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Catalytic Reforming for Refining & Petrochemicals

5 days RAF/CAREF-E
Level
Proficiency
Audience
  • Engineers, senior operations personnel or technical supervisory staff interested or involved in the operation, optimization and monitoring of hydrogen and aromatics production units.
  • Engineers from research centers and engineering companies involved in the different aspects of the operation and process control of these processes.
Purpose
  • To provide a thorough technical understanding of semi-regenerative or continuous regenerative catalytic reforming processes, for refining and petrochemicals.
  • To enable optimization and troubleshooting.
Learning Objectives
  • To assess the influence of operating parameters on a unit performance.
  • To optimize the process to achieve the targeted yield in BTX, from the design to the operation.
  • To grasp the essence of catalyst regeneration.
  • To learn about potential upsets and troubleshooting.
  • To acquire the best practices for unit start-up, normal operation and shutdown.
Ways and means
  • Applications, teamwork, case studies and interactive workshops based on typical real situations.
Observation
Der Vortrag über dieses Thema kann auch auf Deutsch gehalten werden.

THE CATALYTIC REFORMER WITHIN THE REFINERY SCHEME 0.5 day
  • Quality specifications of gasolines; reformulated gasoline and future trends.
  • Octane improving processes, integration within the refining processes.
  • Needs in hydrogen. Aromatic complex overview, need for benzene, toluene and xylenes.
  • Influence of feedstocks origins and characteristics on the performances of the units: IBP, FBP, composition (N,A, etc.), physical properties, impurities content.
  • Current yields and properties of the reformate in relation with severity.
OPERATING PARAMETERS OF A CATALYTIC REFORMER 1 day
  • Process flow diagrams and operating parameters of a catalytic reforming unit: semi-regenerative and continuous regenerative. Main control loops.
  • Material balance. Energy consumption.
  • Semi-regenerative processes
  • Operating variables: WABT, WAIT, H2/HC ratio, flow rates, water and chlorine injection, recycle gas and hydrogen rich gas characteristics, flash drum conditions.
  • Main equipment and metallurgy: features of reactors, heat exchangers and furnace technology, corrosion issues.
  • Low pressure technology: continuous regenerative processes
  • Low pressure equipment, recontacting section, catalyst circulation: lifts, ∆P control, seal legs, nitrogen loops for regeneration, etc.
  • Analyzers and process control.
CATALYTIC REFORMING REACTIONS AND CATALYSTS 1 day
  • Review of the characteristics of all the chemical reactions: thermodynamics and kinetics.
  • Influence of the operating parameters on the production of aromatics, hydrogen, octane number, and other yields. Consequences for semi-regenerative and continuous regenerative processes.
  • Catalyst properties: role of the acidic and metallic functions, of the support, of the different promotors and their impact on chemical reactions and yields. Water/chlorine balance and management.
  • Catalyst composition and selectivity, poisons and ageing factors.
  • Catalyst activity follow up and cycle length prediction for semi-regenerative units.
  • Catalyst regeneration. Role of each step for an optimal activity. Operating parameters for CCR regeneration loops.
OPERATION AND OPTIMIZATION FOR CATALYTIC REFORMING 1 day
  • Unit operation: monitoring the operating variables and optimization, for semi-regenerative and regenerative units. Operation case studies.
  • Flexibility of the continuous process. Performance follow-up.
  • Maximizing the performances of the unit under constraints or limit conditions.
  • Main steps for start-up and shutdown.
TROUBLESHOOTING FOR CATALYTIC REFORMING 0.5 day
  • RON or aromatic content decrease: causes, diagnostic and remedies.
  • Moisture in the feed, sulfur peak, chlorine peak: diagnosis and remedies.
  • Recycle or separation problems, recycle gas analysis.
  • Reactor temperature run-off.
  • Specific troubles of CCR units: catalyst circulation, regeneration loops, chilling system, nitrogen lift pollution.
  • CCR operation with catalyst regeneration problems.
FROM A REFINING TOOL TO A PETROCHEMICAL TOOL 1 day
  • Outlets and main use of BX (Benzene, Xylenes), ethylbenzene.
  • Technical key points to manage with: catalytical, operating conditions in order to adapt the catalytic reforming unit.
  • Basic scheme to upgrade benzene and paraxylene.
  • Benzene recovery unit: implementation of an extractive distillation section.
  • Implementation of an aromatic loop: addition of an isomerization section to optimize the paraxylene recovery unit.
  • Operating conditions for a typical arrangement. Main associated key steps during start-up and shutdown. Main operating variables and parameter.