jawad reforming

8/7/2019 jawad reforming

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(Platforming of Naphtha)

CatalyticReforming

By: M.J.Raza

312746

T.S.M Operations


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Things to be Discussed.

Introducing Reforming.

Need of Reforming

The RONc Concept.

What is Knocking???

Reforming Process PFD.

The Reforming Reactions & Catalyst.

The Process Sections & P&IDs.


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Introducing Reforming.

Catalytic reforming is a chemical process used to

convert petroleum refinery Naphtha, typically having

low octane ratings, into high-octane liquid products

called REFORMATE which are components of high-

octane gasoline

As evidence from the name, the term Reforming

Refer to the Rearranging the molecular structure,just like a straight chain paraffin molecule reform to

a branched chain molecule through a chemical

Reaction.


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Need of Reforming.

To increase Octane Number of the

hydro-carbons, which mean decreasing

anti-knocking ability of the fuel in thecombustion engine, which otherwise

tend to damage the vehicle hardware.

To increase the ease of combustion offuel inside the engine .


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The RONc Concept.

Mechanically Octane Number can be

defined as The anti-knocking ability

of fuel in the internal combustionengine, if little knocking in engine,

means fuel is of good RON.

Chemically Percentage by volume ofiso-octane in a mixture of iso-octane

and n-heptane.


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What is Knocking???

For better operation of an engine, it is

necessary that all molecules, burning in the

engine, should be of same fashion, havingequal ignition temperature, because when

spark is provided, all molecules should burn at

same time to give power stroke.


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What is Knocking???

If molecules of varying size enter in thecombustion engine, then small moleculesignite firstly and gives power stroke, whenpiston travel back after power stroke, thenlarge molecules ignite, so piston want to movein reverse direction, hence it creates sound in

engine called knocking. Knocking cause sudden stress on piston

which can damage piston / compression rings.


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Reforming

Process

PFDs


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Reforming Process PFD.

Some terms needed to understand Reformer PFDare:

FBRN: Full Boil Range Naphtha.LSRN: Light Straight Run Naphtha.

HSRN: Heavy Straight Run Naphtha.

HTN: Hydro-treated Naphtha.RON: Research Octane Number.


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The Reforming Reactions.

Following Reaction takes place in

Reforming reactors.

Dehydrogenation. Isomerization

Dehydro-Cyclization

Hydro Cracking


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The Reforming Reactions.


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Dehydrogenation.

This Reaction converts Naphthenes to

Aromatics.

Metal Promoted Reaction. This reaction is highly endothermic.

(+50 Kcal/mol)

Methyl-Cyclohexane (a naphthene) hasRON of 84, when dehydrogenize,

converted to toluene (An aromatic)

which has RON of 107.


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Isomerization

This Reaction converts straight chain

paraffins to branch chain paraffins.

Acid Promoted Reaction. This reaction is also endothermic. Requires

2KCal/mol of energy.

Hexane (n-paraffin) when converted to iso-hexane (iso-paraffin), its octane number

improve from 26 to 73.


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Dehydro-Cyclization

This reaction converts Naphthenes to

Aromatic.

Hydrogen is Removed from Naphthenes. This Reaction is endothermic + 60kCal/mol

and hydrogen is produced

Methyl-cylcohexane converted to toluenegives 107 octane from 84. (Both Metal &

Acid Promoted)


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Hydro-Cracking

In this reaction, large molecules of straight

chain paraffins converted to small chain

paraffins. This reaction consumes hydrogen and is

the only exothermic reaction - 10KCal/mol

occurring in last reactor.

Acid promoted Reaction.


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The Reforming Catalyst.

The Plat-forming catalyst is R-56.

This is a UOP Designed catalyst, in which metals

of Pt & Rh are coated homogeneously over thesurface of Alumina base.

The catalyst is Extrude in shape, just like a rice

grain, having off-white color.

Pt & Rh are most expensive metals. Pt is present 0.25 % and Rh is 0.4 % in catalyst.

The UOP Platforming catalyst has been chosen to

meet yield, activity and stability needs.


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TheReforming

Process.


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Reforming Process Section

Reforming process can be divided into four

inter connected sections:

Splitter SectionHydro-Treating Section

Reforming Section

Stabilizer section.


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Splitter Section

Splitter section is used to control the IBP of

the Reformer feed.

The streams from the Splitter section are:LSRN: (IBP: 31 C, FBP: 91 C)

Solvent Cut: (IBP: 45 C, FBP: 1225 C)

HSRN: (IBP: 96 C, FBP: 158 C)


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Splitter Section

Splitter Top Conditions are:

Temp: 96 C, Pressure: 2.8 Kg/Cm2

Splitter Trays: 50Feed Tray: 37

Splitter Bottom Conditions are:

Temp: 167 C, Pressure: 3.2Kg/Cm2


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Hydro-Treating Section

The Purpose of the section is to remove the

sulphur in the feed.

The reactor is designed to remove max 158ppm of sulphur from the HSRN.

Maximum allowable limit of sulphur to

reforming section is < 0.5 ppm.


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Hydro-Treating Section

The reactor operating condition are:

RIT: 315 C, ROT: 313 C

Pressure: 19 kg/Cm2Reactor Type: Down flow.


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Reforming Section

Plat-forming process consist of

following steps:

Feed Pre-Heating. Reactor Heater assembly.

Cooling of product stream.

Separator


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Feed Pre-Heating Feed pumped through a high pressure

centrifugal pump from Stripper bottom.

Hydrogen comes from Recycle gas

compressor at high pressure. Both hydrogenand feed combined through a line.

The combine feed enters in the exchanger

series, where it is pre-heated through thecounter coming hot product stream. Thisfeed enters in Reformer Heater 1.


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Heater & Reactor A specific ratio of water and chloride is injected

to maintain chloride level over the catalystsurface, which otherwise may change the catalystcomposition.

The Cl injected, not only maintain Cl level oncatalyst, but also promotes acid promotedreactions, because it produces acid environmentin reactor.

The Hot feed after exchanger enters in ReformerFirst Heater where it is heated up-to 500 oC temp.

Hot feed enters in first Reactor. Reactor is Radial

flow.


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Heater & Reactor This feed is heated again in Second heater of

Reformer where temp is again raised to 500 oC

so that reactions can takes place at this designated

temp & then feed enters in 2nd Reactor. Temp again drops as a result of reactions, so feed

is again heated to required temp and passes

through 3rd Reactor. The Hot products stream

cooled through feed/Products exchangers and trimcooler.


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Reaction Conditions Reformer Reactors are operated at 20 Kg pressure

and 500 oC inlet temperature.

System pressure is maintained through separator

(pressure), which operate at 16.1 kg/cm2. Feed passes through reactor with a specific max

rate called LHSV.

A Specific H2 to HC ratio is maintained to setresidence time of feed within the Reactor system.

(H2/HC ratio = 4.5 min)


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Stabilization Section. A pump takes suction from the separator bottom

and send to stabilizer pre-heat exchanger and thento Stabilizer.

Stabilize is a high pressure vessel operates at 19kg pressure.

Purpose of stabilizer is to remove the LPG,formed by hydro-cracking reaction, which isoccurred in last reactor. In this way, Naphthastabilizes and its RVP controlled.


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Stabilization Section. Heated Feed enters in stabilizer feed plate.

The lighter molecules which are formed bybreaking of large chain molecules, travels to topof the tower.

A condenser condenses the LPG heavy endswhich are circulated back in tower to controltower temp and pressure.

The un-condensable molecules are fed as gas tothe fuel gas system.


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The Reformate. The final product from bottom is sent to

condenser and trim cooler for cooling without any

pump, as pressure of stabilizers enough for

transferring this liquid to storage. Final product is named as Reformate, in which

a specific ratio of LSRN is mixed to form PMG.

All Specification of this product are achieved

before marketing.


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Thank you

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