Method for revamping fixed-bed catalytic reformers

Abstract

A fixed-bed catalytic reformer unit is converted to moving bed reactor/cyclic regenerator operation by re-using the fixed bed reactors of the original unit as regenerator vessels operated in cyclic regeneration mode in a new catalyst regeneration section. A flow connection, suitably a liftpipe, is provided to convey spent catalyst from the spent catalyst outlet of a new moving bed reactor section to the converted regenerator section, together with a flow connection for regenerated catalyst from the regenerator section to the regenerated catalyst inlet of the new moving bed reactor section. A flow control distributor directs spent catalyst sequentially to each of the regenerator vessels to carry out the regeneration with regeneration gas. Each regenerator vessel is cycled through a fill, regeneration, discharge sequence to maintain a continuous flow of catalyst to and from the reactor section.

1 . A method for the conversion of a fixed bed catalytic reformer unit having at least one fixed-bed catalytic reforming reactor to moving bed reactor/cyclic regenerator operation, the method comprising: 
 providing a moving bed, continuous reforming reactor section for carrying out catalytic reforming reactions on a reformer feed;    converting at least one fixed bed reforming reactor of the fixed-bed catalytic reformer unit to a catalyst regenerator vessel in a catalyst regeneration section;    providing a flow connection for spent catalyst from a spent catalyst outlet of the moving bed reactor section to the catalyst regenerator vessel and    providing a flow connection for regenerated catalyst from a regenerated catalyst outlet of the catalyst regenerator vessel to a regenerated catalyst inlet of the moving bed reactor section.    
   
   
       2 . A method according to  claim 1  in which the fixed-bed catalytic reformer unit has a plurality of fixed-bed catalytic reforming reactors which are converted to a plurality of cyclic operation catalyst regenerator vessels.  
   
   
       3 . A method according to  claim 2  which includes providing (i) a flow connection for spent catalyst from the spent catalyst outlet of the moving bed reactor section to one of the catalyst regenerator vessels and (ii) a flow connection for regenerated catalyst from the regenerated catalyst outlet of one of the catalyst regenerator vessels to the regenerated catalyst inlet of the moving bed reactor.  
   
   
       4 . A method according to  claim 3  in which the flow connection for the spent catalyst from the spent catalyst outlet of the moving bed reactor section is connected at the end remote from the reactor section to a spent catalyst flow distributor for selectively directing spent catalyst to one of the plurality of catalyst regenerator vessels.  
   
   
       5 . A method according to  claim 3  in which the flow connection for the regenerated catalyst from the catalyst regenerator vessel is connected at the end remote from the catalyst regenerator vessel to a regenerated catalyst collector for directing regenerated catalyst to the catalyst inlet of the moving bed reactor section.  
   
   
       6 . A method according to  claim 4  in which each regeneration vessel has an inlet and an outlet for reforming catalyst regeneration gas.  
   
   
       7 . A method according to  claim 1  in which the moving bed, continuous reforming reactor section comprises a plurality of reforming reactors in a vertically stacked configuration and the catalyst regeneration section comprises a plurality of catalyst regeneration vessels converted from the fixed bed reactors of the fixed bed reforming unit.  
   
   
       8 . A method according to  claim 7  in which the spent catalyst outlet of the moving bed reactor section is connected for spent catalyst flow to a spent catalyst lift engager which has a spent catalyst outlet connected for spent catalyst flow to a liftpipe to convey spent catalyst to a spent catalyst flow distributor for directing spent catalyst to one of the plurality of catalyst regenerator vessels.  
   
   
       9 . A method according to  claim 8  in which each of the plurality of catalyst regenerator vessels is connected for regenerated catalyst flow to a regenerated catalyst lift engager which has an outlet for regenerated catalyst flow to a liftpipe to convey regenerated catalyst to the catalyst inlet of the moving bed reactor section.  
   
   
       10 . A method according to  claim 9  which includes means for selectively directing regenerated catalyst flow from each of the plurality of catalyst regenerator vessels in sequence to the regenerated catalyst lift engager.  
   
   
       11 . A method for the conversion of a fixed-bed catalytic reformer unit having a plurality of fixed bed catalytic reforming reactors to moving bed reactor/cyclic regenerator operation and for the operation of the converted unit, the method comprising: 
 providing a fixed bed catalytic reforming unit having a plurality of fixed bed reforming reactors in which catalytic reforming reactions on a reformer feed are carried out,    providing a moving bed, continuous reforming reactor section for carrying out catalytic reforming reactions on a reformer feed;    converting a plurality of the fixed bed reforming reactors of the fixed-bed catalytic reformer unit to catalyst regenerator vessels in a catalyst regeneration section which is connected for spent and regenerated catalyst flow between the moving bed reactor section and the catalyst regeneration section;    providing a flow connection for spent catalyst from a spent catalyst outlet of the moving bed reforming reactor section to each catalyst regenerator vessel and    providing a flow connection for regenerated catalyst from a regenerated catalyst outlet of each catalyst regenerator vessel to the regenerated catalyst inlet of the moving bed reactor section,    providing a flow controller for selectively directing reforming catalyst regeneration gas to each catalyst regeneration vessel    reforming a reformer feed in the moving bed rector section,    removing spent reforming catalyst from the spent catalyst outlet of the moving bed reactor section,    passing the spent reforming catalyst removed from the catalyst outlet of the moving bed reactor section to a catalyst regeneration vessel in the catalyst regeneration section    regenerating the spent reforming catalyst in the catalyst regeneration vessel by directing reforming catalyst regeneration gas through the catalyst in the regeneration vessel,    withdrawing regenerated reforming catalyst from the regeneration vessel when regeneration is complete, and    returning the regenerated reforming catalyst to the catalyst inlet of the reforming reactor section.    
   
   
       12 . A method according to  claim 11  in which the fixed-bed catalytic reformer unit includes a plurality of fixed bed reforming reactors each of which is converted to a catalyst regenerator vessel in the catalyst regeneration section, each catalyst regeneration vessel having (i) a spent catalyst inlet connectable for spent catalyst flow to the spent catalyst outlet of the moving bed reactor section and (ii) a regenerated catalyst outlet connectable for regenerated catalyst flow to the catalyst inlet of the moving bed reactor section.  
   
   
       13 . A method according to  claim 12  in which the inlets of the catalyst regenerator vessels are each sequentially connected for spent catalyst flow between the spent catalyst outlet of the moving bed reactor section and the spent catalyst inlet of the regenerator vessel to admit spent catalyst to the regenerator vessel in sequence for regeneration.  
   
   
       14 . A method according to  claim 13  in which each catalyst regenerator vessel sequentially; first, receives spent catalyst from the spent catalyst outlet of the moving bed reactor section; second, receives reforming catalyst regeneration gas to regenerate the spent reforming catalyst in the regeneration vessel; third, discharges regenerated catalyst for return to the catalyst inlet of the moving bed reactor section.  
   
   
       15 . A method according to  claim 14  in which each of the catalyst regenerator vessels is sequentially connected for regenerated catalyst discharge to a regenerated catalyst lift engager which has an outlet for regenerated catalyst flow to a liftpipe to convey regenerated catalyst to the catalyst inlet of the reactor section.  
   
   
       16 . A method according to  claim 15  which includes means for selectively discharging regenerated catalyst flow from each of the plurality of catalyst regenerator vessels in sequence to the regenerated catalyst lift engager.  
   
   
       17 . A method according to  claim 13  in which the spent catalyst outlet of the reactor section is connected for spent catalyst flow to a spent catalyst lift engager which has a spent catalyst outlet connected for spent catalyst flow to a liftpipe to convey spent catalyst to a spent catalyst flow distributor for directing spent catalyst sequentially to each of the catalyst regenerator vessels.  
   
   
       18 . A method according to  claim 11  in which the fixed bed catalytic reforming unit is a cyclic reforming unit including a regeneration circuit which is incorporated into the converted unit to direct catalyst regeneration gas through the catalyst in the regeneration vessel during the regeneration step.  
   
   
       19 . A method according to  claim 18  in which the catalyst regeneration gas directed through the catalyst includes a sequence of purge gas, oxidative gas to remove coke from the catalyst and halogen-containing gas for catalyst rejuvenation.  
   
   
       20 . A method according to  claim 13  in which the moving bed, continuous reforming reactor section comprises a plurality of reforming reactors in a vertically stacked configuration and the catalyst regeneration section comprises a plurality of catalyst regeneration vessels converted from the fixed bed reactors of the fixed bed reforming unit.