Preemraff Operator Training - afrra.org · • UOP licensed Reformer-1 Mohammedia, ... H2/HC mol...
Transcript of Preemraff Operator Training - afrra.org · • UOP licensed Reformer-1 Mohammedia, ... H2/HC mol...
Presentation of the unit
REFORMING
SAMIR-MAROC
16-17 December 2008
by Mr. A. ELOTMANI
Mr. Y.SABIL
Conference on catalytic reforming units organized by the A.R.A, ALGIERS SAMIR-MAROC
Outline
• Introduction
• Feature and special Configuration
• Process diagram
• Regulating parameters
• Difficulties
• Regeneration and related difficulties
• Revamping project of the Reformer
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
1-Refinery of Mohammedia Refining capacity: 6 250 000 T/year of crude oil. potential production capacity of base oils: 150 000 T/year The first units started up in 1960
SAMIR has 2 refineries:
Introduction
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
2- Refinery of Sidi kacem Refining capacity : 1 500 000 T/an The first units started up in 1954
SAMIR has four Reformers whose capacity is 3 000
t/day : • UOP licensed Reformer-1 Mohammedia, operated in 1960
• UOP licensed Reformer-2 Mohammedia, bringing into
production in 1978
• IFP licensed Reformer-1 Sidi Kacem, operated in 1966
• IFP licensed Reformer-2 Sidi Kacem, started in 1972
Introduction
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Feature and special Configuration
The Moroccan marketplace is featured by the following:
• High demand in LPG
• relatively low demand in gasoline
In the face of such a situation, SAMIR opted for a LPG
high-yielding Reformer to the detriment of the Reformate.
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
SAMIR’s Option
A special Reformer, Reforming-2 with three reactors, UOP licensed :
- 1st reactor: Bimetallic Catalyst R86 (Pt § Rh)
- 2nd reactor: Bimetallic Catalyst R62 (Pt § Rh)
- 3rd reactor: Monometallic Catalyst R15 (Pt) (Platinum: 0.6%pds)
This unit is preceded by a HDT unit that processes and prepares the load devoted to Platforming. The catalyst used is called S120 (Co Mo)
Feature and special Configuration
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
LPG-operated
High-H2 Gas to HDT-2 (Net Gas) 3.1 % (V % H2 = 65%)
Gas to SFG 3.2 %
LPG 30.5 %
C5+ 63.2 %
TOTAL 100%
The Reformer-2 can differentiated as compared with mainstream units in terms of a high LPG output (mass utilization ratio 30.5%) and gasoline base (output not exceeding 65%).
Feature and special Configuration
Output of the unit
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Reactor
initials
Catalyst
initials
Quantity
( Kg) %pds
REFORMING 2
96R1 R86 15 860 23.0
96R2 R62 24 000 35.5
96R3 R15 27 350 41.5
Feature and special Configuration
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Reformer-2 Process Diagram
Ballon de reflux
Stabilisateur
Réacteur R2
E205
SFG B.DHDT/HDS/CHL
SFG
B.D
Récupération GPL
GPL
Reformat
Essence HSR du HDT
Pompe de charge
Réacteur R1 Réacteur R3 Séparateur
Four F1
Four F3
Turbo-compresseur
de recyclage de H2
Four F2
Aéro
Aéro
Aéro Aéro
LPG RECOVERY
STABILIZING COLUMN
Main Regulating Parameters
LPG-operated, SOR LPG-operated, EOR
Pressure of reaction circuit 28 Kg/cm2 26 Kg/cm2
Inlet temperature 96R1/ DT 495/40 530/18
Inlet temperature 96R2/DT 495/20 530/0
Inlet temperature 96R3/DT 403/-38 460/3
LHSV 0.75 à 1.1
H2/HC mol ratio 5.5
H2 purity 60% - 55%
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Loading Specifications
Reforming-2 Unit processes the HSR gasoline section with the
following characteristics :
PI : 85°C
PF: 170°C
Density : 0.734
PONA : 68.2/1/18.9/11.9 ( Brut A.L)
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Main Regulating Parameters
Platformat produces along the following specifications:
NO: 95 minimum
Density at 15°C : 0.750 - 0.775
TVR: 0.650 Kg/cm2 maximum
LPG : C5+ : Max 2% vol.
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Main Regulating Parameters
Products Specifications
Difficulties
1. The Reformer configuration is featured by the lack of a furnace
at the inlet of the 3rd reactor , preheating temperature is low and
creates a lot of demand on the furnace of the 1er reactor, thereby
leading to fuel overconsumption.
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
2. High H2 consumption due to hydrocracking reactions noted in
the 3rd reactor (41% of catalyst total weight). This creates a lack of
H2 within the HDT units and the others. By way of remedy, the
temperature for the first two reactors will be increased without
moisture content reaches the value recommended capable of
better fixing chlorine gas:
SOR temperature or following every start-up of the unit has
increased from 470 to 488°C
Difficulties in fixing chlorine gas during start up.
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Difficulties
Regeneration and its related difficulties
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
•SAMIR has cumulated a work experience recognized by UOP and
capable of achieving regeneration without any outside assistance.
1. Conduct of the operations
•Carbon burn-off is done at 385°C as follows:
- 36 h at 1st reactor
- 100 h at 2nd reactor
- 24 h at 3rd reactor
•% Carbon burnt off: 9 to 10% of cat. weight
•Oxidization stage is achieved with the following T°: 510-530-490°C for 24h.
2. Difficulties and constraints
• Due to the lack of the 3rd furnace, the difficulty involved is the non-
achievement of the T° required at the 3rd reactor during carbon burn-off,
oxidization and reduction stages.
Regeneration and its related difficulties
•Reduction stage is achieved with reactors exit T°: 480-490-430 °C
for 15 to 20 hours.
• Unloading, screening and reloading of the catalyst is achieved following the 3rd
regeneration.
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
• How long regeneration last is the main concern of all refiners.
SAMIR submitted a project to UOP to start carbon burn-off from the 2nd
reactor in paralel with the first one. UOP gave a positive response.
Regeneration and its related difficulties
• Carbon burn-off duration from the 2nd reactor is too long. Consequently,
the inner parts of the reactor burn off especially the scalops. % of burnt-off
carbon in that reactor is too high.
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
• Recurrent corrosion related issues of the sea water cooler tube stack.
These tubes are B111 GR 443.
SAMIR planned to replace it by B111 GR 715.
Revamping project of the Reformer
Following changes in the local market terms, SAMIR embarked on a
Revamping project for the unit of Reformer-2 aiming at operating
successfully the unit through gasoline. That project will help increase
gasoline output at the expense of LPGs.
LPG operated Gasoline-operated Discrepancy
High- H2
Gas to HDT-
2 (Net Gas)
3.1 % (V %
H2 = 65%)
8 %
(V % H2 = 88,6%)
+1.7 %
Gas to SFG 3.2 %
GPL 30.5 % 15% -15.5%
C5+ 63.2 % 77% +13.8 %
TOTAL 100% 100%
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
New regulating parameters:
LPG-operated,
EOR
Gasoline-operated,
EOR
Pressure of the reaction
circuit
32 Kg/cm2 15 Kg/cm2
Inlet temperature 96R3 460°C 530°C
Revamping project of the Reformer
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Modifications to be carried out:
• Replacement of the catalyst of 3rd reactor by a bimetallic catalyst.
• Replacement of the cargo pump
• Replacement of the blade for the rotor recycle compressor
• Installation of a new furnace at the inlet of the 3rd reactor
• Installation of a new compressor to feed the other units with H2
• Installation of a new pump to feed the stabilization column
Revamping project of the Reformer
Conference on catalytic reforming units organized by the A.R.A, ALGIERS
SAMIR-MAROC
Reformer Process Diagram (Revamped)
Ballon de reflux
Stabilisateur
Réacteur R2
SFG B.DHDT/HDS/CHL
SFG
B.D
Récupération
GPL
Reformat
Essence HSR du HDT
Pompe de charge
Réacteur R1 Réacteur R3 Séparateur
Four F1
Four F3
Turbo-compresseur
de recyclage de H2
Four F2
Aéro
Aéro
Aéro Aéro
Four F2
GPL
Com presseur
Alternatif H2 vers
utilisateurs
E205
Four F4