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Counter-current Continuous Catalytic Reforming Process

  • Introduction
  • Technical Characteristics

Introduction

A new continuous reforming process called counter-current continuous catalytic reforming process has been developed by SINOPEC. The regenerated catalyst firstly enters the last reactor. Then it’s conveyed to the first reactor while the feed still flows from the first reactor to the last one. After reaction, the spent catalyst is lifted to the regenerator to be regenerated. Catalyst has the highest activity in the last reactor and the lowest activity in the first reactor. In this way, the high activity catalyst is used to promote the difficult reactions and low activity catalyst is used in the easy reactions, which makes the catalyst activity matches with the reaction difficulty. So the counter-current catalytic reforming process has overcome the limitation of the traditional co-current process. 

Counter-current continuous catalytic reforming process not only improves the reaction conditions, but also creates a new catalyst circulation method with simplified operation. Compared with the traditional process, this process has three remarkable features. Firstly, the flow direction of catalyst is from the last reactor to the first reactor. Secondly, catalyst transportation from low pressure to high pressure is achieved by means of catalyst sealing legs instead of the complicated lock-hopper and relevant control system. Thirdly, there is only one catalyst dust elutriation system.

Technical Characteristics

1. Reaction Section
1) Catalyst counter-current flow optimizes the reaction conditions, which increases the yields of both liquid products and hydrogen. Compared with the co-current process, the yields of C5+ product and hydrogen can be approximately increased by 0.5%~1.0% and 5%~10% respectively.
2) Reactors are arranged side by side. The specification of four reactors are identical so that design, fabrication, install and maintenance are much easier than different specification reactors. Spare parts are universal for four reactors.
3) The average reaction pressure and the pressure of gas-liquid separator are kept at 0.35 MPag and 0.24 MPag, respectively.
2. Catalyst Circulation Section
1) The traditional method of increasing pressure by lock-hopper system has been abandoned. Catalyst is delivered from low pressure to high pressure by catalyst sealing legs. In this way, the catalyst transport system is simplified.
2) The process is simplified by the design of spend catalyst dust elutriation system due to dramatic decreases of catalyst attrition. 
3) Spent catalyst is lifted by nitrogen while regenerated catalyst is lifted by hydrogen.
3. Catalyst Regeneration Section
1) The regenerator pressure is lower than that in the first reactor and higher than that in the last reactor, which is beneficial to both catalyst regeneration and catalyst transportation.
2) The burning zone consists of two moving beds. The bed temperature increases gradually so that temperature runaway can be avoided.
3) A cold loop process is introduced to the regeneration gas circulation.
4) A cooling zone is installed at the bottom of regenerator.


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