07/04/2021 Catalytic Reforming Processes

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Catalytic Reforming Processes

Catalytic Reforming Processes

Even in the presence of hydrogen during reforming reactions, catalysts are deactivated by coke
deposition. Commercial catalytic cracking processes are classified based on how catalysts are
regenerated, as shown below, as semi-regenerative, cyclic, and continuous reforming processes. The
first commercial catalytic reforming process was introduced by UOP in 1949 as the PlatformingTM
process that used three fixed-bed reactors. Figure 8.4 (on next page), shows a process with two
reactors. The reactors operate in series with furnaces placed before each reactor to heat the feedstock
and the reactor effluents to 500–530°C before entering each reactor because the predominant
reforming reactions are highly endothermic. These units, called “semi-regenerative catalytic reformers,”
need to be shut down once every 6–24 months for the in-situ regeneration of catalysts that are
deactivated by coke deposition. Later designs included an extra reactor (a swing reactor) to enable
isolation of one reactor at a time to undergo catalyst regeneration, whereas the other three reactors are
running (Cyclic). This configuration enables longer on-stream times (up to 5 years) before scheduled
shutdowns for catalyst regeneration, but it has not become popular. In the HYSYS Project 2, you will be
comparing the performance of the three different configurations of catalytic reforming processes.

Catalytic Reforming Processes

Catalytic Reforming Processes Based on Catalyst Regeneration

1. Semi-regenerative (1949) – unit taken off-stream anywhere from every 3 to 24 months

2. Cyclic (1960) – involves swing reactor. Basically, operate 3 out of 4 and use extra reactor to take
one offline.
3. Continuous (1971) – catalyst is removed and replaced during the operation. Maintains high
activity. Expensive.

Licenced Processes (differences in catalysts and reactor configurations)

1. Platforming (UOP process) (1949)

2. Powerforming (Exxon)
3. Ultraforming (Amoco)
4. Catalytic Reforming (Engelhard)
5. Magnaforming (Arco)
6. Reforming (IEP)
7. Rheniforming (Chevron)

Continuous Catalyst Regeneration

Continuous Catalyst Regeneration

A continuous catalyst regeneration (CCR) scheme for reforming came on stream in 1971. Figure
8.5 shows a flow diagram for the CCR process. The reactors are stacked with a moving bed of catalyst
trickling from the top reactor to the bottom reactor by gravity. Partially deactivated catalyst from the
bottom of the reactor stack is continuously withdrawn and transferred to the CCR regenerator. The
regenerated catalyst is re-injected to the top of the first reactor to complete the catalyst circulation
cycle. Hydrotreated naphtha feed is combined with recycled hydrogen gas and heat exchanged with the
reactor effluent. The combined feed is then raised to the reaction temperature in the charge heater and
sent to the first reactor section. Because the predominant reforming reactions are endothermic, an
inter-reactor heater is used to reheat the charge to the desired reaction temperature before it is

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introduced to the next reactor. The effluent from the last reactor is heat exchanged with the combined
feed, cooled, and separated into vapor and liquid products in a separator.

Figure 8.4. A semi-regenerative catalytic reforming process.

Source: Dr. Semih Eser

The vapor phase is rich in hydrogen gas, and a portion of the gas is compressed and recycled back to
the reactors. Recycling hydrogen is necessary to suppress coking on the catalysts. The hydrogen-rich
gas is compressed and charged together with the separator liquid phase to the product recovery
section. The performance of the unit (i.e., steady reformate yield and quality) depends strongly on the
ability of the CCR regenerator to completely regenerate the catalyst. In addition to UOP’s Platforming
process, the major commercial catalytic reforming processes include PowerformingTM (ExxonMobil),
UltraformingTM and MagnaformingTM (BP), Catalytic Reforming (Engelhard), Reforming (IFP), and
RheniformingTM (Chevron).

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Figure 8.5. A continuous catalytic reforming process.

Click here for a text description of Figure 8.5
Source: Dr. Semih Eser

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