CCR PlatformingTM Technology:

Advancing the State of the Art

Mike Salem
UOP Limited
Guildford England

© 2005 UOP LLC. All rights reserved. UOP 4474F-01

 Agenda
◼ Market Drivers
◼ Process: UOP has unique design advantages
and is continuously improving the
technology.
◼ Regeneration: UOP regeneration capability
is unmatched in the industry. New advances
move the technology forward even further.
◼ New catalyst option for increased
profitability: R-264 catalyst for increased
capacity, activity, or yield in your reforming
unit.

UOP 4474F-02
 Market Drivers
◼ Product demand:
– Tight supply for gasoline in the US
– Benzene and Xylene
◼Specification drivers:
– Desulfurization in transportation fuels
– Increased octane for gasoline in Asia
◼ Efficiency:
– Improve feed utilization
– Reduce costs per BBL

UOP 4474F-03
 191 Operating CCR Platforming Units
37 in Design and Construction
Commissioned CCRTM ◼ First generation ➔ Atmospheric
Regenerators Types
Pressurized
◼ Second Generation ➔ Pressurized
24 Sequential
CycleMaxTM 1 ◼ Current state of the art high
41 capacity regeneration ➔
CyclceMaxTM
◼ Newest small capacity regenerator
➔ Sequential

Atmospheric
125

Vast experience base

UOP 4494B-08
 191 Operating CCR Platforming Units
37 in Design and Construction
CCR Platforming unit
Design Capacities, BPD
5 units operating > 60,000 BPD Less than 10,000
9 units
3 units operating > 80,000 BPD 10,000 – 20,000
72 units
at high severity Greater than 30,000
36 units

20,000 – 30,000
74 units

Unmatched experience with large

capacity units
UOP 4474F-05
 CCR Platforming Process
Customers’ Experience
◼ Number of repeat technology selections after having
a first CCR Platforming unit in operations.
– 85
◼ Many companies license exclusively from UOP
– All world scale companies have only CCR
Platforming units
– There are more than 15 companies around the world
which only license from UOP

Why? Proven performance. Best service.

Best technology
UOP 4474F-06
 Reactor Configuration
UOP offers both side-by-side and stacked
reactor designs. UOP has designed and has in
operation Platforming units with 3+1, 2+1, and
2+2 stacked reactor configuration. Most
customers prefer a single stacked reactor.
Stacked reactors result in:
◼ Lower capital cost
◼ Fewer pieces of equipment
◼ Smaller plot space
◼ Lower catalyst attrition
◼ Lower operating maintenance costs

UOP has designed many

different reactor configurations
UOP 4474F-07
Upflow Centerpipe Reactor Advantages
Vapor Flow

Higher velocity head

◼ Downflow centerpipes
are obsolete
◼ The upflow centerpipe
is a UOP unique design
◼ Vapor flow distribution
is optimized in an
upflow design

Optimized vapor
distribution results in best
catalyst utilization UOP 4494B-13
 Improved Reactor Upflow Centerpipe

◼ Benefits of Upflow Centerpipe

– Easy socket assembly
– Less maintenance
– Assured catalyst containment
– Uniform catalyst withdrawal
at base of centerpipe.

Machine Socket
Most reliable mechanical assembly. (Female End)
Ensures best utilization
of catalyst

UOP 4474F-09
 Reduction
Zone Smooth Catalyst Movement
◼ Only 2 lifts
◼ Straight upward lift lines
◼ Horizontal flow – only at
downward slope
Last ◼ No operating valves in
Reactor
catalyst lines
◼ Smooth flow control with
Catalyst
Collector unique L-valve
Lock
Hopper
◼ “Impactless” elbows
Booster
N2 Gas H2

Fewer lifts, bends and valves result

in lower catalyst attrition UOP 4494B-16
 Market Trends Toward Large Units
Largest CCR Platforming Units
Design by Decade
100
◼ Units in operation from
80 6000 BPD to 85,000 BPD
1000's of BPD

60
◼ Current design ranges
are 12,000 to 95,000+
40 BPD
20 ◼ Careful attention to
design is critical
0
1970s 1980s 1990s 2000s

UOP has the most experience and expertise

for design of large units
UOP 4474F-12
Examples of Recent Design
Improvements
◼ Redesigned
– Scallops – D style and
Optimizers
– Centerpipes
– Internal heads
◼ Improved seal ventilation
◼ Virtually eliminated heel
catalyst
◼ Cooldown mode - increased
reliability during startup
and shutdown
Continuous innovation – particularly
important for super-sized units
UOP 4474F-13
 CycleMax Regenerator
Feature Benefit
Superior catalyst reconditioning - Best catalyst performance
- Ultra-long catalyst life
Low fines make - Less catalyst makeup
- Higher reliability
Fewer pieces of equipment - Easier and cheaper to
construct and maintain
No waste liquid or solids - No disposal costs
Low maintenance requirements - Can match desire for 3 to 5
year turnaround schedule
on reactors

Premier regenerator
UOP 4474F-14
 CycleMax Regenerator Burn Zone
Feature Benefit
Tapered screen : ◼ Maintains good Pt
Shorter residence time at dispersion
peak temperature ◼ Ultra-long catalyst life
Low O2 concentration: ◼ Ultra-low fines production
Low peak burn Special
Thermocouples
temperature

UOP catalyst with good burn ◼ Complete coke removal in

characteristics single burn zone
Stable catalyst performance ◼ Minimal equipment
Simple operating scheme ◼ No waste liquid or solid
disposal

Long catalyst life is achieved with

UOP catalyst in simple to operate
CycleMax regenerator
UOP 4474F-15
 CycleMax Regenerator Experience
through Year 2005 Commissioning
Catalyst life is a function of operating severity + ability
to successfully rejuvenate the catalyst

2nd Load 3rd Load ◼ Few units have reloaded

17% 0% with catalyst since
commissioning.
◼ First unit commissioned is
operating with its original
catalyst after >9 year
operation at high severity.
◼ Because so many units are
1st Load still on first load of catalyst
83% it is impossible to report
average life
UOP catalyst and the CycleMax regenerator produce
the longest catalyst life in the industry
UOP 4474F-16
Long Catalyst Life with Constant Yields
100.00 40.0
C5+ Yield 30.0
95.00
Delta Temp from Predicted

Delta Temperature, deg C

20.0
C5+ Yields, LV%

90.00
10.0

85.00 0.0
-10.0
80.00
-20.0
75.00
-30.0

70.00 -40.0
Over 8 years

Stable yields for more than 8 years

At 103 to 105 RONC
UOP 4474F-17
Reduction Zone Advantages
Catalyst In
Reduced Catalyst

Reactor No. 1 Feed

Reactor No. 1 Effluent

Catalyst
Transfer Pipes

UOP reduction zone results in better Pt

dispersion and catalyst performance UOP 4474F-18
 CCRTM Regenerator
with ChlorsorbTM System

Disengaging
Vent Gas ◼ Caustic scrubbing is
Hopper
Catalyst
< 30 ppm HCl outdated
◼ Chlorsorb system
Chlorsorb results in:
Vessel – No waste water
– Minimal chloride
Regeneration Burn Zone injection due to
Tower Gas extensive chloride
recycle

>99% Chloride removal efficiency –

with no waste products or moving parts
UOP 4474F-19
Chlorsorb System Performance Data
100
99
98
Percent Reduction

97
96
95
94
93
92
91
90
TCDD I-TEF CL-BZ PCB HCL Total
CCR Regenerator Vent Gas Compounds

Excellent commercial performance

UOP 4474F-20
 Chlorsorb Experience

Operating
Design and
construction
Successfully Operating
◼ 4 CycleMax regenerators
◼ 11 Atmospheric regenerators

◼ 22 more in design and construction

UOP 4474F-21
 R-264 Catalyst
for the CCR Platforming Process
◼ R-264 catalyst performance
– Catalyst yields
– Catalyst comparisons
– Physical characteristics
◼ R-264 catalyst commercialization
– Commercial status
– Commercial data

High Density, Highest Activity, Low Coke,

High Hydraulic Capacity

UOP 4474F-23
 R-264 Catalyst Benefits
One Catalyst – Two Operating Modes
Maximum Yield Mode
◼ ~0.6 wt% yield advantage
◼ ~ 7 Nm3/m3 Hydrogen
◼ Same activity as R-134 catalyst

Relative to R-134 Catalyst

Maximum Activity Mode

◼ ~2-4 oC activity advantage
◼ Same yields as R-134 catalyst

18% less coke make than R-134 catalyst in either mode

UOP 4474F-24
R-264 Catalyst – Breakthrough Performance
R-264 catalyst flexibility -
Higher yield or greater activity

R-274 R-264 High Yield Mode

Yield

R-264 catalyst
R-234 performance line

Yield
R-264 High
R-134 Activity Mode
Activity
UOP 4474F-25
 Third Party Catalyst Testing
R-264, R-134, Competitor Catalyst
◼ Catalyst “A” has poorer selectivity to H 2, C5+, and
aromatics than R-264 or even R-134 catalyst
◼ R-264 catalyst exhibits better selectivity
– R-264 catalyst has a large selectivity advantage
over competitor’s catalyst A
– Selectivity advantage increases with lower
pressure and higher severity
◼ R-264 catalyst shows
– More C5+
– More aromatics and hydrogen
– Less A6 and more A8+
UOP 4474F-26
 3rd Party Evaluation
R-264, R-134, Competitor Catalyst

Cat. A R-134 R-264

C5+, wt% - 0.5 + 1.2
H2, wt% -0.05 +0.12
Total A, wt% - 0.4 +1.1
Bz SAME
Base -0.1
Tol SAME SAME
Xyl - 0.2 +0.6
A9+ -0.2 +0.6
Coke make, +8% -26 %
% Kg/hr change

UOP 4474F-27
R-264 Catalyst – Physical Properties
◼ More open pore structure – higher throughput
operation
– Low coke
– Faster burning rate
◼ Higher density
– Higher pin margin for more throughput
◼ Higher strength
– Lower fines make
◼ Surface area stability
– Catalyst life equal to the best in the industry
(R-134)

UOP 4474F-28
 R-264 Commercial Status
◼ 8 refiners have selected R-264
– 6 are in operation
– 1 more will load 4th quarter 2005
– 1 will load 1st quarter 2006
◼ A commercial example
– Switched from R-134 ( nearly 10 years old)
– Wanted flexibility for high selectivity or activity
– Immediate need for more reformate

UOP 4474F-29
 R-264 Catalyst
Feed & Operating Conditions
P/N/A, lv% 43/36/21
IBP / 50% / EP, °C 99/127/179
RONC Typical 99-100
R-264 Catalyst Mode High Activity

Relatively consistent feed rate, PNA, distillation

and RONC before and after catalyst change-out

UOP 4474F-30
R-264 Catalyst Commercial Performance
Improved Yields
C5+ Yield H2 Yield
90 1400
C5+ Yield, LV% H2 Yield
89 1300
C5+ Yield, LV%

H2 Yield, SCFB
88
R-134 1200
87
86 1100
85 1000
84 R-134 R-264
83 R-264 900
82 800
12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05 12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05
Date Date

◼ C5+ yield increased by 1-2 LV%

◼ Hydrogen yield up by ~20 Nm3/m3

R-264 catalyst delivers higher yield

UOP 4474F-31
 R-264 Catalyst Commercial Performance
WAIT and LHSV
1000 2.20

995
2.15
11º C more active 990

LHSV, 1/hr
WAIT, °F
985 R-264 Catalyst
R-134 Catalyst 2.10
980

975 WAIT, deg F 2.05

Fines Make, Lbs/Day LHSV
50 970
45 Fines Make, Lbs/Day 965 2.00
40 12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05
35 Date
Fines, Lbs/Day

30
R-134 Catalyst
25
20
15
R-264 Catalyst 50% less fines make
10
5
0
12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05
R-264 catalyst is more active with
lower fines make!
UOP 4474F-32
 R-264 Catalyst Commercial
Performance Summary
◼ Activity increased by ~ 11°C
◼ C5+ yield increased by ~ 1-2 lv %
◼ Hydrogen yield increased by ~ 20 NM3/m3
◼ Chloride use reduced by ~70%
◼ Fines make reduced by 50%

R-264 catalyst meeting

process objectives.
Customer delighted with
performance
UOP 4474F-33
 Commercialization Summary
◼ Eight customers have selected
R-264 catalyst
◼ R-264 catalyst has provided
◼ Higher activity – key requirement
allowing for :
✓ Increased throughput
✓ Increased octane-barrels
◼ Lower coke
◼ Lower catalyst makeup

Successful Commercialization of R-264 Catalyst

UOP 4474F-34
 Summary
UOP continues to innovate and improve
the Platforming process
– UOP has unique design advantages in
CCR Platforming
– CCR Platforming process is being
continuously improved
– UOP regeneration capability is
unmatched in the industry

UOP 4474F-35
 Summary Cont’d
UOP continues to innovate and improve
the Platforming process
– UOP has the skill and experience to design
CCR Platforming units to meet the needs
of all markets
– R-264 catalyst is the highest performance
catalyst available today

UOP 4474F-36
UOP 4474B-37