Rate continuous catalyst regeneration

This is a very slow reaction under normal reforming operation. Feed composition, temperature, H2/hydrocarbon ratio, and the pressure strongly influence the rate of coke deposition. Modern catalysts produce less coke and allow operation under more severe conditions, such as those used in the cyclic and in the continuous catalyst regeneration (OCR) reformers. The different reforming technologies are briefly described later. 

I 5 Predictive Modeling of the Continuous Catalyst Regeneration (CCR) Rrforming Process Table 5.4 Key rate equations from Taskar et al. [4, 5],... 

In the major catalytic processes of the petroleum and chemical industries, continuous and steady state conditions are the rule where the temperature, pressure, composition, and flow rate of the feed streams do not vary significantly. Transient operations occur during the start-up of a unit, usually occupying a small fraction of the time of a cycle from start-up to shut-down for maintenance or catalyst regeneration. 

Continuous processes are designed to operate 24 hours a day, 7 days a week, throughout the year. Some downtime will be allowed for maintenance and, for some processes, catalyst regeneration. The plant attainment or operating rate is the percentage of the available hours in a year that the plant operates, and is usually between 90 and 95%. 

The rate at which the catalyst is lost or degrades has a major influence on the design. If degradation is rapid, the catalyst needs to be regenerated or replaced on a continuous basis. In addition to the cost implications, there are also environmental implications, since the lost or degraded catalyst represents waste. While it is often possible to recover useful materials from degraded catalyst and to recycle those materials in the manufacture of new catalyst, this still inevitably creates waste, since the recovery of material can never be complete. 

In addition to the advantage of high heat transfer rates, fluidized beds are also useful in situations where catalyst particles need frequent regeneration. Under these circumstances, particles can be removed continuously from the bed, regenerated, and recycled back to the bed. In exothermic reactions, the recycling of catalyst can be... 

Several processes based on non-precious metal also exist. Because of high catalyst deactivation rates with these catalyst systems, they all require some form of continuous regeneration. The Fluid Hydroforming process uses fluid solids techniques to move catalyst between reactor and regenerator TCR and Hyperforming use some form of a moving bed system. 

---