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1
PRESENTATION
OF REFORMING FOR NAFTEC
REFINERIES
NAFTEC/Spa
AFRICAIN REFINERS ASSOCIATION
- ARA
Workshop on Catalytic reforming - Algiers Refinery - 16 & 17 December 2008
PRESENTATION OF REFORMING FROM NAFTEC’S REFINERIES
2
Table of Contents I- REFINERY of SKIKDA (RA1K)
I-1 Reforming Data Sheet (REF1 and REF2)
I-2 Dispatching of the catalyst into the reactors
I-3 Modifications to RA1K Reforming units
II- REFINERY of ARZEW (RA1Z)
II-1 Reforming Data Sheet
II-2 Dispatching of the catalyst into the reactors
II-3 Modifications to Reforming units of RA1Z
III- REFINERY of ALGIERS (RA1G)
III-1 Reforming Data Sheet
III-2 Dispatching of the catalyst into the reactors
III-3 Modifications to RA1G Reforming units
IV PRECIOUS METAL BALANCE FOR CATALYSTS
V OPERATION DIFFICULTIES
VI PROSPECTS BY 2013
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
4
I-1 Reforming Data Sheet I-1-a Data Sheet for Reforming 1 (REF1)
Mark : U100
Start-up of the unit : May 1980
Capacity : 30 000 BPSD
License : Arco-Engelhard
Role : Aromatic (BTX)
On-stream pressure : 3rd catalyst pressure (on stream since October 2004)
• Type of catalysts : E801 in reactors R1 et R2
E803 in reactors R4 et R5 (Engelhard)
• Precious metal content : E801 : 0.26 % Pt and 0.26 % Rh
E803 : 0.22 % Pt and 0.42 % Rh
• Form : extruded
• Loaded quantity : E801: 14 543 Kg / E803: 49 233 Kg
Total : 63 776 Kg
RA1K
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
5
I-1-a Data Sheet for Reforming 1 (REF1)
Process Conditions; Design
• Temperature at the beginning of the cycle : 522°C
• Temperature at the end of the cycle : 543 °C
• Hydrogen purity : 80 % Molar
• Molar Ratio H2/HC : 11
• Pressure at separator balloon : 8.9 kg/cm2
• Space speed : 2.3 h-1
• Reformate output : 80 % Pds
• Clear NO : 99
• Cycle Duration : 13 months at 100%
• Life warrantee : 5 years, i.e.136 m3/kg or 390 bbl/lb.
I-1 Reforming Data Sheet …
RA1K
AH
1.10. B
y
-
p
a
s
s
Vers Colonne C7
1.15. E
-
8
1.3. E
-
4
1.11. C
h
a
r
g
e
1.12. M
P
-
2
1.14. M
P
-
4
By
-Pa
ss
Se
cti
on
Ca
taly
tiq
ue
NAPHTA
T
r
a
i
t
é
Vers Section Magnaforming
1.7. M
P
-
3
1.18. K
-
1
1.19. A
/
B
1.17. E
-
9
1.22. K
-
2
1.23. A
/
B
LIC 5
1.13. E
-
2
E-1AD
1.20. E
-
3
A
/
B
1.21. V
-
1
PRC 3
1.5. V
-
2
1.9. F
-
2
FRC 6
FRC 4
1.6. F
-
1
1.4. R
-
1
1.8. C
-
1
1.1. F
G 1.2. M
E
A
1
LIC 6
FRC 5
PRC 3
1.16. E
-
1
5
FRC 30
1.24. V
-
3
C-2
By-PassVers Refoulement MP-7A/B
PRC 7
Catalytic pretreatment section (REF 1)
R1 V2
C1 F1
V1
V3
F2
K1 K2
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
6 RA1K
Toward magna-
Forming Section
By-Pass toward MP-7A/B
Discharge
Toward
Column C7
MP-7
E-12
A/B/C
E-11 A/B E-10 A/B
MEA-3
R-
2
R-
3 R-
4
R-
5
Magnaforming Section (REF 1)
F- 4 F- 5 F- 6 F- 7
TK -3
FR
c
12
FR
13
FR
81
FR
22
P
Rc
99
lic
8
V
-5 Reformate
towards C-4
stabilizer
Load of
processed
Naphta
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
7 RA1K
E-14
E-16
C- 4
MP- 8
EA- 4 E-13 FR
26
PR C
7
LIC
10
V-6
FR C
14
Reformate
Reforming1 (V -5)
From bottom-hole
V -4
LR
C
9
frc
25
FR
27
Depentanized reformate
toward fractionation (BTX
toward column C-5)
LPG & Pentanes
toward C-7 column
MC
MS
Network-
wards F.G (C-4) Reformate Stabilizer
Simplified Schematic
Platformat makeup
for Reforming 2
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
8 RA1K
CW Stabilized
Reformate
load
Light Reformate unit load
extraction of
Benzene /
Toluene
A H
F-9
E-18
C- 5 MP- 13
EA- 5 •p
rc
43
LI
C
20
V-11
FR C
52
F
R
5
3
C-5 fractionation column
simplified schematic
N2
B.D
MP- 14
fr
c 51
lic 19
FR
C
42
9 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES RA1K
Heavy-duty
Reformate
unit load splitting of
xylems
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
10
I-1-b Data Sheet for Reforming 2 (REF2)
Mark : U103
Start-up of the unit : October 1993
Capacity : 30 000 BPSD
License : UOP
Role : Gasoline
On-stream pressure : First catalyst pressure (since October 1993) • Type of catalysts : R-62 (UOP)
• Precious metal content : 0.22 % and 0.44 % Rh
• Form : spherical shape
• Loaded quantity : 145 288 Kg of catalyst
I-1 Reforming Data Sheet …
RA1K
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
11
I-1-b Data Sheet for Reforming 2 (REF2)
Process conditions Design
• Temperature at the beginning of the cycle : 490 °C
• Temperature at the end of the cycle : 543 °C
• Hydrogen purity : 75 % Molar
• Molar Ratio H2/HC : 6 minimum
• Pressure at separator balloon : 12.3 kg/cm²
• Space velocity : : 1.0 h-1
• Reformate output : 80 % Pds
• Clear NO : 101
• Duration of the cycle : 12 months at 100%
• Lifetime Warranty : 5 years, i.e.156 bbl/lb
or 54.4 m3/kg
I-1 Reforming Data Sheet …
RA1K
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
12
% Catalyst Quantity (kg) Catalyst Reactors
9 5 932 E801 100R2
13 8 611 E801 100R3
39 24 616 E803 100R4
39 24 617 E803 100R5
100 63 776 TOTAL
I-2-a REFORMING 1
I-2 Dispatching of the catalyst into the reactors
RA1K
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
13
I-2 -b REFORMING 2
% Catalyst Quantity (kg) Catalyst Reactors
10 14 140 R62 R31
15 21 703 R62 (+R86) R32
25 36 435 R62 R34
50 73 010 R62 R35
100 145 288 TOTAL
I-2 Dispatching of the catalyst into the reactors
RA1K
14 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
► Optimization of the operation of Aromatic units :
Design of a six-inch line allowing to feed Reforming 1 fractionation section
through the reformate of Reforming 2 in order to increase or maintain the
production of aromatic hydrocarbons (BTX) in case Reforming 1 load is
stopped or decreased.
► Flexible feeding of Reforming units in relation to Hydrogen :
Design of a two-inch line 2 connecting two Reforming units and ensuring the
availability of hydrogen in case of stoppage of either unit.
► Improving the security of the unit by substituting the combined
E10/E11 exchangers of the preheating train for Reforming 1 :
Substituting combined E10 A/B and E11 A/B exchangers has helped fix the
issue of recurrent leaking from the expansion joints initially designed within
the shell (outer part).
Modifications to RA1K Reforming units
RA1K
E-14
E-16
C- 4
MP- 8
EA- 4 E-13 FR
26
PR C
7
LIC
10
V-6
FR C
14
Reformate for
reforming 1
From the bottom-
hole V -4
LR
C
9
frc
25
FR
27
Fractionation wards
Toward
column C-7
And LPG units
MC
MS
Toward
F.G Makeup of platformat for reforming 2
toward 100C-4 column
Makeup of platformat
for Reforming 2
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
15 RA1K
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
17
Mark : U12
Start-up of the unit : 1972
Capacity : 8 360 BPSD
License : UOP
On-stream pressure : 3rd catalyst pressure (since September 1997) • Type of catalysts : R-62 (UOP)
• Precious metal content : 0.22 % Pt and 0.44 % Rh
• Form : spherical form
• Loaded quantity : 24 396 Kg of catalyst
Reforming Data Sheet
RA1Z
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
18
Process Conditions, Design
• Temperature at the beginning of the cycle: 470 °C
• Temperature at the end of the cycle : 543 °C
• Hydrogen purity : ≥ 75 % Molar
• Molar ratio H2/HC : 3.5 à 6
• Space velocity : 1.6 h-1
• Pressure at separator balloon : 17.5 kg/cm2
• Reformate output : 80 % Pds
• Clear NO : 98
• Warranty cycle time : 12 months à 100%
• Warranty lifetime : 5 years 308 bbl/lb, i.e. 108 m3/kg
Reforming Data Sheet
RA1Z
12-FRC5 12-FR4
12-G3A/B
12-LR3
12-G8A/B
12-G4A/B
12-C1
12-E3
12-E2 A/B
12-FRC1
12-G1A/B
12-E1 A/B/C
CHARGE NAPHTA
12-LIC2
12- D1
12-E6
GAZ VERS TOPPING
PENTANES VERS TOPPING
12 -F1 /
Chambre 1
12-LIC1
12-F1
12-D2 12-LIC4
12-FR3
NAPHTA PRETRAITE VERS
PLATFORMING
12-E7
12-FR2
12-PRCV-4A
Hydrogène vers unites
Lubrifiants
INJECTION TCE
12-G14 B/D
APPOINT
HYDROGENE
12-E4A/B
12-PR1
8
20
12-C2
1
12 -F1 / Chambre 2
Pretreatment Section - (U12 RA1Z)
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
19 RA1Z
Hydrogen toward
Lubricant Units
GAZ TOWARD
TOPPING
12-F1/
Chamber 1
12-F1/
Chamber 2
PENTANE
TOWARD TOPPING
HYDROGEN
MAKEUP
NAPHTA
LOAD
PRETREATED
NAPHTA TOWARD
PLATFORMING
Catalytic Section - Platforming (U12 - RA1Z)
12-PRCV 12-PRC6
12-FRC14
12-LIC 8
12-FR 13
12-FRC 9A/B
12-G7 LPG toward
Gas-Plant
PLATFORMAT STABILISED
TOWARD STORAGE
PRETREATED
NAPHTA LOAD
12-FR 16
12-PRC
H2 TOWARD FUEL
NETWORK
12-C6
30
16
1
12-E12 12-E11 12-E 13
12-FR15
6
12-LIC 6
H2 toward
Pretreatment
12-FRAL 8
Gas
toward
Topping
12 C3 12 C4 12 C5
12 G9 A/B
12 F3
12 F2
12 D5
12 E9 A/B/C
12 E10
12 E14
12 G11 A/B
Hydrogen Compressor
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
20 RA1Z
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
21
% Catalyst Quantity (kg) Catalyst Reactors
20 4 693 R62 12 C3
30 7 374 R62 12 C4
50 12 329 R62 12 C5
100 24 396 TOTAL
Dispatching into the reactors
RA1Z
22 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
► Replacement of raw water by distilled water to cool 12 G12 A/B-type
condensate scavenge pumps and thereby avoid pollution of the steam
condensate (9 t/h).
► Installation of nitrogen lines for topping columns and stripping-stabilizing
circuits as a replacement of water vapor. This is time-saving and allows
rapid elimination of show of water from circuits in relation to start-up
operations.
► Utilization of gas process (Hydrogen-rich) instead of electrolytic Hydrogen
following regeneration. That utilization allows to compensate the
unavailability of electrolytic Hydrogen.
Modifications to the RA1Z Reforming unity
RA1Z
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
24
III-1 Reforming Data Sheet
Mark : U200
Start-up of the unit : march 1964
Capacity : 16 000 BPSD
License : UOP
On-stream pressure : 13th pressure of the catalyst (since June 2007)
• Type of catalysts : R-11 (UOP) - monometallic
• Precious metal content : 0.375 % Pt
• Form : spherical form
• Loaded quantity : 33 600 Kg of catalyst
III- REFINERY OF ALGIERS (RA1G)
RA1G
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
25
III-1 Reforming Data Sheet
Process Conditions, Design
• Temperature at the beginning of the cycle : 490 °C
• Temperature at the end of the cycle : 538 °C
• Hydrogen Purity : 66 % Molar
• Molar Ratio H2/HC : 7 à 8
• Space velocity : 0.9 à 1.5 h-1
• Reformate output : 80% Vol.
• Clear NO : 93
• Warranty cycle time :12 months at 100%
• Warranty lifetime : 3 years equivalent
to 342 bbl/lb
III- REFINERY OF ALGIERS (RA1G)
RA1G
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
26
III-2 Dispatching of the catalyst into the reactors
% Catalyst Quantity (kg) Catalyst Reactors
20 6 700 R11 R202
30 10 700 R11 R203
50 16 200 R11 R204
100 33 600 TOTAL
III- REFINERY OF ALGIERS (RA1G)
RA1G
27 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
► Regeneration procedure for R11 catalyst of the Reforming :
Modifications were made since 2001 in collaboration with the UOP licensor by
applying the R-62 catalyst regeneration procedure for R-11 catalyst.
This led to better regeneration and thereby contributed to make cycles longer.
Modifications to the RA1G Reforming Unit
RA1G
28
IV- PRECIOUS METAL BALANCE FOR
REFORMING CATALYSTS
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
29
Kg
Rh
(%)
Rh
Kg
Pt
(%)
Pt
CATALYST Capacity
(BPSD) Reforming Refinery Quantity
(Kg) Type
245 0.42 146 0.26
0.22 63 776
E 801
E 803 30 000
U100
(Engelhard) RA1K
639 0.44 321 0.25
0.22 145 288
R 86
R 62 30 000 U103 (UOP)
107 0,44 54 0.22 24 396 R62 8 360 U12 (UOP) RA1Z
- - 126 0.375 33 600 R11 16 000 U200 (UOP) RA1G
991 647 267 060 84 360 NAFTEC
PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
REFORMING CATALYSTS
Precious Metal Balance
31 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
• Recurrent malfunctions of on-stream analyzers (moisture and
Hydrogen) make more sensitive the control of water/chlorine balance.
• Clogging of the preheating train exchangers during pretreatment due to
build-up of coke as a result of lack of nitrogen to cover tanks and
thereby giving rise to reduced rate of capacity utilization.
• Pressure drop within the catalytic circuit of RA1K Reforming 1.(*)
• Leaking from water cooling towers.
• Limitation of the rate of capacity utilization by 80% of pressure because
of pressure drop and low H2/HC ratio for RA1K reforming 1.(*)
• Falling off of rotor blades from the 100TK3-Turbine of RA1K Reforming
1. (*)
• Switching-on of Units as a result of lack of electrical power (inner or
outer causes).
(*): These concerns will be taken care of as part of rehabilitation.
VI- OPERATION DIFFICULTIES
33 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
► Skikda Refinery :
To improve the rate of capacity utilization of Reforming 1 unit
which is currently limited to 80 % and in order to allow the
production of 100-NO reformate, the following has been
planned:
• Increase the quantity for the catalyst from 64 000 Kg
to 120 000 Kg.
• Replace cycle gas compressor.
V- PROSPECTS BY 2013
34 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
► Arzew Refinery :
In order to increase the output and NO of the reformate, the following
has been planned:
• Replacement of Catalyst R-62 by Catalyst R-86.
• Replacement of the cycle gas compressor.
V- PROSPECTS BY 2013
35 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES
► Algiers Refinery : Replacement of the existing unit by a new one has been planned.
Continuous Catalyst Regeneration (CCR) through licensed AXENS to :
• Increase the NO of reformate up to 102.
• Increase production of gasoline.
• Allow changeover to unleaded gasoline.
V- PROSPECTS BY 2013