2721_06_01en

7/29/2019 2721_06_01en

http://slidepdf.com/reader/full/27210601en 1/6

APPLICATION REPORT

2721 / 0 6 / 01 • 5 / 2 011

Continuous catalytic reforming –catalyst valves

FurnacesReactors

Regenerator

C a t a l y

s t t o

r e g e n e r a t o

r

Catalyst additionCatalyst removal

Fuel gas

Feedstock

Reformateto fractionation

Vent

Vent

Vent

Vent

R e g

e n e r a t e d c a t a l y s t

Lockhopper

Lockhopper

Additionhopper

Removalhopper

Chlorine agent

Diagram is intended to be representationand not to be viewed as actual process flow diagram.

Process overviewTh proc c b rrdd th rr’

tool to control gasoline octane level. The catalytic

reformer takes low octane value feedstock and

converts it into relatively stable high octane value

gasoline blending components. In the process, hy-

drogen gas is produced as byproduct. The excess

hydrogen produced by this process is a valuable

fdtock to othr rr proc tht rqr

additional hydrogen.

The reforming process operates at high tempera-

tr p to 550 °C (1025 °F). Or prod

of time, the catalyst becomes coated with coke, a

natural byproduct of the reforming process, and

rqr rrto.

Od rforr t xd bd rctor r.

Typically, three to four reactor beds are used in a

cascade arrangement. These units are referred to

as semi-regenerative catalytic reformers. Remov-

ing one bed at a time from service and physically

opening the reactor and removing and replac-

ing the catalyst achieve regeneration of this type

of process. The modern catalytic reformers use

side-by-side or stacked reactors with a continu-

o ctt rrtor (CCR), whr th ctt

is continuously withdrawn from the reactor, then

regenerated, and fed back to the stacked reactor

bed. A series of lock hoppers, typically four com-

plete lock hopper arrangements, are used to move

catalyst from the reactor to the regenerator and

eventually back into the reactor.

7/29/2019 2721_06_01en


2721/06/01 COnTinuOus CaTalyTiC ReFORming – CaTalysT valves

2 aPPliCaTiOn RePORT 5/11

Catalytic reforming challengesThe CCR process has high yields with low op-

erating pressures. Continuously regenerated

catalyst makes it possible to manage the high

catalyst coking rate. A constant non-declining

yield is important in the reforming economics.

The constancy of the yields is achieved by the

CCR section, which ensures the reactors are

continuously supplied with freshly regenerated

catalyst, and product yields are maintained at

fresh catalyst levels. Catalyst handling valves

play an important role in ensuring proper CCR

performance. Reliable and accurate control, on-

off and ESD-valve performance is important for

total process efficiency.

Health, Safety, Environment – v k

poses both an environmental and safety issue due

to rk of r, toxct d ott of . er -

gency shutdown and on/off valves must be ableto prfor thr cto proc or qpt

failure.

Top-class products at maximum yield – Th

rkt c for c prodct d hh qt. it

portt tht th proc tb, xb d

under control. Proper control valve performance in

furnace and fractionation improves the accuracy

of throughput control and adversely affects to the

plant performance and also the downstream pro-

cesses.

Maintenance costs - Critical valves in catalyst

handling lock-hoppers, venting, catalyst withdrawal

and addition play an extremely important role in

successful catalyst regenerating process perfor-

mance. Poorly performing valves in the process

must be serviced because they will have a direct

pct o th fcc of th proc.

Plant run-time – Rr r ook for or

plant run-times since downtime means production

losses and is a remarkable cost including mainte-

c cot. Th rqr rb qpt d

process control.

Metso solutionsWe are all tuned up to answer these challenges

through our refining application experience

and product offering for control, safety and

automated on/off duty that ensure high valve

performance in continuous catalytic reforming

processes. Our catalyst handling valves have

proven performance history and are designed

for efficient and reliable process operation.

Safety - mto tt h b d-

signed to provide market leading safety. Rotary

stem opeartion reduces fugitive emissions and pro-

tct fro k. mto th o orc

emergency shutdown valve supplier who has the

experience and knowledge to combine intelligence

with most reliable valves and actuators. Technol-

ogy selections like rotary stem operation and inher-

t r f d r tht tt o

d r ft tdrd c b ppd. Rb wth rt tt, sil3 pprod ft

valve controller and partial stroke testing system

n vgrdTm will ensure that plant emergen-

cy shutdown valves will always perform properly

when needed.

Efficiency - Throughput losses and poor con-

trol performance will be avoided with intelligent

control valves. Flow through the process unit may

be changed as the need arises with rangeability

of 150:1 d frthr wth f bor b . Or

advanced intelligent digital valve controllers for cotro, o-off d esD ppcto r hh

positioning accuracy and fast response. Correct

cto d z wth or nprof-pror

we can assure the best valve performance and

process control.

Availability - sp rotr d, fc-to-

face dimensions, and global service network and

inventory management will help you to optimize

your maintenance activities. Rotary valves have

b rc for r r wthot rqr -

ing maintenance and show no sign of leakage.

Th pro prforc of mto wth o

lasting metal seat tightness and shut-off capabili-

ties makes them an ideal solution for control, on-off

and critical catalyst handling applications.

Reliability - Valve performance trend data col-

lected by our smart valve controllers and analysed

b mto FdCr, op FDT/DTm tchoo

bd corto d codto otor oft-

ware, makes it possible to predict and respond to

tc rqrt d rdc chd-

uled downtime. This gives full transparency to the

valve performance in process control.

7/29/2019 2721_06_01en


COnTinuOus CaTalyTiC ReFORming – CaTalysT valves 2721/06/01

aPPliCaTiOn RePORT 5 /11 3

The sequence of lock hopper function is as fol-

lows:

Ctt rqr rrto thrd •

the reactor disengaging zone.

Ctt ow toppd b pc -•

mented ball valve located immediately below

the disengaging zone and upstream of the

two n ock hoppr bock . Th two

valves above the lock hopper are fully open

bfor ctt owd to ow throh

them.

The segmented valve is then opened allow-•

ctt to ow to th ock hoppr.

When the lock hopper is full the segmented•

cod. aftr th ow of ctt

copt toppd, th two n r

closed, isolating the lock hopper.

The lock hopper is then inerted with nitrogen.•

Following this, the two lock hopper blockvalves located below the lock hopper are

opd ow th rtd ctt to ow,

by gravity, into a lift engager for transport to

the next part of the process.

Catalyst falling from the reactor into the lock•

hopper contains a fairly large amount of hy-

dro. aftr , ot d rt th

lock hopper the gases are vented through the

lock hopper vent valve. This valve must vent

highly abrasive, catalyst-entrained gas while

simultaneously achieving Class VI shut off.

A special double-seated globe valve previ-ously served this application. This design had

one metal seat, intended to resist abrasion

d prtd b th d, d o oft

seat, intended to achieve the desired shut off

ccto. Th oto h htorc

been plagued with leakage problems as well

as high cost of repair.

Metso solution

Valve type - mto tz f-bor d

lock hopper service. All counter bores and transi-

tions in diameter are removed from the waterway

of the valve. This causes the valve to look like a

pc of ooth pp to th ow d ordr

to eliminate the possibility of pulverizing expensive

catalyst. It also minimizes the possibility of internal

valve damage by the highly abrasive catalyst. The

bod cotrctd of a351 CF8m for th

longest possible life while subjected to the extreme

thermal transients associated with this process.

Ball - Th b cotrctd of a351 CF8m wth

nck Boro cot. Th b tr of th

w cho to prod for cofct of x-

po r to th bod. Th rqrd

to maintain seat to ball tightness as the valves

xprc r br of ct thr

trt. Th nck Boro cot ppd to

raise the surface hardness of the ball to Rockwell

C68-C70. Th cr to prod for o

component life in this highly abrasive service.

Seat - mto tz 316ss t wth Chro

Crbd (CrC) cot for th ppcto. Th -

terial combination was again chosen for compat-

b cofct of xpo w pror

abrasion resistance. The seat energizer, perhaps

the most important design feature of the valve, is

mto’ q “od-proof” cotrcto. Th

t bck ct copt d wth rphtstack. The graphite seat back material achieves

two portt tk: 1) t r t rzr.

The graphite allows for repeatable valve shutoff

dpt th xtr tprtr. 2) Th rph-

t tck copt th t bck ct. Th

t th pobt of ctt cc-

lating behind the seat. This is extremely important

ctt bhd th t c c th

rqrd torq to cr oh to xcd th

maximum output capability of the actuator.

Controller - n swtchgrd sg9000 intelligent on-off valve controller that is specially

designed to meet challenges of process critical

o-off ppcto. sg9000 th pobt

to t th o-off trok t d pro

according to the process needs. Its high pneumat-

ics capacity also gives the possibility to reach fast

stroking times without the need for any additional

ccor ch o bootr or qck

exhaust valves. In addition, predictive maintenance

can be practised with the help of the diagnostics

tht sg9000 prod o th o-off pr -

formance. To simplify the installation, different

mechanical or inductive proximity switches can be

td d th sg9000 ho.

a opto for sg9000, mto c o prod

traditional control solution based on separate sole-

noid valve and limit switches.

1. The Lock hopper block and vent valves

7/29/2019 2721_06_01en


2721/06/01 COnTinuOus CaTalyTiC ReFORming – CaTalysT valves

4 aPPliCaTiOn RePORT 5/11

Valve model example:

XA03DWUUS6SLJBDD

XA Full bore seat supported ball valve

03 v z, tpc 2” to 6”

D ansi c 300

W ansi B16.5 rd fc

uu F copc wth uOP pccto 671

s6 asTm a351 CF8m / ss316 t t

body construction

sl ss316/nBo b cotrcto

J sod proof t cotrcto

B CrC cot o t

D a rpht t d pck wth t

stem bearings

D B8 td d B8m t

Benefts

This demanding application led to the successful

dopt of mto oto, th n X-mBv

ball valve. The special end-to-end dimension al-

ow th X-mBv to rtrot pc of ob

wthot pp odcto. Th n J tp od

proof seat prevents catalyst dust from getting be-

hd th b. Th prcd th pobt of torq

increase or seat back cavity abrasion damage. The

materials of construction are selected for maximum

resistance to abrasion damage allowing for long

f. Th n X-mBv b h bpcc dd to t th proc rqr-

t, ch uOP pccto 671. eqppd

wth mto ptc cdr cttor d n

swtchgrd tt o-off cotror, pro-

vides the ideal lock hopper vent valve solution.

The catalyst addition system is the point in process

whr w ctt ddd to rpc th qtt

of catalyst that is withdrawn and discarded from

the system after it can no longer be regenerated.Th w ctt ow b rt to th -

tem through a catalyst addition hopper at ambient

temperature. The new catalyst passes through the

rt ddto d to th ddto ock hop-

pr. Th rt , bo th ock hoppr, th

closed and the second valve, below the lock hop-

per, is opened admitting the new catalyst into the

process.

Valve requirements

Tight shut-off •

Catalyst friendly design•

sft trock t•

Metso solution

Th Jbr 9150 r oft-td b

with Xtreme seats and pneumatic actuator has

prod to b th rht choc b rr th coto rfor proc. mto

qppd wth n swtchgrd tt

on-off valve controller gives the possibility to con-

trol the valve opening and closing strokes and also

provides diagnostics on the valve performance. A

safety interlock system is needed to prevent both

the valve above and below the lock hopper from

opening at the same time.


9150 31 3600XTZ

9150 F Bor ansi C 150 b 31 Rd fc , Fr Tt, t pportd

3600 st t cotrcto

XTZ Xtreme seats

2. The Catalyst addition and removal valves

Intelligent seat supported ball valve

7/29/2019 2721_06_01en


COnTinuOus CaTalyTiC ReFORming – CaTalysT valves 2721/06/01

aPPliCaTiOn RePORT 5 /11 5

3. Chlorine addition valve

spt ctt tr th top of th rrto

tower where the coke is burnt off the catalyst at

high temperature and low oxygen concentration.

Catalyst then passes into the chlorination zone. In

this area, the catalyst is oxidized at high tempera-

ture and high oxygen concentration in the presence

of organic chloride injected into the circulating gas

to achieve the proper catalyst chloride balance.

Valve requirements

Bbb-tht ht-off •

Inconel® wetted parts•

low o pck d kt•

Metso solution

Th n W1 sr h b pc-

cally designed to meet the chlorine application

rqrt ch th uOP pccto 671.

eqppd wth mto ptc cdr cttord n swtchgrd tt o-off co-

troller, it provides the ideal solution for the control

of organic chlorides. provides the ideal solution for

th cotro of orc chord. Th co-

rd wfr t ansi c 300 f bor b

. Dpd of th cpct of th CCR, th

w b ppd 3⁄4”, 1”, or 11⁄2” z. Th

t jort of th t th 3⁄4” ppd.

All Inconel construction is used for its metallurgi-

cal compatibility with the highly corrosive organic

chord. To t r prodd to prod th

bbb tht ht off rqrd.


W1BU007IIT01-BCM-LS-SV

W1 Full bore wafer style ball valve

B ansi 300 do

u uOP d d cotrcto tt to uOP

671 pccto

XXX v z 3⁄4”, 1”, 11⁄2”

I Inconel 600 body

I Inconel 600 stem ball

T Rforcd PTFe t

01 TFe

B1C Dob ct cttor

Chloride regeneration isolation valve

7/29/2019 2721_06_01en


The information provided in this bulletin is advisory in nature, and is intended as a guideline only.

For specic circumstances and more detailed information, please consult with your local automation expert at Metso.

Metso Automation Inc.

Europe, Vanha Porvoontie 229, P.O. Box 304, FI-01301 VANTAA, Finland.Tel. +358 20 483 150. Fax +358 20 483 151

North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA.Tel. +1 508 852 0200. Fax +1 508 852 8172

South America, Av. Independéncia, 2500- Iporanga, 18087-101, Sorocaba-São PauloBrazil. Tel. +55 15 2102 9700. Fax +55 15 2102 9748/49

Asia Pacific, 20 Kallang Avenue, Lobby B, #06-00, PICO Creative Centre, Singapore 339411, Singapore.Tel. +65 6511 1011. Fax +65 6250 0830

China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaoyang Dist, 100022 Beijing, China.Tel. +86-10-6566-6600. Fax +86-10-6566-2575

Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai,United Arab Emirates. Tel. +971 4 883 6974. Fax +971 4 883 6836

www.metso.com/valves

APPLICATION REPORT

Documents

2721_06_01en