Naphtha reforming, catalytic octanizing process

Reforming, In refining, a catalytic process in which naphtha molecules are cracked, rearranged, and/or recombined for the purpose of increasing the octane number of the naphtha. Reforming is also the process of converting hydrocarbons and steam to synthesis gas (carbon monoxide and hydrogen). 

Catalytic reforming. Catalytic reforming is a process for increasing the octane number of naphthas. It involves isomerisation of alkanes, dehydrogenation of cyclohexanes to aromatic hydrocarbons, isomerisation and dehydrogenation of alkylcyclopentanes, and dehydrocyclisation of alkanes. 

The catalytic reforming process is, together with catalytic cracking, one of the most important processes in modem refinery schemes. It is used to convert low octane n-alkanes and cycloalkanes with 5 to 10 carbon atoms contained in the petroleum naphtha into high-octane isoalkanes and aromatics gasoline components and hydrogen. Typically, reformer reactors operate at temperatures of 425-525 °C and hydrogen pressures of 0.5-3.0 MPa. 

As shown in Figure 1, hydrocracking often is an in-between process. The required hydrogen comes from catalytic reformers, steam/methane reformers or both. Liquid feeds can come from atmospheric and/or vacuum distillation units delayed cokers fluid cokers visbreakers or FCC units. Middle distillates from a hydrocracker usually meet or exceed finished product specifications, but the heavy naphtha from a hydrocracker usually is sent to a catalytic reformer for octane improvement. The fractionator bottoms can be recycled or sent to an FCC unit, an olefins plant, or a lube plant. 

Problem 3-1 (Level 1) Radial reactors are sometimes used in catalytic processes where pressure drop through the reactor is an important economic parameter, for example, in ammonia synthesis and in naphtha reforming to produce high-octane gasoline. 

Increasing the octane number of a low-octane naphtha fraction is achieved by changing the molecular structure of the low octane number components. Many reactions are responsible for this change, such as the dehydrogenation of naphthenes and the dehydrocyclization of paraffins to aromatics. Catalytic reforming is considered the key process for obtaining benzene, toluene, and xylenes (BTX). These aromatics are important intermediates for the production of many chemicals. 

Introduction of zeolites into catalytic cracking improved the quality of the product and the efficiency of the process. It was estimated that this modification in catalyst composition in the United States alone saved over 200 million barrels of crude oil in 1977. The use of bimetallic catalysts in reforming of naphthas, a basic process for the production of high-octane gasoline and petrochemicals, resulted in great improvement in the catalytic performance of the process, and in considerable extension of catalyst life. New catalytic approaches to the development of synthetic fuels are being unveiled. 

---