Catalytic reforming is the chemical process in oil refineries for converting the low-value
heavy naphtha fraction of crude oil into high octane reformate, aromatics rich feed-stock and hydrogen. High octane reformate is a premium blending component for a refinery gasoline pool with a 30~50 % share. The aromatics-rich (benzene, toluene, and xylene) product serves as a vital petrochemical feedstock. The hydrogen product is utilized in other refinery hydroprocessing units.
Naphtha catalytic reforming process is the key process in oil refining to meet the demands of gasoline fuel specifications and hydrogen gas for hydrotreating and isomerization units. But one bottleneck of high aromatics content in gasoline may restrict the naphtha reforming process due to strict environmental regulations.
Naphtha catalytic reforming processes are classified as continuous, cyclic, or semi-regenerative depending upon the frequency and mode of reforming catalyst regeneration.
1. Continuous Reforming Process is designed to continuously remove small quantities of reforming catalyst from a live reactor, transfer to a regeneration section, regenerate and return back to the reactor system. In the moving-bed design, all the reforming reactors are stacked on top of one another. The reactors have a common catalyst bed system that moves as a column of particles from top to bottom of the reactor section. The exhausted catalyst with coke on its surface is withdrawn from the last reactor and sent to the regeneration reactor, where the catalyst is regenerated on a continuous basis. The continuous reforming process has the advantage of operation at low pressures and high severity. Additional benefits include elimination of downtime for catalyst regeneration and steady production of high octane reformate and hydrogen of constant purity.
2. The Semi-regenerative Reforming Process on the other side requires the unit to be taken off-stream for catalyst regeneration. Depending upon the severity of the operation, regeneration is required at intervals of 1~2 years. High hydrogen recycles rates and operating pressures are utilized to minimize coke laydown and resultant loss of catalyst activity. It is a conventional reforming process, as the catalytic activity decreases the reformate RON and hydrogen purity drops. As the catalyst activity declines, reactor temperatures are increased to maintain the desired product quality.
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