Development of A Kinetic Model For Catalytic Reforming
Development of A Kinetic Model For Catalytic Reforming
Development of A Kinetic Model For Catalytic Reforming
Abstract
The
Catalytic
Reforming
is
the
main
process
in
a
refinery
to
produce
gasoline
with
a
high
octane
number.
It
is
equally
an
excellent
producer
of
hydrogen
reused
for
hydrotreatment
processes
and
BTX
production
(benzene,
toluene
and
xylene)
widely
used
in
petrochemical
industry.
The
aims
of
this
work
were
monitoring
an
industrial
unit
of
catalytic
reforming
and
study
a
kinetic
model
developed
by
CEPSA
Company
for
a
year
of
cycle.
The
monitoring
was
performed
in
order
to
understand
the
functioning
of
an
industrial
unit.
The
unit
diagram
was
studied
in
detail,
the
process
variables
were
collected
and
subsequently
represented
in
order
to
understand
their
variations.
The
kinetic
selected
for
this
model
was
Henningsen
and
Bundgaard
–
Nielson
in
which
the
reaction
rates
are
represented
by
simple
first
order
and
the
reaction
rate
constants
shown
by
Arrhenius
Law.
Posteriorly
simulations
were
realized
to
comprehend
if
the
chosen
kinetic
would
be
the
most
appropriated.
It
was
also
tested
the
calculus
change
of
RON
and
it
was
verified
that
the
initial
correlation
produces
better
results
than
other
correlations.
The
model
developed
by
CEPSA
Company
presents
consistent
data
with
the
real
ones,
noting
that
the
chosen
kinetic
for
the
model
was
a
good
possibility.
Keywords:
Catalytic
Reforming,
Monitoring,
Kinetic
Model,
Simulations,
Octane
Number
The first Catalytic Reforming industrial unit was gasoline to resist knocking during combustion of the
developed in 1940 by UOP and is worldwide air-‐gasoline mixture in the engine. This number is
The goal of this process is to convert naphtha with blending with n-‐heptane that equals the knocking
low octane number into high octane number gasoline performance of the gasoline. By definition the octane
called reformate as a blending component of motor number of n-‐heptane is zero and the octane number
aromatics used in the petrochemical industry. Normally there are two ways to measure octane
1
2.
Catalytic
Reforming
Process
by
the
effluent-‐to-‐feed
heat
exchanger
for
maximum
A typical feed to Catalytic Reforming is a mixture of heat recovery.
medium and heavy straight run naphtha obtained After the effluent is charged to the separation
directly from the atmospheric crude oil distillation section, where the liquid and gas products are
paraffins, 20-‐50 wt.% naphthenes, 5-‐20 wt.% A fraction of the gas from the separator is
aromatics and 0-‐2 wt.% olefins. [1] compressed and recycled back to the reactor section.
The distribution of paraffins, olefins, naphthenes The separator liquid is pumped to the reformate
and aromatics in the feed to catalytic reforming stabilizer for separate the desired product, reformate,
determines the richness of the feedstock, which is from the rest of hydrogen and light hydrocarbons.
Presently
the
standard
operating
conditions
in
this
These
processes
are
commonly
classified
according
process
are
elevated
temperature
(450-‐520ºC)
and
to
the
frequency
and
mode
of
catalyst
is
regenerated,
moderate
pressure
(4-‐30
bar).
[1]
into
semiregenerative,
cyclic
regeneration
and
A
large
number
of
reactions
occur
in
catalytic
continuous
regeneration.
The
main
difference
reforming
such
as
dehydrogenation
of
naphthenes
to
between
the
three
types
of
processes
is
the
need
of
aromatics,
isomerization
of
paraffins
and
naphthenes,
shutdown
of
the
unit
for
catalyst
regeneration
in
the
dehydrocyclization
of
paraffins
and
hydrocraking
of
case
of
semiregenerative
process,
the
use
of
an
paraffins
and
naphthenes
to
lower
hydrocarbons.
additional
swing
reactor
for
catalyst
regeneration
for
All
reactions
are
desirable
except
hydrocraking,
the
cyclic
process
and
catalyst
replacement
during
which
occurs
at
high
temperature
and
consumed
a
normal
operation
for
the
continuous
regeneration
high
amount
of
hydrogen.
type.
2
The
addition
of
components
to
the
acid
function,
carbons
atoms
within
each
class.
Hydrogen
and
light
such
as
chloride
or
fluoride,
changes
the
strength
and
gases
were
also
taken
into
account.
amount
of
support
acid
sites.
This
model
involves
five
pseudocomponents:
A
simplified
schematic
diagram
of
the
alumina
paraffins,
naphthenes,
aromatics,
light
gases
and
functionality
is
given
in
Figure
2.
hydrogen
and
four
reactions.
[5]
3
account
for
the
influence
of
temperature
and
catalyst
phases,
one
solid
and
other
vapour.
Reactors
are
deactivation
were
also
included
in
the
model.
[5]
tubular
fixed-‐bed
with
axial
or
radial
flow
and
work
in
A
heat
balance
was
added
into
the
system
of
the
adiabatic
regime.
equations.
This
was
a
considerable
improvement
on
the
previous
models
that
treated
catalytic
reforming
as
an
isothermal
system.
[6]
The
differential
equations
that
describe
the
reaction
rates
are
equations
(1)
to
(6).
[6]
[7]
𝑑C
= 𝑘! (𝑃!" + 𝑃!" )
(1)
𝑑𝜏
𝑑𝑁𝑃
= −(𝑘! + 𝑘! + 𝑘! + 𝑘! )𝑃!" + 𝑘! 𝑃!"#
𝑑𝜏 (2)
+ 𝑘! 𝑃!"# + 𝑘! 𝑃!"
𝑑𝐼𝑃
= −(𝑘! + 𝑘! + 𝑘! + 𝑘!" )𝑃!" + 𝑘! 𝑃!"#
𝑑𝜏 (3)
+ 𝑘! 𝑃!" + 𝑘!! 𝑃!"#
𝑑𝐴𝐶𝐻
= −(𝑘! + 𝑘! + 𝑘!" + 𝑘!" )𝑃!"# + 𝑘! 𝑃!"
𝑑𝜏 (4)
+ 𝑘! 𝑃!" + 𝑘!" 𝑃!"#
𝑑𝐴𝐶𝑃
= −(𝑘! + 𝑘!! + 𝑘!" )𝑃!"# + 𝑘! 𝑃!"
𝑑𝜏 (5)
+ 𝑘!" 𝑃!" + 𝑘!" 𝑃!"#
𝑑𝐴𝑅
= 𝑘!" 𝑃!"#
(6)
𝑑𝜏
The
differential
equation
that
describes
the
heat
balance
is
equation
(7).
[6]
[7]
!" !
=− (𝑘! 𝑃!" ∆𝐻!"→! + (7)
!" !! !!!
𝑘! 𝑃!" ∆𝐻!"→! + 𝑘! 𝑃!"# ∆𝐻!"#→!" + 𝑘! 𝑃!" ∆𝐻!"→!"# +
Figure
5
–
Model
calculation
flowchart
𝑘! 𝑃!"# ∆𝐻!"#→!" + 𝑘! 𝑃!" ∆𝐻!"→!"# + 𝑘! 𝑃!" ∆𝐻!"→!"# +
𝑘! 𝑃!"# ∆𝐻!"#→!" + 𝑘! 𝑃!" ∆𝐻!"→!" + 𝑘! 𝑃!" ∆𝐻!"→!" +
𝑘!" 𝑃!" ∆𝐻!"→!"# + 𝑘!! 𝑃!"! ∆𝐻!"#→!" + Since
the
differential
equations
described
by
𝑘!" 𝑃!"# ∆𝐻!"#→!"# + 𝑘!" 𝑃!"# ∆𝐻!"#→!"# + Henningsen
and
Bundgaard
–
Nielson
kinetic
are
𝑘!" 𝑃!"# ∆𝐻!"#→!" )
complex
equations
is
necessary
use
a
numerical
method
to
solve
these
equations.
The
method
chosen
was
the
Euler
method
described
by
the
equation
(8)
3. Analysis
of
Kinetic
Model
with
unit
step
size.
For
a
better
understanding
of
the
model
𝑑𝑦
developed
by
CEPSA
Company
was
made
a
detailed
𝑦 𝑡 + ∆𝑡 = 𝑦 𝑡 + ∆𝑡
(8)
𝑑𝑡
study
and
in
Figure
5
is
shown
a
flowchart
to
explain
the
functioning
of
the
simulator.
The
reactors
used
in
this
type
of
processes
are
heterogeneous
because
there
is
a
presence
of
two
4
4. Experimental
section
35
30
operated
and
how
the
process
variables
were
changed
3500
200
180
Adjustment
FuncJon
3000
through
the
working
days.
160
IteraJon
Time
2500
140
After
this
first
approach
it
was
verified
that
for
a
120
2000
100
better
utilization
of
the
simulator
it
would
be
better
to
1500
80
60
use
more
data
to
have
a
greater
range
of
values
for
1000
40
500
comparison.
To
accomplish
this
goal
it
were
extracted
20
0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
further
data,
in
this
case
18
months
of
operation.
Number
of
IteraJons
Figure
8
–
Adjustment
Function
and
Iteration
Time
as
function
of
number
of
iterations
As
show
in
Figure
8
the
adjustment
function
decreases
steeply
until
3000
iteration,
and
this
value
is
relatively
lower.
It
is
also
perceptible
that
from
5000
5
iterations
the
value
of
adjustment
function
does
not
The
chosen
correlation
is
described
by
equation
change
too
much
and
since
the
simulation
time
begins
(10),
and
it
takes
into
account
the
contributions
of
to
be
excessive,
the
best
choice
is
5000
iterations
to
each
hydrocarbon
family
presents
in
reformate.
[8]
have
one
minimization
of
adjustment
function
and
a
simulation
time
reasonable.
𝑅𝑂𝑁 = 𝑥!" 𝑅𝑂𝑁 !" + 𝑥!" 𝑅𝑂𝑁 !" + (10)
Moreover to prove the choice of 5000 iterations 𝑥! 𝑅𝑂𝑁 ! + 𝑥!" 𝑅𝑂𝑁 !"
results were consistent. Where xNP, xIP,xN, xAR are molar fraction of n-‐
95
HC
a
b
c
d
e
90
Family
In Figure 9 is visible that RON calculated by the Aromatics 145,66 -‐54,33 16,27 0 0
simulator follows the same trend as the real RON, but
their values are always higher. Due to this fact it was In Figure 10 is visible that the correlation described
tested
a
new
correlation
for
the
calculated
RON.
by
equation
(10)
despite
follows
the
same
tendency
as
the
real
RON
is
not
appropriate
because
its
values
show
a
percentage
error
of
16
%
while
the
values
of
6
RON
calculated
by
equation
(9)
show
an
error
of
5%
From
Figure
12
it
is
observed
that
production
of
compared
to
the
real
values.
aromatics
present
consistent
values
with
experimental
110
105
Mol
%
Real
AR
in
Reformate
100
Mol
%
Model
AR
in
Reformate
90
95
RON
85
Mol%
of
AromaJcs
90
80
85
75
80
70
65
75
186
196
206
216
226
236
60
Days
of
OperaJon
55
50
91
141
191
241
291
341
391
441
491
Figure
10
-‐
Comparison
between
Real
RON
and
calculated
RON
by
equation
(9)
and
(10)
Days
of
OperaJon
Due
to
these
results,
the
equation
(10)
was
Figure
12
–
Comparison
between
the
percentage
real
and
modified
to
take
into
account
only
the
compounds
calculated
of
aromatics
in
reformate
with
a
high
value
of
octane
number,
such
like
iso-‐ The
process
variable
most
frequently
used
by
paraffins
and
aromatics.
This
new
correlation
is
refiners
to
control
reformer
operation
is
weighted
described
by
equation
(12)
and
the
calculation
method
average
inlet
temperature
(WAIT).
This
variable
is
the
is
the
same
described
previously.
sum
of
the
inlet
temperature
to
each
reactor
𝑅𝑂𝑁 = 𝑥!" 𝑅𝑂𝑁 !" + 𝑥!" 𝑅𝑂𝑁 !"
(12)
multiplied
by
the
weight
percent
of
total
catalyst
in
each
reactor.
Likewise
equation
(12)
is
not
appropriated
for
522
adjustment
the
real
data.
Therefore
the
correlation
520
described
by
equation
(9)
remains
the
best
option,
as
518
516
confirmed
in
Figure
11.
514
WAIT
(ºC)
512
510
Real
RON
RON
Equagon
9
508
RON
Equagon
10
RON
Equagon
12
506
110
504
502
105
91
141
191
241
291
341
391
441
491
541
100
Days
of
Operation
95
RON
7
mol%
nP
mol%
IP
mol%
N
to
a
pilot
unit
and
how
to
change
any
variable
affects
mol%
AR
mol%
C
the
whole
production
of
reformate.
50
45
A
study
of
the
optimal
number
of
iterations
was
40
Mol%
of
Compounds
35
done
to
ensure
that
the
adjustment
function
would
be
30
minimized
within
a
reasonable
simulation
time.
We
25
20
conclude
the
more
appropriate
number
of
iterations
is
15
10
5000.
5
The
correlation
used
initially
by
kinetic
model
for
0
EvoluJon
over
of
reacJon
system
estimate
of
RON
is
the
best
option
despite
having
higher
values
than
the
real.
Figure
14
–
Evolution
of
compounds
along
reforming
catalytic
The
real
values
were
compared
with
those
calculated
by
the
model.
The
values
for
the
aromatics,
Figure
14
shows
the
evolution
of
compounds
n-‐paraffins
and
iso-‐paraffins
are
consistent
with
present
in
naphtha
along
the
reaction
system.
It
is
percentage
error
of
2%.
observed
that
molar
percentage
of
aromatics
through
However
in
relation
to
naphthenes
there
is
a
the
reaction
system
increases
while
molar
percentage
greater
discrepancy
in
the
values.
This
difference
can
of
naphthenes
and
paraffins
decreases,
as
expected,
be
explained
by
the
fact
that
their
values
are
lower
because
aromatics
formation
by
dehydrogenation
and
the
possible
integration
errors
made
in
reaction
requires
a
lower
amount
of
naphthenes
and
chromatography
equipment
(GC-‐Reformulizer).
consequently
the
formation
of
naphthenes
leads
to
a
On
the
other
hand
one
of
the
assumption
of
reduction
of
the
amount
of
paraffins.
chosen
kinetic
indicates
there
is
a
distinction
between
It
is
also
noted
that
the
largest
decrease
in
the
the
behaviour
of
alkyl-‐cyclopentanes
and
alkyl-‐
naphthenes
percentage
occurs
in
the
first
reactor,
cyclohexanes.
However
this
assumption
in
the
model
because
hydrogenation
reaction
is
the
fastest
and
the
was
not
considered,
feedstock
presents
only
alkyl-‐
most
endothermic
reaction
happens
mainly
in
the
first
cyclohexanes
and
reactions
where
ACP
appears
were
reactor.
not
taken
into
consideration.
This
fact
can
also
be
a
Furthermore
it
is
observed
that
the
molar
possible
reason
for
the
disparity
of
values.
percentage
of
cracked
products
undergoes
a
The
difference
between
model
yield
and
real
one
is
significant
increase
in
the
second
and
third
reactor,
5%
and
it
is
considered
acceptable.
because
these
reactions
are
considered
the
slowest
In
a
following
work
the
model
used
should
be
reactions.
complemented
using
more
reactions
to
describe
the
process
as
well
as
improve
the
way
of
calculating
the
6. Conclusions
RON.
The
kinetic
model
developed
by
Cepsa
Company
was
applied
to
real
data
of
an
industrial
unit
of
reforming
catalytic.
In
relation
to
the
monitoring
carried
out
it
was
observed
the
behaviour
of
an
industrial
unit
compared
8
7. Nomenclature
Jersey:
John
Wiley
&
Sons,
Inc,
2011.
∆𝐻!→!
-‐
Heat
of
reaction
[6]
Raseev,
Serge;,
"Chapter
13
-‐
Catalytic
Reforming,"
𝐶!
-‐
Heat
capacity
in
Thermal
and
Catalytic
Processes
in
Petroleum
𝑘!
–
Reaction
rate
constant
Refining.
New
York:
Marcel
Dekker,
Inc.,
2003,
pp.
𝑃!
-‐
Partial
pressure
of
the
component
i
771-‐786.
ACH
–
Alkyl-‐cyclohexanes
[7]
Henningsen,
J;
Bundgaard-‐Nielson,
M;,
"Catalytic
ACP
–
Alkyl
–
cyclopentanes
Reforming,"
Bristish
Chemical
Engeneering,
vol.
15,
AR
–
Aromatics
no.
11,
pp.
1433-‐1436,
November
1970.
C
–
Hydrocraking
products
[8]
M.
R.
Riazi,
Characterization
and
Properties
of
HC
-‐
Hydrocarbon
Petroleum
Fractions,
1st
ed.,
AMERICAN
SOCIETY
IP
–
iso-‐Paraffins
FOR
TESTING
AND
MATERIALS,
Ed.
Philadelphia,
𝑛
-‐
Hydrogen/Hydrocarbon
ratio
PA,
2005.
N-‐Naphthenes
NP-‐
normal-‐Paraffins
WAIT
-‐
Weighted
Average
Inlet
Temperature
τ
–
Reaction
time
8. Bibliography
[1]
Antos,
George
J;
Aitani,
Abdullah
M;,
Catalytic
Naphtha
Reforming,
2nd
ed.
New
York:
Marcel
Dekker,
Inc.,
2004,
Revised
and
Expanded.
9