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


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


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.


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)



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%).


Output of the unit


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



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%


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)


SAMIR-MAROC


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.


SAMIR-MAROC


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.


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.


SAMIR-MAROC

Difficulties

Regeneration and its related difficulties


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.


•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.


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.


• 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.


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%


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



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



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

THANK YOU FOR KIND ATTENTION

Conference on catalytic reforming units organized by the A.R.A, ALGIERS SAMIR-MAROC

REFORMING SAMIR-MAROC

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