jawad reforming
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(Platforming of Naphtha)
CatalyticReforming
By: M.J.Raza
312746
T.S.M Operations
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Things to be Discussed.
Introducing Reforming.
Need of Reforming
The RONc Concept.
What is Knocking???
Reforming Process PFD.
The Reforming Reactions & Catalyst.
The Process Sections & P&IDs.
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Introducing Reforming.
Catalytic reforming is a chemical process used to
convert petroleum refinery Naphtha, typically having
low octane ratings, into high-octane liquid products
called REFORMATE which are components of high-
octane gasoline
As evidence from the name, the term Reforming
Refer to the Rearranging the molecular structure,just like a straight chain paraffin molecule reform to
a branched chain molecule through a chemical
Reaction.
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Need of Reforming.
To increase Octane Number of the
hydro-carbons, which mean decreasing
anti-knocking ability of the fuel in thecombustion engine, which otherwise
tend to damage the vehicle hardware.
To increase the ease of combustion offuel inside the engine .
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The RONc Concept.
Mechanically Octane Number can be
defined as The anti-knocking ability
of fuel in the internal combustionengine, if little knocking in engine,
means fuel is of good RON.
Chemically Percentage by volume ofiso-octane in a mixture of iso-octane
and n-heptane.
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What is Knocking???
For better operation of an engine, it is
necessary that all molecules, burning in the
engine, should be of same fashion, havingequal ignition temperature, because when
spark is provided, all molecules should burn at
same time to give power stroke.
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What is Knocking???
If molecules of varying size enter in thecombustion engine, then small moleculesignite firstly and gives power stroke, whenpiston travel back after power stroke, thenlarge molecules ignite, so piston want to movein reverse direction, hence it creates sound in
engine called knocking. Knocking cause sudden stress on piston
which can damage piston / compression rings.
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Reforming
Process
PFDs
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Reforming Process PFD.
Some terms needed to understand Reformer PFDare:
FBRN: Full Boil Range Naphtha.LSRN: Light Straight Run Naphtha.
HSRN: Heavy Straight Run Naphtha.
HTN: Hydro-treated Naphtha.RON: Research Octane Number.
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The Reforming Reactions.
Following Reaction takes place in
Reforming reactors.
Dehydrogenation. Isomerization
Dehydro-Cyclization
Hydro Cracking
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The Reforming Reactions.
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Dehydrogenation.
This Reaction converts Naphthenes to
Aromatics.
Metal Promoted Reaction. This reaction is highly endothermic.
(+50 Kcal/mol)
Methyl-Cyclohexane (a naphthene) hasRON of 84, when dehydrogenize,
converted to toluene (An aromatic)
which has RON of 107.
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Isomerization
This Reaction converts straight chain
paraffins to branch chain paraffins.
Acid Promoted Reaction. This reaction is also endothermic. Requires
2KCal/mol of energy.
Hexane (n-paraffin) when converted to iso-hexane (iso-paraffin), its octane number
improve from 26 to 73.
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Dehydro-Cyclization
This reaction converts Naphthenes to
Aromatic.
Hydrogen is Removed from Naphthenes. This Reaction is endothermic + 60kCal/mol
and hydrogen is produced
Methyl-cylcohexane converted to toluenegives 107 octane from 84. (Both Metal &
Acid Promoted)
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Hydro-Cracking
In this reaction, large molecules of straight
chain paraffins converted to small chain
paraffins. This reaction consumes hydrogen and is
the only exothermic reaction - 10KCal/mol
occurring in last reactor.
Acid promoted Reaction.
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The Reforming Catalyst.
The Plat-forming catalyst is R-56.
This is a UOP Designed catalyst, in which metals
of Pt & Rh are coated homogeneously over thesurface of Alumina base.
The catalyst is Extrude in shape, just like a rice
grain, having off-white color.
Pt & Rh are most expensive metals. Pt is present 0.25 % and Rh is 0.4 % in catalyst.
The UOP Platforming catalyst has been chosen to
meet yield, activity and stability needs.
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TheReforming
Process.
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Reforming Process Section
Reforming process can be divided into four
inter connected sections:
Splitter SectionHydro-Treating Section
Reforming Section
Stabilizer section.
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Splitter Section
Splitter section is used to control the IBP of
the Reformer feed.
The streams from the Splitter section are:LSRN: (IBP: 31 C, FBP: 91 C)
Solvent Cut: (IBP: 45 C, FBP: 1225 C)
HSRN: (IBP: 96 C, FBP: 158 C)
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Splitter Section
Splitter Top Conditions are:
Temp: 96 C, Pressure: 2.8 Kg/Cm2
Splitter Trays: 50Feed Tray: 37
Splitter Bottom Conditions are:
Temp: 167 C, Pressure: 3.2Kg/Cm2
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Hydro-Treating Section
The Purpose of the section is to remove the
sulphur in the feed.
The reactor is designed to remove max 158ppm of sulphur from the HSRN.
Maximum allowable limit of sulphur to
reforming section is < 0.5 ppm.
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Hydro-Treating Section
The reactor operating condition are:
RIT: 315 C, ROT: 313 C
Pressure: 19 kg/Cm2Reactor Type: Down flow.
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Reforming Section
Plat-forming process consist of
following steps:
Feed Pre-Heating. Reactor Heater assembly.
Cooling of product stream.
Separator
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Feed Pre-Heating Feed pumped through a high pressure
centrifugal pump from Stripper bottom.
Hydrogen comes from Recycle gas
compressor at high pressure. Both hydrogenand feed combined through a line.
The combine feed enters in the exchanger
series, where it is pre-heated through thecounter coming hot product stream. Thisfeed enters in Reformer Heater 1.
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Heater & Reactor A specific ratio of water and chloride is injected
to maintain chloride level over the catalystsurface, which otherwise may change the catalystcomposition.
The Cl injected, not only maintain Cl level oncatalyst, but also promotes acid promotedreactions, because it produces acid environmentin reactor.
The Hot feed after exchanger enters in ReformerFirst Heater where it is heated up-to 500 oC temp.
Hot feed enters in first Reactor. Reactor is Radial
flow.
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Heater & Reactor This feed is heated again in Second heater of
Reformer where temp is again raised to 500 oC
so that reactions can takes place at this designated
temp & then feed enters in 2nd Reactor. Temp again drops as a result of reactions, so feed
is again heated to required temp and passes
through 3rd Reactor. The Hot products stream
cooled through feed/Products exchangers and trimcooler.
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Reaction Conditions Reformer Reactors are operated at 20 Kg pressure
and 500 oC inlet temperature.
System pressure is maintained through separator
(pressure), which operate at 16.1 kg/cm2. Feed passes through reactor with a specific max
rate called LHSV.
A Specific H2 to HC ratio is maintained to setresidence time of feed within the Reactor system.
(H2/HC ratio = 4.5 min)
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Stabilization Section. A pump takes suction from the separator bottom
and send to stabilizer pre-heat exchanger and thento Stabilizer.
Stabilize is a high pressure vessel operates at 19kg pressure.
Purpose of stabilizer is to remove the LPG,formed by hydro-cracking reaction, which isoccurred in last reactor. In this way, Naphthastabilizes and its RVP controlled.
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Stabilization Section. Heated Feed enters in stabilizer feed plate.
The lighter molecules which are formed bybreaking of large chain molecules, travels to topof the tower.
A condenser condenses the LPG heavy endswhich are circulated back in tower to controltower temp and pressure.
The un-condensable molecules are fed as gas tothe fuel gas system.
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The Reformate. The final product from bottom is sent to
condenser and trim cooler for cooling without any
pump, as pressure of stabilizers enough for
transferring this liquid to storage. Final product is named as Reformate, in which
a specific ratio of LSRN is mixed to form PMG.
All Specification of this product are achieved
before marketing.
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Thank you
Q&As