RELATIVE CATALYST

FOULING RATE

DESIGN

GAS/OIL RATIO SCF/BBL

Figure 3-5. The effect of the gas/oil ratio on the catalyst fouling rate.

where T1 is the bed inlet temperature; T 0 is the bed outlet temperature;

and A1, A2, A3, and A4 are the volume fractions of the total reactor
catalyst in the individual bed. A typical hydrocracker reactor temperature
profile is shown in Figure 3-6.

CATALYST FOULING RATE

The design of a hydrocracker unit is based on a specified conversion

rate of the feed and a specified catalyst life, usually 2-3 years between
catalyst regeneration. During the course of the run, the activity of the
catalyst declines due to coke and metal deposits, and to maintain the
design conversion rate, the temperature of the catalyst has to be increased.
The catalyst manufacturers specify a maximum temperature, called the
end of run temperature, which signifies the EOR condition. When this
temperature is reached, the catalyst must be regenerated or discarded.
The rate of increase in average reactor catalyst temperature (to main-
tain the design conversion rate) with time is called the catalyst fouling
rate. It is an important parameter, used to make an estimate of time when
the EOR conditions are likely to be reached. The refinery keeps a record
of the reactor average temperature with time, starting from the day the
feed is introduced into the reactor after the new catalyst has been loaded.
A graph is drawn between the time on stream vs. the average reactor
temperature (Figure 3-7). The data may show scatter, so a straight line is
drawn through the data. From this curve, an estimate of the catalyst
fouling rate and remaining life of the catalyst can be estimated.