1. Petroleum and Gas Processing(TKK-2136)
14/15 Fall semester
Petroleum and Gas Processing(TKK-2136)
Instructor: Rama Oktavian
Office Hr.: M.13-15, Tu , W , Th , F

2. Outlines 1. Catalytic reforming 2. Reformer configuration
3. Reformer material balance
4. Isomerization

3. Catalytic reforming

4. Catalytic reforming Catalytic reforming process
a catalytic process which converts low octane naphthenic into higher octane reformate products. It is a highly endothermic process requiring large amounts of energy.
the process of transforming C7–C10 hydrocarbons with low octane numbers to aromatics and iso-paraffins which have high octane numbers
gasoline blending and aromatic rich reformate for aromatic production

5. Catalytic reforming
Reformer feed characterization

6. Catalytic reforming FEED PRODUCT Paraffins 30-70 30-50 Olefins 0-2
Reformer feed and product characterization
FEED
PRODUCT
Paraffins
30-70
30-50
Olefins
0-2
Naphthenes
20-60
0-3
Aromatics
7-20
45-60

7. Catalytic reforming Research Octane Number (RON)
the percentage by volume of iso-octane in a mixture of iso-octane and n-heptane

8. Catalytic reforming
Role of reformer

9. Catalytic reforming
Role of reformer
The catalytic reformer is one of the major units for gasoline production in refineries.
It can produce 37 wt% of the total gasoline pool.
Other units
- fluid catalytic cracker (FCC)
- alkylation unit
- isomerization unit

10. Catalytic reforming Reforming reaction
Naphthene Dehydrogenation of Cyclohexanes
Paraffin Dehydrogenation
Dehydrocyclization
Isomerization
Hydrocracking Reactions
Coke Deposition
Reforming reaction network

11. Catalytic reforming
Calculating dehydrogenation reaction

12. Catalytic reforming Reforming reaction
Naphthene Dehydrogenation of Cyclohexanes
Paraffin Dehydrogenation
Dehydrocyclization
Isomerization
Hydrocracking Reactions
Coke Deposition

13. Catalytic reforming Process step in catalytic reforming
Feed preparation: Naphtha Hydrotreatment
removal of the various catalyst poisons - sulfur, nitrogen, halogens, oxygen,
water, olefins, di olefins, arsenic and other metals

14. Catalytic reforming Process step in catalytic reforming
2. Preheating: Temperature Control
3. Catalytic Reforming and Catalyst Circulation and Regeneration incase of continuous reforming process
4. Product separation: Removal of gases and Reformate by fractional Distillation
5. Separation of aromatics in case of Aromatic production

15. Catalytic reforming Classification of process
Semi-Regenerative Fixed Bed reactors
Cyclic Fixed Bed Reformers - Adding an extra-reactor to avoid shutting down the whole unit during regeneration. Three reactors can be running while the forth is being regenerated
Continuous Reformers

16. Catalytic reforming Classification of process
Semi-Regenerative Fixed Bed reactors

17. Catalytic reforming Semi-Regenerative Fixed Bed reactors
Reactions such as dehydrogenation of paraffins and naphthenes which are very rapid and highly endothermic
first reactor

18. Catalytic reforming
Semi-Regenerative Fixed Bed reactors
Reactions that are considered rapid, such as paraffin isomerization and naphthens dehydroisomerization, give moderate temperature decline
second reactor

19. Catalytic reforming
Semi-Regenerative Fixed Bed reactors
slow reactions such as dehydrocyclization and hydrocracking give low temperature decline.
Third reactor

20. Catalytic reforming Classification of process
Semi-Regenerative Fixed Bed reactors

21. Catalytic reforming Classification of process 3. Continuous Reformers
Licensed by CCR Platforming UOP Process
Process description
The catalyst moves downwards by gravity from the first reactor (R1) to the forth reactor (R4)
The catalyst is sent to the regenerator to burn off the coke and then sent back to the first reactor R1
The final product from R4 is sent to the stabilizer and gas recovery section
Process variable
operated at lower hydrogen partial pressure (PH2 = 3 bar)
reformate yield gain of nearly 10 vol%

22. Catalytic reforming
Classification of process
3. Continuous Reformers

23. Catalytic reforming Variable process
Catalyst type – affect basic catalyst formulation (metal-acid loading), chloride level, platinum level, and activator level - The catalyst used for reforming is a bifunctional catalyst composed of platinum metal on chlorinated alumina
Reaction temperature – control the reaction rate and product, usually operates at 560 C, above that temperature will form petroleum coke
Space velocity – higher space velocity will decrease residence time and lower Octane number of product
Reactor pressure – will affect to yield of product or hydrogen formation
Hydrogen/Hydrocarbon ratio

24. Catalytic reforming
Catalyst type
The catalyst used for reforming is a bifunctional catalyst composed of platinum metal on chlorinated alumina.
the centre for the dehydrogenation reaction
Platinum
an acidic site to promote structure changes
- cyclization of paraffins
- isomerization of the naphthenes.
chlorinated alumina

25. Catalytic reforming
Catalyst type
Impurities that might cause deactivation or poisoning of the catalyst include: coke, sulphur, nitrogen, metals and water.
The reformer should be operated at high temperature and low pressure to minimize coke deposition.

26. Catalytic reforming
Process comparison

27. Catalytic reforming Calculating material balance in catalytic reformer
Yield correlations for the reformer were developed as given

28. Catalytic reforming Calculating material balance in catalytic reformer
Example
Solution

29. Catalytic reforming Calculating material balance in catalytic reformer
Solution

30. Isomerization
Isomerization of Light Naphtha
Isomerization is the process in which light straight chain paraffins of low RON (C6, C5 and C4) are transformed with proper catalyst into branched chains with the same carbon number and high octane numbers.
Light naphtha from the hydrotreated naphtha (HTN) C5=80 ˚C is used as a feed to the isomerization unit.

31. Isomerization
Isomerization reaction
Isomerization is a reversible and slightly exothermic reaction:
The conversion to iso-paraffin is not complete since the reaction is equilibrium conversion limited. It does not depend on pressure, but it can be increased by lowering the temperature.
However operating at low temperatures will decrease the reaction rate. For this reason a very active catalyst must be used.

32. Isomerization Two types of isomerization catalysts
The standard Pt/chlorinated alumina with high chlorine content
The Pt/zeolite catalyst

33. Isomerization
Standard isomerization catalysts
This bi-functional nature catalyst consists of highly chlorinated alumina responsible for the acidic function of the catalyst.
Platinum is deposited (0.3–0.5 wt%) on the alumina matrix.
Platinum in the presence of hydrogen will prevent coke deposition, thus ensuring high catalyst activity.
The reaction is performed at low temperature at about 130 ˚C to improve the equilibrium yield.

34. Isomerization
Zeolite catalyst
Zeolites are used to give an acidic function to the catalyst.
Metallic particles of platinum are impregnated on the surface of zeolites and act as hydrogen transfer centres.
The zeolite catalyst can resist impurities and does not require feed pretreatment, but it does have lower activity and thus the reaction must be performed at a higher temperature of 250 ˚C (482 F).

35. Isomerization
Isomerization catalyst comparison

36. Isomerization
Isomerization yield
The reformate yield from light naphtha isomerization is usually very high (>97 wt%).
Typical yields are given in Table

37. Isomerization
Isomerization yield balance

38. Isomerization
Solution
Isomerization yields