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Isomerization Process, Reactions, Effects of Process Variables. Isomerization
Isomerization Process, Reactions, Effects of Process Variables. Isomerization
Isomerization process, Reactions, Effects of process
variables.
Isomerization[13]
The octane numbers of the LSR naphtha [C5180oF (C582oC)] can
be improved by the use of an isomerization process to convert
normal paraffins to their isomers.This results in significant octane
increases as npentane has an unleaded (clear) RON of 61.7 and
isopentane has a rating of 92.3. In oncethrough isomerization
where the normal and iso compounds come essentially to
thermodynamic equilibrium, the unleaded RON of LSR naphtha can
be increased from 70 to about 82–84. If the normal components are
recycled, the resulting research octane numbers will be about 87–
93 RONC.
Reaction temperatures of about 200–400oF (95–205oC) are
preferred to higher temperatures because the equilibrium
conversion to isomers is enhanced at the lower temperatures. At
these relatively low temperatures a very active catalyst is necessary
to provide a reasonable reaction rate. The available catalysts used
for isomerization contain platinum on various bases. Some types of
catalysts require the continuous addition of very small amounts of
organic chlorides to maintain high catalyst activities. This is
converted to hydrogen chloride in the reactor, and consequently the
feed to these units must be free of water and other oxygen sources
in order to avoid catalyst deactivation and potential corrosion
problems. A second type of catalyst uses a molecular sieve base
and is reported to tolerate feeds saturated with water at ambient
temperature.
A third type of catalyst contains platinum supported on a novel
metal oxide base. This catalyst has 150oF (83oC) higher activity
than conventional zeolitic isomerization catalysts and can be
regenerated. Catalyst life is usually three years or more with all of
these catalysts. An atmosphere of hydrogen is used to minimize
carbon deposits on the catalyst but hydrogen consumption is
negligible .The composition of the reactor products can closely
approach chemical equilibrium. The actual product distribution is
dependent upon the type and age of the catalyst, the space
velocity, and the reactor temperature. The pentane fraction of the
reactor product is about 75 to 80 wt% isopentane, and the hexane
fraction is about 86 to 90 wt% hexane isomers .
Isomerization Processes[15]
Vapor phase process
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Isomerization Processes[17]
Pros
Reforming conditions not appropriate for the paraffinic
components in SRG.
Essentially zero benzene, aromatics, & olefins.
Very low sulfur levels.
Cons
High vapor pressure.
Moderate octane levels — (R+M)/2 only 85.
Feedstocks
Products
Products
Isoparaffins and cycloparaffins.
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Small amounts of light gasses from hydrocracking .
Unconverted feedstock.
Increased severity increases octane but also increases yield of
light ends.
Yields depend on feedstock characteristics and product octane.
Poor quality feeds might yield 85% or less liquid product.
Good feeds might yield 97% liquid product.
Catalytic Reforming and Isomerization[39]
If the normal pentane in the reactor product is separated and
recycled the product RON can be increased by about 3 numbers (83
to 86 RONC).If both normal pentane and normal hexane are
recycled the product clear RON can be improved to about 87 to 90.
Separation of the normals from the isomers can be accomplished by
fractionation or by vapor phase adsorption of the normals on a
molecular sieve bed. The adsorption process is well developed in
several large units.
Some hydrocracking occurs during the reactions resulting in a loss
of gasoline and the production of light gas. The amount of gas
formed varies with the catalyst type and age and is sometimes a
significant economic factor. The light gas produced is typically in the
range of 1.0 to 4.0 wt% of the hydrocarbon feed to the reactor. For
preliminary estimates the composition of the gas produced can be
assumed to be 95 wt% methane and 5 wt% ethane. For refineries
that do not have hydrocracking facilities to supply isobutane for
alkylation unit feed, the necessary isobutane can be made from n
butane by isomerization. The process is very similar to that of LSR
gasoline isomerization but a feed deisobutanizer is used to
concentrate the nbutane in the reactor charge. The reactor product
is about 58 to 62 wt% isobutane. A representative flow scheme for
an isomerization unit is shown in Figure below.
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Fig:7.1 A representative flow scheme for an isomerization
unit
Isomerization Chemistry
Cycloparaffins (naphthenes) may isomerize and break the ring
forming an olefin.
Cyclobutane to butene.
Example
Cost Included
1. Feed Drying
2. Drying of hydrogen makeup
3. Complete preheat reaction and hydrogen circulation facilities
4. Product stabilization
5. Sufficient heat exchange to cool product to ambient
temperature
6. Central control
7. Paid up royality
Cost not Included
1. Hydrogen source
2. Cooling water,steam and water supply
3. Feed desulfurization
4. Intial catalyst charge about $100/BPD of reactor feed
Royalities
Paid up rayalty is about $90 to$160/BPD
Utility data(per bbl,"fresh"feed)
Power Kwh 1.0
Cooling water gal(0CoF) 6001000
Fuel(LHV),MMBtu 0.20
Catalyst replacement,$ 0.05
Hydrogen makeup,sef 40
Example Problem
Calculate the length of time between regeneration of catalyst in a
reformer operating at the following conditions:
Liquid hourly space velocity (LHSV) = 3.0 v/hr/v
Feed rate = 5000 BPSD
Feed gravity = 55.0oAPI
Catalyst bulk density =50 lb/ft3
Hydrogentofeed ratio = 8000 scf/bbl
Number of reactors =3
Catalyst deactivates after processing 90 barrels of feed per pound of
catalyst.If the catalyst bed is 6 ft deep in each reactor, what are the
reactor inside diameters? Assume an equal volume of catalyst in
each reactor.
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Solution
Time between regenerations:
5000 BPD =1170 ft3/hr
Total catalyst = 1170/3 = 390 ft3
(390 ft3) (50 lb/ft3) = 19,500 lb
(19,500 lb) (90 bbl/lb)/5,000 bbl/day = 351 days
Inside diameter:
Volume of catalyst per reactor = 390/3 = 130 ft3
Inside area = (130 ft3)/(6 ft) = 21.67 ft2
Inside diameter = 5.25 ft
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