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Catalytic Reforming technology - Infographics IFP Fixed-bed Semi-regenerative Unit Revamps, Troubleshooting IFP (CCR) Technology Optimization In trying to determine the potential benefits from revamping a Fixed-bed Semi-Regenerative catalytic reformer, a refiner must evaluate several areas of operation: — What is the unit operating objective? — What degrees of freedom are available for revamp /optimization? — Can refinery margins, and the discretionary capital budgeting program support the revamp / optimization? Refiners must select the catalytic reformer operating point that will maximize profit within the following: 1) the mechanical constraints of the unit and 2) the short term unit operating objectives. projects that improve operating profit are compared with the required capital investment. This is done using discounted cash flow, or one of a number of other capital budgeting analysis tools, and those projects with the greatest return are put at the top of the capital budget list.
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List of Typical Process Equipment in Reforming Section (Reactors and Columns)
List of Typical Process Equipment in Reforming Section (Vessels) (Continued)
List of Typical Process Equipment in Reforming Section (Other Equipment)
List of Typical Process Equipment in Reforming Section (Tubular Furnaces)
List of Typical Process Equipment in Reforming Section (Shell and Tube Coolers / Heat Exchangers)
List of Typical Process Equipment in Reforming Section (Air Coolers)
List of Typical Process Equipment in Reforming Section (Pumps)
List of Typical Process Equipment in Reforming Section (Compressors and Blowers) (Continued)
List of Typical Process Equipment in Catalyst Regeneration Section (Electric Heater)
List of Typical Process Equipment in Catalyst Regeneration Section (Reactors and Columns)
List of Typical Process Equipment in Catalyst Regeneration Section (Vessels)
List of Typical Process Equipment in Catalyst Regeneration Section (Shell and Tube Coolers/Heat Exchangers)
Comparison of Licensed-in CCR Process and Licensed-in Semi-Regeneration Reforming Process
Option I Option II Item for Comparison CCR Process Semi-Regeneration Reforming
Process RON 102 95
WAIT/WABT ℃ 520/495 505/480 Average Reaction Pressure, MPa 0.35 1.5
LHSV h-1 1.8 2.0 H2/HC mol/mol 2.5 6.0 C5+ Yield, wt% 88 85 H2 Purity, v% 92.0 85
Pure H2 Yield, wt% 3.3 2.7 Operation Cycle, month More than 24 months 12
Comparison of UOP’s Caclemax Process and IFP’s RegenC Process Item UOP IFP
Cyclemax Regen C 1、Technical Features ⑴Process Parameters
Catalyst Model R-234 CR401 ⑵Structural Features for
Reactors Layout Superimposed Paralleled
Inlet Gas Flow Distribution Scallop shaped Round shaped Gas/Solid Flow Direction Radial Radial
Inlet/Outlet Gas Flow Direction Fed from top and withdrawn from top Fed from top and withdrawn from bottom
Catalyst Transfer between Reactors From top to down by gravity Lifted via lifter ⑶Catalyst Regeneration
Pressure, MPa(G) 0.25 (lower) 0.55 (higher) Regeneration Method One continuous coke burning system Two continuous coke burning
systems in batch-wise Gas/Solid Flow Direction Radial Countercurrent Flow Radial Concurrent Flow Regenerator Structure Two layers of screens in inverted
trapziod structure Two layer of screens in round
sleeve OCr18Ni12Mo2Ti (suitable for high 1Cr18Ni9Ti (suitable for low
Regenerator Material moisture content and high chlorinating
moisture content and low
agent environment) chlorinating agent environment) Moisture in Regeneration 35000 (high moisture level imposes 2000 (low moisture level extends
Gas, ppm impact to catalyst service life) catalyst service life) Tail Gas Flow Direction in
Chlorination Section To coke burning section To caustic scrubbing section
⑷Regeneration Gas Recycle System
Recycle Gas Transfer Power Hot Blower Cold State Compressor Item UOP IFP
Regenerator – Heat Exchanger – Recycle Flow Regenerator – Blower – Air Cooler –
Electric Heater - Regenerator Air Cooler – Scrubber – Dryer – Compressor – Heat Exchanger –
Electric Heater – Regenerator ⑸Catalyst Lift
Lift Method L-Valve Manifold Lifter Lift Gas: Catalyst for Regeneration N2 N2
Regenerant H2 H2
⑹Locked Hopper Location Below the Regenerator Above the Regenerator
Oper. Stream H2 N2
Function Locked hopper, which is controlled via lock hopper controller, is served to
transfer regenerated catalyst into regenerant lifter in batch-wise based on the recycle volume required, and
pressure balance is served to control catalyst flowing, no valves are
required.
Locked hopper is served to transfer catalyst into the
regenerator, where both the top and bottom special-purpose valves
are controlled based on the setpoints of timer, and thus recycle volume of catalyst for regeneration
is controlled. ⑺Catalyst Reduction
Location At the top of Reactor 1# Above Reactor 1# Reduction Method Two-stage reduction One-stage reduction
Purity Requirements for Reduction H2 Reformer H2 can be used 99mol% H2 required
⑻Dust Elutriation Oper. Stream N2 N2
Dust Collection System Number (set) 1 2 ⑼Instruments/Control
Systems In addition to one DCS system, an Catalyst regeneration control
Instruments/Control independent CRCS (catalyst regeneration
program is incorporated into DCS
Systems control system) system is provided as system, and no other control
well. program is provided. ⑽Land Occupation Lower 2~3% higher
2、Commercialization Number for CCR Units More Less
Ultra-Low Pressure CCR Process
Commercialized in In 1996 In 1991 3、Project Engineering Rich Rich
Comparison of Items related to UOP Processes and IFP Process Licensing
S/N UOP Process IFP Process 1 License Fee and PDP Fee License Fee and PDP Fee 2 Reactor and Regenerator Internals Reactor and Regenerator Internals 3 Feed Heat Exchanger (Plate Heat
Exchanger) Feed Heat Exchanger (Plate Heat Exchanger)
4 Booster Compressor Gas Coalescer ---
5 Electric Heater Electric Heater 6 --- H2 Purification System (Membrane Separation) 7 Regeneration Gas Air Cooler Air Dryer and Regeneration Gas Dryer 8 Regeneration Blower, Dust
Collection Blower and Lift Blower Dust Collection Blower
9 Dedicated Ball Valve and Special Control Valve for Catalyst Pipeline
Dedicated Ball Valve and Special Control Valve for Catalyst Pipeline
10 On-line Analyzer and Radioactive Level Meter
On-line Analyzer and Radioactive Level Meter
11 Catalyst Regeneration Control System (CRCS), Distributed Control
System (DCS) and Emergency Shutdown System (ESD)
Distributed Control System (DCS) and Emergency Shutdown System (ESD)
Summary of Recommended Process/Technology Assessment
GBHE S/N
Item Assessment
1 Cutting-edge performance 2 Operational Flexibility 3 Operational Reliability 4 Operation Safety 5 Economic Profit 6 Development Outlook 7 Technical Investment per Unit
Product 8 Total Investment per Unit Product 9 Product Quality 10 Improvement Margin for Product
Quality 11 Technical Performance for
Maintaining Product Quality 12 Flexibility to Raw
Materials/Feedstocks 13 Proper Design for Process Flow 14 Process Suitability to Cleaner
Production 15 Process Availability 16 Flexibility to Natural Conditions 17 Total Operation Cost 18 Product Competitiveness 19 Cost Reduction Possibility 20 Concerns and Improvements
Prior to Modifications
After Modifications
Units
OperationCycle Length daysEOR WAIT °F H2:HC RatioBarrels per pound of catalyst BBL/lbSeparator Pressure psig
RegenerationCarbon burn time HoursCalculated Carbon on Catalyst Lbs
Average Cycle Feed PropertiesCharge MBPDFeed Gravity °API Feed 95% °FFeed N+3.5A LV%
Average Products and YieldsRONC H2 Purity mole% C5+ Yield LV%H2 Yield SCFB
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