International Science and Investigation Journal

ISSN: 2251-8576

2015, 4(3)

Journal homepage: www.isijournal.info

Received September 2014; accepted 1 March 2015

Simulation the Continuous Catalytic Reforming (Octanizer)

Unit of Isfahan Refinery Gasoline Production Complex with
PETROSIM Software
Kasra Kavousi1, Nader Mokhtarian2
1

Department of Chemical Engineering, Shahreza Branch, Islamic Azad University,

Shahreza, Iran
Email: kasrakavousi185@gmail.com
2
Department of Chemical Engineering, Shahreza Branch, Islamic Azad University,
Shahreza, Iran
Email:nmmokhtarian@yahoo.com
*Corresponding authors E-mail: nmmokhtarian@yahoo.com
Abstract
Naphtha catalytic reforming is one of the most important and key processes in any refineries. In this
process, mainly gasoline is produced with high octane number and in petrochemical complexes
expensive Aromatics such as benzene, toluene and xylene are also produced. Considering increasing
need and the importance of quality and quantity of desirable gasoline , it is necessary to simulate the
process of naphtha catalytic reforming to achieve the best values of operational variables , enforcing
the best solution in dealing with fluctuations and changes in processing conditions, identification and
removing bottlenecks , reducing production costs by the simulation of above mentioned process. In
this research, firstly the processes leading to the production of high octane gasoline in the naphtha
catalytic reforming are explained with continuous catalyst regeneration unit of Esfahan oil refinery then
has been stimulated by PETROSIM software.
Keywords: Octane Number, Naphtha Catalytic Reforming, Simulation, Petrosim

Introduction
One of the most important processes in any refineries is naphtha catalytic reforming.
In this process gasoline with high octane number is produced. In petrochemical
complexes expensive aromatics such as benzene, toluene and xylene by this process
are also produced. According to the importance of fuel and producing more gasoline
from oil raw material and the possibility of optimization and improvement of catalytic
reactor operation to increase the quality and quantity of products, simulation and
checking the process parameters and improvement in its operation seems to be
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This process consists of three radial flow reactors, Furnaces, separator vessels, a
number of heat exchangers and compressors. In these reactors more than three
hundred reactions happened. To simulate these reactions the presented kinetic models
should be used. In Refineries the inlet temperature of three reactors are the same but as
the catalyst activity decreases this temperature increases based on the products quality.
Also change in entrance feed features and its flow fluctuations affect products
distribution and products octane number and make it unstable. The naphtha catalytic
reforming unit by continuous regeneration under Octanizer trade name in Esfahan
refinery with the capacity of 30000 barrels per day with the goal of increasing octane
number in refined heavy naphtha flow up to 100 and with launching this unit, Esfahan
Refinery has been needless to import 3milion liters of octane booster. Actually the
same amount of gasoline has been added to processing units [1].
In addition, the quality of gasoline produced in refinery enhanced from octane 85 to
octane 95 but reaching the ideal and desired conditions and characteristics of
reformate gasoline produced in catalytic reforming unit according to obligatory
changes of unit capacity, composition of feed percentage, changes in upstream units,
fluctuation in controlled parameters, different operating conditions and problems of
sidelong services and utility and etc., won't become successful without finding partial
solutions and optimization of processes. So, to achieve the mentioned purposes we
need an exact simulation, the real conditions of gasoline production unit, and the
feasibility study to find appropriate practical solutions.
We can submit available and real different process scenarios with paying attention to
all of the problems, oscillations ,deviations of operational variables , possible changes
of process condition in different unit's capacity .It is also necessary to consider
laboratory data about simulation condition and real control parameters of plant to
produce desired product with the most possible capacity. Overall, naphtha's catalytic
reforming is a kind of refinery's process in which the heavy naphtha feed passes from
catalytic bed of some reactors in high temperature and with suitable pressure.
Aromatic compounds in naphtha increases and finally its octane number increase too.
In naphtha hydro treatment unit all of the impurities such as sulfur and nitrogen which
cause poisoning the catalyst in downstream catalytic units are removed from pure
naphtha [6].
This process is done by passing the impure naphtha from a catalytic bed in adiabatic
reactor by using hydrogen gas. The product of this unit is pure light and heavy naphtha.
The capacity of this unit is 60/000 barrels per day. In the continues regeneration
catalytic reforming unit, by slow passing of heavy naphtha from catalytic bed of 3
adiabatic reactors using hydrogen , the reaction is done and catalytic conversion
happens and a layer of coke covers the catalytic bed. So in this unit, the catalyst is
regenerating and retrieving continuously. The main product of this section is gasoline
with octane number 100 and its lateral product is liquefied petroleum gas (LPG) and
its capacity of gasoline is 30/000 barrels per day [2].
Continuous catalytic reforming Unit (Octanizer) of Isfahan Refinery
The catalytic reforming with continues regeneration in Esfahan refinery consist of two
main sections. One of them is the section of gasoline to raise octane number which is
named (unit number 722) and the other is continues regeneration section which is
named (unit number 723). The purpose of the Unit 722 is to reform treated naphtha in
order to produce reformate a send to the gasoline pool. Unit 723's is in charge of
continues regeneration of consumable catalyst for 722 unit number during the period
of operation [3]. Octanizing is AXENS registered trade name of the reforming

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process using continuous catalyst regeneration. The capacity of this unit is 3000
barrels per day and producing gasoline with octane number 100. The products of this
unit are:
1) Reformate product (gasoline with high octane number)
2) Hydrogen rich gas stream with high purification
3) Liquefied petroleum gas (LPG)
4) Fuel gas
The main duty of unit number 722 is either the reformate product with high octane
number or hydrogen with high purification and consists of 3 main sections:
1) Reaction section
2) Compression and re contacting section
3) LPG recovery and stabilization section
This process is accordant with catalyst moving bed technology of AXENS Company.
The naphtha hydro treatment stream sets in 3 reactors with moving catalyst in the
presence of hydrogen in low pressure. The catalyst goes out of the reaction with fixed
rate and regenerates in unit number 723 before coming back to reactors again. This
continuous regeneration lets the catalyst beds to work with the least amount of coke in
the surface of catalyst so we can be completely sure of its high performance in
operational condition. The goal of unit number 723 is to continuous regeneration of
catalysts during the normal reaction of Octanizer unit and also keeping the amount of
catalytic cokes inside the reactors at low level and optimizing the operational
condition for Octanizer unit [4].
This condition is fixed, except the end of the catalyst age. Circulation of catalyst inside
the reactors and inside the regenerating system happens automatically. The design
capacity of the catalyst regeneration system is 58 kg of coke burnt per hour, with
catalyst design flow rate equal to 820 kg/h.
Fundamental Reactions of Unit 722:
The fundamental reforming reactions can be split into two parts:
Positive reactions i.e. reactions which lead to an aromatic content increase, these are
the reactions we wish to promote.
Negative reactions i.e. reactions which not only lead to an octane decrease but to a
loss of reformate yield. These reactions are obviously the ones we wish to avoid [8].
Process flow description of unit 722
1Reaction Section
Feed to the Catalytic Reforming unit is the hydro treated heavy naphtha from the
bottom of the naphtha splitter column. This feed enters the reforming unit directly. A
chloride agent and water are injected as the feed enters the unit to control the waterchloride equilibrium (if the continuous regenerator is out of service) for optimum
reforming catalyst performance. As well, a sulfide agent is added at the feed inlet to
the unit. Added in very small quantity, the sulfide agent prevents from coke deposit in
heaters and on reactor walls. After entering the unit and the chemicals injection, the
feed is passed through filters to remove any particulate matter which may deposit in
the welded plate exchanger. The feed is then mixed with the recycle hydrogen gas
from the recycle compressor in the welded plate heat exchanger. The combined feed
and recycle hydrogen are preheated here against the third reactor effluent and then are
further heated to the required first reactor inlet temperature in preheater furnace. The
reactors are radial flow types, as its shown in figure 1 the feed flowing through the
catalyst bed from the outer circumference towards the center pipe [5].

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Figure 1: A picture of radial flow type of feed contact with catalytic bed in
Octanizer reactors unit
In the first reactor, the reactions are predominantly endothermic and therefore the
reactor effluent requires reheating in the first inter heater to the required inlet
temperature of the second reactor. The reactions in this reactor are less endothermic
but still require reheating before entering the third reactor. The effluent leaves the third
reactor at approximately 451-473C and 3.3 bar g. The inlet temperatures of the three
reactors are identical. These inlet temperatures are gradually increased through the
catalyst life time. In the three reactors the feed is contacted with the reforming catalyst
which is divided approximately in the ratio 20/30/50%. The catalyst circulates
continuously:
In the reactors, in the space between the scallops and the central pipe from the top to
the bottom,
From one reactor bottom to the top of the next one,
From the last reactor to the regeneration unit for regeneration,
From the regeneration unit, the regenerated catalyst returns to the 1st reactor.
In the regeneration unit, the catalyst is regenerated by a means of an automatic
regeneration loop system. Catalyst circulation is achieved either by gravity flow or by
gas lift systems (figure 2).

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Figure 2: A picture of regeneration catalyst loop system in the catalytic reforming

reactors
Leaving the third reactor, the effluent after in welded plate heat exchanger against
reactor feed and is cooled by air and water heat exchangers in respectively before
entering the separator drum. A portion of the separated gas is compressed in the
recycle gas compressor and is recycled to the reactors. The remaining gas which
constitutes the hydrogen production gas is routed to a compression and re contacting
section to improve hydrogen purity and liquid hydrocarbons yield [6].
2- Compression and re contacting section
The hydrogen production gas is mixed with the hydrogen gas stream from the
Continuous Catalyst Regeneration section (Unit 723) and routed to the booster
compressor after passing through the K.O drum. This booster compressor provides a
three-stage compression of the H2 production gas from 2.1 bar g to 27.5 bar g.
Between this compressors stages, inter stage water coolers are used to cool the
compressed gas and after each water cooler a K.O drum is used to separate and
remove the current condensed hydrocarbons liquid. The third stage discharge flow is
combined with the liquid hydrocarbons from the separator re contacting pumps and the
two-phase flow is routed to the re contacting section. The re contacted mixture is then
cooled against water in the re contacting trim cooler before entering the re contacting
drum. The target temperature is38C at 37 bar g in the re contacting drum. These
conditions of the final stage separator for the hydrogen production gas are designed to
maximize the concentration of hydrogen in the hydrogen rich gas product. The
separated liquid from the re contacting drum is sent under flow control with level reset
to the LPG recovery and stabilization section (Figure 3).
3LPG recovery and stabilization section
The separated liquid from high pressure absorption drum is contacted with stabilizer
off-gas and allowed to separate in the LPG absorber drum. The purpose of this step is
to recover the maximum quantity of LPG, i.e. C3 and C4s from the stabilizer
overhead. The output gas from LPG absorber drum is sent to fuel gas. This stream is
predominantly light ends i.e.C1 and C2s and this controls the stabilizer operating
pressure. Separated liquid from LPG absorber drum is pumped through the stabilizer
feed/bottom exchanger and then enter the stabilizer column on tray 18. This tower
contains 34 trays and operating at 15.5 bar g at the top allows reducing the C4 fraction
in reformate to less than 1.0 vol. % and the C5+ fraction in the LPG to less than 0.5 %

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wt. A portion liquid of the bottom of the stabilizer tower gets heated in the furnace in
four equal passages which are considered as tower re boiler and returns under the first
tray of tower to supply required energy for vaporing light materials. Stabilizer
overhead is partially condensed in Stabilizer Air cooler Condenser and in Stabilizer
Trim water cooler Condenser, to collect in Stabilizer Reflux Drum. The reflux drum
overhead vapor is routed back to LPG absorber drum for LPG recovery. A part of the
separated liquid is pumped back to stabilizer column as reflux. The remaining part of
the separated liquid is routed to the battery limits. Reformate from the bottom of the
stabilizer is cooled in the Stabilizer Feed/Bottom Exchangers, and further cooled down
in Reformate Air Cooler and Reformate Trim water Cooler before being sent to
storage (Figure 4).

Figure 3: Reaction and Compression and re Contacting Section of Esfahan

Refinery

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Figure 4: LPG Recovery and Stabilization Section of Esfahan Refinery

Simulation of the Continuous Catalytic Reforming (Octanizer) Unit of Isfahan
Refinery
Simulation of naphtha catalytic reforming process is possible by using palette menu of
the simulation software tools with choosing refinery operations icon (switch) and
using library of refinery processes. As shown in figure 5, from between these
processes of PETROSIM library, the catalytic reformer is chosen. After connecting the
feed stream, the kind of process and operational information should be entered into the
system. To enter operational data such as inlet temperature of reactors, the purity of
recycle gas, catalyst density, reactors number , flow rate and feed conditions that
means temperature and inlet pressure and so on the design pages and operational
datasheets of PETROSIM software should be completed (figure 6-11).

Figure 5: Catalytic reformer icon from palette menu in PETROSIM software

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Figure 6: Connections page of catalytic reformer in PETROSIM software

Figure 7: Parameters page from operating data of catalytic reformer in

PETROSIM software

Figure 8: General page from operating data of catalytic reformer in PETROSIM

software

Figure 9: Compressors page from operating data of catalytic reformer in

PETROSIM software

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Figure 10: Separators page from operating data of catalytic reformer in

PETROSIM software

Figure 11: Reactors data page from operating data of catalytic reformer in
PETROSIM software
After entering the operational data the kinetics of reactions should be set according to
the type of process and operational conditions and catalyst used in refinery. To
determine the kinetics of reactions we need to perform the calibration for naphtha
catalytic reforming process in REF-SIM module which is in the Excel spreadsheets
program.
Calibration the kinetics of naphtha catalytic reforming reactions by REF-SIM
module
This module is in the Excel spreadsheets program and it is based on the kinetics
models which are mostly used for simulation of naphtha catalytic reforming unit. This
module allows the user to simulate the unit and predict the products yield in a wide
range of operating conditions. For beginning the REF-SIM module we can use the
calibration page of catalytic reformer from PETROSIM simulator as shown in Fig 12.

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Figure 12: Beginning the REF-SIM module from calibration page of catalytic
reformer in PETROSIM

Figure 13: The design page for catalytic reforming calibration in REF-SIM
module
The notable point in this module is that there is no need to catalyst information for
calculating the kinetics of catalytic reforming reactions and knowing Density is
enough. The catalyst is evaluated according to its performance based on operational
information. The calibration factors is not limited to kinetics of reactions and includes
factors related to released heat in reaction, the catalyst activity, liquid vapor
equilibrium factors, calculations of pressure drop and also includes the modification
of thermodynamic properties.
Due to the importance and accuracy of the mass and material balance of the
operational data of input feed characteristics and products, in kinetics modeling of
catalytic reforming reactions by calibration in REF-SIM, an especial section, REFBAL is designed. REF-BAL assesses input information of test run to check its
suitability for calibration. In case of acceptability of test run input data from plant,
they will be used in calibration section of REF-SIM module [1].
In the first phase of data collection and evaluation of entry for calibration of naphtha
catalytic reforming reactors by REF- BAL section, four groups of data were collected.
In the first group the operational information of distributed control system (DCS)

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were collected on 23/3/2014 and values of the laboratory results were collected on
15/12/2013. In the second group, the operational information are selected from the
average values of the control system from 1/12/2013 to 13/7/2014 and the laboratory
results are collected on the same date , 15/12/2013. But the third group process data
includes collecting operational information from the average values of control system
in above mentioned dates of second group and average of laboratory results from
12/10/2013 to 20/7/2014. The fourth group data consists of operational information of
control system dated 23/3/2014 and laboratory results of average values of third group.
At the second phase, all the operational and laboratory data were collected on the same
day simultaneously in the form of test run to increase accuracy and reduce the
calibration errors. These dates are separated in 3groups and each group is related to the
special time. The first group consists of all the operational data of control system and
laboratory data in 20/8/2014 which is set in the seventh column of REF_BAL input
page. Second group is related to 20/9/2014 which is presented in the eighth column of
REF_BAL input page and third group of data is for 27/9/2014 which is shown in the
ninth column of REF_BAL input page.

Figure 14: Data related to flow rate and density and laboratory results of
naphtha catalytic reforming unit in REF_BAL input page for all the groups

Figure 15: Information about the feed composition percentage of naphtha

catalytic reforming unit in REF_BAL input page for all the groups

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Figure 16: Data about flow rate, density and laboratory results of reformate
product components of naphtha catalytic reforming unit in REF_BAL input page
for all the groups

Figure 17: Data information about the other products of naphtha catalytic
reforming unit in REF_BAL input page for all the groups
After each group data completed, run the program to prepare the result of mass and
material balance assessments and data of mentioned group by REF-BAL (Fig 18 &
19). By observing the results of first four groups, poor assessment of hydrogen

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equilibrium is completely clear. After investigating the issue, it was revealed that flow
transmitter of control system related to hydrogen product has error.
After correction this flow the best result of this evaluation was determined from the
fourth group. Therefore, among collected data of four groups in phase one, only the
Fourth group data which its hydrogen flow was corrected (the six column), was
selected to transfer to the calibration section. Collected data of three groups which are
the result of second phase test run, has strong acceptable balance assessment result.
These all three have been selected to perform calibration.

Figure 18: Evaluation of mass and material balance results from input
operational information of all the groups in REF_BAL result page

Figure 19: The resume of Evaluation of mass and material balance results from
input operational information of all the groups in REF_BAL result page

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After assessment, the results and characteristics of selected sixth to ninth columns of
four groups were transferred to the REF_SIM input page of calibration module as
shown in figure 20 - 22. On this page the needed data for calibration kinetics of
reactions is as following:
- Feed full information such as flow, temperature, pressure and boiling range and
composition of components.
- Operational condition of process such as temperature and pressure
- Data about reactors such as the amount of catalyst or the severity rate of the
deactivation of the catalyst
- The amount of recycle hydrogen gas and make up gas and their analysis
- Full information about product properties.

Figure 20: Input operation data for calibration the kinetics of reactions of
naphtha catalytic reforming in REF-SIM module

Figure 21: The rest of operational data entry for calibration the kinetics of
reactions of naphtha catalytic reforming in REF-SIM module

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Figure 22: The rest of operational data entry for calibration the kinetics of
reactions of naphtha catalytic reforming in REF-SIM module
After completing operational information such as input and output requirements data
of plant in calibration input page, the program should be run until the module by using
the optimization and least squares methods, to be calculated and determined the
optimal kinetics coefficients (calibration factors) as shown in figure 23. After
determining the calibration factors in the calibration result page, these factors should
be transferred to the PETROSIM software to complete the simulation of naphtha
catalytic reforming by using these calibration factors.

Figure 23: The determined kinetics coefficients results of calibration of naphtha

catalytic reforming by REF-SIM modules
In the resume of simulation process the determined kinetics coefficients in REF_SIM
module is transferred to the calibration factor page of PETROSIM environment. As
we mentioned in addition to the kinetics coefficients, the coefficients about reaction

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heat, yield properties, flash drams and other coefficients are optimized and transferred
to this page as shown in figures 24 - 29.

Figure 24: The created calibration factors related to reactors

Figure 25: The created calibration factors related to the yield products

Figure 26: The created calibrations factors related to the flash drams

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Figure 27: The created calibrations factors related to the reactions rates

Figure 28: the resume of created calibrations factors related to the reactions rates

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Figure 29: The created calibration coefficients related to the kinetics of reactions
When the calibration process of naphtha catalytic reforming which only applies to
reactors section, low pressure separator, compression and re contacting section
completed the resume of unit simulating which is LPG recovery and stabilization
section is done in the PETROSIM environment (Fig 30).

Figure 30: The simulation of LPG recovery and stabilization section of naphtha
catalytic reforming unit with PETROSIM
The verification of simulation results of naphtha continuous catalytic reforming
To verify and check the accuracy of this simulation, the main features obtained from
actual operational data and laboratory results compared with the final reformate
product result of naphtha catalytic reforming simulation which is an indication of
consistency and accuracy of this simulation. The comparison between the simulation
results of naphtha catalytic reforming unit and collected operational data of Esfahan
oil refinery is shown in the table below. It should be noted that laboratory collected

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results is related to 7/8/2014 and average values of distributed control system results
are related to 1/12/2013 - 13/7/2014.
Table 1: The comparison between simulated and actual values of final product
(gasoline)
Variable
Mass flow rate
Specific gravity
Octane number
Yield
Reid vapor pressure
Initial boiling point
5%
10%
30%
50%
70%
90%
95%
Final boiling point

Measure value

Measure value

(simulation)

(actual)

126.6

127.39

0.8066
98.6

0.808
97.4

92.4

92.4

42.12
35.37
58.53
87.23
122.2
138.4
148.1
156.1
161.8
180.7

39
45
70
96
116
125
142
159
167
187

Unit
Ton per
hour
----Volume
percentage
K Pa
C
C
C
C
C
C
C
C
C

Different factors can affect observed errors in above table. The most important ones
are as below:
1- Errors caused by measurement equipment of control instrumentation systems during
reading and data gathering.
2 Laboratory errors of feed properties results and unit products in particular, the
result of hydrogen gas has errors because of the calibration problems of laboratory
measuring devices.
3 The errors of PETROSIM software
4 Lack of enough gas chromatography results about the composition of feed and unit
products (PIONA) which reduced the accuracy of kinetics reaction calibration process
in REF-SIM modules.
5 Impossibility of entering the C10+ components in the components composition of
plant data group in refinery assay input section in PETROSIM software which cause
error in final boiling point value of reformate product. Surely there are amounts a
little heavier than the 10 carbon compounds in feed of the unit which are presented in
gas chromatography results as unknown components.

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