Refinery catalytic reforming best practices

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBHE Technical Bulletin CTB #53
Catalytic Reforming
Critical Variables in Catalytic Reforming and Unit
Monitoring Best Practices
Information contained in this publication or as otherwise supplied to Users is believed to
be accurate and correct at time of going to press, and is given in good faith, but it is for
the User to satisfy itself of the suitability of the information for its own particular purpose.
GBHE gives no warranty as to the fitness of this information for any particular purpose
and any implied warranty or condition (statutory or otherwise) is excluded except to the
extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance
on this information. Freedom under Patent, Copyright and Designs cannot be assumed.

Table of Contents
Best Practice
Identify
Employ
Export
Update
Critical Variables for Catalytic Reforming Examples
Example: CAT
Example: Recycle Gas C1/C2 Ratio
Minimum Critical Variables
Conclusion
Appendix
Principles and Practices Used in Catalytic Reformer Optimization
Management Continuum
Catalyst & Equipment Management
On-line Optimization
Operating Practices

Best Practice
Identify
– Variables to be monitored in each section of the plant (e.g., feed
composition in feed section)
– The goal (No LPO or incidents, optimize operating costs, maximize
product upgrade). Impacts of each variable on that goal
– The relative importance of each variable
– Who is responsible for each variable
– Frequency of monitoring and practical control range
– Response to “out of range” variables
Employ
– Refinery data management system to automate the process to the
extent possible
• Alarm data in refinery data management system if possible
– The requisite lab data to close a material balance on the unit (+/- 2%)
– Kinetic or empirical programs for catalyst activity and yield monitoring
Export
– Procedures and findings to operating business unit and other interested
parties
• Refinery reliability program (bad actors)
• Refinery Planning group (LP)
• Upstream and downstream units
• Process engineering and operator training departments

Update
– The process annually and at TAR events
• Update responsibilities to fill gaps
• Reporting procedures
• Laboratory methods to streamline data turnaround
• New software developments
– More automation
– Kinetic programs
• Flow meters for material balance
• Catalyst sampling devices
Critical Variables for Catalytic Reforming Examples

Example: CAT
Goals:
1. Run reliably/ incident prevention
2. Optimize operating costs
3. Maximize yields
All three apply
Importance:
A. Critical to daily operation; large impact on goals
B. Impacts long-term operation
C. Troubleshooting
A. Applies
Who monitors
– Operations and Process Engineering
Frequency
– Once per shift
Alarm on Critical Variable monitoring program (Refinery Data management
system

Example: Recycle Gas C1/C2 Ratio
Goals:
1. Run reliably/ incident prevention
2. Optimize operating costs
3. Maximize yields
1. Applies
Importance:
A. Critical to daily operation; large impact on goals
B. Impacts long-term operation
C. Troubleshooting
B. Applies
Who monitors
– Process Engineering
Frequency
– At performance test or Troubleshoot
No alarm

Minimum Critical Variables
Conclusion
Create
– A refinery specific monitoring program
• Start with a minimum critical variable list and create a refinery
specific list
• Include engineering, operations, planning, and reliability
• Set goals for the program
Update
– The program frequently
• Audit to ensure goals are met
– Profitability
– Availability
– Reliability

Appendix
Principles and Practices Used in Catalytic Reformer Optimization
Overview of Reformer Optimization: Key Questions
• What is the purpose of reformer optimization?
• Where does reformer optimization fit in an operating plant?
• What is Reformer Optimization?
Oil refineries process crude oil into gasoline and other transportation distillates.
Principle 1 of Reformer Optimization: Define the Objective Function! Must
be Quantifiable
- Maximizing Octane Barrels
- Maximizing Cash Flow
- Maximizing Return on Investment
- Maximizing Through-put

Principle 2 of Reformer Optimization: Layered Practices
- Implementation and Execution of the Plan
- Planning and Scheduling Activities
- Fundamental Process Design and Maintenance

Optimizing Operating Practices
- Active Supervision
Operating Targets
Review Performance
- Engineering Support
Catalyst Performance Monitoring
Environment Monitoring / Control
LP Vectors for Planning and Scheduling
- Best Practices
Laboratory Techniques
Catalyst Regenerations
Reactor Loading Procedures
- Use of Experts for Support
Operator / Engineer Training
Proprietary Techniques
Performance Audits

Optimization through Catalyst & Equipment Management
Catalyst Management
Activity Control
Catalyst Selection
Catalyst Replacement
Equipment Management – Maintenance
Exchanger Cleaning
Fired Heaters
– Tube Cleaning
– Tube Replacement
– Box Management
Equipment Management – Capitol Projects
- Feed / Effluent Heat Exchange
- Add a new reactor
Equipment Management – Instruments
- Instrument Selection
- Instrument Tuning
- Functional Analyzers
On-line Optimization
Opportunity for significant Return on Investment
Chemicals operations
Multiple reformers
Multiple degrees of freedom
Multiple unit constraints

Not for all Applications
- Significant cost
- On-going manpower requirements
- Wide range of Return on Investment
RTO - Traditional Thinking
- Thinking of the process in terms of the process unit configuration
- Matching the process instrumentation - detailed feed-back system to
ensure model consistency with measured process variables
- Matching the process yields
- Precise process modeling
Leads to False Approaches
1. If the unit is modeled in sufficient detail, the economics can be
calculated
2. Make the optimizer a “Super-Controller”
An Alternate Way of Thinking: Optimize the Process
- Economic Boundaries
- Economic Drivers
- Where in the process are the “Economic Flex Points”
- On-line optimization - a “Planning Tool” not a “Super-controller”.

Economic Drivers:
Internal Drivers
• Unit severity
• Utilities
• Incremental product recoveries
External Drivers
• Feed allocation between units
• Alternate feed specifications
Economic Flex Points:

Structure of On-line Optimization Solution

Modeling Approaches
Rigorous models – used where needed
FCC Reactor
Reformer Reactor
Simplified Models – used as applicable
Fractionation
Naphtha Hydrotreater
Optimization Model Structure

Three Keys for Selection of On-line Optimization of Reformer Operation
Feedstock
Naphtha Splitting
Severity of Reaction
Optimization – Example 1

Optimization – Example 2
On-line Optimization: Intangible Benefits
- Exploration of new modes of operation
- S t r e t c h i n g of bounds
- Brings economics into the control room
- Accountability in financial terms

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