PRESENTATION OF REFORMING FOR NAFTEC REFINERIES · of reforming for naftec refineries ... process conditions; design ... presentation of reforming for naftec’s refineries 25

1

PRESENTATION

OF REFORMING FOR NAFTEC

REFINERIES

NAFTEC/Spa

AFRICAIN REFINERS ASSOCIATION

- ARA

Workshop on Catalytic reforming - Algiers Refinery - 16 & 17 December 2008

PRESENTATION OF REFORMING FROM NAFTEC’S REFINERIES

2

Table of Contents I- REFINERY of SKIKDA (RA1K)

I-1 Reforming Data Sheet (REF1 and REF2)

I-2 Dispatching of the catalyst into the reactors

I-3 Modifications to RA1K Reforming units

II- REFINERY of ARZEW (RA1Z)

II-1 Reforming Data Sheet

II-2 Dispatching of the catalyst into the reactors

II-3 Modifications to Reforming units of RA1Z

III- REFINERY of ALGIERS (RA1G)

III-1 Reforming Data Sheet

III-2 Dispatching of the catalyst into the reactors

III-3 Modifications to RA1G Reforming units

IV PRECIOUS METAL BALANCE FOR CATALYSTS

V OPERATION DIFFICULTIES

VI PROSPECTS BY 2013

3

I- REFINERY OF SKIKDA (RA1K)

PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES


4

I-1 Reforming Data Sheet I-1-a Data Sheet for Reforming 1 (REF1)

Mark : U100

Start-up of the unit : May 1980

Capacity : 30 000 BPSD

License : Arco-Engelhard

Role : Aromatic (BTX)

On-stream pressure : 3rd catalyst pressure (on stream since October 2004)

• Type of catalysts : E801 in reactors R1 et R2

E803 in reactors R4 et R5 (Engelhard)

• Precious metal content : E801 : 0.26 % Pt and 0.26 % Rh

E803 : 0.22 % Pt and 0.42 % Rh

• Form : extruded

• Loaded quantity : E801: 14 543 Kg / E803: 49 233 Kg

Total : 63 776 Kg

RA1K


5

I-1-a Data Sheet for Reforming 1 (REF1)

Process Conditions; Design

• Temperature at the beginning of the cycle : 522°C

• Temperature at the end of the cycle : 543 °C

• Hydrogen purity : 80 % Molar

• Molar Ratio H2/HC : 11

• Pressure at separator balloon : 8.9 kg/cm2

• Space speed : 2.3 h-1

• Reformate output : 80 % Pds

• Clear NO : 99

• Cycle Duration : 13 months at 100%

• Life warrantee : 5 years, i.e.136 m3/kg or 390 bbl/lb.

I-1 Reforming Data Sheet …

RA1K

AH

1.10. B

y

-

p

a

s

s

Vers Colonne C7

1.15. E

-

8

1.3. E

-

4

1.11. C

h

a

r

g

e

1.12. M

P

-

2

1.14. M

P

-

4

By

-Pa

ss

Se

cti

on

Ca

taly

tiq

ue

NAPHTA

T

r

a

i

t

é

Vers Section Magnaforming

1.7. M

P

-

3

1.18. K

-

1

1.19. A

/

B

1.17. E

-

9

1.22. K

-

2

1.23. A

/

B

LIC 5

1.13. E

-

2

E-1AD

1.20. E

-

3

A

/

B

1.21. V

-

1

PRC 3

1.5. V

-

2

1.9. F

-

2

FRC 6

FRC 4

1.6. F

-

1

1.4. R

-

1

1.8. C

-

1

1.1. F

G 1.2. M

E

A

1

LIC 6

FRC 5

PRC 3

1.16. E

-

1

5

FRC 30

1.24. V

-

3

C-2

By-PassVers Refoulement MP-7A/B

PRC 7

Catalytic pretreatment section (REF 1)

R1 V2

C1 F1

V1

V3

F2

K1 K2


6 RA1K

Toward magna-

Forming Section

By-Pass toward MP-7A/B

Discharge

Toward

Column C7

MP-7

E-12

A/B/C

E-11 A/B E-10 A/B

MEA-3

R-

2

R-

3 R-

4

R-

5

Magnaforming Section (REF 1)

F- 4 F- 5 F- 6 F- 7

TK -3

FR

c

12

FR

13

FR

81

FR

22

P

Rc

99

lic

8

V

-5 Reformate

towards C-4

stabilizer

Load of

processed

Naphta


7 RA1K

E-14

E-16

C- 4

MP- 8

EA- 4 E-13 FR

26

PR C

7

LIC

10

V-6

FR C

14

Reformate

Reforming1 (V -5)

From bottom-hole

V -4

LR

C

9

frc

25

FR

27

Depentanized reformate

toward fractionation (BTX

toward column C-5)

LPG & Pentanes

toward C-7 column

MC

MS

Network-

wards F.G (C-4) Reformate Stabilizer

Simplified Schematic

Platformat makeup

for Reforming 2


8 RA1K

CW Stabilized

Reformate

load

Light Reformate unit load

extraction of

Benzene /

Toluene

A H

F-9

E-18

C- 5 MP- 13

EA- 5 •p

rc

43

LI

C

20

V-11

FR C

52

F

R

5

3

C-5 fractionation column

simplified schematic

N2

B.D

MP- 14

fr

c 51

lic 19

FR

C

42

9 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES RA1K

Heavy-duty

Reformate

unit load splitting of

xylems


10

I-1-b Data Sheet for Reforming 2 (REF2)

Mark : U103

Start-up of the unit : October 1993


License : UOP

Role : Gasoline

On-stream pressure : First catalyst pressure (since October 1993) • Type of catalysts : R-62 (UOP)

• Precious metal content : 0.22 % and 0.44 % Rh

• Form : spherical shape

• Loaded quantity : 145 288 Kg of catalyst


RA1K


11

I-1-b Data Sheet for Reforming 2 (REF2)

Process conditions Design

• Temperature at the beginning of the cycle : 490 °C


• Hydrogen purity : 75 % Molar

• Molar Ratio H2/HC : 6 minimum

• Pressure at separator balloon : 12.3 kg/cm²

• Space velocity : : 1.0 h-1


• Clear NO : 101

• Duration of the cycle : 12 months at 100%

• Lifetime Warranty : 5 years, i.e.156 bbl/lb

or 54.4 m3/kg


RA1K


12

% Catalyst Quantity (kg) Catalyst Reactors

9 5 932 E801 100R2

13 8 611 E801 100R3

39 24 616 E803 100R4

39 24 617 E803 100R5

100 63 776 TOTAL

I-2-a REFORMING 1


RA1K


13

I-2 -b REFORMING 2


10 14 140 R62 R31

15 21 703 R62 (+R86) R32

25 36 435 R62 R34

50 73 010 R62 R35

100 145 288 TOTAL


RA1K

14 PRESENTATION OF REFORMING FOR NAFTEC’S REFINERIES

► Optimization of the operation of Aromatic units :

Design of a six-inch line allowing to feed Reforming 1 fractionation section

through the reformate of Reforming 2 in order to increase or maintain the

production of aromatic hydrocarbons (BTX) in case Reforming 1 load is

stopped or decreased.

► Flexible feeding of Reforming units in relation to Hydrogen :

Design of a two-inch line 2 connecting two Reforming units and ensuring the

availability of hydrogen in case of stoppage of either unit.

► Improving the security of the unit by substituting the combined

E10/E11 exchangers of the preheating train for Reforming 1 :

Substituting combined E10 A/B and E11 A/B exchangers has helped fix the

issue of recurrent leaking from the expansion joints initially designed within

the shell (outer part).

Modifications to RA1K Reforming units

RA1K

E-14

E-16

C- 4

MP- 8

EA- 4 E-13 FR

26

PR C

7

LIC

10

V-6

FR C

14

Reformate for

reforming 1

From the bottom-

hole V -4

LR

C

9

frc

25

FR

27

Fractionation wards

Toward

column C-7

And LPG units

MC

MS

Toward

F.G Makeup of platformat for reforming 2

toward 100C-4 column

Makeup of platformat

for Reforming 2


15 RA1K

16

II- REFINERY OF ARZEW (RA1Z)



17

Mark : U12

Start-up of the unit : 1972


License : UOP

On-stream pressure : 3rd catalyst pressure (since September 1997) • Type of catalysts : R-62 (UOP)

• Precious metal content : 0.22 % Pt and 0.44 % Rh

• Form : spherical form


Reforming Data Sheet

RA1Z


18

Process Conditions, Design

• Temperature at the beginning of the cycle: 470 °C


• Hydrogen purity : ≥ 75 % Molar

• Molar ratio H2/HC : 3.5 à 6

• Space velocity : 1.6 h-1

• Pressure at separator balloon : 17.5 kg/cm2


• Clear NO : 98

• Warranty cycle time : 12 months à 100%

• Warranty lifetime : 5 years 308 bbl/lb, i.e. 108 m3/kg

Reforming Data Sheet

RA1Z

12-FRC5 12-FR4

12-G3A/B

12-LR3

12-G8A/B

12-G4A/B

12-C1

12-E3

12-E2 A/B

12-FRC1

12-G1A/B

12-E1 A/B/C

CHARGE NAPHTA

12-LIC2

12- D1

12-E6

GAZ VERS TOPPING

PENTANES VERS TOPPING

12 -F1 /

Chambre 1

12-LIC1

12-F1

12-D2 12-LIC4

12-FR3

NAPHTA PRETRAITE VERS

PLATFORMING

12-E7

12-FR2

12-PRCV-4A

Hydrogène vers unites

Lubrifiants

INJECTION TCE

12-G14 B/D

APPOINT

HYDROGENE

12-E4A/B

12-PR1

8

20

12-C2

1

12 -F1 / Chambre 2

Pretreatment Section - (U12 RA1Z)


19 RA1Z

Hydrogen toward

Lubricant Units

GAZ TOWARD

TOPPING

12-F1/

Chamber 1

12-F1/

Chamber 2

PENTANE

TOWARD TOPPING

HYDROGEN

MAKEUP

NAPHTA

LOAD

PRETREATED

NAPHTA TOWARD

PLATFORMING

Catalytic Section - Platforming (U12 - RA1Z)

12-PRCV 12-PRC6

12-FRC14

12-LIC 8

12-FR 13

12-FRC 9A/B

12-G7 LPG toward

Gas-Plant

PLATFORMAT STABILISED

TOWARD STORAGE

PRETREATED

NAPHTA LOAD

12-FR 16

12-PRC

H2 TOWARD FUEL

NETWORK

12-C6

30

16

1

12-E12 12-E11 12-E 13

12-FR15

6

12-LIC 6

H2 toward

Pretreatment

12-FRAL 8

Gas

toward

Topping

12 C3 12 C4 12 C5

12 G9 A/B

12 F3

12 F2

12 D5

12 E9 A/B/C

12 E10

12 E14

12 G11 A/B

Hydrogen Compressor


20 RA1Z


21


20 4 693 R62 12 C3

30 7 374 R62 12 C4

50 12 329 R62 12 C5

100 24 396 TOTAL

Dispatching into the reactors

RA1Z


► Replacement of raw water by distilled water to cool 12 G12 A/B-type

condensate scavenge pumps and thereby avoid pollution of the steam

condensate (9 t/h).

► Installation of nitrogen lines for topping columns and stripping-stabilizing

circuits as a replacement of water vapor. This is time-saving and allows

rapid elimination of show of water from circuits in relation to start-up

operations.

► Utilization of gas process (Hydrogen-rich) instead of electrolytic Hydrogen

following regeneration. That utilization allows to compensate the

unavailability of electrolytic Hydrogen.

Modifications to the RA1Z Reforming unity

RA1Z

23

III- REFINERY OF ALGIERS (RA1G)



24


Mark : U200

Start-up of the unit : march 1964


License : UOP

On-stream pressure : 13th pressure of the catalyst (since June 2007)

• Type of catalysts : R-11 (UOP) - monometallic

• Precious metal content : 0.375 % Pt

• Form : spherical form



RA1G


25


Process Conditions, Design

• Temperature at the beginning of the cycle : 490 °C


• Hydrogen Purity : 66 % Molar

• Molar Ratio H2/HC : 7 à 8

• Space velocity : 0.9 à 1.5 h-1

• Reformate output : 80% Vol.

• Clear NO : 93

• Warranty cycle time :12 months at 100%

• Warranty lifetime : 3 years equivalent

to 342 bbl/lb


RA1G


26

III-2 Dispatching of the catalyst into the reactors


20 6 700 R11 R202

30 10 700 R11 R203

50 16 200 R11 R204

100 33 600 TOTAL


RA1G


► Regeneration procedure for R11 catalyst of the Reforming :

Modifications were made since 2001 in collaboration with the UOP licensor by

applying the R-62 catalyst regeneration procedure for R-11 catalyst.

This led to better regeneration and thereby contributed to make cycles longer.

Modifications to the RA1G Reforming Unit

RA1G

28

IV- PRECIOUS METAL BALANCE FOR

REFORMING CATALYSTS


29

Kg

Rh

(%)

Rh

Kg

Pt

(%)

Pt

CATALYST Capacity

(BPSD) Reforming Refinery Quantity

(Kg) Type

245 0.42 146 0.26

0.22 63 776

E 801

E 803 30 000

U100

(Engelhard) RA1K

639 0.44 321 0.25

0.22 145 288

R 86

R 62 30 000 U103 (UOP)

107 0,44 54 0.22 24 396 R62 8 360 U12 (UOP) RA1Z

- - 126 0.375 33 600 R11 16 000 U200 (UOP) RA1G

991 647 267 060 84 360 NAFTEC


REFORMING CATALYSTS

Precious Metal Balance

30

V- OPERATION DIFFICULTIES



• Recurrent malfunctions of on-stream analyzers (moisture and

Hydrogen) make more sensitive the control of water/chlorine balance.

• Clogging of the preheating train exchangers during pretreatment due to

build-up of coke as a result of lack of nitrogen to cover tanks and

thereby giving rise to reduced rate of capacity utilization.

• Pressure drop within the catalytic circuit of RA1K Reforming 1.(*)

• Leaking from water cooling towers.

• Limitation of the rate of capacity utilization by 80% of pressure because

of pressure drop and low H2/HC ratio for RA1K reforming 1.(*)

• Falling off of rotor blades from the 100TK3-Turbine of RA1K Reforming

1. (*)

• Switching-on of Units as a result of lack of electrical power (inner or

outer causes).

(*): These concerns will be taken care of as part of rehabilitation.

VI- OPERATION DIFFICULTIES

32

V- PROSPECTS BY 2013



► Skikda Refinery :

To improve the rate of capacity utilization of Reforming 1 unit

which is currently limited to 80 % and in order to allow the

production of 100-NO reformate, the following has been

planned:

• Increase the quantity for the catalyst from 64 000 Kg

to 120 000 Kg.

• Replace cycle gas compressor.



► Arzew Refinery :

In order to increase the output and NO of the reformate, the following

has been planned:

• Replacement of Catalyst R-62 by Catalyst R-86.

• Replacement of the cycle gas compressor.



► Algiers Refinery : Replacement of the existing unit by a new one has been planned.

Continuous Catalyst Regeneration (CCR) through licensed AXENS to :

• Increase the NO of reformate up to 102.

• Increase production of gasoline.

• Allow changeover to unleaded gasoline.



THANKS FOR YOUR

ATTENTION

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PRESENTATION OF REFORMING FOR NAFTEC REFINERIES · of reforming for naftec refineries ... process conditions; design ... presentation of reforming for naftec’s refineries 25