Two-stage reforming process configured for increased feed rate to manufacture reformate

Abstract

Described herein is a two-stage reforming process using a unique configuration which allows the reforming unit to operate at a higher naphtha feed rate as compared to conventional reforming configurations. In the unique reforming process described herein, a naphtha feedstock undergoes a distillation step prior to the first reforming stage. The distillation step separates the naphtha feedstock into a top light a C7 stream, which typically accounts for between 5 and 20 percent of the overall feedstock, and a C8+ stream. The C8+ stream undergoes reforming in a first stage consisting of at least one reactor containing conventional metallic reforming catalyst, under conditions sufficient to convert the C8+ stream into a first intermediate reformate. The C7 stream, bypasses the first stage and is combined with the intermediate reformate, and reformed in the second stage, at lower pressure than in the first stage, over a reforming catalyst containing a medium pore zeolite.

Description

FIELD OF THE INVENTION[0001]Described herein is a two-stage reforming process using a unique configuration which allows the reforming unit to operate at a higher feed rate as compared to conventional reforming configurations.[0002]The term “two-stage reforming process” refers to a reforming processing wherein a naphtha feedstock is subjected to reforming conditions in one or more reforming reactors containing conventional metallic reforming catalyst (first stage) to form an intermediate reformate having a target Research Octane Number (RON) which is greater than the naphtha feedstock RON. The intermediate reformate is then subjected to reforming conditions in one or more reforming reactors containing one or more medium pore zeolite-based catalysts (second stage) to form a final reformate having a higher RON than the intermediate reformate RON.BACKGROUND OF THE INVENTION[0003]Catalytic reforming is a petroleum refining process for upgrading light hydrocarbon feedstocks, frequently re...

AI Technical Summary

Benefits of technology

The patent describes a new way to convert naphtha into fuel using a two-stage reforming process. The process uses a special catalyst that allows the first stage to operate at higher rates, resulting in more fuel produced. This allows the refiner to run the first stage at high rates with less material to convert. In the second stage, a different catalyst is used that is better suited to convert a specific part of the naphtha feedstock. By removing this specific part in the first stage, the first stage can operate at higher rates and produce more fuel. Overall, this process increases the efficiency of converting naphtha to fuel.

Problems solved by technology

Furthermore, the presence of halogens such as chlorine during regeneration results in the formation of corrosive by-products such as HCl and NH4Cl.

These compounds can cause damage to equipment used in the reforming process such as heat exchangers, liquid / gas separators and reactor internals.

The halogen containing compounds and their products used for platinum re-dispersion are highly toxic as well.

Conventional methods for regeneration of reforming catalysts take several days, and the equipment is exposed to hydrochloric acid during this period.

In addition, the shut-down, regeneration and start-up of a reformer reactor can pose a risk to the health and safety of the environment and refinery personnel.

In addition, the reforming configuration illustrated in FIG. 1 has a disadvantage.

While the addition of reforming units allows refiners to potentially lengthen the time between catalyst regeneration cycles, or more tailor the reformate product slate, the addition of reforming units does not allow the refiner to increase the feed rate, and therefore the reformate production rate, of the reforming unit for the case where feed rate is limited by factors such as feed pump size or furnace size.

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