Fundamentals of Reforming Catalyst and Advances: Dr. Y. K. Kuchhal
Fundamentals of Reforming Catalyst and Advances: Dr. Y. K. Kuchhal
DR. Y. K. KUCHHAL
INTRODUCTION
CATALYST FUNDAMENTALS
CATALYST COMPOSITION
METALLIC / ACIDIC FUNCTION
POISONS (TEMPORARY / PERMANENT)
EFFECT OF POISONS ON CATALYST ACTIVITY & THEIR
REMEDIES
ADVANCEMENT IN REFORMING CATALYST
INTRODUCTION
FIRST CATALYST USED IN CATALYTIC REFORMING WAS 9-10%
CHROMIUM - OXIDES OR MOLYBEDNUM OXIDES, ON ALUMINA TO
CATALYZE HYDROGENATION AND DEHYDROGENATION REACTIONS TO
PRODUCE HIGH OCTANE GASOLINE
CONTD.
1. HIGH PURITY ALUMINA GIVE LONGER LIFE (STABILITY)
ACTIVITY
IT IS GENERALLY REPRESENTED BY THE TEMPERATURE
REQUIRED TO PRODUCE A GIVEN OCTANE NUMBER
REFORMATE. THE LOWER THE TEMPERATURE, THE MORE
ACTIVE THE CATALYST.
THE HIGHER THE SPACE VELOCITY, THE MORE ACTIVE THE
CATALYST
SELECTIVITY
REGENERABILITY
CONTD.
CONTD.
FUNCTION OF CATALYST
REFORMING CATALYST IS BIFUNCTIONAL IN NATURE.
METAL FUNCTION (HYDROGENATION / DEHYDROGENATION)
ACIDIC FUNCTION (ISOMERISATION, HYDROCRACKING ETC.)
INCREASE IN ACID FUNCTION
REASON
HIGH CHLORINE CONTENT
EFFECT
INCREASE IN HYDROCRACKING AND ISOMERISATION REACTIONS
RESULT
INCREASE IN THE PRODUCTION OF LPG
DECREASE IN THE RATIO OF C1/C2 + C3 + C4
REDUCTION IN THE PURITY OF RECYCLE GAS
DECREASE IN TEMPERATURE DROP IN THE TAIL REACTOR DUE
TO EXOTHERMICITY OF HYDROCRACKING
SLIGHT DECREASE IN OCTANE NUMBER
DECREASE IN ACID FUNCTION
REASON
ELUTION OF CHLORINE DUE TO HIGH MOISTURE
CONTENT OR TOO DRY A CATALYST
EFFECT
DECREASE IN HYDROCRACKING AND ISOMERISATION
REACTIONS
RESULTS
DECREASE IN OCTANE NUMBER
REDUCTION IN LPG PRODUCTION
DECREASE IN METALLIC FUNCTION
REASON
POISON BY SULPHUR / OTHER METALS
EFFECT
DECREASE IN METAL FUNCTION EFFECT THE
DEHYDROGENATION REACTIONS
RESULTS
DROP IN OCTANE NUMBER
DECREASE IN T IN 1ST REACTOR
INCRASE IN T IN 2ND REACTOR (IN CASE OF METAL
POISONING)
DROP IN THE PURITY OF THE RECYCLE GAS
DECREASE IN THE PRODUCTION OF C 1 & C2
REACTION PATH IN CATALYTIC
REFORMING OF C6 HYDROCARBON
CATALYST SELECTION
1. HIGH ACTIVITY
HIGHER WHSV
LOWER REACTOR TEMPERATURE
2. HIGH SELECTIVITY
3. HIGH STABILITY
4. GOOD REGENERABILITY
5. COST EFFECTIVE
1. TEMPORARY POISONS
2. PERMANENT POISONS
MECHANISM
POISONING IS CAUSED BY THE H 2S EITHER CONTAINED IN
THE FEED OR RESULTING FROM THE DECOMPOSITION. H 2S
REACTS WITH PLATINUM ACCORDING TO THE EQUILIBRIUM
Pt + H2S Pt S + H2
AND WITH Re AS
Re + H2S Re S + H2
THE SULPHIDE FORMATION CONSEQUENTLY REDUCES THE
ACTIVITY OF THE CATALYST AS THE METALLIC CONTACT
AREA REDUCES
CONTD
EFFECT
SULPHUR POISON INHIBITS THE METAL FUNCTION OF
THE CATALYST.
A DECREASE IN H2 YIELD
A DECREASE IN RECYCLE PURITY
PRODUCES SULPHATE DURING COKE BURN ON
ALUMINIUM SUPPORT, IF S IS NOT REMOVED BEFORE
REGENERATION
ENHANCE RATE OF COKING AND THUS DECREASE
CYCLE LENGTH
REASON
POOR OPERATION OF THE PRE-TREATER
EITHER LOW ACTIVITY OF HYDROTREATER CATALYST
OR TOO LOW HYDROTREATER REACTOR TEMPERATURE
UN-SATISFACTORY OPERATION OF THE HYDROTREATER
STRIPPER
CONTD
DETECTION
INDICATION
CONTD
PRECAUTIONS
CONTD
NITROGEN
CONTD
MECHANISM
NH3 FORMED BY DECOMPOSITION OF ORGANIC
COMPUNDS REACTS WITH CHLORINE DECREASING
THE ACIDIC FUNCTION OF THE CATALYST AND
PRODUCING AMMONIUM CHLORIDE NH4Cl. THIS
COMPOUND IS VOLATILE UNDER REACTOR
CONDITIONS.
CONTD
EFFECT
NITROGEN REDUCES THE ACID FUNCTION
A DECREASE IN OCTANE
SLIGHT INCREASE IN H2 PRODUCTION
NH4Cl IN THE RECYCLE GAS WILL DEPOSIT IN
COOLERS, SEPARATORS, STABILIZER COLD TRAYS
AND CAN CREATE MECHANICAL PROBLEMS IN THE
RECYCLE COMPRESSORS.
NOTE
0.5 PPMW OF NITROGEN IN FEED PRODUCES ABOUT
2 TONS NH4Cl IN 106 T UNIT PER YEAR
CONTD
PREVENTION
ORGANIC NITROGEN REMOVAL IS ACHIEVED BY
HYDROTRATING THE FEED. EFFICIENTLY
NAPHTHA WITH HIGH NITROGEN CONTENT MUST BE FED
TO A PRETREATER HAVING HDN ACTIVITY ALSO
DETECTION
LABORATORY ANALYSIS OF THE FEED TO DETECT
NITROGEN COMPONENTS
REMEDIES
INCREASE THE CHLORINATING AGENT INJECTION
DO NOT INCREASE THE REACTOR TEMPERATURE TO
COMPENSATE OCTANE LOSS. THIS WILL ONLY INCREASE
THE LOSS OF CHLORINE
TAKE NECESSARY STEPS TO REDUCE NITROGEN
COMPONENTS IN THE REFORMER FEED TO < 0.5 PPMW
CHLORINE
REFORMER CATALYST CONTAIN ABOUT 1% wt CHLORINE
MECHANISM
WATER EFFECTS THE ACIDIC FUNCTION OF THE CATALYST AND
THUS DECREASES THE DE-HYDROCYCLISATION AND
ISOMERISATION REACTIONS
PREVENTION
WATER IS GENERALLY REMOVED IN THE HYDROTREATER STRIPPER.
ITS POOR OPERATION MAY RESULT MORE WATER IN HYDRATED
NAPHTHA .
DETECTION
ON LINE MOISTURE ANALYSER IS USUALLY PROVIDED IN THE
RECYCLE GAS
WATER CONTENT IN THE RECYCLE GAS MUST BE IN THE RANGE 15-
20 PPMV AND THE ASSOCIATED CHLORINE LEVEL IS 0.5 PPMV
ABOVE 50 PPMV, THE REACTOR TEMPERATURE MUST BE LOWERED
TO REDUCE THE CHLORINE LEACHING FROM THE CATALYST
50 PPMV WATER TEMPERATURE < 480oC
100 PPMV WTER < 460oC
BELOW 10 PPMV WATER IN THE RECYCLE GAS, WATER INJECTION
MUST BE USED.
1 PPMV WATER IN THE FEED RESULTS 3-4 PPMV, IN THE RECYCLE
GAS
REMEDIES
EFFECT
A DRAMATIC DECREASE IN T OF THE FIRST REACTOR AND
INCREASE T OF THE SECOND REACTOR
A DECREASE IN OCTANE
AN INCREASE IN LIQUID PRODUCT YIELD
PREVENTION
GENERALLY, METAL POISONS ARE RETAINED BY THE
UPSTREAM HYDROTREATING CATALYSTS. HOWEVER, THE
RETENTION CAPACITY IS LIMITED AND BREAK THROUGH
MAY OCCUR
IMPORTANT TO CHECK THE METAL CONTENT OF
HYDROTREATER IN FEED AND PRODUCT
COKE
MECHANISM
EFFECT
SOLUTION
DECREASE H2 YIELD
NON ACIDIC AND THEREFORE HAS LOW ACTIVITY FOR ACIDIC CATALYSED CRACKING REACTIONS.
COMMERCIALLY DEMONSTRATED
YIELD DISTRIBUTION OF R-32 & RZ-100
COMPONENTS R-32 RZ-100
H2 2.4 4.2