Catalytic Reforming 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 Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.



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



Catalytic Reforming Key Considerations for a Reforming Unit Revamp

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