CATALYTIC

REFORMING
CONTENTS PAGE

INTRODUCTION

HOW TO USE THE PROGRAM MATERIALS , . . .. . . . . . . . . . .. . . . . . . ii

HOW TO u·se THE SELF�TEACHING FRAMES .. ' ... ' .......... ' . ' iii

SAMPLE FRAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Workbook Period 1 . . . . . . , .. , , ......... , .. , ...... , .... , . . . . 1

Characteristics of Hydrocarbons, The Reforming Reactions. The
Catalyst

Workbook Period 2 , , . . . . . , . . _ . . _ _ _ _ . . . . . . . _ . . _ . . _ . . . . . _ 13
Reformer Equipment, Regenerating the Catalyst

Workbook Period 3 . . . . . .. . . .
_ . . . . . . . . . . . . . . . . . . . . . 27
Operating Variables in the Catalytic Reforming P rocess,
Instrumentation and Control

Workbook Period 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operator Duties, Sampling and Testing, Daily Inspections,
A bnormal Operating S i tuations

Review and Self-Test . . . . . . . . . . . . _ . . . . . , . . . . . . . _ . . .. , . . . . . . . . . . . 57

SHOWING THE PROGRAM . . . . . . . . . . . . . . . . _ . . . , . . . _ . . . . . . . . . . . . 63

 INTRODUCTION

Catalytic reforming is a process that converts a row octane feed into a high octane product called reformate. This is
accomplished through a series of chemical reactions which rearrange the structure of hydrocarbon molecules. The
reformate product is generally used as a gasoline blending component or as a feedstock for petrochemical opera·
lions.

This program is a basic course on how the process works. We'll show you the equipment that makes up a reformer
unit and describe its operation. You will also ream how the unit is operated to maximize product yields and quality.
Finally, we'll discuss what an operator's duties are on a catalytic reformer.

Before starting the program, read "HOW TO USE THE PROGRAM MATERIALS" and "HOW TO USE THE SELF·
TEACHING FRAMES" on the following pages.
 HOW TO USE THE PROGRAM MATERIALS

First, you watch and listen to the audio-visual part of the program that runs for about five minutes. Then.
you tum to an exercise in the workbook, as indicated by instructions given in the taped narration.

The workbook introduces you to new learning material and reviews what you learned in the audio-visual
segment, Once you have finished working and reviewing the workbook material. instructions in the workbook
tell you to start the next part of the audio-visual program.

Going from the audio-visual material into the workbook and back to the audio-visual material again helps
you apply what you are learning. This instruction method also reinforces impartant information, so you can
feel that you know one piece of information before you go on to learn another piece.

Here is how instructions in the workbook are arranged:

• !NS'j:Rt)'CtiON� TEI;�NG YO� TO T�·

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wo� !'Rcisi,i::M� 1N T1JE w��iss<;>qiC
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Most workbook exercises will follow this outline:

1. You view part of the audio-visual program.

2. The taped narration tells you to stop the audio-visual equipment.

3. In the workbook. you read over several vocabulary words until you are familiar with them.

4. You read a short paragraph that introduces some new learning material.

6. At the end of the workbook period, you work a short review. The review questions are a self-test for
your benefit so you can check your learning progress.

7. After the review. you view the next part of the program.

This program is available in several different video formats. Before you start the program. you should get
instructions from the person who administers your training on how to use your video equipment if you will be
operating it.

!"OW; RE.AD "HOW TO t::!SE THE SELF­

T� <'.HIN� 'FRAMES,.. ON ffj,E NEXT
FA<;<�.

ii
 HOW TO USE THE SELF·TEACHING FRAMES

The workbook questions and problems included in the new learning material are written in a series of self-teaching
"frames." Each frame gives you some information and asks you to make use of it Or, the frame refers to a drawing
and asks questions or poses a problem about it

Self-teaching frames are divided into two columns. The left-hand column on the page has the learning material. You
read this material first The right-hand column has the correct response or responses for the frame. You read the
right-hand column after you write in or select a correct answer to the frame.

Here's an example.

The material to learn or read is always on the left-hand side of

the page. Answers are on the right-hand side.

You should cover up the (right-/ left-} hand side ol the page. right-

It's important to know that self.teaching frames are not a test They are a way to help you learn faster and more
effectively. You learn the correct response to each frame before you move to the next frame and learn additional
material.

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iii
 SAMPLE FRAMES

Read this frame and use the information it gives to fill in the blank. Cover the right-hand column.

A micrometer is an instrument designed to measure in

thousandths of an inch.

A micrometer is a good tool for measuring very

______ differences in size. small

Move the mask down to uncover the word at the right of the frame. If you filled the blank with "small" or a word
that means the same, go to the next frame.

This drawing of a micrometer provides information that will

help you fill in the blanks.

OBJECT
TO BE
MEASURED

Seven major parts are shown in the drawing, but only the
and the contact the anvil; spindle
object to be measured.

iv
The next sample frame calls for a choice. Circle or underline the appropriate word.

Of the two parts that contact the object. only the ( anvil I
spindle) moves. spindle

The self-teaching frames in the workbook will be similar to the frames you just worked. Remember to cover the
response column with the cardboard mask.

Read the frame.

Use the information, a set of drawings, or information you have already learned to fill in the blanks or make
a choice.

Move the mask down and check the response column.

Go on to the next frame.

Be sure that you write in all your answers. This helps you learn more than if you just think about the correct
answer for each frame,

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 ------- -- ------ -------- ------- --- ----- - ------- ---- ---

WORKBOOK PERIOD
NUMBER 1

VOCABULARY Re� 9ver th� definition� until YOIJ are familiar v,oi1;h them
.. ·

� .....
_-,. .

HYDROCARBON - a molecule made up of hydrogen and carbon atoms. Crude oil is

composed of a variety of hydrocarbons that have bonded together
in different sizes and shapes.

HYDROCARBON SERIES - hydrocarbons are normally grouped into four major series or
classes. These include paraffins, olefins, naphthenes, and aromat­
ics. The hydrocarbons within each class are structured alike and
have many of the same characteristics.

CATALYST - a substance that facilitates or causes a chemical reaction but is not

itself changed by that reaction. Reforming catalysts are usually
made of platinum or of platinum-rhenium on an alumina base.

CATALYTIC REFORMING FEED
- feed to a reformer is usually a straight run naphtha that has been
produced by distillation of crude oil. Naphthas from other processes
such as thermal cracking, coking, and hydrocracking can also be
used as feedstocks. The naphtha feed generally contains a high
concentration of paraffins and naphthenes which have a low octane
rating.

CATALYTIC REFORMING
- a process which uses heat, pressure, and a catalyst to convert a
low octane naphtha into a high octane product called reformate.
Chemical reactions that take place in the catalytic reforming pro­
cess rearrange the structure of hydrocarbon molecules. The most
important reactions convert paraffins and naphthenes into aromatic
compounds.

I �'i'o�NEXTP;\qi;:,
.

1
 REFORMATE - the main catalytic reforming product. The reformate is primarily
composed of aromatic hydrocarbons like benzene, toluene, and
xylene that have a high octane rating. Reformate is normally used
as a gasoline blending component or as a feedstock for petrochem­
ical operations.

OCTANE NUMBER - a measure of the antiknock quality of a gasoline. Knocking occurs

in an engine when gasoline in a cylinder ign�es at the wrong time.
This is usually an indication that the gasoline octane rating is too
low. Different types of engines have different octane requirements.
Powerful engines with high compression ratios require high octane
fuels. Gasoline is blended in the refinery to meet specific octane
requirements for different grades of fuel.

... -- .

NEW LEARNING MATERIAL

. . :, . ,.

Work the self-teaching frames starting on the next page. Be sure to use the cardboard mask to cover the response
column on the right-hand side of each page.

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Introduction
1. In the audio-visual segment we said that crude oil is com­
posed of hydrogen and carbon atoms that have bonded
together to form molecules. hydrocarbon

2. The composition of a hydrocarbon molecule can be repre­

sented with a structural formula like this.

H H H H
I I I I
H-C-C-C-C-H
I I I I
H H H H

BUTANE

This butane molecule contains four atoms carbon

and ten atoms. hydrogen

3. Another way to represent hydrocarbons is with a chemical

formula.

C.H1•

HEXANE

This molecule of hexane is made up of carbon 6

atoms and hydrogen atoms. 14

4. The hydrocarbons in crude oil are arranged in a variety of

different shapes and sizes. This chart shows the chemical
formulas for some of these hydrocarbons.

�lin"9 Temp;
(� 14.7 !'$If<)

- .
. ' - '"" ..,.,

"��-124�1-�-�- ·�

Heptane,,,
,
c;fi�
··� - '
.,:zo_9.2�.F '• .�.
2PSIA
..... ;;!-•
,,, ...:..,,.
• • ' '-'•""

You can see that different size hydrocarbons have (the same I
different ) characteristics. different

3
 5. Propane, the smallest or lightest hydrocarbon listed, has the
highest ------ vapor pressure

6. Heptane, the heaviest hydrocarbon on the list, has the highest

boiling temperature

7. So, the characteristics of a particular hydrocarbon are

affected by its ------ size

8. The shape or structure of a hydrocarbon also affects its

characteristics.

• NORMAL PENTANE ISOPENTANE ,

. (C,H,J . (CJ:l,J' j' .

H H ff H H
L I I ·I I
H'"-C-C-C-'C-C-H
I I
. I. I I
H H H H H

ti0rnm1 Pentane . 1sopii'ntane

. .
'
' .

Boiling Temp. a1 14.7 PSIA 96.9°F 82.1°F

· '

Vapor Press. at 100°F 1 6 PSJA .20 PSIA

Density 1.935 lb/gal 1.95s 1019a1

In this example, normal pentane and iso-pentane each have

____ carbon atoms and hydrogen atoms. 5; 12

9. But, the atoms in each of these hydrocarbons are arranged

differently

10. You can see lhat the boiling temperature, vapor pressure,
and density of normal pentane and iso-pentane are also
different

11. So, hydrocarbons that are identical in size can still have
different ______ characteristics

12. The characteristics of hydrocarbons are affected by both the

------ and of the molecules. size; shape, or structure

4
The Hydrocarbon Series

Refer to Exhibit 1

13. Hydrocarbons are nonnally grouped into four major series or

classes.

These are the paraffins; naphthenes

______ ,and _ _____
olefins; aromatics

14. The hydrocarbons in each class have a similar

shape, or structure

15. They also have many o f the same characteristics. Paraffins,

for example, are all marked b y octane low
numbers.

16. Naphthenes are (straight chain I cyclic) hydrocarbons. cyclic

17. Olefins do not occur naturally in crude oil. They are man­
made compounds formed by various ------­ cracking
processes.

18. Aromatics are chemically active. As a group, they also have

high ____________ octane numbers

19. For use as petrochemical feedstocks and for gasoline blend-

ing, the are the most desirable class of aromatics
hydrocarbons.

catalytic Reforming

20. Catalytic reforming is a process that rearranges the

------ of hydrocarbons. shape, or structure

21. This is accomplished by a series of chemical reactions which

use heat, pressure, and a ··-- to reshape the catalyst
molecules.

22. The feed to the catalytic refonner is a naphtha that contains a

high concentration of (paraffins and naphthenes I aromatics ): paraffins and naphthenes

23. During the reforming process, paraffins and naphthenes are

converted into ------ aromatics

- -------
24. Let's take a look at the major reactions that occur during
reforming.

This reaction is called ------- dehydrogenation

25. Dehydrogenation is the most important and frequent reform­

ing reaction. It converts a naphthene into an
. aromatic

26. Another product of this reaction i s hydrogen

27. Dehydogenation is considered a favorable reaction because

the aromatic produced has a higher ------­ octane
------ than the naphthene. number

28. The hydrogen is also a valuable, or important

product because it can be recycled or used in other refinery
processes.

29. Dehydrogenation is an endothennk: reaction. This means

that it absorbs heat.

Because energy is absorbed by the reaction, more heat must

be to the reformer to keep subsequent added
reactions going.

30. Some chemical reactions release heat. These are called

exothennic.

An exothermic reaction ( uses I produces) heat. produces

6
31. Dehydrogenation is a heat user, so it is classified as an
(endothermic I exothermic) reaction. endothermic

32. Here is another reaction that occurs during reforming.

-:;�:�:;:·:;,'.. :Q':(��t<i1·:;::1::: ,; l
_ _

:,�:·::,- � :� :' -�.. Bffetr�� i!ArlNG:�'tfii i��,:�.;;

This reaction is called ------- dehydrocyclization

33. Dehydrocycli zation converts a paraffin into a

naphthene

34. This is considered a good reaction because the naphthene

produced will undergo dehydrogenation and be converted into
an _______ aromatic

35. DehydrocycliZation also ( uses I produces) hydrogen. produces

36. The reaction absorbs heat which means it is ( endothermic I

exothermic ), endothermic

37. Here is another reforming reaction.

This one is called ------- isomerization

38. lsomerization converts a paraffin into an ------- isoparaffin

39. lsomerization is a good reaction because the isoparatfins

have ( lower I higher) octane numbers than normal paraffins. higher

7
40. The reaction is slightly exothermic which makes isomerization
a heat ( user I producer ) . producer

41. Here is the fourth main reaction that occurs during reforming.

L· · HYpR_OcAA��� � �·�, :--� �·�::: rl

. .
/""�.

'
Paraffins JI<

tt tt M fi fi fi )I IO
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. 11-c-<:-c-c-c-c-c-c-"'
I ·1 1 T -� I .l !
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-17 (Mot<:ll'.)
OCTANE l'IATiNGS

This reaction is called -- ------ hydrocracking

42. One type of hydrocracking reaction breaks naphthenes into

paraffins

43. Another type of reaction cracks paraffins into

------- paraffins. smaller

44. Hydrocracking reactions are not considered favorable

because we would prefer to make rather aromatics
than paraffins.

45. In addition, hydrocracking is a hydrogen ( user I producer). user

46. Hydrocracking releases a great deal of heat so it is classified

as a very ( endothermic I exothermic ) reaction. exothermic

47. The net effect, however, of the four primary reforming reac­
tions is endothermic.

So, heat must be added to the process to keep it operating at

a temperature. steady, or proper

48. The most desirable reforming reactions convert paraffins and

naphthenes into isoparaffins and ------ aromatics

8
49. These reactions reform the naphtha feed into a ( lower I
higher ) octane product. higher

50. This high octane product is called ______ reformats

51. Other products produced by the reforming reactions include

light hydrocarbons and ------ hydrogen

The Reforming Catalyst

52. The base of the catalytic reforming catalyst is made out of

alumina which is a type of aluminum oxide.

ACID SITES
(Chlorides)

CATALYST BASE
(Alumina)

..

�ctil!!IS 9atalyzed

: tlfllly!llr"9enation
•

Platinum - flheniom
!)etiydr<?C;tcfi�iGn
.. . .. .. . ' .. .
.

ptilQrides l�meri?ation
.
. '"• ..

Dispersed across the alumina base are both

------ and sites. metal; acid

53. The metal sites are usually composed of platinum or a combi­

nation of platinum and ------- rhenium

54. Platinum and rhenium promote the and dehydrogenation

------- reactions that occur during reforming. dehydrocyclization

55. The acid sites are normally provided by ------ chlorides

56. These chlorides catalyze ·----- reactions. isomerization

57. So, the major reforming reactions are promoted by two differ­
ent types of sites dispersed across an alumina-base catalyst.

The metal sites are composed of ------ , while platinum, or rhenium

chlorides make up the ------- sites. acid

9
Review

58. The characteristics of a particular hydrocarbon are determined

by its and ______ size; shape, or structure

59. Hydrocarbons are normally grouped into four major series or

classes. These are the ------ paraffins; naphthenes
---- ,and _______ olefins; aromatics

60. The hydrocarbons with the highest octane ratings are

aromatics

61. The feed to a catalytic reformer is usually a ( naphtha I raw

crude). naphtha

62. During reforming the feed is heated, pressurized, and put in

contact with a ------- catalyst

63. The catalyst promotes several chemical reactions which

------- the structure of the hydrocarbon molecules. rearrange, change, or reform

64. Dehydrogenation and dehydrocyclization convert paraffins and

naphthenes into ------- aromatics

65. lsomerization converts paraffins into ------ isoparaffins

66. Hydrocracking breaks paraffins and naphthenes into smaller

( paraffins I aromatics). paraffins

67. The main product produced by these lour reactions is called

reformate

68. Reformate has a high octane rating because it contains iso-

paraffins and ______ aromatics

69. Other products produced by catalytic reforming include

______ and light ______ hydrogen; hydrocarbons

70. The major effect of the reforming reactions is ( endothermic I

exothermic ). endothermic

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10
 REVIEW
WORKBOOK PERIOD
NUMBER 1

1. The catalytic reforming reactions are promoted by:

A. endothermic reactions.
B. a catalyst.
C. sulfur.
D. hydrocracking.

2. Which of the following is not a reaction that takes place during catalytic
reforming?

A. Dehydrogenation
B. Dehydrocyclization
C. lsocracking
D Hydrocracking

3. The hydrocarbons with the highest octane ratings are the:

A. paraffins.
B. naphthenes.
C. olefins.
D. aromatics.

4. The major effect of the reforming reactions is:

A. endothermic.
B. exothermic.

5. Catalytic reforming produces:

A. retormate.
B. hydrogen.
C. light hydrocarbons.
D. All of the above

11
 ANSWERS
ITEMS 1 THROUGH 5

1. B. a catalyst.

2. C. lsocracking

3. D. aromatics.

4. A. endothermic.

5. D. All ol the above

THIS IS THE END OF WORKBOOK

PERIOD I. CLOSE YOUR WORK!lOOK
ANO START nm TAPE.

12
 WORKBOOK PERIOD
NUMBER 2

VOCABULARY J ever th� p�fln_iti{ins un.til yoi.J ar� �iliai ivitft them.
.. Rea . . . .
. . '

.
.. . . .

DESULFURIZATION OR a process that removes sulfur, lead, arsenic, nitrogen, and other
HYDROTREATING contaminants from naphtha. The feed to a catalytic reformer is usu­
ally hydrotreated to remove impurities that could damage the
reforming catalyst.

SEMIREGENERATIVE REFORMER - with this type of reformer, the reactors are run continuously for long
periods of time. When the catalyst becomes deactivated, the entire
unit is shutdown so that all of the catalyst can be regenerated at
the same time.

CYCLIC REFORMER - a cyclic reformer utilizes an extra reactor so that catalyst through­
out the system can be regenerated in cycles. Three reactors are
always in operation while the catalyst in the fourth or swing reactor
is being regenerated. With this method of reforming, the catalyst
can be regenerated without shutting down the unit.

CONTINUOUS REFORMER - in a continuous reformer, a portion of the catalyst is continuously

sent to a separate regenerator where it is cleaned and conditioned
prior to being returned to the system.

I NEW CEARNONG •.,..,.,

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Work the self-teaching frames starting on the next page. Be sure to use the cardboard mask to cover the response
column on the right-hand side of each page.

13
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Introduction

1. Catalytic reforming is a process that converts a low octane

into a high octane product called naphtha
reformate

2. This is accomplished by rearranging the ------- of structure, or shape

the hydrocarbon molecules.

3. The naphtha feed often contains impurities such as sulfur,

nitrogen, arsenic, and lead.

These impurities can poison or deactivate the reforming

catalyst

4. So, before the naphtha is reformed, the impurities must be

removed

5. Normally, this is done by pretreating the feed in a

desulfurizer, or hyd retreater

Reformer Equipment

Refer to Exhibit 2

6. Exhibit 2 is a diagram of a typical catalytic reformer. The

reformer equipment includes three and reactors
furnaces

7. Other major pieces of equipment include a ------ separator

a and a recycle _____ _ stabilizer; compressor

8. Let's work through the process. The first step in reforming is

to mix the feed with a -rich gas. hydrogen

9. Then, the feed passes through a furnace, where it is heated to

around "F and vaporized. 900;950

10. From the furnace, the feed-hydrogen mixture is charged to

the first
------ reactor

15
11. Basically, there are two different types of reformer reactors.
This is a down flow reactor.

DOWN FLOW
REACTOR

ALUMINA
BALLS

ALUMINA
BALLS

UNLOADING
NOZZLE

f ouT LET

When the feed enters the reactor, it contacts a

______ plate. deflector

12. The deflector plate ______ the vapors across the spreads, or deflects
top of the catalyst bed.

13. The vapors then pass through a layer of ______ alumina

______ whose purpose is to keep the catalyst in balls
place.

14. As the naphtha passes through the catalyst bed, several

chemical reactions occur. These reactions change the
------ of the hydrocarbon molecules. shape, or structure

15. At the bottom of the reactor, the feed passes through another
layer of alumina balls and a ______ screen

16. The screen prevents the catalyst or the alumina balls from
------ the reactor with the naphtha. leaving

16
 17. Here is the second type of reactor that is used for reforming.

ALUMINUM
BALLS

•
It's called a ______ reactor. radial

18. In a radial reactor, the feed enters the catalyst bed from the
------ instead of the top. sides

19. Both downflow and r adial reactors have certain advantages

and disadvantages. The. type of reactor that is used in your
particular unit ( is I is not) a design consideration. is

Refer again to Exhibit 2

20. After leaving the first reactor, the feed is reheated and sent
through other reactors. two

21. The same basic process repeats itself in the remaining two
reactors.

When the feed contacts the catalyst, chemical reactions occur

which the shape of the hydrocarbons. change, reform, or rearrange

22. The fastest reforming reactions are dehydrogenation and

dehydrocyclization.

So, the majority of these reactions take place in the (first I

third) reactor. first

23. lsomerization and hydrocracking are slower reactions.

They show their ettects in the (first I second and third) second and third
reactor(s).

17
 24. The product leaving reactor 3 is still in the vapor state. This
stream contains hydrogen, light hydrocarbon gases, and the
reformed _ ______ feed, or naphtha

25. The next step in processing is to send these vapors through a

heat exchanger

26. The heat exchanger cools and condenses the majority of the
vapors back to _______ liquid

27. The hydrogen and light hydrocarbon gases do not condense

because thsy have a very low boiling point. These compo-
nents remain in the state. vapor

28. From the heat exchanger, the vapor-liquid mixture is chan-

neled to the , where the uncondensed separator
_______ are removed overhead. gases, or vapors

29.. Some of the hydrogen-rich gas is sent to the refinery gas

plant for additional processing. This stream is an important
source of for other refinery processes. hydrogen

30. The rest of the hydrogen is moved out of the separator by a

recycle and then mixed with fresh reactor compressor
feed

31. Some of this hydrogen will eventually react wtth carbon atoms
inside the reactors and form hydrocarbons.

These reactions are important because they reduce the

amount of carbon that can be deposited on the
·catalyst

32. Let's return to the separator. Liquid is pumped from the bot-
tom of this vessel into a __ __ ___ stabilizer

33. The stabilizer is a distillation column that separates out any

light that still remain in the liquid. hydrocarbons, ends,
or fractions
34. The product drawn from the bottom of the tower is the stabi-
lized ______
_
reformate

35. The reformate is a primary source for benzene, toluene, and

xylenes.

These are ( paraffinic I aromatic ) hydrocarbons. aromatic

Catalyst Regeneration

36. During the reforming process, carbon is gradually deposited

on the catalyst as coke.

These deposits deactivate the catalyst, making it ( less I

more) difficult to reform the feed. more

18
 37. So, periodically the catalyst must be ______ cleaned, or regenerated

30. This is accomplished by ------ the coke off the burning

catalyst with combustion air.

Reier to Exhibit 3

39. Reforming operations are often classified by the way in which

they regenerate the catalyst. There are three different ways to
do this.

Exhibit 3 is an example of a semiregenerative reformer.

With a semiregenerative reformer, the reactors are run contin­

uously until the catalyst requires ------
cleaning, or regeneration

40. Al this point, the entire unit is shutdown so that ( part I all ) of all
the catalyst can be regenerated at the same time.

41. Before the coke can be burned off the catalyst, the reactors
must be isolated from the source of any hydrocarbons.

So, a metal blind is placed across the ______ inlet feed

line.

42. All hydrocarbons inside the reactors must also be removed.

This is acco mplished by purging the reaciors with

nitrogen

43. When the reactors are free of all hydrocarbons, a blind is

placed in the product outlet lines.

This prevents hydrocarbons in other parts of the system from

backing up into the ------- reactors

44. After the reactors are purged and blinded, the coke is burned
off the catalyst by adding combustion to the air
reactors.

Refer to Exhibit 4

45. Exhibit 4 shows a cyclic reformer.

This type of system utilizes a ------- reactor. fourth or swing

46. Three reactors are always in operation while catalyst in the

fourth is being ______ regenerated, or cleaned

47. Cyclic reforming allows us to regenerate the catalyst withOut a

unit ------- shutdown

48. Each regeneration stage or cycle cleans (all /one quarter) of one quarter
the catalyst in the system.

19
 49. Before the catalyst in any of the reactors is cleaned, all
------- must be removed from that vessel. hydrocarbons

50. And, the product inlet and feed outlet lines must be
blinded, or isolated

Refer to Exhibit 5

51. Exhibit 5 is a diagram of a continuous reformer.

In this type of operation, the reactors are usually

------- on top of one another . stacked, or placed

52. Catalyst from the botlom of reactor 3 is sent to a separate

------- vessel. regenerating

53. Alter cleaning, the catalyst is returned to the top of reactor

1

54. During the reforming operation, the fresh catalyst gradually

flows through the other reactors. down

55. When it reaches the bottom of reactor 3, the catalyst is again

sent out for _______ cleaning, or regeneration

56. This· method of reforming allows us to regenerate the cata­

lyst in a continuous cycle.

And, during the actual regeneration ( none I one I all ) of the none
reactors are shutdown.

Reactivating the Catalyst

57. Regardless of what method of reforming is used, catalyst

regeneration involves several different steps.

You have already learned that the first regeneration step is

to burn the off the catalyst with combus­ coke
tion air or oxygen.

58. The catalyst can be permanently damaged by overheating,

so the during regeneration must be care- temperatures
fully controlled.

59. The temperature of the catalyst is controlled by limiting the

amount of that is added to the regenera- air, or oxygen
tion vessel.

60. During this stage of regeneration, some of the oxygen

chemically combines with the platinum in a reaction known as
oxidation.

When the platinum is oxidized, i t ( contains I does not

contain ) oxygen. contains

20
61. Despite the care taken to avoid excessive temperatures, the
heat generated during the carbon bum off will cause much of
the platinum to agglomerate or ball up.

To restore the catalyst to its original active state, the platinum

must be redispersed across the base of the ------ catalyst

62. Another essential conditioning step is to restore the chloride

level on the catalyst.

Chlorides, as you recall, promote ( isomerization I

hydrocracking ) reactions. isomerization

63. Chlorides and platinum are redispersed by the next step in

regeneration called chloridization.

The catalyst is chloridized by adding water and

------- to the system. chlorine

64. This reaction partially dissolves the platinum into chloroplatinic

acid

65. The chloroplatinic acid flows over the surface of the catalyst
and in this manner redisperses the and platinum
chlorides

66. At this point, the platinum is still in an oxidized state making

it inactive for reforming reactions.

Before
the catalyst can be returned to service,
------- must be removed from the platinum. oxygen

67. This is accomplished by the next regeneration step called

reduction.

The platinum is reduced by adding ------- to the ·hydrogen

system.

66. In the resulting reaction, hydrogen combines with oxygen to

form -------
water

21
69. Following reduction, the catalyst is in an extremely active
state. If it is put back into operation in this condition, too
many reforming reactions may take place too quickly.

-------
This could coke up the catalyst and make another
necessary. regeneration

70. So, after reduction the catalyst is usually passed through

one final step called sulfidizing.

In this step, sulfides are applied to the catalyst to temporar­

ily (diminish I increase ) its activity. diminish

71. When the catalyst is put back in operation, the sulfides are
gradually washed off its surface which maintains the desired
catalyst _ _ _ _ __ activity

72. This chart summarizes the five main steps that occur during
catalyst regeneration.

�:1:�-���m:; ������!�r�-�Jf�,�
·

.'
'

.2: OXidB.iiOli.-i:\; i ;c��eh

......
&lmbi�\\1tt\ Pii\i�um. :�
:=t;
· ·
_;;'_"!";.,JJi#.
·' ·
, f.f" - ·' , �· -· · 't' • •....... . "=-"-:· ·_1,;-: Y ·- ..•.-·"·if'.· '":"
·.-·.'."·« - -

'if'le<:l!Sj)el'll!l ptalii'iµinan<t · .. ;;t: �'·0:

. ·--- - "1'-"'" •'· ·. -"

. '3;·chtoridizatKl1(
-· ""' ",,.,,.:;::,"' , ·.·. --:"." �-->1.;,:
.· .· .•

':�'. ....• ;·�r;: :::.· ···w���tt%�;::�i;�

The specific manner in which these regeneration steps are

accomplished ( will I will not ) vary from unit to unit. will

-------
73. So. it is essential that an operator follow the actual detailed
for his unit's regeneration. instructions, or
specifications
 REVIEW
WORKBOOK PERIOD
NUMBER 2

1. The catalytic reforming feed is usually hydrotreated to:

A. add hydrogen.
B. regenerate the catalyst.
C. remove impurities.
D. crack the naphtha.

2. The actual reforming occurs inside the:

A. furnaces.
B. reactors.
C. separator.
D. stabilizer.

3. Hydrogen-rich gas is removed from the liquid product in the:

A. reactor.
B. separator.
C. stabilizer.
D. regenerating vessel.

4. In the stabilizer:

A. light hydrocarbons are removed from the reformate.

B. the catalyst is regenerated.
C. chlorides are added to the system.
D. hydrogen is added to the liquid product.

5. Which type of reformer requires a shutdown in order to regenerate the

catalyst?

A. Semlregenerative reformer
B. Cyclic reformer
C. Continuous reformer

6. The system that regenerates a portion of the catalyst In a swing reactor

i s called a:

A. semiregenerative reformer.
B. cyclic reformer.
C. continuous reformer.

23
 ANSWERS
ITEMS 1 THROUGH 6

1. C. remove impurities.

2. B. reactors.

3. B. separator.

4. A. light hydrocarbons are removed from the reformate.

5. A. Semiregenerative reformer

6. B. cyclic reformer.

24
 EXHIBIT BOOKLET

CATALYTIC
REFORMING

This center section contains the exhibits. It rnay be pulled out of the
book tor easy reference with.out upsetting the frame sequence.

© 1983, Howell Training Company

 EXHIBIT 1
T HE HYDROCARBON SERIES

H H H H H H H H H
I I I I I I I I I
H-C-C-C-C-H H-C-C-C-C-C-H
PARAFFINS
I I I I I I I I I
H H H H H H H H H

Normal Butane Normal Pentane

{C.H,,) (C,H,J

H H
I \
H- c -
c -H
H, I \ ,...H
c
; ....... C / ,
H / '- H
H H

Cyclopentane Cyclohexane
(C,H,0) (C,H,J

H H H
I OLEFINS I I
H-C-C = C--H H-C-C-C=C-H
I I I I I I I
H H H H H H H

Propylene Butylene
(C ,H,) (C,H,)

H
I
H �c, H
'c...- c"

AROMATICS
I II
c c
,,. .::::::- ,,...- 'H
H c
I
H-C-H
I
H

Benzene Toluene
(C ,H,) (C,H,)
 :JJ m
m><
,, z
o­
:JJ !!!
TO GAS s:: ....
m""
PLANT JJ
RECYCLE
c
COMPRESSOR z
=i

HYDROGEN-RICH
GAS

BUTANE AND
LIGHTER

REACTOR REACTOR REACTOR

FEED REFORMATE
FURNACE
 TO GAS
PLANT

RECYCLE
COMPRESSOR BLIND
r
r------...ilf--------1-------;P · . i,....,..,.._______.....
! '
\'. . - ;�
COMBUSTION AIR

NITROGEN

LIGHT
-._ ·,,

+\ ·� ENDS
,)ij REACTOR REACTOR REACTOR
.,, .�
i

BLIND ;, ;,;_ -' \

-.,...-i�· sEf>t6i�Air.eR))
, ' -,

FEED __ - -5.� - .,,,--·; :; RE FORMATE

CATALYST REGENERATION
:J•Bllnd1fiieCl•lillc1t.(rid1:produo1.oui1e111tties,: ":<'Ji BLIND
·-.PU(g!1 reaclOl'S'Wlth, nlttqgen !(Hemove· ,
�liyd�cioatbona ,; " ,;;;·,,
•
.
.1i
:reurn :co1<e·eff:oala:1�a1 with. .comblisllon:·ltlr ';!
··

..
 om
-<><
TO GAS (l :c
,-
- ID
PLANT
RECYCLE (l ::j
J) ....
COMPRESSOR m
,,
0
J)
;::
m
J)
HYDROGEN-RICH
GAS

LIGHT
ENDS

�t REACTOR REACTOR ' REACTOR

\HEAT
EXCHANGER

FEED REFORMATE

CATALYST REGENERATION

. ii.t�g. Emer11t. lo. � p,ysletn, ; tor, eMli>teaotot.

' - S6patlrt
� :-ISd!aJe and:pJir@ 111dJYJ!lu!il•i:eaetors·, .
.
 RECYCLE
COMPRESSOR

..

r
, HYDROGEN-RICH GAS

REACTORS LIGHT
ENDS

r .... �
(
1
:

l'
1
i:n':
;�:��;-
I
I
�
i
' ' <

�""'"''

I I ..

•
'{

I ..,,,, '

L..,_j
�
I
L GENERATED
CATALYST
I ' • ,

L -+ - -..... _J
SPENT CATALYST REFORMATE

8
�
z
CATALYST REGENERATION
FEED
§
c
,, "-:filorilM·Of ,1f1e:c111111ysl.ls•regene.n1teil'' Ul
·continuously ·wllfloul.a •teactor> : :D
'
· •

mm
ehuldpwn,phase ,,�· .,, )(
0
l
::c
:n­
!!!
s:
m-1
:D "'
 •
HTG
A km>w/edge uansfer ccmpany

13831 Northwest Freeway, Suite 520

Houston, Texas 77040-5215
(713) 460-4460
(800) 527-1851
7. In this type of reformer, a portion of the catalyst is constantly being
circulated to a separate vessel for regeneration.

A. Semiregenerative reformer
B. Cyclic reformer
C. Continuous reformer

e: During the catalyst regeneration:

A. coke is bumed off the catalyst.

B. chlorides are redispersed across the catalyst surface.
C. sulfides are applied to the catalyst.
D. All of the above

25
 ANSWERS
ITEMS 7 AND 8

7. C. Continuous reformer

8. D. All of the above

1 HIS IS THE END O�' WORKBOOK

PERIOD 2. CLOSE YOUR WORKBOOK
AND STARl THE TAPE.

26
 WORKBOOK PERIOD
NUMBER 3

VOCABULARY

OPERATING VARIABLES - process conditions such as a reactor temperature or the hydrogen

recycle rate. whose value can change. Operating variables must be
kept within a desired range of values for the unit to produce quality
products and sufficient yields.

INSTRUM)::NTATION most operating variables for a catalytic reforming unit are sensed, ·

measured, and controlled by instruments. These instruments may

work automatically or require manual control. An operator is
responsible for monitoring and adjusting the condition of process
variables to make sure they stay within the desired range of values.

NEW LEARNING MATERIAL

Work the self-teaching frames starting on the next page. Be sure to use the cardboard mask to cover the response
column on the right-hand side of each page.

27
 SELF-TEACHING FRAMES

Operating Variables

1. The goal in catalytic reforming is to convert a naphtha

feed into a high product called octane
reformate

2. Other products produced include light hydrocarbons and

hydrogen

3. A primary reforming reaction is dehydrogenation.

This reaction converts naphthenes into ( paraffins I aromatics). aromatics

4. Dehydrocyclization and isomerization ( also improve I do not

affect ) the octane rating of the naphtha. also improve

5. In order to realize the desired product yields and quality,

certain operating conditions or must be variables
controlled.

6. By keeping the unit operating variables within their allowable

tolerances, we ensure the most favorable reforming
_______ will occur. reactions

Product Yields Versus·Quallty

7. Normally a reformer is operated to produce the maximum

amount of reformate that meets a !liven -----­ octane
specification.

8. This chart shows a typical relationship that exists between refor­

mate yields and octane number.

as
I '
'
' i '
i j ! ' I '
;
' • ! ! I I i ; i
'
84 '
! ; i I ' l i I j

' I '
82 ' '
' ! : ' :
' ! I I ' i I ;

80 ! I i-- I i I I ; 1
REFORMA.TE ! i ' ,_, : '' i l
I I I
YIELD
I I I I I ,, ! ! ' '
%VOL. 78 ' ''
' I
' l I
' ' i I"" ! I
I ' i"'- l i
' I
' I ' ! I
76 ' ' '
I I 1 ' ! I ! !'-
'
I I .
I I
I I I I I ' f'!
I
74 '
i ' I I I .. 'I ' I ! :
' I I I
! ' I : I I I !
90 92 94 96 96 100

REFORMA.TE OCTA.NE NUMBER

You can see that as the octane number goes up, the volume
of reformate produced ------- decreases

29
 9. So, if a unit is producing a proctuct that is above octane
specs, reformate are being wasted. yields

10. And, when yields are wasted, money is needlessly lost. There·
fore, a reformer should be operated to (just meet I exceed ) just meet
octane specifications.

1 1. Product yields and octane number are controlled by adjusting

the unit operating _______ variables

Reactor Temperature

12. Because the net effect of the reforming reactions is endother­

mic, a constant supply of heat must be added to the reactors.

This makes the ------- in the reactors a key opera­ temperature

ting variable.

13. Reactor temperatures are maintained by passing the feed

through a prior to each reactor. furnace

14. When the reactor temperatures are increased, more reforming

occurs.

If the reactor temperatures are raised by 3 to 5°F, the octane

number of the reformate will usually ( decrease I increase) increase
by 1.

15. Octane number adjustments are usually made by changing

the temperatures. reactor

16. To increase the octane number, you ------ the raise, or increase
reactor temperatures.

17. In most operations, the reactor temperatures are kept at a set

value on a day by day basis.

But, catalyst deactivation or feed quality changes ( may I will

not) cause the reformate octane rating to gradually fall off. may

1 a. If this happens, you may need to raise the reactor tempera-

tures to meet specs. octane

30
19. By monitoring the reactor inlet and outlet temperatures, an
operator can often identify operating problems.

OUTLET TEMP. 920°F

Since the net effect of the reforming reactions is endothermic,

there is a temperature across each drop, or decrease
reactor.

20. In this example, the temperature drop is ____ °F. 50

21. If the catalyst starts to coke up, however, ( less I more) less
reforming will take place.

22. So, less heat is consumed and the temperature drop across
the reactor becomes ( smaller / larger ). smaller

23. A reduction in the temperature drop across a reactor may

indicate that the is covered with coke. catalyst

24. Contaminants in. the feed, like sulfur, may suddenly change
the temperature drop across a reactor. Sudden temperature
chang�s usually indicate ( less I more ) serious problems. more

25. One way for an operator to determine if his unit is operating

efficiently is to monitor the reactor and inlet
______ temperatures. outlet

Pressure

26. Another important operating variable is the reformer pressure.

Pressure is controlled by regulating the flow of

______ out of the separator. hydrogen

27. Basically, reforming is a high pressure operation. The system

pressure may range from 200 to 500 PSI.

Pressure in the system is created by both hydrogen and

______ gases. hydrocarbon

31
 28. Hydrogen is a product of several of the reforming reactions.

And, hydrogen is also mixed with the feed to protect the

catalyst from excessive deposits. coke

29. Hydrocarbon gases are formed because the feed is

______ as it passes through the furnace. vaporized, or heated

30. The system pressure is a design feature and is not normally

adjusted to change product _______ yields, or quality

31. If the system pressure is allowed to increase, more hydro­

cracking occurs in the reactors in return for less dehydro­
genation.

This increases the yield of hydrocarbon gases, but decreases

the production of hydrogen and _ _ _ _ __ reformate

32. A drop in the system pressure increases hydrogen and re­

formate yields.

But, at lower pressures (less I more) coke is deposited on more

the catalyst.

33. So, the system pressure (need not I should always ) be main­ should always
tained at a specified constant level.

34. A pressure difference or drop occurs across each of the

reactors.

This is because the vapors encounter resistance as they flow

through the _______ catalyst

35. If the catalyst starts to plug up, this resistance will

increase

36. And, the differential pressure across the reactors will also
increase

37. An operator can check the condition of the catalyst by moni-

toring the across each of differential pressure
the reactors.

Feed Rate

38. A specified amount of feed is charged to a reformer each day.

The feed is moved into the unit by a (compressor I pump). pump

39. The feed rate is usually kept at a constant value to maintain a

balance throughout the system. But feed availability problems
or mechanical difficulties may force a feed rate reduction.

If the feed rate changes, other operating variables (will I will

not) be affected. will

32
 40. With a lower feed rate, the desired yields and octane can be
obtained at lower reactor temperatures.

So, it may be necessary to ______ the reactor tem- reduce, or adjust

peratures to keep the system in balance.

41. Under normal operating conditions, however, the

is kept at a constant feed rate
value.

Feed Composition

42. Naphthenes are easier to reform and produce a higher octane

reformate than paraffins.

Therefore, the most desirable reformer feed will contain a

high concentration of ______ naphthenes

43. The composition of the feed can be determined by a PONA

analysis. This test tells us what concentration of paraffins,
olefins, naphthenes, and aromatics are present in the feed.

The PONA content of the feed ( will I will not) affect how a will
reformer is operated and what types of products it produces.

44. The feed is also checked for heavy, high boiling point hydro­
carbons.

This is because heavy material in the feed may

_______ up the catalyst. coke

45. Contaminants, such as water or sulfur, are sometimes present

in the feed.

These contaminants (will I will not) interfere with the smooth will
operation of a reformer unit.

46. It is important to identify contaminants in the feed so that

these components can be prior to removed
reforming.

Hydrogen Recycle Ratio

47. To protect the catalyst from excessive coke deposits,

_______ is recycled and mixed with the feed. hydrogen

48. The hydrogen recycle is expressed as a ratio.

i-IYOFlQl3EN )lYl;)R()GEN IN Ri;CYQl.E AA� ,

RECYCLE
RAno.- ... ,.

This ratio compares the amount of hydrogen in the recycle

gas to the amount of being hydrocarbons, or feed
charged to the unit.

33
 49. The hydrogen recycle ratio must be maintained at or above a
minimum value to reduce of the catalyst. coking

50. There are several conditions that can cause a reduction in the
hydrogen recycle ratio without a specific change being made
in the unit operation.

For example, if the percent of hydrogen in the recycle gas

decreases, the hydrogen recycle ratio will ( fall I rise ). fall

51. The ratio will also decrease if the recycle compressor loses
some of its capacity to compress recycle _______ gases

Catalyst Activity

52. The ability of the catalyst to promote the desired reforming

reactions is dependent upon the catalyst ------ activity

53. You already learned that contaminates like coke and sulfur
can the catalyst. deactivate

54. When the catalyst becomes inactive, it must be cleaned or

regenerated

55. Another condition that affects the catalyst activity is the level
of chlorides on the catalyst surface.

Chlorides ( promote I retard ) isomerization reactions. promote

56. Chlorides can be injected into the feed or the recycle gas
streams.

These injection rates are normally set by the ( operator I

supervisory staff). supervisory staff

57. An operator's job is to test and monitor the ______ chloride

level.

58. A small amount of water is sometimes injected into the feed

or recycle gas streams to the chlorides spread, or disperse
across the surface of the catalyst.

59. To ensure the proper dispersement of chlorides across the

catalyst, _______ injection rates must be carefully water
controlled.

34
Vapor Pressure

60. Vapor pressure is a measure of a liquid's tendency to vapor­

ize at a given temperature.

You can see from this chart that light hydrocarbons, like pro­
pane and butane, have ( low I high ) vapor pressures and boil
·
high
at ( low I high ) temperatures. low

These characteristics cause propane and butane to

------- at normal temperatures and pressures. vaporize, or boil

61. We want the reformate to have a low vapor pressure so that it

will stay in the ( vapor I liquid ) state under average climatic liquid
conditions.

62. Prior to stabilization, the reformate vapor pressure is usually

higher than 100 PSIA.

-----to- LIGHT
HYDROCARBON
GASES

REFORMATE
STABILIZER
Vapor Pressure
100 PSIA or higher

REFORMATE
Vapor Pressure
..._
___ ...,.. 4 6 PSIA
-

Stabilization removes light hydrocarbons from the reformate

reducing its vapor pressure to between 4
____ PSIA . 6

63. The reformate vapor pressure is controlled by adjusting

temperatures inside the stabilizer.

Higher temperatures boil away more light material which

( reduces I increases ) the vapor pressure of the reformate. reduces

64. If the reformate does not meet vapor pressure specifications,

it may be necessary to adjust the inside the temperature
stabilizer.

35
Instrumentation

65. Most operating variables in the catalytic reforming process are

sensed, measured, and controlled with ------ instruments

66. Some of these instruments automatically adjust the condition

of operating------ variables

67. Others require ------ control to change the value manual

of an operating condition.

68. Instruments are used to both monitor and -----­ control, or adjust
the reformer operating variables.

69. These variables must be kept within a specified range of

values to maintain stability throughout the system.

This is because a change in the condttion of one process

variable ( affects I does not affect ) the condition of other affects
variables.

70. For example, if the hydrogen recycle ratio falls below a cer-
tain value, excessive will be deposited on coke
the catalyst.

71. This, in turn, will reduce reformate ------- and yields

quality

72. A reformer is usually operated to meet _______ octane

specifications for the reformate.

73. You already learned that as the octane number increases,

yields ------- decrease

74. So, reformate is being wasted if the unit is operated {below I

above ) octane specifications. above

75. Octane number adjustments are usually made by changing

the temperature in the reactors.

As the reactor temperatures increase, the octane number

( decreases I increases ). increases

76. But, a higher octane number means ------ yields. lower

36
 REVIEW
WORKBOOK PERIOD
NUMBER 3

1 . When. a reformer is operated to produce greater yields, the reformate

octane number:

A. decreases.
B. increases.
C. is not affected.

2. The reformate octane number can be raised by increasing the:

A. feed rate.
B. system pressure.
C. reactor temperatures.
D. hydrogen recycle rate.

3. Which of the following would be an indication that the catalyst is coking

up?

A. The temperature drop across the reactors decreases

B. The temperature drop across the reactors increases
C. The reformate octane number rises
D. Hydrogen production increases

4. If the system pressure increases, reformate yields will:

A. decrease.
B. increase.
C. not be affected.

5. The PONA analysis is a:

A. recycle gas test.

B. feed composition test.
C. catalyst activity test.
D. chloride test.

37
 ANSWERS
ITEMS 1 THROUGH S

1. A. decreases.

2. C. reactor temperatures.

3. A. The temperature drop across the reactors decreases

4. A. decrease.

5. B. feed composition test.

38
6. The hydrogen recycle minimizes catalyst:

A. oxidation.
B. reduction.
C. chloridization.
D. coking.

7. Which of the following affects the catalyst activity?

A. Sulfur
B. Chloride injection
C. Water injection
D. All of the above

B. The reformate vapor pressure is adjusted in the:

A. reactors.
B. furnaces.
C. separator.
D. stabilizer.

39
 ANSWERS
ITEMS 6 THROUGH 8

6. D. coking.

7. D. All of the above

8. D. stabilizer.

THIS IS THE END OF WORKBOOK

PERIOD 3. CLOSE YOUR WORKBOOK

AND START THE TAPE.

40
 WORKBOOK PERIOD
NUMBER 4

VOCABULARY

OPERATOR DUTIES An operator is usually responsible for sampling and testing the
feed, reformate, and recycle gas streams, adjusting the unit opera­
ting variables, making daily inspections and keeping the unit log,
and responding to abnormal operating situations.

--_ . ·;;::tr::'"' .-:

·.:'J?
NEW LEARNING MATERIAL
·� ''>"··

.._,,;0._;:.,"'*-· ' " ;,. ,.;._ :�---:c,;,__..,,

Work the sell-teaching frames staning on the next page. Be sure to use the cardboard mask to cover the response
column on the right-hand side of each page.

1--- ' -

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41
 SELF-TEACHING FRAMES

OPERATOR DUTIES

Sampling and Testing

1. Catalytic reforming is a complex process. To make sure that

the unit is running properly. there are several critical areas of
the process that must be checked regularly.

For example, we need to ensure that the desulfurizer is

removing from the feed. sulfur

2. Another critical aspect of the process is the hydrogen recycle

ratio.

Sufficient hydrogen must be mixed with the feed to prevent

______ of the catalyst. coking

3. The reformate must also be checked to see that it meets

product ------- specifications

4. An operator is responsible for monitoring these critical areas

of the process. This is done by periodically -----­ sampling
and the feed, reformate and recycle gas testing
streams.

ASTM Distillation Test

5. The ASTM distillation test identifies hydrocarbons in the feed.

by their respective boiling points.

Light hydrocarbons, for example, require less heat to vaporize

so they boil at (lower I higher) temperatures than the heavy lower
molecules.

6. The ASTM distillation test is performed by gradually heating

and vaporizing a sample of the feed. The vapors are collected
and condensed back to liquid in a separate container.

The temperature at which the first drop of condensate i s col­

lected is called the ( initial I end ) boiling point. initial

7. The initial boiling point is the temperature at which the

(lightest I heaviest ) material in the sample starts boiling. lightest

a. The end boiling point is the temperature at which the (first I

last ) drop of liquid vaporizes during the test. last

9. So, the end boiling point identifies the (lightest I heaviest) heaviest
material in the sample.

43
 10. The data from the ASTM distillation test is often plotted on
graph paper lo form a distillation curve.

10 20 30 40 50 60 70 80 90 100
FEED -CUMULATIVE% VOLUME

The distillation curve tells you the ______ of ma· volume

terial that boils between given temperatures.

11. In this example, ____ % of the feed boils between 250- ao

3250F.

12. The end point of the reformer feed is especially critical. For
most operations it should never be higher than 400°F.

Hydrocarbons boiling above 400°F are fairly

heavy

13. This heavy material will deposit excessive -----­ coke

on the reforming catalyst.

Doctor Test

14. We said that the reformer feed is checked for sulfur.

Sulfur should be removed when the feed passes through the

desulfurizer

15. If sulfur is allowed to enter the reformer, it will deposit on and

deactivate the reforming ------ catalyst

44
 16. There are several ways to test the feed for sulfur. One of the
most common methods is called a Doctor Test.

In the Doctor test, a sample of feed is mixed with a chemical

that reacts with------- sulfur

17. If the sample reacts with the chemical, it will turn black in
color.

This indicates that the feed (contains I does not contain) contains
sulfur.

Testing the Recycle Gas

18. Normally, the recycle gas is checked once per shift for hydro­
gen purity.

This is an important test because a specified amount of

hydrogen must be recycled and mixed with the
feed

19. The recycle gas is often tested with a gas analyzer.

The analyzer gives a direct reading of the percent of

---- in the recycle gas. hydrogen

20. Some analyzers can also identify hydrogen chloride and

impurities like hydrogen sulfide.

The concentration of hydrogen chloride in the recycle gas is

important because it helps us determine if the desired
------- injection rates are being maintained. chloride

21. Hydrogen sulfide in the recycle gas indicates that sulfur is

present in the feed.

The sulfur should be ------- before the feed enters removed

the reformer.

22. Another way to check for hydrogen sulfide and hydrogen chlo­
ride is with a Draeger tube. The tube contains special chemi­
cals that will react with the substances in the recycle gas.
When a reaction occurs, the chemical changes color.

When testing the recycle gas with a Draeger tube, a color

change indicates a ( negative I positive) test. positive

Octane Testing

23. The primary measure of reformate quality is its

octane number

24. Octane number is a guide to the anti-knock qualities of a

motor fuel.

High quality fuels have (low I high) octane numbers. high

45
25. Reformate's octane number is determined by
______ its knocking characteristics with those of matching, or comparing
two fuels whose octane numbers are known.

26'. We do this by using reformate as a fuel in a test engine. The

compression ratio of the engine is adjusted to a point where
knocking occurs. The data is then entered on a graph.

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OCTANE NUMBER

In this example, the engine begins knocking at a compression

ratio of ____ 7.8

27. Then two blends of gasoline with known octane numbers are
run through the same test procedure, and the compression
ratios are noted.

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OCTANE NUMBER

The compression ratios for the two blends are ---- and 7.2
8.4

46
 28. By drawing a line through the data points, the octane number
of the reformate can be read off the graph. Our data shows
the reformate has an octane rating of ____ 92

29 . . Because of the complexity of the testing procedure, octane

tests are usually performed by ( an operator I the lab ). the lab

Vapor Pressure

30. The reformate product must also meet certain vapor pressure
specifications.

Vapor pressure is a measure of a liquid's tendency to

------ at a given temperature. vaporize

31. Small or light hydrocarbons which vaporize easily have (low I

high) vapor pressures. high

32. Gasoline must have a high enough vapor pressure to permit

easy starts.

But, if the vapor pressure is too high, the gasoline will

------- before it is pumped into the engine. vaporize

33. Vapor pressure is determined by heating a sample in a closed

container to a specific temperature, usually 100°F.

HEATER
AIR
CHAMBER

SAMPLE
CHAMBER

The pressure exerted at this temperature is the liquid's

vapor pressure

34. The drawing above shows the apparatus for measuring vapor
pressure using the Reid method. Test results from this type of
apparatus are called vapor pressures. Reid

Color Tests

35. The feed and reformate are checked regularly for color,

If the feed is brown or black in color, this is an indication of

contamination by ( light I heavy ) hydrocarbons. heavy

47
------
---
-- ----
------- --- ----- - ------ ----
----- --- - ----
---- - ----
-- --
-- --

36. Excessive cracking in the reactors will give the reformate a

(bluish I yellowish) hue. yellowish

37. An operator needs to check the ------ of both the color

feed and the reformate.

Testing for Wat e r

38. A small amount of water is intentionally added to the feed or

recycle gas streams to help spread chlorides across the
catalyst

39. If an insufficient amount of water is used, the chlorides will

not be thoroughly dispersed across the catalyst base.

Too much water, on the other hand, will ______ the wash
chlorides oft the catalyst

40. Water in the feed and recycle gas streams is usually moni­
tored with a moisture analyzer.

The analyzer automatically records the ------ of amount, or quantity

moisture in the process stream.

Adjusting the Unit Operating Variables

41. II test results indicate there is a problem somewhere in the

system, an operator may have to adjust one or more of the
unit operating _____ _ variables

42. For example, if the ASTM distillation test or color test show
there is too much heavy material in the feed, it may be neces­
sary to bypass the feed around the unit until the problem is
resolved

43. Feed composition problems are often caused by an upset in a

unit upstream from the reformer.

When the upset is corrected, the feed composition will usually

return to ------ normal

44. Suppose the Doctor test or the recycle gas test indicates
there is sulfur in the feed.

This contaminant is supposed to be removed by the

desulfurizer

45. In many instances, the problem can be corrected by increas­

ing the temperature in the desutfurizer.

The temperature increase causes more of the sulfur to be

------ out of the reformer feed. stripped, or vaporized

46. Recall that the hydrogen recycle ratio must be kept above a
minimum value to protect the from coking catalyst
up.

48
47. So, if the hydrogen purity of the recycle gas decreases, it may
be necessary to ( decrease I increase) the recycle gas rate. increase

48. We said that the octane rating of the reformate must be main­
tained within specifications.

If the octane number is above specs, product yields are being

lost, or wasted

49. When the reformate octane is below specifications, product

(quality I quantity) suffers. quality

50. Normally, the octane number of the reformate is adjusted by

changing the reactor (temperatures I pressures). temperatures

51. When the reactor temperatures are increased, more reforming

reactions take place.

This causes the octane number to ------ rise

52. Another critical specification is the vapor pressure of the refor­

mate. You already learned that vapor pressure is a measure
of a liquid's tendency to vaporize

53. Light hydrocarbons which vaporize easily have (low I high ) high
vapor pressures.

54. Usually, the vapor pressure of the reformate is maintained at

very low levels. This is done by removing ( light I heavy) light
hydrocarbons from the reformate during stabilization.

55. Vapor pressure adjustments are usually made by changing

the temperature in the stabilizer.

Higher temperatures cause more light material to boil out of

the reformate. This (reduces I increases) the vapor pressure reduces
of the product.

56. The amount of water in the feed and the recycle gas streams
must also be carefully watched. We want to keep the total
amount of water throughout the system fairly
constant

57. Suppose the amount of water in the feed starts to increase.

We can compensate for this by the amount decreasing

of water that is injected into the recycle gas stream.

49
Daily Inspections and Keeping the Unit Log

58. Another operator duty is daily inspections. These are made by

walking through the unit and visually checking the condition of
equipment.

The equipment checked during daily inspections includes

______ ,and pumps; compressors; furnaces
heat exchangers

59. While making the rounds, an operator should listen for any
unusual sounds.

Strange noises coming from a pump or a compressor may

indicate a potential ------ problem, or failure

60. Furnaces are checked by opening the inspection doors and

making sure the flames do not strike the -----­ tubes
and that the tubes are the correct ------ color

61. The lubrication systems on ______ should also be compressors

checked.

62. During the daily inspection, you should keep a lookout for any
leaks.

This is because hydrogen and hydrocarbons are both very

flammable

63. You will probably be required to take instrument readings

while making the daily inspection.

These readings should be recorded in the unit

log book

64. The data in the log book (allows I does not allow ) you to allows
follow the long term unit operating trends.

50
 65. For example, a gradual increase in the differential pressure
across the reactor beds indicates the catalyst may be starting
to ______ _ plug

66. The information obtained during daily inspections should

always be in the log book. recorded

Abnormal Operating Conditions

67. An operator must also be able to respond to abnormal opera-.

ting conditions such as a feed pump failure or a loss of
power.

These situations will usually cause a sudden and drastic

change in the condition of the unit operating
variables

68. Here is a list of some of the more common abnormal opera­

ting situations.

All of these are considered emergency conditions in which an

operator must respond to keep the process quick, or fast
under control.

69. In some situations, this means starting up a back-up piece of

------- or an alternate source of _______ equipment ; power

70. Other situations may require an emergency ------­ shutdown

of the entire unit.

71. Emergency operations will vary from unit to unit. In every situ­
ation, however; you will have specific tasks to perform.

To ensure the safety of personnel and equipment, an operator

should the emergency procedures that are know
followed on his particular unit.

51
 REVIEW
WORKBOOK PERIOD
NUMBER 4

1. Normally, the end boiling point of the feed should not be ahove:

A. 100° F
B. 200° F
c. soo• F
D. 400° F

2. The Doctor test is used to detect

A. ammonia.
B. coke.
C. sulfur.
D. chlorides.

3. You can check for impurities in the recycle gas with a:

A. Draeger tube test.

B. Doctor test.
C. test engine.
D. PONA test.

4. A test engine is normally required for:

A. recycie gas testing.

B. octane testing.
C. a Doctor test.
D. an ASTM distillation test.

5. Gasoline must have a certain minimum vapor pressure to:

A. prevent it from totally vaporizing.

B. permit easy starts.
C. keep it from freezing.
D. stop boil-overs.

53
 ANSWERS
ITEMS 1 THROUGH 5

1. D. 400° F

2. C. sulfur.

3. A. Draeger tube test.

4. B. octane testing.

5. B. permit easy starts.

54
6. A small amount of water is added to the feed or to the recycle gas
stream to:

A. control the temperature inside the reactors.

B. keep impurities off the catalyst.
C. trim the octane rating.
D. spread chlorides across the catalyst.

7. Coking of the catalyst may be caused by:

A. heavy material in the feed.

B. a reduction of the hydrogen purity in the recycle gas.
C. an extremely active catalyst.
D. All of the above

B. Product yields are being wasted when the reformate octane number is:

A. below specification.
B. above specification.

55
 ANSWERS
ITEMS 6 THROUGH 8

6. 0. spread chlorides across the catalyst.

7. D. All of the above

B. B. abOve specification.

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