A comparative study on optimised and non‐optimised axial flow,spherical reactors in naphtha reforming process

In this study, the operating conditions of an axial flow spherical reactor have been optimised using a reliable optimisation technique and the results are compared with the results of non‐optimised conditions. The dynamic behaviour of the reactor has been considered in the optimisation process and orthogonal collocation method has been used in order to solve the obtained equations from mathematical modelling of the process. The goal of this study is to maximise the aromatics and hydrogen production rate. Therefore, the objective function is the combination of two terms which include the production rate of the mentioned components. The catalyst distribution for each reactor, the inlet pressure of the system, Length per radius for each reactor, the naphtha feed molar flow rate and the hydrogen mole fraction in the recycle stream as well as the inlet temperature of each reactor have been optimised in this study. © 2011 Canadian Society for Chemical Engineering     

Hydrodynamics characterization of the Maxblend impeller

The hydrodynamic characteristics of the Maxblend^TM impeller have been investigated in the case of viscous Newtonian fluids. Both laboratory experiments and 3D finite element based computational fluid dynamics (CFD) simulations have been carried out. The power consumption, the mixing evolution yielding the mixing time, and the effect of baffles in the laminar and transition flow regimes have been determined. It was found that the limit Reynolds number between the laminar and transition regimes is approximately 25 and 38 for the unbaffled and baffled configurations, respectively. Based on the range of Reynolds numbers studied in this work, the best window performance of the Maxblend^TM mixer where fast and homogenous mixing is achieved is the end of the laminar regime and the early transition regime with baffles.     

Modeling of an axial flow,spherical packed-bed reactor for naphtha reforming process in the presence of the catalyst deactivation

Improving the octane number of the aromatics’ compounds has always been an important matter in refineries and lots of investigations have been made concerning this issue. In this study, an axial-flow spherical packed-bed reactor (AF-SPBR) is considered for naphtha reforming process in the presence of catalyst deactivation. Model equations are solved by the orthogonal collocation method. The AF-SPBR results are compared with the plant data of a conventional tubular packed-bed reactor (TR). The effects of some important parameters such as pressure and temperature on aromatic and hydrogen production rates and catalyst activity have been investigated. Higher production rates of aromatics can successfully be achieved in this novel reactor. Moreover, results show the capability of flow augmentation in the proposed configuration in comparison with the TR. This study shows the superiority of AF-SPBR configuration to the conventional types.     

Mathematical modeling of a multi-stage naphtha reforming process using novel thermally coupled recuperative reactors to enhance aromatic production

In this study, a novel thermally coupled reactor containing the naphtha reforming process in the endothermic side and the hydrogenation of nitrobenzene to aniline in the exothermic side has been investigated. Considering the higher thermal efficiency as well as the smaller size of the reactor, utilizing the recuperative coupled reactor is given priority. In this novel configuration, the first and the second reactor of the conventional naphtha reforming process have been substituted by the recuperative coupled reactors which contain the naphtha reforming reactions in the shell side, and the hydrogenation reaction in the tube side. The achieved results of this simulation have been compared with the results of the conventional fixed-bed naphtha reforming reactors. Acceptable enhancement can be noticed in the performance of the reactors. The production rate of the high octane aromatics and the consumption rate of the paraffins have improved 17% and 72%, respectively. The conversion of the nitrobenzene is acceptable and the effect of the number of the tubes also has been taken into account. However, the performance of the new configuration needs to be tested experimentally over a range of parameters under practical operating conditions.     

Combining continuous catalytic regenerative naphtha reformer with thermally coupled concept for improving the process yield

Advancements in the catalytic naphtha reforming process, as one of the main processes in petrochemical industry, contributed to development of continuous catalytic regenerative naphtha reformer units. Increasing the yield of aromatic and hydrogen as well as saving the energy in this process through the application of thermal coupling technique is a potentially interesting idea. This novel idea has been assessed in this paper. In the proposed configuration, continuous catalyst regeneration naphtha reforming process is coupled with hydrogenation of nitrobenzene in a two co-axial reactor separated by a solid wall, where the generated heat in nitrobenzene hydrogenation reaction transfers to naphtha reforming reaction medium through the surface of the tube. A steady-state, homogeneous, two-dimensional model is used to describe the performance of this configuration and a kinetic model including 32 pseudo-components with 84 reactions is considered for naphtha reforming reaction. After validating the model with the commercial data of a domestic plant, the obtained results of coupled reactor are compared by the conventional one. The obtained results show the superiority of CCR coupled reactor against the conventional one.     

Theoretical investigation of aromatics production enhancement in thermal coupling of naphtha reforming and hydrodealkylation of toluene

In the current research, an exothermic reaction is proposed to be coupled with naphtha reforming reactions. Hydrodealkylation (HDA) of toluene, which is a well-known petrochemical reaction, is discussed and is suggested as a potential exothermic reaction to be coupled with the endothermic naphtha reforming reactions. The first, the second, and the third reactor of the conventional naphtha reforming process have been substituted in three different cases by thermally coupled reactors and optimized parameters of the final case have been investigated. Considering lower operational costs due to the elimination of inter stage heaters, investigation of thermally coupled reactors has been the first priority of this research. The investigation shows that substitution of the first two reactors and, in the final case, all conventional reactors by the new configuration can improve the production yield of the aromatics by 14% and 21%, respectively compared with conventional naphtha reforming process. The final case has been optimized as well, and 45% and 11% improvement in aromatics and hydrogen production has been observed.     

Optimal design of a radial-flow membrane reactor as a novel configuration for continuous catalytic regenerative naphtha reforming process considering a detailed kinetic model

The significance of the catalytic naphtha reforming process in the petroleum refining and petrochemical industry generates continuous evolution of the technology. These improvements would be observed in presenting more efficient reactor setups in order to improve production yield and operating conditions, as well as elucidating better kinetic and deactivation models with higher predicting ability. Both of these items have been considered in this work. An optimized radial-flow moving bed membrane reactor has been proposed as a novel configuration for naphtha reforming process. Optimization has been carried out by differential evolution (DE) method considering 40 decision variables. A detailed kinetic model has also been presented. The proposed kinetic model consists of 32 lumped pseudo-components and 84 reactions. Deactivation rate of catalyst has also been taken into account by considering coke deposition on both acidic and metallic sites. Plant data have been used to validate the modeling results. In order to assess the performance of the proposed configuration, the obtained modeling results have been compared with those of conventional configuration, which shows the superiority of the presented one.     

Kinetic study of methane hydrate formation in the presence of carbon nanostructures

The effect of synthesized nanostructures,including graphene oxide,chemically reduced graphene oxide with sodium dodecyl sulfate(SDS),chemically reduced graphene oxide with polyvinylpyrrolidone,and multi-walled carbon nanotubes,on the kinetics of methane hydrate formation was investigated in this work.The experiments were carried out at a pressure of 4.5 MPa and a temperature of 0 ℃ in a batch reactor.By adding nanostructures,the induction time decreases,and the shortest induction time appeares at certain concentrations of reduced graphene oxide with SDS and graphene oxide,that is,at a concentration of 360 ppm for reduced graphene oxide with SDS and 180 ppm for graphene oxide,with a 98% decrease in induction time compared to that in pure water.Moreover,utilization of carbon nanostructures increases the amount and the rate of methane consumed during the hydrate formation process.Utilization of multi-walled carbon nanotubes with a concentration of 90 ppm showes the highest amount of methane consumption.The amount of methane consumption increases by 173% in comparison with that in pure water.The addition of carbon nanostructures does not change the storage capacity of methane hydrate in the hydrate formation process,while the percentage of water conversion to hydrate in the presence of carbon nanotubes increases considerably,the greatest value of which occurres at a 90 ppm concentration of carbon nanotubes,that is,a 253% increase in the presence of carbon nanotubes compared to that of pure water.     

Thermal Integration of Sulfuric Acid and Continuous Catalyst Regeneration of Naphtha Reforming Plants

An optimal reactor design is proposed that simultaneously improves the naphtha reforming reactor performance and increases sulfur trioxide production. In this new configuration, the naphtha reforming process as an endothermic reaction is coupled with the oxidation reaction of sulfur dioxide, which is an exothermic reaction. The differential evolution optimization technique is applied to maximize the produced amounts and yields of aromatics and hydrogen. The results obtained with the optimized thermally coupled reactor are compared with those of the conventional and thermally coupled reactors, proving the superiority of the proposed configuration.     

Modeling of naphtha reforming unit applying detailed description of kinetic in continuous catalytic regeneration process

Naphtha reforming is one of the most important processes in refineries in which high value-added reformate for gasoline pool and aromatics such as benzene, toluene, and xylene are produced. It is necessary to establish new naphtha reforming units and develop the traditional units to increase the efficiency of the processes. In this study, according to the recent progresses in the naphtha reforming technology, mathematical modeling of this process in continuous catalyst regeneration mode of operation is accomplished in two dimensions (radial and axial) by considering cross flow pattern. In addition, a new catalyst deactivation model has been proposed and a new reaction network model based on 32 pseudo-components with 84 reactions is investigated. Then, this model has been validated by comparing with industrial data, and its results have acceptable agreement.