Refinery Process Fundamentals Curriculum

Module 3 - Catalytic Reforming

Module from the Refinery Process Fundamentals Curriculum curriculum.

CATALYTIC REFORMING · Learning Objectives · 1. Explain the chemistry of catalytic reforming (dehydrogenation, isomerization, cyclization, hydrocracking) 2. Compare fixed-bed semi-regenerative vs. CCR Platforming reactor systems 3. Understand the role of platinum-based catalysts and their deactivation mechanisms 4. Identify key operating parameters: WAIT, pressure, space velocity, H2/HC ratio 5. Describe reformate composition and octane-severity relationships · Reforming Reaction Chemistry

Reaction Type	Example	ΔH (BTU/lb)	Effect on Octane	Effect on H2	Catalyst Function	Favored By
Dehydrogenation of Naphthenes	Cyclohexane → Benzene + 3H2	+1080 (endothermic)	Major increase (+20-30 RON)	Produces H2	Metal (Pt) function	High temp, low pressure
Dehydrocyclization of Paraffins	n-Hexane → Cyclohexane → Benzene + 4H2	+1200 (endothermic)	Major increase	Produces H2	Dual function (acid + metal)	High temp, low pressure
Isomerization of Paraffins	n-Pentane → iso-Pentane	Near zero	Moderate increase (+10-15 RON)	Neutral	Acid function (chloride)	Moderate temp
Isomerization of Naphthenes	5-ring → 6-ring naphthenes	Near zero	Moderate increase	Neutral	Acid function	Moderate temp
Hydrocracking	C10 paraffin → C5 + C5	-600 (exothermic)	Decrease (light gas loss)	Consumes H2	Acid function	High temp, high pressure
Coking / Dehydropolymerization	Aromatics → Coke on catalyst	Endothermic	N/A (catalyst poison)	N/A	Catalyst deactivation	High temp, low H2/HC
CCR Platforming vs Fixed-Bed Reforming
Feature	CCR Platforming	Semi-Regenerative Fixed-Bed	Cyclic	Advantage of CCR	Notes
Reactor Configuration	Stacked radial-flow reactors with continuous catalyst circulation	3-4 fixed-bed reactors in series	3-4 fixed-bed + 1 swing reactor	No shutdown for regeneration	CCR = continuous catalyst regeneration
Operating Pressure	50-100 psig	200-350 psig	200-350 psig	Lower pressure = higher octane, more H2	Lower pressure favors desired reactions
Catalyst Type	Pt-Sn/Al2O3 (bimetallic on chlorided alumina)	Pt-Re/Al2O3 (bimetallic)	Pt-Re/Al2O3	Sn promotes selectivity at low pressure	R-264, R-274 catalyst grades
RONC (Clear Octane)	100-104	92-98	95-100	5-8 RON higher	Higher severity possible without coking shutdown
H2 Production	1400-1800 SCF/bbl	800-1200 SCF/bbl	1000-1400 SCF/bbl	40-60% more H2	Critical for refinery H2 balance
Cycle Length	Continuous (catalyst circulates)	6-18 months between regen	6-12 months per reactor	No downtime for regeneration	Catalyst lifetime 6-10 years (CCR)
C5+ Yield	82-86 vol%	78-84 vol%	80-85 vol%	2-4% higher yield	Less hydrocracking at low pressure
Source: FOS Chief Files — Module 07 (Catalytic Reforming), Platforming Customer Training, CCR procedures

Source: Refinery_Process_Fundamentals_Curriculum_v1.xlsx · Sheet: Module 3 - Catalytic Reforming

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