CCR Platforming & Oleflex

Ensure reliable, low-maintenance operation, maximize your platforming and Oleflex profitability

Moving bed reactor systems are key to the attractive economic performance of UOP’s Platforming and Oleflex processes. UOP supplied equipment insures reliable, long-term performance while minimizing operating and maintenance costs.

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UOP control systems assure high regenerator on-stream efficiency with superior catalyst performance and life

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Catalyst Regeneration Control System (CRCS)

The UOP Catalyst Regeneration Control System (CRCS) performs the key functions of monitoring the catalyst regeneration to ensure optimum process performance, and ensure isolation of the hydrogen and oxygen environments involved in the various catalyst transfer and regeneration steps.

Key benefits of UOP’s CRCS are:

  • Optimum catalyst regeneration for maximum process profitability
  • Reliable regenerators operation, high on-stream factor
  • Faster start-up and recovery from non-steady state operation
  • Protection of catalyst and equipment resulting in maximum catalyst life and minimum maintenance requirements
  • Safe operation; automatic regenerator shutdown should abnormal conditions be encountered; independent operation from the DCS if required

UOP designed the CRCS with a TÜV-rated programmable electronic system (PES) for both high reliability and availability. The CRCS also provides the interface for two-way communication with the plant distributed control system (DCS). This allows operators to monitor and control the process from the DCS operator console(s). A local display (HMI) is also included to allow operation of the CRCS from the cabinet location. It also provides the capability to obtain information for system diagnostics and for process and controller troubleshooting.

Retrofits of Older Lock Hopper Control Systems

In 1985, UOP commercialized the Lock Hopper Control System (LHCS) to provide the highest quality CCR regenerator control system then available for a CCR PlatformingTM unit. Since then, the LHCS has been installed in more than 120 locations worldwide with more than 2000 years of cumulative operating experience. With on-going technological advancement, components used in earlier systems are obsolete. UOP developed a LHCS retrofit for easy replacement that offers the most current technology, to overcome the parts support issue and to enhance process availability by reducing hardware downtime. New features include hot shutdown state, white burn inhibit mode, and regeneration burn zone temperature protection.

The LHCS retrofit controls all the valve sequences, heaters, chemicals, protection-related interlocks, and shutdowns in the CCR regenerator. It also includes distributed control system (DCS) interface that allows operator control from the DCS.

Key benefits from the LHCS retrofit are:

  • Enhanced on-stream efficiency, maximum process-side performance
  • Reduced maintenance and spare-parts problems
  • Improved catalyst conditioning and longer catalyst life
  • On-schedule and on-budget implementation without the need to shut-down the process-side operation

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Safe and Simple Catalyst Sampling for Monitoring Catalyst Condition

View Larger ImageSafe and Simple Catalyst Sampling for Monitoring Catalyst Condition

The UOP Catalyst Sampler gives refiners a simple, safe means of sampling catalysts on-line, directly from a fixed bed reactor such as a catalytic reforming unit. Without disrupting the bed or the reaction, the Sampler fluidizes a small amount of catalyst through a sample probe positioned within the catalyst bed and collects the sample in a receiver located outside the reactor. There are four key reasons for on-stream catalyst sampling and analysis:

  • Process Optimization – typically chloride on catalyst which allows optimization of the water/chloride balance in the unit
  • Contaminant detection – contaminants such as carbon, sulfur, and metals can be detected and process or pretreatments changes can be initiated
  • Catalyst Regeneration – parameters such as carbon, sulfur, surface area, and platinum distribution can indicate needs for regeneration and/or the effectiveness of catalyst regeneration procedures
  • Trouble shooting

Key benefits of monitoring catalyst condition and process optimization are:

  • Maximum process yields while operating at desired process severity
  • Long catalyst cycle lengths
  • Minimum regeneration downtime
  • Long ultimate catalyst life and low catalyst costs

The UOP Catalyst Sampler utilizes a number of unique design features that provide safe, low-maintenance and trouble free operation. The Catalyst Sampler is fit with a sampling probe custom-designed for operation in a given reactor. The probe is installed through the existing reactor nozzle and fixed directly in the catalyst bed. The sample receiver and all moving parts are installed outside the reactor. This configuration requires absolutely no modification of the reactor and is easy to maintain. The Catalyst Sampler meets UOP Process specification 860 and European Pressure Equipment Directive – Catalyst Sampler CE A1 Certificate

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Minimize Cost, Timing, and Risk with a Modular CCR Regenerator

Minimize Cost, Timing, and Risk with a Modular CCR Regenerator

UOP’s CCR Platforming and Oleflex processes utilize continuous catalyst regeneration to maintain the catalyst in optimum condition and to allow the process side to operate at the most economic conditions. With over 200 UOP designed CCR regenerators in operation, UOP has unparalleled experience in the design, layout, and construction of these regenerators to achieve reliable, low-cost operation at the lowest capital cost.

As an alternative to field construction, UOP offers modular supply of the regeneration section with UOP taking full responsibility for design, construction, supervision of on-site installation, and full commissioning support. Benefits of UOP Modular CCR Regenerator supply are:

  • Optimized layout for ease of operation and maintenance
  • Excellent quality with adherence to project requirements
  • Reduced project schedules
  • Reduced capital cost
  • Reduced risk with fixed price contracts

UOP incorporates its vast operating and design experience from the equipment and piping layout to the final piping and instrumentation details, producing a low cost but easy to operate and maintain unit that incorporates UOP’s engineering design specifications, customer specifications and applicable codes. The inherent productivity advantage of shop fabrication along with avoidance of rework in the field shortens project schedules, getting the unit on-stream in the shortest possible time, increases construction safety by removing high elevation construction work. Schedule is also reduced by eliminating the issue of formal basic design and project specification documents, and subsequent contractor communications and hand-offs. Capital costs are reduced relative to field construction due to the efficiency and lower labor cost associated with shop fabrication. Fixed-price quotes and delivery terms reduce risk for both the unit operator and the general contractor in overall execution of the new CCR Platforming or Oleflex project.

Revamping Exisiting Regenerators

UOP’s capability and experience in the design, fabrication, and delivery of modular CCR Regeneration units can be applied to the revamping of existing CCR regenerators, whether they were originally supplied as field constructed or as modular supply. Typical reasons for regenerator revamps are:

  • Addition of Chlorosorb technology
  • Increased CCR Circulation Capacity
  • Increased Regeneration Capacity
  • Other CCR Technological Advancements

Typical UOP scope of supply in regenerator revamp projects is:

  • Process design
  • Project design, Detailed design, and layout
  • Equipment procurement
  • Inspection during fabrication
  • Site advisor services during revamp implemenation

*Site fabrication is done by a local contractor in close collaboration with UOP project specialists.

Benefits of a UOP managed CCR regenerator revamp project are:

  • Maximum certainty for process and equipment design works.
  • minimum regenerator down-time
  • maximum operability and proper interface with CCR control system
  • maximum reliability and minimum maintenance requirements
  • minimum project cost

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Maximize Valuable Product Recovery from your Reforming Unit with Recovery Plus

The Recovery Plus system is a processing system for recovering valuable product that would otherwise be lost in the reformer net-gas. The system can be designed to maximize either C5+ or C3+ recovery, depending on the customer’s needs. However, virtually 100% of reactor effluent C5+ is recovered in the system.

The Recovery Plus system offers:

  • Recovery of valuable product from reformer net-gas
  • Improved hydrogen purity of reformer net-gas
  • Proven design — over 35 operating units world wide
  • Simple payback in 3 to 18 months.

The Recovery Plus system is sold as a packaged system consisting of modules that are delivered to the refinery for simple site installation. The package design uses a pre-engineered system template that provides the benefits of early interface information, minimum site installation work, and enhanced quality control.

The Recovery Plus system is usually operated as an integral part of a UOP CCR PlatformingTM unit. The equipment selection is conventional for refinery and petrochemical plants, the modules are designed to minimize field work during installation while maintaining equipment accessibility. No additional personnel are required and maintenance is minimal.

Since its introduction in 1986, Recovery Plus technology has been selected for over 35 projects throughout the world. Capacities range from 11,000 Nm3/hr to 132,000 Nm3/hr.

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The CatMax™ Platforming Reactor Internal (CatMax PRI) System Maximizes Moving-Bed Reactor Performance

View Larger ImageCATMAX Internals

CCR Platforming unit reactor design has progressed from the first units in the early 1970’s. Earliest CCR Platforming units employed a profile wire type cylindrical outer screen basket to contain the moving catalyst bed in the annular space between the outer screen basket and centerpipe. These baskets were soon replaced with more robust and lower cost Punch Plate Scallops. These punched plate scallops offered many advantages over the screen basket, including easier installation and maintenance, improved mechanical durability and catalyst containment, and lower cost and weight. Operating experience in over 200 CCR Platforming units has proven the superiority of scallops over baskets since their introduction.

UOP’s currently offers two enhanced-strength scallop designs that offer significant improvements relative to standard punch plate. Key benefits are:

  • Improved resistance to bending, twisting and buckling–especially in very tall reactors
  • Smooth catalyst flow (reduced catalyst attrition) through use of continuous vertical slots and fewer expander rings
  • Virtual elimination of plugging with catalyst and fines through the use of Profile Wire Slot design
  • Lower unplanned costs during turnaround due to unexpected scallop crushing
  • Quicker installation due to fewer expander rings required

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