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reforming yields
Case study where a CCR Platforming process unit increased profitability by changing to
a high-density catalyst. Higher aromatic yields and the ability to load new catalyst
without a unit shutdown helped to justify the costs
S
ince the commercialisation of available CCR Platforming catalysts. In
the first UOP continuous catalyst UOPs R-264 is the terms of platinum costs, the total amount
regeneration (CCR) Platforming of platinum loaded in a reactor for the
unit in 1971, these catalytic reforming newest CCR Platforming higher-density R-264 catalyst is similar to
units have become the preferred catalyst on the market that required for the lower-density UOP
choice for converting naphthas into R-134 and R-234 catalysts. This makes
high-octane product for the gasoline that allows continuous- change-outs to R-264 economically
pool, aromatics for petrochemicals regeneration units to attractive. Overall, R-264s properties
production and hydrogen for clean fuels allow it to be a drop-in replacement
hydroprocessing. There are currently increase throughput and/ catalyst for most existing continuous-
over 200 of these units in operation, with or yields while reducing regeneration reforming units.
more than 50 additional units in various R-264 is used in both new and
stages of design and construction. Many coke production existing reforming units. The catalyst
reforming units originally designed was first loaded in an existing European
and built as semi-regen fixed-bed units CCR reforming unit in 2004.3 Since
have been revamped to continuous- and a re-optimised metal/acid balance. then, it has been operating well in over
regeneration units, with almost all new These properties result in enhanced two dozen CCR Platforming units
reforming units being the continuous- yield activity performance with worldwide.
regeneration type. approximately 20% less coke make. The With the ability to maximise yields,
The continuous burning of coke from catalyst can be operated in either a high R-264 is preferred for almost all new
the catalyst was a large step-change in activity mode to process more feed or CCR Platforming units for both motor
reforming performance, since it achieve higher octane, or in a high yield fuel and aromatics applications. The
permitted operations at low pressures mode to achieve higher yields. In industry trend for new CCR Platforming
and high conversions to achieve much addition, the tailored pore structure units has been towards larger-capacity
higher product yields. Continuous minimises very small pores, which units. The average capacity of a unit
innovation in both CCR catalyst and allows for faster coke burning rates in designed over the past few years has
processing technologies has enabled the regenerator. increased from 25 000 bpd (166 m3/hr)
even higher performance and The R-264 catalyst has the ability to to 40 000 bpd (265 m3/hr). The high-
profitability. Loading an improved debottleneck units that are pinning density catalyst formulation facilitates
catalyst remains one of the most constrained. Catalyst pinning is the smaller-sized reactors and smaller
economical methods for further condition where the force from the regenerators, resulting in lower
improving reformer capabilities. horizontal flow of feed across the equipment costs and project net present
Combining this with the on-the-fly downflowing catalyst results in the values. For designs that employ lower-
reloading capability of CCR Platforming catalyst being held up against the centre density catalyst, the catalyst offers an
units, a new type of catalyst can be pipe screen.2 Pinning should be avoided economical means of obtaining
added to the unit while the older since it impairs the reactant flow additional capacity without capital
catalyst is withdrawn without shutting distribution, leading to lower conversion expenditure.
down the unit. Since production losses and significantly higher coke
during catalyst reloading are minimised, production. The catalysts physical R-262 catalyst
the on-the-fly method enables the properties reduce pinning, allowing a A small number of CCR Platforming
changing of catalysts with minimal higher feed throughput. As a result, the units operate under severe or non-
processing penalty. hydraulic capacity in many CCR standard conditions and experience a
Platforming units can be increased by diminished metal function. For example,
CCR catalysts approximately 1020%, depending on a few units operate with higher sulphur
UOPs R-264 is the newest CCR whether the hydrogen-to-hydrocarbon in their naphtha feedstock. Sulphur is a
Platforming catalyst on the market that (H2/HC) ratio or recycle gas flow remains known poison to platinum in catalysis.
allows continuous-regeneration units to constant. The increased product volume The R-262 catalyst was designed
increase throughput and/or yields while from a higher feed rate results in specifically for the above types of CCR
reducing coke production. Compared to significant increases in profitability. Platforming applications and contains a
UOPs R-130 series catalysts, R-264 The catalyst also has high chloride higher platinum level than R-264. The
consists of a higher-density alumina retention and high surface area stability higher platinum content in R-262
support with a tailored pore structure compared to other commercially maintains the proper metal function in