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    CPT - Lecture 9 - Oil Refinery - 2022

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    Anjan Kumar
    The document discusses various processes involved in oil refining, including catalytic cracking, catalytic reforming, and flexi-coking. It focuses on catalytic reforming, describing it as a key process for producing high-octane gasoline and aromatics. Catalytic reforming involves the rearrangement of hydrocarbons through reactions such as dehydrogenation of naphthenes to aromatics. Early processes like semi-regenerative reforming used multiple fixed-bed reactors at high pressure, while later continuous regenerative reforming uses a circulating catalyst at low pressure to allow for continuous regeneration and minimize coking.

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    CPT - Lecture 9 - Oil Refinery - 2022

    Uploaded by

    Anjan Kumar
    35 views28 pages
    The document discusses various processes involved in oil refining, including catalytic cracking, catalytic reforming, and flexi-coking. It focuses on catalytic reforming, describing it as a key process for producing high-octane gasoline and aromatics. Catalytic reforming involves the rearrangement of hydrocarbons through reactions such as dehydrogenation of naphthenes to aromatics. Early processes like semi-regenerative reforming used multiple fixed-bed reactors at high pressure, while later continuous regenerative reforming uses a circulating catalyst at low pressure to allow for continuous regeneration and minimize coking.

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    The document discusses various processes involved in oil refining, including catalytic cracking, catalytic reforming, and flexi-coking. It focuses on catalytic reforming, describing it as a key process for producing high-octane gasoline and aromatics. Catalytic reforming involves the rearrangement of hydrocarbons through reactions such as dehydrogenation of naphthenes to aromatics. Early processes like semi-regenerative reforming used multiple fixed-bed reactors at high pressure, while later continuous regenerative reforming uses a circulating catalyst at low pressure to allow for continuous regeneration and minimize coking.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    35 views28 pages

    CPT - Lecture 9 - Oil Refinery - 2022

    Uploaded by

    Anjan Kumar
    The document discusses various processes involved in oil refining, including catalytic cracking, catalytic reforming, and flexi-coking. It focuses on catalytic reforming, describing it as a key process for producing high-octane gasoline and aromatics. Catalytic reforming involves the rearrangement of hydrocarbons through reactions such as dehydrogenation of naphthenes to aromatics. Early processes like semi-regenerative reforming used multiple fixed-bed reactors at high pressure, while later continuous regenerative reforming uses a circulating catalyst at low pressure to allow for continuous regeneration and minimize coking.

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    © All Rights Reserved
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    of 28

    Lecture – 9 and 10 - (Oil

    refining)
    Chemical Process Technology
    (CHE F419)

    BITS Pilani, Pilani Campus


    To start with…..

    • Recap
    • Catalytic Reforming
    • Winding up with Oil refinery portion

    BITS Pilani, Pilani Campus


    To start with…..

    Table 1
    Carbon 83-87%
    Hydrogen 10-14%
    Nitrogen 0.1-2%
    Oxygen 0.1-1.5%
    Sulfur 0.5-6%
    Metals < 0.1%

    BITS Pilani, Pilani Campus


    Catalytic Cracking process

    • Most important catalytic processes in the oil


    refinery, in terms of throughput,
    1. Fluid catalytic cracking (FCC)
    2. Hydro treating,
    3. Hydro cracking
    4. Catalytic reforming
    5. Alkylation

    BITS Pilani, Pilani Campus


    BITS Pilani, Pilani Campus
    Revisiting – Flexi coking
    process
    • Explain the flexi-coking process.
    • What are process conditions (Temperature and
    Pressure) for the overall process?
    • How is the fluidized conditions maintained in the
    flexi-coking process?
    • Why is heater provided in between reactor and gasifier in
    the flexi-coking process?
    • How is the heat of reaction maintained in the process?
    • Design the flexi-coking process based on the Exxon ?
    • Explain the pollution abatement techniques in the
    flexi-coking process.

    BITS Pilani, Pilani Campus


    Revisiting – FCC process

    • Why is FCC process called as heat balanced process?


    • Explain the fluidization concept with regard to the FCC
    process?
    • Why is riser utilized in the FCC process?
    • Design the complete FCC process with reactor,
    regenerator, abatement technique, and the product
    streams.
    • Why is ESP designed in the overall process flow sheet of
    the FCC process?

    BITS Pilani, Pilani Campus


    Catalytic reforming

    • Catalytic reforming is a key process in the

    • production of gasoline components with a high octane


    number

    • Also plays an important role in the production of aromatics


    for the chemical industry

    • Furthermore, catalytic reforming is a major source of


    hydrogen

    BITS Pilani, Pilani Campus


    Component Feed Product
    Paraffin 30 -70 30 -50
    Catalytic reforming
    Olefins 0–2 0–2
    Napthenes 20 -60 0–3
    • Feed stocks: Aromatics 7 - 20 45 - 60
    • naphtha and feeds in the gasoline boiling range
    (about C6 – C11)
    • Heavy straight run gasoline
    • Heavy straight run naptha
    • Heavy hydrocracker naptha

    • Products:
    • Transforms low octane naphtha into high-octane motor gasoline
    blending stock and
    • aromatics rich in benzene, toluene, and xylene with hydrogen
    • and LPG gas as a byproduct

    BITS Pilani, Pilani Campus


    Catalytic reforming

    • Octane no.:
    • Octane number is a measurement of antiknock characteristics of
    fuels

    • Among the same carbon number compounds, the order of Octane


    Number ) Paraffins < Naphthenes < Aromatics
    • Branched paraffins also have high octane no. & it increases with
    degree of branching

    • With the fast growing demand in aromatics and


    demand of high - octane numbers,
    • catalytic reforming is likely to remain one of the most important unit
    processes in the petroleum and petrochemical industry
    BITS Pilani, Pilani Campus
    So what happens in
    catalytic reforming

    • change in molecular weight of the feed is


    relatively small, as the process mainly involves
    internal rerargagenent of dhyroracbons

    • rearrangement of hydrocarbons

    BITS Pilani, Pilani Campus


    • Dehydrogenation of naphthenes to aromatics
    • De hydro cyclisation of paraffins to aromatics
    • Highly endothermic, very high reaction rates
    • Isomerisation of paraffins and naphthenes
    • Endothermic, slightly exothermic
    Catalytic reforming:
    Reactions
    Desirable
    • Dehydrogenation of naphthenes to aromatics
    • Iso merisation of paraffins and naphthenes
    • De hydro cyclisation of paraffins to aromatics

    Undesirable
    • Hydro cracking of paraffins to coke
    • Hydro de alkylation of aromatics such as
    toluene and ethyl benzene

    BITS Pilani, Pilani Campus


    Thermodynamically favorable reaction
    conditions
    • At atmospheric pressure,
    thermodynamically
    attainable conversion is essentially
    100% at temperatures over 620 K

    • At higher pressure much higher


    temperatures are required for high
    conversions

    BITS Pilani, Pilani Campus


    Reforming process

    • Most important issue in the development of a catalytic


    reforming process is to find a tradeoff

    • between optimal octane number and product yield


    (low hydrogen pressure) and optimal catalyst stability,
    i.e minimal coke formation (high hydrogen pressure
    optimal)

    • Two main types of processes applied in catalytic


    reforming are
    • semi-regenerative reforming (SRR) and
    • continuous-regenerative reforming (CRR)

    BITS Pilani, Pilani Campus


    Flow sheet development

    Feed: Naptha
    Operating conditions: 720 K & 25 – 30 bar
    Catalysts: Al Cl3 based catalyst
    A typical catalytic reforming unit consists of a feed
    system, several heaters, reactors in series, and a flash
    drum.

    BITS Pilani, Pilani Campus


    Flow sheet development

    Feed: Naptha
    Operating conditions: 720 K & 25 – 30 bar
    Catalysts: Al Cl3 based catalyst
    A typical catalytic reforming unit consists of a feed
    system, several heaters, reactors in series, and a flash
    drum. Part of the flashed hydrogen is recycled to the
    feed before it enters the first heater, while the liquid is
    sent to the fractionation section (stabilizer). The
    reformate is obtained as a bottoms product from the
    stabilizer. Off-gas and liquefied petroleum gas (LPG) are
    recovered from the top of the stabilizer

    BITS Pilani, Pilani Campus


    Semi-regenerative
    reforming (SRR)

    BITS Pilani, Pilani Campus


    Semi-regenerative
    reforming (SRR)
    1. Since most of the reforming
    reactions are endothermic, several
    heaters are used to maintain the
    reactor temperature at the desired
    levels (400 to 500°C)
    2. As the feed flows through the
    catalytic bed in the reactor, the
    major reaction is the
    dehydrogenation of naphthenes to
    aromatics, which is fast and highly
    endothermic, resulting in a large
    decrease of temperature within the
    reactor
    3. Product from the first reactor is
    reheated and fed to the following
    reactor

    BITS Pilani, Pilani Campus


    • SRR units consist of several (three to four) adiabatic fixed bed reactors in series with
    intermediate heating

    • Feed is preheated and sent to the first reactor


    • In this reactor the kinetically fastest reactions occur
    • These are the dehydrogenation reactions of naphthenes to aromatics
    • To maintain high reaction rates, product gases are reheated in a furnace before
    being sent to a second reactor, and so on
    • Early SRR units (∼1950) were operated at relatively high pressure (25–35 bar) in
    order to maximize catalyst life (higher hydrogen pressure minimizes the coke
    formation)

    • Development of improved catalysts that had a lower tendency for coke formation
    enabled operation at lower pressure (15–20 bar), while maintaining the same catalyst
    life (typically one year).
    Catalytic reforming

    • For further reduction of the operating pressure


    • to improve the product octane number and
    • the yield on liquid products and hydrogen,

    • Only catalyst development was not


    sufficient
    • Therefore, _________innovations were
    needed

    BITS Pilani, Pilani Campus


    Fully-regenerative
    reforming
    • 1960s, fully-regenerative or cyclic regenerative reforming was
    developed

    • This technology employs fixed bed reactors, but an


    additional “swing” reactor is present

    • It is thus possible to take one reactor off line, regenerate the


    catalyst, and then put the reactor back on line

    • In this way regeneration is possible without taking the


    reforming unit off stream and losing production

    BITS Pilani, Pilani Campus


    Continuous regenerative reforming
    (CRR)

    • With a moving catalyst bed, which enabled continuous regeneration


    of the catalyst, that is, the CRR process

    • Process, introduced by UOP and IFP, enabled the use of a much


    lower operating pressure (3–4 bar), since coke deposits were no
    longer such an issue, as they were continuously being burned off

    BITS Pilani, Pilani Campus


    Continuous regenerative reforming
    (CRR)

    • Regenerated catalyst enters the first reactor at the top


    • Catalyst withdrawn from the bottom enters the next
    reactor, and so on
    • Catalyst from the fourth reactor is sent to the
    regenerator
    • continuous flow of catalyst particles is crucial for this
    system

    BITS Pilani, Pilani Campus


    http://what-when-how.com/petroleum-refining/the-catalytic-reforming-process/

    BITS Pilani, Pilani Campus


    Catalytic reforming

    • Processes have developed with time & operating pressures have


    reduced due to development of catalysts as coke formation has been
    reduced even operating at higher temperature but medium pressure

    BITS Pilani, Pilani Campus


    Catalytic reforming:
    Process
    1. Feed preparation: Naphtha Hydro treatment
    2. Preheating: Temperature Control
    3. Actual process: Catalytic Reforming
    4. Catalyst Circulation and Regeneration in case
    of continuous reforming process
    5. Product separation: Removal of gases and
    Reformate by fractional Distillation
    6. Separation of aromatics in case of Aromatic
    production

    BITS Pilani, Pilani Campus

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