Q&A

(2015) Question 17: What considerations should you make when contemplating changing catalyst supplier from the original unit licensor?

Changing catalyst suppliers is not an uncommon practice. It is done successfully in many different locations. Typically, cost and yield improvements are the most influential factors. However, there are some other key considerations before making the change.

(2015) Question 18: Due to lower product octane requirements, has your strategy for dumping and screening fixed-bed reforming catalyst changed from the standard recommendation of three years or three in-situ regenerations?

As with any catalyst, the deactivation rate is a function of processing similarity; and consequently, if the unit is targeting lower octane values, regeneration requirement can become less frequent. It is really up to the refiner to make the decision as to whether or not to let the cycle extend out longer because of the lower production of the coke or to regenerate more proactively on an annual basis to ensure that the yield losses are maintained at a minimum.

(2015) Question 19: What is the maximum recommended nitrogen content of reformer feed for continuously regenerated units? What is its impact on chloride consumption and ammonium chloride generation?

The typical licensor guideline is 0.5 ppm maximum nitrogen in the feed. When nitrogen contacts the catalyst in the reforming unit, it essentially strips chloride from the catalyst. The reduced chloride on catalyst results in reduced catalyst activity.

(2015) Question 20: What are common causes for platinum agglomeration and the catalyst of continuously regenerated reforming units, and what are the common solutions to address these issues?

I am not a reforming expert, but I often travel with one. I have to listen to these discussions [laughter]. What Kiran said is all correct; it gets down to procedures. After you come out of the burn, you must go into the rejuvenation step. It is critical to do that properly, so it needs to be monitored.

(2015) Question 21: What is the impact on unit performance when different qualities of hydrogen are used for the reduction step in a fixed-bed reforming unit?

Hydrogen needs to be dry and have less than 20 ppm of contaminants such as water, light hydrocarbons, CO, CO2, H2S, and NH3. Each of these can have different effects on the catalyst’s final activity. The purpose of the reduction step is to remove the oxygen from the catalytic metals while minimizing chloride stripping.

(2015) Question 22: How frequently do you change [or changeout?] the catalyst in reforming units? What are the appropriate economic criteria to evaluate?

For semi-regenerative reformers, catalyst life is often dependent on contamination or upset-related issues. Lead reactors can become contaminated with iron, which ultimately affects the product yields. Skimming or possible replacement to prevent downstream contamination is a common practice.

(2015) Question 23: In continuously regenerated reforming units, are there valves in cyclic service that have demonstrated superior performance compared to the originally installed valves? How can maintenance of these valves have an impact on their longterm performance and reliability?

From the question, it is not clear which style of valve in cyclic service is of the highest interest. There are two types of cyclic services that are specific to the CCR process, each with different requirements and potential pitfalls. There are on/off valves in vapor service with catalyst dust, such as those that vent the lock hoppers, and the on/off valves in flowing catalyst service, such as those used for catalyst flowing in and out of the lock hoppers.

(2015) Question 24: During the oxidation step in the regeneration of fixed-bed catalytic reformers, how does varying the length and oxygen concentration affect the unit performance?

The length of the oxidation period will vary from a minimum of 11 hours up to 24 hours. The timeframe will depend on the amount of platinum agglomeration, surface area, oxygen content, and chloride injection rate. Minimizing the burn temperature during the primary burn will minimize agglomeration.

(2015) Question 25: Have you detected any hydrogen chloride slip in the stabilizer bottoms for any gasoline units (isomerization or reformer)? What are your Best Practices to prevent downstream unit corrosion?

Occasionally, isomerization units will slip some HCl or organic chlorides at the bottom of the stabilizer. The key here is having the proper reflux ratio on that tower because you need to keep the partial pressure of the HCl low enough that it will not overheat.

(2015) Question 26: What is your Best Practice for packing (material and shape) in isomerization unit off gas caustic scrubbers?

UOP recommends carbon Raschig rings. The key here is to specify to the vendor that this be used for caustic service so that the rings will be formed with the proper binder. If you get the wrong binder, the rings will dissolve. We have a similar service in HF alky units where we use carbon Raschig rings; and there, you have to make sure that the binder is resistant to acid.

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