REFORMING SAMIR-MAROC

Transcription

1 Presentation of the unit REFORMING December 2008 by Mr. A. ELOTMANI Mr. Y.SABIL

2 Outline Introduction Feature and special Configuration Process diagram Regulating parameters Difficulties Regeneration and related difficulties Revamping project of the Reformer

3 Introduction SAMIR has 2 refineries: 1-Refinery of Mohammedia Refining capacity: T/year of crude oil. potential production capacity of base oils: T/year The first units started up in Refinery of Sidi kacem Refining capacity : T/an The first units started up in 1954

4 Introduction SAMIR has four Reformers whose capacity is 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

5 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.

6 Feature and special Configuration SAMIR s Option A special Reformer, Reforming-2 with three reactors, UOP licensed : - 1 st reactor: Bimetallic Catalyst R86 (Pt Rh) - 2 nd reactor: Bimetallic Catalyst R62 (Pt Rh) - 3 rd 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)

7 Feature and special Configuration Output of the unit LPG-operated High-H2 Gas to HDT-2 (Net Gas) 3.1 % (V % H2 = 65%) Gas to SFG 3.2 % LPG 30.5 % C % 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%).

8 Feature and special Configuration Reactor initials Catalyst initials Quantity ( Kg) %pds REFORMING 2 96R1 R R2 R R3 R

9 Reformer-2 Process Diagram HDT/HDS/CHL SFG B.D Turbo-compresseur de recyclage de H2 Réacteur R1 Réacteur R2 Réacteur R3 Séparateur Aéro SFG Récupération GPL B.D LPG RECOVERY Aéro Ballon de reflux Four F1 Four F2 GPL Stabilisateur STABILIZING COLUMN E205 Aéro Essence HSR du HDT Four F3 Pompe de charge Reformat

10 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/ /3 LHSV 0.75 à 1.1 H2/HC mol ratio 5.5 H2 purity 60% - 55%

11 Main Regulating Parameters Loading Specifications Reforming-2 Unit processes the HSR gasoline section with the following characteristics : PI : 85 C PF: 170 C Density : PONA : 68.2/1/18.9/11.9 ( Brut A.L)

12 Main Regulating Parameters Products Specifications Platformat produces along the following specifications: NO: 95 minimum Density at 15 C : TVR: Kg/cm2 maximum LPG : C5+ : Max 2% vol.

13 Difficulties 1. The Reformer configuration is featured by the lack of a furnace at the inlet of the 3 rd reactor, preheating temperature is low and creates a lot of demand on the furnace of the 1 er reactor, thereby leading to fuel overconsumption.

14 Difficulties 2. High H2 consumption due to hydrocracking reactions noted in the 3 rd 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.

15 Regeneration and its related difficulties 1. Conduct of the operations SAMIR has cumulated a work experience recognized by UOP and capable of achieving regeneration without any outside assistance. Carbon burn-off is done at 385 C as follows: - 36 h at 1 st reactor h at 2 nd reactor - 24 h at 3 rd reactor % Carbon burnt off: 9 to 10% of cat. weight Oxidization stage is achieved with the following T : C for 24h.

16 Regeneration and its related difficulties Reduction stage is achieved with reactors exit T : C for 15 to 20 hours. Unloading, screening and reloading of the catalyst is achieved following the 3 rd regeneration. 2. Difficulties and constraints Due to the lack of the 3 rd furnace, the difficulty involved is the nonachievement of the T required at the 3 rd reactor during carbon burn-off, oxidization and reduction stages. How long regeneration last is the main concern of all refiners. SAMIR submitted a project to UOP to start carbon burn-off from the 2 nd reactor in paralel with the first one. UOP gave a positive response.

17 Regeneration and its related difficulties Carbon burn-off duration from the 2 nd 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. 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.

18 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. High- H2 Gas to HDT- 2 (Net Gas) LPG operated Gasoline-operated Discrepancy 3.1 % (V % H2 = 65%) 8 % (V % H2 = 88,6%) +1.7 % Gas to SFG 3.2 % GPL 30.5 % 15% -15.5% C % 77% % TOTAL 100% 100%

19 Revamping project of the Reformer New regulating parameters: Pressure of the reaction circuit LPG-operated, EOR Gasoline-operated, EOR 32 Kg/cm2 15 Kg/cm2 Inlet temperature 96R3 460 C 530 C

20 Revamping project of the Reformer Modifications to be carried out: Replacement of the catalyst of 3 rd 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 3 rd reactor Installation of a new compressor to feed the other units with H2 Installation of a new pump to feed the stabilization column

21 Reformer Process Diagram (Revamped) HDT/HDS/CHL SFG B.D Com presseur Alternatif H2 vers utilisateurs Turbo-compresseur de recyclage de H2 Aéro SFG Récupération GPL Réacteur R1 Réacteur R2 Réacteur R3 Séparateur B.D Aéro Ballon de reflux GPL Four F1 Four F2 F2 Four F4 Stabilisateur E205 Aéro Essence HSR du HDT Four F3 Pompe de charge Reformat

22 REFORMING THANK YOU FOR KIND ATTENTION