Lecture 6

Catalytic reforming is a process of transforming linear
paraffinic (C7-C10) hydrocarbons contained in crude unit

naphthas, with low octane ratings, are converted in a high
octane reformate containing.
These reformates are a premium blending stock for producing

high octane gasoline.
The reformate is also the main source of bulk aromatic

chemicals such as benzene, toluene, xylene, and ethylbenzene
which serve as feedstock in the manufacture of plastics.
The catalytic reformer is one of the major units for gasoline
production (37 wt% of the total gasoline pool).
The straight run naphtha from the crude distillation unit is

hydrotreated to remove sulphur, nitrogen and oxygen which can all
deactivate the reforming catalyst.
The hydrotreated naphtha (HTN) is fractionated into light naphtha

(LN), which is mainly C5-C6, and heavy naphtha (HN) which is mainly
C7-C10 hydrocarbons.
Light naphtha (LN) is isomerized in the isomerization unit. Light

naphtha can be cracked if introduced to the reformer.
Hydrogen, produced in the reformer can be recycled to the

naphtha hydrotreater, and the rest is sent to other units demanding
hydrogen.
 Highly endothermic process
 Operated in high severity mode to produce mainly

aromatics (80-90 vol%)
 A middle severity mode to produce high octane

gasoline (70% aromatics)
 Feeds are characterized by the Watson’s

characterization factor (K), naphthenes (N) vol% and
aromatics (A) in which (N+2A) must be defined.
 Also, IBP and EP must be characterized for the Feed.

Typical Heavy Naphtha Feedstocks
Mutineer-
Crude oil name Barrow Island CPC Blend Draugen
Exeter
Location Australia Kazakhstan[ North Sea
Australia
Initial boiling
149 140 149 150
point, °C
Final boiling
204 190 204 180
point, °C
Paraffins, liquid
46 62 57 38
volume %
Naphthenes,
42 32 27 45
liquid volume %
Aromatics,
12 6 16 17
liquid volume %
Basic steps in catalytic reforming:
 Feed preparation: Naphtha Hydrotreatment: It
eliminates the impurities such as sulfur, nitrogen,
halogens, oxygen, water, olefins, di olefins, arsenic
and other metals presents in the naphtha feed stock
to have longer life catalyst.
 Preheating: Temperature Control
 Catalytic Reforming and Catalyst Circulation and

Regeneration in case of continuous reforming
process
 Product separation: Removal of gases and

Reformate by fractional Distillation
 Separation of aromatics in case of Aromatic

production
 The four major catalytic reforming reactions are:
 1) The dehydrogenation of naphthenes to convert them into

aromatics as exemplified in the conversion methylcyclohexane (a
naphthene) to toluene (an aromatic), as shown below:
 2) The isomerization of normal paraffins to isoparaffins as

exemplified in the conversion of normal octane to 2,5-
Dimethylhexane (an isoparaffin), as shown below:
 3) The dehydrogenation and aromatization of paraffins to
aromatics (commonly called dehydrocyclization) as exemplified
in the conversion of normal heptane to toluene, as shown below:
 4) The hydrocracking of paraffins into smaller molecules as

exemplified by the cracking of normal heptane into isopentane
and ethane, as shown below:
 The coke laydown and thermodynamic equibrium yields of
reformate are both favored by low pressure operation.
The research octane number (RON) - The percentage
by volume of iso-octane in a mixture of iso-octane
(and n-heptane that knocks with the same intensity
as the test fuel. Variation of research octane number
 Features
 Since endothermal reactions are dominant in
Catalytic Reforming reaction, multiple reactors
are arranged in a series with a reheating furnace
to maintain the reaction rate for reforming
reaction. Catalytic Reforming processes are
classified as continuous, cyclic, or
semiregenerative depending upon the frequency
of catalyst regeneration. The equipment for the
continuous process is designed to permit the
removal and replacement of catalyst during
normal operation.
 Semi-regenerative
 Cyclic:
Fixed bed
Moving bed
 Continuous
Various Catalytic Reforming Processes
Process Licensor
Rheniforming Chevron oil
Power forming ESSO Oil/EXXON
Magna forming Atlantic Richfield oil
Ultra forming British petroleum
Houdriforming Houdry process Platforming Powerforming
CCR Plateforming UOP (UOP) (Exxon)
Octanising Axens
Magnaforming Catalytic
(Engelhard) reforming (IFP)
Rheniforming Ultra forming

(Chevron) (Amoco)
Feature:
 Regeneration of catalyst in fixed bed reactors after
shut down by burning off the carbon formed on the
catalyst surface.
 Reaction like dehydrogenation of paraffins and

occur in the first reactor with high temp. drop.
 Reactions like paraffin isomerization and

naphthene dehydroisomerization occur in second
reactor with moderate temp. decline.
 Dehydrocyclization and hydrocracking occur in the

third giving low temperature decline.
Catalyst features:
1) Highest C5+ and H2 yields

2) Highest aromatic yields
3) Better catalyst stability
4) Extended cycle length
5) Lower rhenium content (0.25% Pt+025% Rh) – lower
fill cost
Other features:
•Hydrogen partial pressure maintained such that
H2/HC is greater than 25 for monometallic catalyst.
•Light HCs (C1-C4) separated from reformate in
stabilizer.
Features:
 Modified semi-regenerative process
 Fourth fixed bed reactor added to semi-
regenerative process
 Avoids the shutting of whole unit during
regeneration
CYCLIC OPERATION OF
FIXED BED REACTORS
Utilizes continuous in-situ regeneration of a portion of
the catalyst in a special regenerator and the continuous
addition of this regenerated catalyst to the reactors.
 There are two primary licensors of CCR technology:
• UOP’s Platformer process
• Axens’ Octanizing Process
 The catalyst in a CCR reformer is usually an alumina

base sphere or extradite which is impregnated with
either platinum, rhenium, or a combination of both.
Features:
 UOP’s is called CCR Platforming
 3or 4 reactors are installed one on top of the
other.
 Effluent from each reactor is sent to coomon
furnace for heating
 Catalyst moves by gravity from 1st reactor
 Product from R4 sent to the stabilizer and gas
recovery.
 Process operated at lower H2 partial pressures (3
bar), with a reformate yield gain of nearly 10
vol%.
Comparison of the three reforming processes

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Lecture 6

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Catalytic reforming is a process of transforming linear

paraffinic (C7-C10) hydrocarbons contained in crude unit

These reformates are a premium blending stock for producing

The reformate is also the main source of bulk aromatic

The straight run naphtha from the crude distillation unit is

The hydrotreated naphtha (HTN) is fractionated into light naphtha

Light naphtha (LN) is isomerized in the isomerization unit. Light

Hydrogen, produced in the reformer can be recycled to the

 Operated in high severity mode to produce mainly

 A middle severity mode to produce high octane

 Feeds are characterized by the Watson’s

 Also, IBP and EP must be characterized for the Feed.

 Preheating: Temperature Control

 Catalytic Reforming and Catalyst Circulation and

 Product separation: Removal of gases and

 Separation of aromatics in case of Aromatic

 1) The dehydrogenation of naphthenes to convert them into

 2) The isomerization of normal paraffins to isoparaffins as

 4) The hydrocracking of paraffins into smaller molecules as

Rheniforming Ultra forming

 Reaction like dehydrogenation of paraffins and

 Reactions like paraffin isomerization and

 Dehydrocyclization and hydrocracking occur in the

1) Highest C5+ and H2 yields

• Axens’ Octanizing Process

 The catalyst in a CCR reformer is usually an alumina

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