98
96
94
RON

92
90
88
86
84
0,0% 20,0% 40,0% 60,0% 80,0%
GAMEngineeringLLC 11
%Aromatics
UnitOptimization
LowpressureandlowH2/HCratiofavor
Higherliquidyields
Higheraromaticyields
Coke
Hightemperaturesfavor
Dehydrogenation
Dehydrocyclization
Hydrocracking
Coke

GAMEngineeringLLC 12
FeedSelection
Highyield Easyfeed
Naphthenicfeeds
ExampleSleipner Condensate
~70%naphthenes
Requirelargereheatfurnaces highendotherms
Highhydrogenandaromaticsyields
LowerYield Moredifficultfeed
Paraffinicfeeds
ExampleLtArabNaphtha
~70%paraffins
Reactorendothermsdecreased
HigherLtendsyields

GAMEngineeringLLC 13
MogasVsAromaticsOperation
Mogasoperation
TargetsC5+RONneededforgasolineblending
Targetcanandwillchangebasedongasolinegradeblended
TypicalRON92to95withshortexcursionsto98asneeded
Aromaticsoperation
Targetmaximumaromaticsconcentrationinreformate
TypicalRONofreformate>98withsomeunitsoperatingupto102
Feedandunittypedependent
Semiregenunitsrequirefrequentregeneration
CyclicandCCRbettersuitedforaromaticsoperation
MinimizeC9nonaromatics

GAMEngineeringLLC 14
YieldversusSeverity
TypicalyieldwithafeedWatsonKof11.8
88

87

86

85

84
C5+Yield

83

82

81

80

79
90 91 92 93 94 95 96 97 98 99 100
RON

GAMEngineeringLLC 15
ExpectedYields
ReformerTypesandYields
95

90

85
C5+Yield

SemiRegen
Cyclic
80 SemiRegen2
CCR

75

70
0 2 4 6 8 10 12 14
Months
AromaticsRecovery
Removelightends
Depentanize viadistillation
Removeheavyends
C8 overheadindistillationtower
CanseparateA8fromA9bydistillation
CannotseparateA8fromP9bydistillation
Azeotropeformed
Mogasand/oraromaticsolvents
C6toC8streamsenttosolventextraction
Raffinate tomogas orspecialtysolvents

GAMEngineeringLLC 17
BTXRecovery
ClayTreater
Fractionation
BZproductO/H
Towerbottomstoanotherfractionator
Tolueneproductoverhead
Towerbottomstoanotherfractionator
ToweroverheadconcentratedParaXylene
SenttoParex forproductionofpurePx
Parex rejectstreamsenttoParaXyleneIsomerazation
Towerbottomssenttoanotherfractionator
ProducesOrthoXylenefromtoweroverhead
Towerbottomssenttomogas

GAMEngineeringLLC 18
AdditionalPx
ProductTolueneisdividedbetweensalesandSTDP
Flowratesdeterminedbyeconomics
STDPFeedsToluene
Majorproductare
Benzene
Paraxylene

GAMEngineeringLLC 19