Critical Variable in Catalytic Reforming and Unit Monitoring Best Practices

GBHE Technical Bulletin CTB #53
Catalytic Reforming
Critical Variables in Catalytic Reforming and Unit
Monitoring Best Practices
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on this information. Freedom under Patent, Copyright and Designs cannot be assumed.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Table of Contents
Best Practice
Identify
Employ
Export
Update
Critical Variables for Catalytic Reforming Examples
Example: CAT
Example: Recycle Gas C1/C2 Ratio
Minimum Critical Variables

Conclusion
Appendix
Principles and Practices Used in Catalytic Reformer Optimization
Management Continuum
Catalyst & Equipment Management
On-line Optimization
Operating Practices
Best Practice
Identify
Variables to be monitored in each section of the plant (e.g., feed
composition in feed section)
The goal (No LPO or incidents, optimize operating costs, maximize
product upgrade). Impacts of each variable on that goal
The relative importance of each variable
Who is responsible for each variable
Frequency of monitoring and practical control range
Response to out of range variables
Employ
Refinery data management system to automate the process to the
extent possible
Alarm data in refinery data management system if possible
The requisite lab data to close a material balance on the unit (+/- 2%)
Kinetic or empirical programs for catalyst activity and yield monitoring
Export
Procedures and findings to operating business unit and other interested
parties
Refinery reliability program (bad actors)
Refinery Planning group (LP)
Upstream and downstream units
Process engineering and operator training departments
Update
The process annually and at TAR events
Update responsibilities to fill gaps
Reporting procedures
Laboratory methods to streamline data turnaround
New software developments
More automation
Kinetic programs
Flow meters for material balance
Catalyst sampling devices
Critical Variables for Catalytic Reforming Examples
Example: CAT
Goals:
1. Run reliably/ incident prevention
2. Optimize operating costs
3. Maximize yields
All three apply
Importance:
A. Critical to daily operation; large impact on goals
B. Impacts long-term operation
C. Troubleshooting
A. Applies
Who monitors
Operations and Process Engineering
Frequency
Once per shift
Alarm on Critical Variable monitoring program (Refinery Data management
system
Example: Recycle Gas C1/C2 Ratio

Goals:
1. Run reliably/ incident prevention
2. Optimize operating costs
3. Maximize yields
1. Applies
Importance:
A. Critical to daily operation; large impact on goals
B. Impacts long-term operation
C. Troubleshooting
B. Applies
Who monitors
Process Engineering
Frequency
At performance test or Troubleshoot
No alarm
Minimum Critical Variables
Conclusion
Create
A refinery specific monitoring program
Start with a minimum critical variable list and create a refinery
specific list
Include engineering, operations, planning, and reliability
Set goals for the program
Update
The program frequently
Audit to ensure goals are met
Profitability
Availability
Reliability
Appendix
Principles and Practices Used in Catalytic Reformer Optimization
Overview of Reformer Optimization: Key Questions

What is the purpose of reformer optimization?
Where does reformer optimization fit in an operating plant?
What is Reformer Optimization?
Oil refineries process crude oil into gasoline and other transportation distillates.
Principle 1 of Reformer Optimization: Define the Objective Function! Must
be Quantifiable
-
Maximizing Octane Barrels
Maximizing Cash Flow
Maximizing Return on Investment
Maximizing Through-put
Principle 2 of Reformer Optimization: Layered Practices

-
Implementation and Execution of the Plan
Planning and Scheduling Activities
Fundamental Process Design and Maintenance
Optimizing Operating Practices

-
Active Supervision
Operating Targets
Review Performance
Engineering Support
Catalyst Performance Monitoring
Environment Monitoring / Control
LP Vectors for Planning and Scheduling
Best Practices
Laboratory Techniques
Catalyst Regenerations
Reactor Loading Procedures
Use of Experts for Support

Operator / Engineer Training
Proprietary Techniques
Performance Audits
Optimization through Catalyst & Equipment Management

Catalyst Management
Activity Control
Catalyst Selection
Catalyst Replacement
Equipment Management Maintenance
Exchanger Cleaning
Fired Heaters
Tube Cleaning
Tube Replacement
Box Management
Equipment Management Capitol Projects
-
Feed / Effluent Heat Exchange
Add a new reactor
Equipment Management Instruments

-
Instrument Selection
Instrument Tuning
Functional Analyzers
On-line Optimization
Opportunity for significant Return on Investment
Chemicals operations
Multiple reformers
Multiple degrees of freedom
Multiple unit constraints
Not for all Applications

-
Significant cost
On-going manpower requirements
Wide range of Return on Investment
RTO - Traditional Thinking

-
Thinking of the process in terms of the process unit configuration
Matching the process instrumentation - detailed feed-back system to

ensure model consistency with measured process variables
Matching the process yields
Precise process modeling
Leads to False Approaches

1. If the unit is modeled in sufficient detail, the economics can be
calculated
2. Make the optimizer a Super-Controller
An Alternate Way of Thinking: Optimize the Process

-
Economic Boundaries
Economic Drivers
Where in the process are the Economic Flex Points
On-line optimization - a Planning Tool not a Super-controller.
Economic Drivers:
Internal Drivers
Unit severity
Utilities
Incremental product recoveries
External Drivers
Feed allocation between units
Alternate feed specifications
Economic Flex Points:
Structure of On-line Optimization Solution
Modeling Approaches
Rigorous models used where needed
FCC Reactor
Reformer Reactor
Simplified Models used as applicable
Fractionation
Naphtha Hydrotreater
Optimization Model Structure
Three Keys for Selection of On-line Optimization of Reformer Operation

Feedstock
Naphtha Splitting
Severity of Reaction
Optimization Example 1
Optimization Example 2
On-line Optimization: Intangible Benefits

-
Exploration of new modes of operation
S t r e t c h i n g of bounds
Brings economics into the control room
Accountability in financial terms

Critical Variable in Catalytic Reforming and Unit Monitoring Best Practices

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GBHE Technical Bulletin CTB #53

Information contained in this publication or as otherwise supplied to Users is believed to

Minimum Critical Variables

Critical Variables for Catalytic Reforming Examples

Example: Recycle Gas C1/C2 Ratio

Minimum Critical Variables

Overview of Reformer Optimization: Key Questions

Maximizing Octane Barrels

Maximizing Cash Flow

Maximizing Return on Investment

Principle 2 of Reformer Optimization: Layered Practices

Implementation and Execution of the Plan

Planning and Scheduling Activities

Fundamental Process Design and Maintenance

Optimizing Operating Practices

Use of Experts for Support

Optimization through Catalyst & Equipment Management

Feed / Effluent Heat Exchange

Add a new reactor

Equipment Management Instruments

Not for all Applications

On-going manpower requirements

Wide range of Return on Investment

RTO - Traditional Thinking

Thinking of the process in terms of the process unit configuration

Matching the process instrumentation - detailed feed-back system to

Matching the process yields

Precise process modeling

Leads to False Approaches

An Alternate Way of Thinking: Optimize the Process

Where in the process are the Economic Flex Points

On-line optimization - a Planning Tool not a Super-controller.

Structure of On-line Optimization Solution

Three Keys for Selection of On-line Optimization of Reformer Operation

On-line Optimization: Intangible Benefits

Exploration of new modes of operation

Brings economics into the control room

Accountability in financial terms

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