Catalytic Reforming
Catalytic Reforming
Catalytic Reforming
KLM Technology
Group
Rev: 01
Practical Engineering ENGINEERING SOLUTIONS
Guidelines for Processing
Plant Solutions Rev 1 April 2017
www.klmtechgroup.com
Co Authors
KLM Technology Group Kolmetz Handbook Rev 1 Apriliana
P. O. Box 281
Bandar Johor Bahru,
of Process Equipment Design
80000 Johor Bahru,
Johor, West Malaysia Editor / Author
REFINERY CATALYTIC REFORMING
UNIT SELECTION, SIZING Karl Kolmetz
AND TROUBLESHOOTING
TABLE OF CONTENTS
INTRODUCTION 5
Scope 5
DEFINITION 23
NOMENCLATURE 25
CCR Platforming 35
Common Problems 53
Reactor 54
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(ENGINEERING DESIGN GUIDELINES)
Catalysts 56
Process Variables 64
Troubleshooting 71
APPLICATION
REFEREENCE 84
LIST OF TABLE
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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April 2017
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(ENGINEERING DESIGN GUIDELINES)
Table 11: Operational response for water, sulphur and nitrogen upset 74
LIST OF FIGURE
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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April 2017
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(ENGINEERING DESIGN GUIDELINES)
Figure 22: Furnace (F1, F2, F3) and reactor (R1, R2, R3) layout. 55
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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April 2017
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(ENGINEERING DESIGN GUIDELINES)
INTRODUCTION
Scope
This guideline provides knowledge on how to design a refining catalytic reforming unit.
This design guideline can assist to understand the basic design of catalytic reforming with
suitable size, material and heat of combustion. Catalytic reforming is a major conversion
process in a petroleum refinery and petrochemical industries.
The problem of low octane ratings of naphtha is solved by increasing the contents of
isomers and aromatics in its composition. In the catalytic reforming unit of a refinery, the
objective is to convert lower octane value naphtha into higher octane reformate that can
be used for gasoline blending. The function of the reformer is to efficiently convert
paraffins and naphthenes to aromatics with as little ring opening or cracking as possible.
Catalytic reforming is a process whereby light petroleum distillates (naphtha) are
contacted with a platinum-containing catalyst at elevated temperatures and hydrogen.
The theory section explains the selection of the catalytic reforming type, calculation of
sizing, trouble shooting, catalyst, and process variable that effect in catalytic reforming.
The application of the catalytic reforming theory with the examples assists the user to
study the catalytic reforming concepts and be prepared to perform the actual design of
the catalytic reforming.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 6 of 94
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(ENGINEERING DESIGN GUIDELINES)
The low octane, paraffin-rich naphtha feed is converted to a high-octane liquid product
that is rich in aromatic compounds. catalytic reforming produces reformate with octane
numbers of the order of 90 to 95. Hydrogen and other light hydrocarbons are also
produced as reaction by-products. In addition to the use of reformate as a blending
component of motor fuels, it is also a primary source of aromatics used in the
petrochemical industry.
The first catalytic reforming units were designed as semi regenerative (SR), or fixed-bed
units, using Pt/alumina catalysts. Semi regenerative reforming units are periodically shut
down for catalyst regeneration. This involves burning off coke and reconditioning the
catalyst’s active metals. To minimize catalyst deactivation, these units were operated at
high pressures in the range of 2,760 to 3,450 kPa (400–500 psig). High hydrogen
pressure decreases coking and deactivation rates.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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(ENGINEERING DESIGN GUIDELINES)
nonexistent in the United States before 1940. The process is really a process of the
1950s and showed phenomenal growth in the 1953–1959 period. As a result, thermal
reforming is now somewhat obsolete.
Feedstocks
The yield of gasoline of a given octane number and at given operating conditions
depends on the hydrocarbon types in the feed. Naphtha feedstocks to reformers typically
contain paraffins, naphthenes, and aromatics with 6–12 carbon atoms. In the majority of
cases the feed may be a straight-run naphtha, but other byproduct low-octane naphtha
(e.g., coker naphtha) can be processed after treatment to remove olefins and other
contaminants. Hydrocarbon naphtha that contains substantial quantities of naphthenes is
also a suitable feed. high-naphthene stocks, which readily give aromatic gasoline, are the
easiest to reform and give the highest gasoline yields.
Most feed naphtha have to be hydrotreated to remove metals, olefins, sulfur, and
nitrogen, prior to being fed to a reforming unit. A typical straight run naphtha from crude
distillation may have a boiling range of 150–400◦F (65–200◦C).
In addition to naphtha from crude distillation, naphtha can be derived from a variety of
other processes that crack heavier hydrocarbons to hydrocarbons in the naphtha range.
Cracked feedstocks may be derived from catalytic cracking, hydrocracking, cokers,
thermal cracking, as well as visbreaking, fluid catalytic cracking, and synthetic naphtha
obtained, for example, from a Fischer–Tropsch process.
Light paraffinic naphtha are more difficult to reform than heavier naphthenic
hydrocarbons. Distillation values for the initial boiling point, the mid-point at which 50% of
the naphtha is distilled over, and the end point are often used to characterize a naphtha
(Figure 1). Paraffinic stocks, however, which depend on the more difficult isomerization,
dehydrocyclization, and hydrocracking reactions, require more severe conditions and give
lower gasoline yields than the naphthenic stocks.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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(ENGINEERING DESIGN GUIDELINES)
The end point of the feed is usually limited to about 190 °C (375 °F), partially because of
increased coke deposition on the catalyst as the end point during processing at about 158
°C (278 °F). Limiting the feed end point avoids re-distillation of the product to meet the
gasoline end-point specification of 205 °C (400 °F), maximum.
Paraffinic Naphthenic
(Arabian Light) (Nigeria)
RON 50 66
Av.Mw 114 119
S (ppm wt) 500 350
Paraffins 66.8 29.3
Naphthenes 21.8 61.85
Aromatics 11.4 8.85
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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The reformate stream from a catalytic reforming unit is invariably used either as a high
octane gasoline blending component or as a source of aromatics—BTX (benzene,
toluene, and xylenes), and C9+ aromatics. Reforming for motor fuel applications still
represents the majority of existing reforming capacity. Reformate specifications (octane,
vapor pressure, end point, etc.) are set to provide an optimum blending product.
The octane requirement is met through the production of high-octane aromatics, the
isomerization of paraffins, and the removal of low octane components by cracking them to
gaseous products. Feedstocks to these units are typically “full range” naphtha, consisting
of hydrocarbons with 6–12 carbon atoms; however, the initial boiling point may be varied
to limit the presence of benzene precursors.
Reforming units for the production of aromatics are often called BTX reformers. Naphtha
for these units are specified to contain mostly naphthenes and paraffins of 6–8 carbons.
The desired reaction is aromatization through dehydrogenation of the naphthenes, and
cyclization and dehydrogenation of the paraffins to the analogous aromatic.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Reformate properties
For motor fuel applications, the octane number is the dominant parameter of product
quality. A higher octane number reflects a lower tendency of the hydrocarbon to undergo
a rapid, inefficient detonation in an internal combustion engine. This rapid detonation is
heard as a knocking sound in the engine, so octane is often referred to as the antiknock
quality of a gasoline. Motor fuel octanes are measured at low engine speeds (research
octane number or RON) or at high engine speeds (motor octane number or MON). Table
3 provides a listing of the various octanes of pure hydrocarbons.
RON MON
Paraffins
n-heptane 0 0
2-methylhexane 42.4 46.3
3-ethylpentane 65.0 69.3
2,4-dimethylpentane 83.1 83.8
Aromatics
Toluene 120.1 103.2
Ethylbenzene 107.4 97.9
Isopropylbenzene 113 99.3
1-methyl-3-ethylbenzene 112.1 100
1,3,5-trimethylbenzene >120 >120
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Normal paraffins have the least desirable knocking characteristics and they become
progressively worse as the molecular weight increase, while iso-paraffins and naphthenes
have higher octane numbers than the corresponding normal paraffins. The octane
number of the iso-paraffins increases with the increase of branching of the chain. Olefins
have markedly higher octane numbers than the corresponding paraffins and aromatics
usually have very high octane numbers.
Comparing the different hydrocarbon series, aromatics – except for Benzene – are the
hydrocarbons with the highest octane numbers. Hence, to increase the octane number of
gasoline, the paraffinic and naphthenic contents in gasoline should be transformed into
aromatics and isoparaffins. Such a transformation process is called the Reforming
Process.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Reforming reactions
The principal reforming reactions are the cracking of paraffins, paraffins isomerisation,
dehydrocyclisation of paraffins to naphthenes and the dehydrogenation of naphthenes.
The cyclisation and dehydrogenation reactions produce valuable aromatics. In BTX
production, the objective is to transform paraffins and naphthenes into benzene, toluene,
and xylenes with minimal cracking to light gases. The yield of desired product is the
percentage of feed converted to these aromatics. In motor fuel applications, octane
values of the feed may be raised via aromatization or through isomerization of the
paraffins into higher octane branched species without sacrificing yield. Yield is typically
defined as liquid product with five or more carbons.
A generalized reaction scheme that identifies these key reactions, as well as the reaction
pathways that are required to achieve high product yields, is depicted below. As shown,
two key catalyst functions are served by acid and metal sites. The performance of the
catalyst system, as measured by its activity and selectivity to the desired reactions, is a
function of the balance achieved between these acid and metal sites.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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(ENGINEERING DESIGN GUIDELINES)
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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The reforming reactions are classified into eight general classes that include the following
reversible reactions:
Typical catalysts that consist of platinum supported on alumina (with or without other
metals or modifiers) are bifunctional in that separate and distinct reactions occur on the
platinum site and on the alumina. The platinum typically performs dehydrogenation and
hydrogenolysis, while the acidic alumina isomerizes, cyclizes, and cracks. The
dehydrogenation of naphthenes to aromatics is probably the most important reaction.
Feeds contain cyclopentanes and substituted cyclopentanes, as well as cyclohexanes
and their homologues. Six carbon ring cyclohexanes, for example, can be directly
dehydrogenated to produce aromatics and hydrogen.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Naphthene De-hydrogenation
Isomerization
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Paraffin conversion is the most difficult step in reforming. For that reason, the ability to
convert paraffins selectively is of paramount importance in reforming. Paraffins may be
isomerized over the acidic function of the catalyst to provide higher octane branched
paraffins.
• Equilibrium limited
• Slightly exothermic – 1.0 kcal
• Favored by low temperatures
• Rate can be expressed by R = k (PHC / PH )0.5
• Change from 0 octane to 89 octane
Hydrocracking
Another acid catalyzed paraffin reaction is cracking to lighter products, thus removing
them from the liquid product. Octane is improved through the removal of low octane
paraffinic species from the liquid product by their conversion to gaseous, lower molecular
weight paraffins.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Paraffin dehydrocyclinization
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Aromatic De-alkylation
• Differs from De-methylation only in the size of the fragment removed from the ring
• Favored by high temperature and high pressure
De-methylation
Small amounts of olefins are formed that also undergo a number of isomerization,
alkylation, and cracking reactions. In particular, they appear to play an important role as
an intermediate in cyclization reactions. The dehydrogenation of naphthenes and
paraffins is rapid and equilibrium concentrations are established in the initial portions of a
catalyst bed. Isomerization reactions are sufficiently fast that actual concentrations are
near equilibrium.
The observed reaction rate for dehydrocyclization is reduced by the low concentrations of
the olefin intermediates that exist at equilibrium. Hydrogen partial pressure significantly
affects olefin equilibrium concentrations and has a significant impact on aromatization and
dehydrocyclization of paraffins. Lowering hydrogen partial pressures results in an
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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As a result of the reactions taking place during the process, reformates consist – mainly –
of branched paraffins and especially aromatics, most of which have fewer than 10 carbon
atoms. Figure 5 shows the total changes taking place in the reformer to produce the
desired aromatics and isoparaffins.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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(ENGINEERING DESIGN GUIDELINES)
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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Process Overview
The catalytic reforming process consists of a series of several reactors, which operate at
temperatures of approximately 480 °C (900 °F). The hydrocarbons are reheated by direct-
fired furnaces between the subsequent reforming reactors. As a result of the very high
temperatures, the catalyst becomes deactivated by the formation of coke (i.e., essentially
pure carbon) on the catalyst, which reduces the surface area available to contact with the
hydrocarbons. Reforming reactions highly endothermic, so several reheats and reactor
stages are used. The basic purpose of the reactors is to reform the “straight chain“
molecules into aromatic and branched aromatic molecules.
Catalytic reforming is usually carried out by feeding a naphtha (after pretreating with
hydrogen if necessary) and hydrogen mixture to a furnace where the mixture is heated to
the desired temperatures 450 °C to 520 °C (840 °F to 965 °F), and then passed through
fixed-bed catalytic reactors at hydrogen pressures of 100 to 1000 psi. Normally, two (or
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 22 of 94
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Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
more than one) reactors are used in series, and reheaters are located between adjoining
reactors to compensate for the endothermic reactions taking place. Sometimes as many
as four or five are kept on-stream in series while one or more is being regenerated. The
on-stream cycle of any one reactor may vary from several hours to many days, depending
on the feedstock and reaction conditions.
The product issuing from the last catalytic reactor is cooled and sent to a high-pressure
separator where the hydrogen- rich gas is split into two streams:
One stream goes to recycle where it is mixed with the feed, and
The remaining portion represents excess hydrogen available for other uses.
The excess hydrogen is vented from the unit and used in hydrotreating, as a fuel, or for
manufacture of chemicals (e.g., ammonia). The liquid product (reformate) is stabilized (by
removal of light ends) and used directly in gasoline or extracted for aromatic blending
stocks for aviation gasoline.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 23 of 94
KLM Technology Kolmetz Handbook
Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
There are several types of catalytic reforming process configurations that differ in the
manner that they accommodate the regeneration of the reforming catalyst. Catalyst
regeneration involves burning off the coke with oxygen. The semi-regenerative process is
the simplest configuration but does require that the unit be shut down for catalyst
regeneration in which all reactors (typically four) are regenerated. The cyclic configuration
uses an additional swing reactor that enables one reactor at a time to be taken off-line for
regeneration while the other four remain in service.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 24 of 94
KLM Technology Kolmetz Handbook
Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 25 of 94
KLM Technology Kolmetz Handbook
Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
DEFINITIONS
Catalytic reforming - a process for improving the octane quality of straight-run naphtha
and of mixed naphtha containing cracked naphtha
Coke - formed in the processes to convert the residuum fuels to the more desirable
distillate products of naphtha and lighter through to the middle distillates
The material balance - the process represented by the process flow diagram is either
shown in table form on the bottom of the flow sheet or on an attached but separate table
Regenerator - A unit including reboiler, still column and other related facilities to
regenerate (or re-concentrate)
Excess Air - The percentage of air in the heater in excess of the stoichiometric amount
required for combustion
Exothermic - A process or reaction that release heat, i.e. a process or reaction for which
the change in enthalpy, ΔH, isnegative at constant pressure and temperature
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 26 of 94
KLM Technology Kolmetz Handbook
Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
Lower Heating Value (LHV) - The theoretical heat of combustion of a fuel, when no
credit is taken for the heat of condensation of water in the flue gas.
Pressure drops - the difference in pressure between two points of a fluid carrying
network. Pressure drop occurs when frictional forces, caused by the resistance to flow
Catalyst - A substance, usually used in small amounts relative to the reactants, that
modifies and increases the rate of a reaction without being consumed in the process.
Space velocity - The relationship between feed rate and reactor volume in a flow
process; defined as the volume or weight of feed (measured at standard conditions) per
unit time per unit volume of reactor (or per unit weight of catalyst).
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 27 of 94
KLM Technology Kolmetz Handbook
Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
NOMENCLATURE
% H2 % H2 in Naphtha (w/w), %
%(C1+C2) % (C1 + C2) in Naphtha (w/w), %
%C3 % C3 in Naphtha (w/w), %
%C4 % C4 in Naphtha (v/v), %
%C5+ % C5+ in Naphtha (v/v), %
%excess Excess air, %
%naphtha % naphtha in crude, %
Cao concentration at XA=0, lbmol/ft3
D Diameter of reactor, ft
FAo molar flow rate in, lbmol/h
GC5+ Volume flowrate of C5+, ft3/h
Gnaphtha Volume flowrate of naphtha, ft3/h
HFG enthalpy flue gas, btu/lb
L Length of reactor, ft
LHV LHV fuel gas, btu/lb
Mr Mass molecule naphtha
nXA=0 order of reaction at XA=0, lbmol
nXA=1 order of reaction at XA=1, lbmol
P Pressure, psia
Qduty Duty, btu/h
Qfired Heat fired, btu/h
rec.H2 H2 recycle, lbmol H2/lb naphtha
SGC5+ Specific gravity of C5+
SGn Specific gravity of naphtha
T Temperature, F
TFG Flue gas temperature, F
Tm Mean temperature, F
V Volume of reactor, ft3
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Page 28 of 94
KLM Technology Kolmetz Handbook
Group of Process Equipment Design
Rev: 01
REFINERY CATALYTIC REFORMING
Practical Engineering
Guidelines for Processing Plant UNIT SELECTION, SIZING
Solutions AND TROUBLESHOOTING
April 2017
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)
Greek Leters
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.