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Documentation Credits
Authors of the current release, listed in order of historical start on project:
Lisa Hugo, BSc, BA; Conrad Gierer, BSc; Chris Strashok BSc; Peter deJonge, BSc; Adeel Jamil,
BSc; Muhammad Sachedina, BASc; Allan Chau, BSc; Nana Nguyen, BSc; Yannick Sternon,
BIng; Kevin Hanson, PEng; Chris Lowe, PEng
Since software is always a work in progress, any version, while representing a milestone, is
nevertheless but a point in a continuum. Those individuals whose contributions created the
foundation upon which this work is built have not been forgotten. The current authors would
like to thank the previous contributors.
A special thanks is also extended by the authors to everyone who contributed through
countless hours of proof-reading and testing.

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Information and Sales: Info@software.aeat.com

Detailed information on accessing Hyprotech Technical Support can be found in the

Technical Support section in the preface to this manual.
 Catalytic Reformer 1-1

1 Catalytic Reformer
BETA DOCUMENTS - March 31, 2000

1.1 Introduction .................................................................................................. 3

1.2 Connection Tab ............................................................................................ 5

1.2.1 Connection Page...................................................................................... 5
1.2.2 User Variables Page................................................................................. 6
1.2.3 Notes Pages............................................................................................. 7

1.3 Operating Data Tab ...................................................................................... 7

1.3.1 Parameters Page ..................................................................................... 7
1.3.2 General Page ........................................................................................... 9
1.3.3 Net Gas Compressor Page .................................................................... 11
1.3.4 Recontactor Page .................................................................................. 12
1.3.5 Separator Page ...................................................................................... 13
1.3.6 Recycle Data Page ................................................................................ 14
1.3.7 Reactor Page ......................................................................................... 15

1.4 Unit Factors Tab ......................................................................................... 16

1.5 Worksheet Tab ............................................................................................ 17

1.6 Output Tab .................................................................................................. 18

1-1
1-2

1-2
 Catalytic Reformer 1-3

1.1 Introduction
The Catalytic Reformer model uses fundamental kinetics to simulate
reforming reactions in regenerative, semi-regenerative and continuous
catalyst regeneration units. For each type of unit, the model includes
the reactors and part of the separation system. You can have up to five
reactors with heaters, a low pressure separator and a recontactor. With
both a separator and a recontactor included, you can specify the
hydrogen recycle from either.

Figure 1.1

The model calculates product yields and properties, determines full

heat and mass balances, and simulate s the reactor recycle stream.

The comprehensive kinetics part of the model consists of three

calculation phases:

feed characterization
reactor calculations
results calculation and reporting.

The Catalytic Reformer operation is added to a simulation in the Main

Simulation Environment. You can add a Catalytic Reformer operation
by selecting Flowsheet-Add Operation from the menu bar (or press
F12) and then selecting Cat Reformer. Alternatively, double click the
Cat Reformer button located on the Object Palette.

1-3
1-4 Introduction

Feed Characterization
The model takes naptha boiling range material as feed. In addition to
composition, flow, T, and P, the feed has also to have information in its
PNA content. There are two calculation routes:

Bulk PNA properties only can be calculated - Here the

model will estimate a detailed PNA breakdown by carbon
number from composition and specific gravity information.
PNA by carbon number directly calculated - The model will
bypass the estimation step and give better results. Detailed
PNA information is provided as naptha component data when
synthsizing a refinery assay in the Oil environment.

Reactor Calculations
The main reforming reactions are

Dehydrogenation of napthenes to aromatics

Cyclization of paraffins to naphthenes
Isomerization of paraffins
Hydrocracking of paraffins

These are modeled as single reaction steps, rather than a series of

combined reactions. The reaction rates and equilibrium composition
are calculated from the catalyst activity, temperature, hydrogen partial
pressure and hydrocarbon concentration, using Arrhenius-type
expressions. The model handles the thermodynamic equilibrium of
paraffin isomers to best represent reformate quality (octane number)
as reactor conditions change.

Catalyst Activity
Catalyst activity is characterized by its performance during Calibration;
you dont need to input specific catalyst data. Catalyst performance
depends on the measured temperature drop across each reactor and
the production of hydrogen. These measurements are used to adjust

metal function of the catalyst, affecting dehydrogenation

acid function of the catalyst, affecting the hydrocracking
capability.

The model then stores the calculated activities for reference. As the
operating conditions change (in a CCR unit) or onstream time changes
(in a regenerative or semiregenerative unit), new catalyst activities are
calculated from the reference activities, and the drop in catalyst

1-4
 Catalytic Reformer 1-5

activities from the changes in operations.

Severity and Hydrogen Recycle Options

The model runs in different ways, depending on the following options:

Closure option for the severity calculations, chosen using

OCTANE CLOSURE on the Parameters page.
Hydrogen recycle option, chosen using H TO HC
CONVERGENCE on the Parameters page.

1.2 Connection Tab

There are three pages on the Connection tab: Connection, User
Varaible and Notes.

1.2.1 Connection Page

Figure 1.2

On the Connections Page, provide the model name as well as the

1-5
1-6 Connection Tab

names of the inlet and outlet streams.

Stream Description
This is the naptha feed to the catalytic reformer. For
Feed best results this should have an assay that contains
a detailed naptha component breakdown.
C4 Minus This is the light/gas C4 minus product stream.
This is the C5 and heavier product stream from the
C5 Plus Reformate
unit.

From the Reformer Type drop down list, you have the option to specify
one of the following:

Reformer Type Description

This type of reformer consists typically of 3 - 4 fixed
bed reactors. The reforming operation is shut down,
and the catalyst regenerated after operating for a
Semiregenerative period of 5 - 15 days. The optimum reforming cycle
length is determined by factors such as the decline in
reformate yield, the effect for the loss of a hydrogen
producer in the refinery and downtime penalties.
This type of reformer consists typically of 4 - 5 fixed
bed reactors. The reforming operation can be
maintained for a much longer period as a part of the
Cyclic Regenerative catalyst is regenerated periodically using a swing
reactor (i.e. a separate regeneration reactor isolated
from the other reactors, but brought online once
needed).
This type of reformer consists typically of 3 - 4 radial
flow reactors (stacked or separate). The reforming
Continuous operation involves having small batches of catalyst
Regenerative being physically drawn off to the regeneration
system and returned to the main reformer reaction
system as a continuous process.

A recontactor can also be added to the model by activating the

Recontactor switch. You can use the appropriate check box in the
Recycle Option group to specify the recycle either from the recontactor
or the separator.

1.2.2 User Variables Page

The User Variables page allows you to attach code and customize your
HYSYS simulation case by adding User Variables. For more information
on implementing this option, see the User Variables chapter in the
Customization Guide.

1-6
 Catalytic Reformer 1-7

1.2.3 Notes Pages

The Notes page provides a text editor where you can record any
comments or information regarding the Catalytic Reformer or
pertaining to your simulation, in general.

1.3 Operating Data Tab

The Operating Data tab allows you to input all the data necessary to
simulate the Catalytic Reformer model. There are seven pages on the
Operating Data tab: Parameters, General, Net gas compressor,
Recontactor, Separator, Recycle data, and Reactor data.

1.3.1 Parameters Page

Figure 1.3

You can specify the main criterion to simulate the model on the
Parameters page. There are four groups and a check box available on
this page.

The Perform reactor delta P calc check box allows you to switch off the
reactor pressure drop calculations. Normally, the model calculates
reactor pressure drops by scaling the base pressure drops
proportionally to the square of the flowrate. If you switch these

1-7
1-8 Operating Data Tab

calculations off, the model predicts reactor pressure drops by simple

scaling, using the previously calculated multiplicative values, Dp
factor, on the Reactor factors page.

Catalytic Activity Group

Catalytic activity is calculated by HYSYS.Refinery for semi-regenerative,
continuous regenerative and cyclic regenerative model. There are three
radio buttons available in this group.

Radio Button Description

If this option is selected then the model assumes that
Compute activity there was no decay at the start of the run. It
from SOR calculates the decay between the start of the sun
and the period of interest.
This option sets the catalytic activity to be held
Fix activity constant, so that various operations can be reviewed
at a fixed point in time.
If this option is selected then the model calculates
future activity based on an integrated value for the
Integrate activity
monitoring run activity. It then uses this activity to
determine yields and operating conditions.

P Closure Group
This group allows you to specify which of the recycle circuit pressures
are held constant in order to close the pressure calculations. The
available options are

Product sparator
Compressor discharge
Reactor 2 inlet pressure
Reactor 3 inlet pressure
Reactor 4 inlet pressure

Octane Closure Group

This group allows you to set the closure option for the severity
calculations. The table shows the options available in the Octane
Closure group and the data required for the severity closure to work.

Option Required Data

Specified C5+ Inlet T data in the Reactor T group.
octane

1-8
 Catalytic Reformer 1-9

Option Required Data

MCP = Methyl Cyclo Pentane
Specified MCP Target C5+ octane in the Octane Closure group.
conversion Inlet T data in the Reactor T group.
Target MCP conversion in the Octane Closure
Specified reactor group.
inlet temperature
Inlet T data in the Reactor T group.

Reactor T Group
You always need to give reactor Inlet T data, although how they are
used depends upon your Octane Closure option. With Specified
reactor inlet temp option, the values are kept fixed. With the other two
options, inlet temperatures are varied to meet the target octane in MCP
value. You can override this by fixing a specific reactor inlet
temperature through activating the Fix check box. At least one value
must be allowed to vary.

1.3.2 General Page

Figure 1.4

1-9
1-10 Operating Data Tab

The General page list the following parameters:

Prarameter Description
This field requires the catalyst age in m3/kg. It is
determined as:

Unit cat age

volume of feed processed to date
catalyst age = -------------------------------------------------------------------------------
total mass of catalyst in unit

Unit cat density Specify the catalyst density in this field.

This field requires the cold feed temperature
Cold feed T measured before the feed/effluent exchanger and
including the hydrogen recycle.
This field requires the preheater inlet temperature,
Preheater inlet T
which is recorded after the feed/effluent exchanger.
This gives the pressure drop between the inlet to the
Feed to rx1 delta P
feed/effluent exchanger and the inlet to reactor 1.
Use this field to give the pressure drop across the
last reactor delta P last reactor, so that the model can calculate the
system pressure from the pressure drop factors.
You have the option to select either Recycle or
Htohc recycle option. If Recycle is selected then the
model uses the recycle rate, specified on the
H to HC Reactor data page, to calculate the molar ratio of
convergence hydrogen in recycle gas to hydrocarbons in feed. If
Htohc is selected then the model calculates the
recycle rate from the hydrogen to hydrocarbon ratio,
specified using H to HC ratio target.
Specify the hydrogen to hydrocarbon ratio to be used
H to HC ratio target
to calculates the recycle rate.
This parameter is only valid for semiregenerative
EOR calculation units. If enabled, the model will calculate the reactor
spec inlet temperature and yield at the end of the run
(EOR).
This parameter specifies the diagnostic level for the
Diagnose
model output.
This field requires the fraction of cyclohexane in C6
Napthenes. This value determines the proportions of
five- and six- membered naphthenes, which in turn
influences the reforming reactions. You can enter
your own value for this parameter, for example by
Cyclehex frac of c6n using assay data. To calculate a value, use

cyclohexane
Cyclohex frac of C6N = -----------------------------------------------
total C6 naphthenes

1-10
 Catalytic Reformer 1-11

1.3.3 Net Gas Compressor Page

Figure 1.5

This page list the following parameters associated with the compressor
operation on the gas recycle.

Parameter Description
This field requires the discharge pressure, which is
Discharge P
used by the model to calculate the system pressure.
Stages Specify the number of compressor stages.
Work Specify the compressor power.
Efficiency Specify the compressor efficiency.

1-11
1-12 Operating Data Tab

1.3.4 Recontactor Page

Figure 1.6

On the Connections page activating the Recontactor switch check box

and selecting the Recycle from recontactor radio, in the Recycle Option
group, allows you to specify the following parameters on the
Recontactor page.

Parameter Description
T Specify the recontactor outlet temperature.
P Specify the recontactor outlet pressure.
Specify the hydrogen purity in the offgas as a mole
H2 purity
%.
Compressor stages Specify the number of compressor stages.
Compressor work Specify the compressor power.
Compressor eff Specify the compressor efficiency.

1-12
 Catalytic Reformer 1-13

1.3.5 Separator Page

Figure 1.7

This page list the following parameters associated with the low pressure
separator after the last reactor.

Parameter Description
T Specify the separator outlet temperature.
P Specify the separator outlet pressure.
Use this field to specify the hydrogen purity in the
H2 purity
offgas as a mole %.

1-13
1-14 Operating Data Tab

1.3.6 Recycle Data Page

Figure 1.8

This page list the operating data for the gas recycle.

Parameter Description
Use this field to specify either the low pressure
Source separator or the recontactor as the source of the
recycle gas.
Compressor This field requires the discharge pressure, which is
discharge P used by the model to calculate the system pressure.
Compressor stages Specify the number of compressor stages.
Compressor work Specify the compressor power.
Compressor Specify the compressor efficiency.
efficiency

1-14

HYSYS.Refinery allows you to
specify the data for up to five
reactors in series.
If you decided to omit Catalyst
density, then you must
include Catalyst loading and
Catalyst vol so that the model
can calculate the density. The
model uses this information to
calculate the liquid hourly
space velocity and the weight
hourly space velocity.
Catalytic Reformer 1-15
1.3.7 Reactor Page
Figure 1.9
This page list the following parameters associated with the conditions
in each reactor.
Parameter Description
Specify the inlet temperature for each of the
Inlet T reactors. These are used to calculate the actual
weighted average inlet temperature.
Specify the inlet pressure for each of the reactors.
The model calculates the pressure drop across each
Inlet P
reactor and the pressure drop factor to match the
inlet pressure.
This field requires the measured temperature drop
Measured dt across each reactor. These are used to calibrate the
catalyst dehydrogenation activity for each bed.
Catalyst loading Specify the mass of the catalyst in each reactor.
Catalyst vol Specify the volume of the catalyst in each reactor.
Catalyst density Specify the density of the catalyst in each reactor.
This field requires the time online for
Catalyst age
semiregenerative and cyclic regenerative units.
This field requires the circulation rate for continuous
Catalyst circ rate
regenerative units.
1-15
1-16 Unit Factors Tab
Usually, you specify the
hydrogen recycle rate to the
first reactor only. If you specify
recycle rate to other reactors,
the model combines the given
recycle rate and the hydrogen
product stream from the
previous reactor.
Refer to the REFSIM Excel
application calibration manual
(ADD REFERENCE).for further
details
1-16
Parameter Description
Specify the hydrogen recycle rate, which is used to
Recycle rate calculate the hydrogen-to-hydrocarbon molar ratio
(the gas-to-oil ratio).
This field is required to calculate the furnance
Measured duty
efficiency.
1.4 Unit Factors Tab
The Unit Factors tab lists the various unit factors (calibration factors)
used to model the Catalytic Reformer. HYSYS.Refinery uses unit factors
to adjust calculations to fit operating conditions.
These factors can be generated using the separate REFSIM Excel
application which utilizes reactor test data to fit these unit factors
Running the Calibration routines in effect forces the model theory to
match real data through the use of various tuning factors. For further
details regarding the use of this external application, refer to......section
describing calibration app.
Figure 1.10

The PF Specs page is relevant
to Dynamics cases only.
Catalytic Reformer 1-17
The unit factors available for the Catalytic Reformer are grouped
together into pages and are described as follows:
Page Description
This page requires the catalyst activity decline
Reactor factors
constant and unit factor for each of the reactor.
Yield property Use this page to enter the yield property unit factors.
factors
Specify the equilibrium separator and recontactor
Flash factors
unit factors.
Use this page to define the recycle, recontactor and
Utility factors
net gas composition unit factors.
This page requires the reaction equilibrium K unit
factors at 980oF (257oC). These are multiplicative
Olefin k factors
unit factors that adjust the temperature response of
each paraffins-to-olefines reaction.
Specify the olefins yield unit factors, which are the
ratio of measured wt% olefins to calculated wt%
Olefin yield factors
olefins, before applying the unit factors. They all
default to 1.0.
Use this page to give the feed and effluent pressure
Delta P factors
drop factors.
This page requires the relative reaction rates of
Rel reaction rate
dehydrogenation, cyclization, and cracking for each
factors
carbon number.
Use this page to specify the catalyst activity
Kinetic factors constants, reforming reaction rate constants and
temperature coefficients.
1.5 Worksheet Tab
The Worksheet tab contains a summary of the information contained
in the stream property view for all the streams attached to the Catalyst
Reformer. The Conditions, Properties, and Composition pages contain
selected information from the corresponding pages of the Worksheet
tab for the stream property view. The PF Specs page contains a
summary of the stream property view Dynamics tab.
1-17
1-18 Output Tab

1.6 Output Tab

Figure 1.11

The Output tab lists the various Catalytic Reformer output factors and
simulation results. HYSYS.Refinery allows you to specify the feed
component balance and uses this information to calculate the product
stream.

The output factors available for the Catalytic Reformer are grouped
together into pages and are described as follows:

Page Description
This page shows the weight, molar and liqvol
C8 aromatics
concentrations for the C8 aromatics breakdown.
This page displays the Recycle and net gas
Gas compositions
composition.
This page allows you to specify the feed component
Component balance balance and view the product as well as the C5+
stream composition.
This page displays the simulation result for each of
Reactor results
the reactor.
This page shows the output parameters for the
Output parameters
model.

1-18