1、APPENDIX NO. IPROCESS DESCRIPTION附件一：工藝描述1 CCR Platforming Process鉑重整工藝I.1.1Advantage of CCR Platforming Process鉑重整工藝的優(yōu)勢Recognizing the need for high octane reformate and aromatics production combined with long run lengths and high yields, UOP developed the CCR Platforming process. Although some hav

2、e tried to duplicate the design, none have been able to equal it. UOP has continued to introduce new innovations which provide benefits to Refiners.由于認(rèn)識對高的辛烷值重整生成油和芳烴產(chǎn)品的需求以及對長周期、高負荷生產(chǎn)的需要, UOP 開發(fā)了鉑連續(xù)重整工藝。雖然也有一些公司也嘗試復(fù)制設(shè)計，但還沒有一家公司與之相當(dāng)。UOP一直致力于引入使煉油廠增加效益的創(chuàng)新技術(shù)。UOP was first to:- Commercialize CCR Platfor

3、ming- Develop a strong spherical catalyst- Reduce the platinum content of reforming catalyst without losing yield or performance- Use innovative reactor designs such as stacked reactors with upflow center pipes and integral catalyst collectorsDesign a reaction system with 3.5 kg/cm2g average reactor

4、 pressure and 2.5 kg/cm2g separator pressureUOP首創(chuàng)：商業(yè)化的連續(xù)鉑重整工藝開發(fā)出了高強度的球形催化劑減少重整催化劑中的鉑含量而不降低收率和性能應(yīng)用創(chuàng)新的疊置式反應(yīng)器、上流式中心管和集成的催化劑回收器。設(shè)計了反應(yīng)器平均反應(yīng)壓力3.5 kg/cm2（g）和分離器壓力3.5 kg/cm2（g）的反應(yīng)系統(tǒng)As a result of this continuous innovation, UOP has always maintained the lead in CCR Platforming sales, currently having approx

5、imately 170 units in operation and over 30 units in design and construction.由于持續(xù)的創(chuàng)新, UOP一直連續(xù)重整技術(shù)銷售方面領(lǐng)先，現(xiàn)在大約有170套裝置在運行中，并且還有超過30套裝置在設(shè)計和建造中。The UOP Platforming process with Continuous Catalyst Regeneration (CCR Platforming) is a well-proven commercial process for reforming hydrotreated naphthas into h

6、igh octane gasoline blending components or petrochemical grade aromatics. Utilizing a combination of state-of-the-art mechanical design and process innovations, the CCR Platforming process represents the most advanced reforming technology available today. Key advantages of this process are as follow

7、s:UOP 帶有連續(xù)催化劑再生的鉑重整工藝是一個已經(jīng)被很好證明的將加氫精制石腦油轉(zhuǎn)化為高辛烷值汽油混合組分或石油級芳烴的商業(yè)化工藝。應(yīng)用新穎的機械設(shè)計和創(chuàng)新工藝，CCR重整技術(shù)代表著當(dāng)今最先進的重整技術(shù)。這一工藝的主要優(yōu)勢如下：lExceptional On Stream Performancel杰出的流動性能Based on surveys on UOPs Platforming licensees, the mean time between reactor section shutdowns is 3.4 years and some Refiners have operated the

8、ir Reactor section for more than 6 years between shutdowns for scheduled maintenance. This exceptional on stream availability is made possible by successful independent operation of the Reactor and catalyst regeneration sections and continuous improvement in the mechanical design of the unit.根據(jù)UOP對鉑

9、重整技術(shù)授權(quán)單位的調(diào)查, 反應(yīng)器部分停車間隔為3.4年，有一些煉油廠反應(yīng)部分計劃檢修停車時間已經(jīng)超過六年。獨立的反應(yīng)器和催化劑再生系統(tǒng)部分以及在裝置設(shè)計中持續(xù)改進的機械設(shè)計讓卓越的流動性成為可能。Catalyst can be withdrawn from the unit, added, or totally replaced if desired, without having to shut down the unit. Many refiners have found this feature to be very useful in maintaining uninterrupted

10、 production of high octane reformate and high purity hydrogen. On-the-fly catalyst loading (i.e. loading catalyst while the unit is operating) contributes to the reliability and flexibility of CCR Platforming technology and is a unique feature of UOPs process.催化劑可以從裝置卸出、加入或者全部更換而不需停車。很多煉油廠發(fā)現(xiàn)這一性能對不間斷

11、生產(chǎn)高辛烷值重整生成油和高純氫氣十分有用。在線催化劑裝填（在裝置運行中裝填催化劑）使得CCR技術(shù)既可靠又靈活，是UOP工藝的獨有特性。lHighest C5+ and Hydrogen Yieldsl高C5+和氫氣收率Reforming catalyst selectivity increases as operating pressure is lowered. The UOP CCR Platforming process operates at lower pressure than any other commercial reforming process. Therefore on

12、ly CCR Platforming can deliver maximum yields of C5+ reformate and hydrogen. UOP continues to be the leader in reforming technology by being the first to reduce reactor operating pressure to 3.5 kg/cm2g. UOP was able to propose this new design with confidence, based on extensive operating experience

13、 with CCR Platforming units. Currently 43 units are operating at 3.5 kg/cm2g reactor pressure and a further 13 units are in various stages of design and construction. A total of 52 operating units have been designed to operate at less than 5.25 kg/cm2g reactor pressure.當(dāng)操作壓力降低后催化劑選擇性提高。采用UOP CCR技術(shù)的鉑

14、重整裝置較其它商業(yè)重整工藝操作壓力更低。因而只有CCR 鉑重整能夠提供最大的C5+重整生成油和氫氣收率。UOP首先把反應(yīng)的操作壓力降到3.5 kg/cm2(g)，在重整技術(shù)上保持領(lǐng)先地位。基于CCR的廣泛操作經(jīng)驗，UOP自信地提出其新設(shè)計。現(xiàn)在有43套裝置運行在3.5 kg/cm2(g)反應(yīng)壓力下，別外還有13套裝置正在設(shè)計和建造的不同階段。總計有52套運行裝置在設(shè)計低于url=5.25 kg/url/cm2(g)微軟用戶1的反應(yīng)壓力下操作。lComplete Regenerabilityl完全再生UOPs advanced Continuous Catalyst Regeneration t

15、echnology ensures that fresh catalyst is always available to the reactor system. Catalyst regeneration conditions have been optimized through extensive pilot plant testing, and confirmed by experience with 190 UOP CCR Platforming units operating throughout the world. UOPs careful design of the regen

16、eration section and Platforming catalysts result in constant yields of C5+ reformate and hydrogen over the expected life of the catalyst.UOP 的先進連續(xù)的催化劑再生技術(shù)可以確保時刻有 新鮮的 催化劑進入反應(yīng)系統(tǒng)。催化劑再生條件已經(jīng)通過大量中試優(yōu)化并且通過世界190套采用UOP重整技術(shù)的裝置驗證。UOP對再生系統(tǒng)和催化劑的精細設(shè)計可得到穩(wěn)定的C5+重整生成油和氫氣收率和超出想象的催化劑壽命。Constant yields combined with prov

17、en mechanical reliability provide the Refiner the confidence in the CCR Platforming unit as a constant source of hydrogen and reformate at consistent quality.穩(wěn)定的收率加上可靠設(shè)備使得煉廠放心將重整裝置作為質(zhì)量穩(wěn)定的氫氣和重整生成油的可靠來源。lRegenerator Designl再生器設(shè)計The original CCR designs utilized atmospheric regeneration sections.While

18、UOP has continued to evolve and improve the atmospheric regeneration section over the last 31 years, a more cost-effective way was sought to handle the increasing coke burning capacities which were required by the refining industry as operational severity was increased. As a result UOP commercialize

19、d a pressurized, valve-less regenerator in 1988 which is designed to operate at a higher pressure and increased coke burning capacity. The pressurized regenerator also incorporates other changes that improve the overall operation of the regeneration section. Some of the advantages of, UOPs pressuriz

20、ed regenerator are highlighted below:最初的 CCR 設(shè)計的再生部分采用常壓再生。在過去的31年里，隨著石油煉制工業(yè)對操作苛刻度的增加，需要尋找更為高效的再生手段來處理生焦的增加。于是1988年UOP推出其加壓無閥再生器，它設(shè)計在高壓下操作，增加了再生器的燒焦能力。加壓再生器連同其它一些優(yōu)化改進了整個再生部分的操作。UOP的加壓再生系統(tǒng)有以下幾個突出特點：Valveless Design, with consequent reductions in mechanical complexity, maintenance costs, and low catal

21、yst attrition rate。無閥設(shè)計, 使得機械復(fù)雜性和維護費用下降，催化劑磨損減少。All-hydrogen lift system, resulting in reduced Nitrogen consumption and elimination of N2 lift gas blower which results in reducing capital cost全氫氣提升系統(tǒng)，使得氮氣消耗下降，取消了氮氣提升風(fēng)機，降低了資金消耗。Optimized platinum dispersion for better yields, longer life, and lower c

22、osts鉑分散優(yōu)化可獲得更高產(chǎn)率，并提高催化劑壽命和降低了成本。Elimination of Chlorination Blower取消了氯化風(fēng)機Improved burn zone, lowering peak temperatures and reducing catalyst surface area decline改良燒焦區(qū), 降低最高燒焦溫度，減少催化劑表面積下降。Twenty-two pressurized regenerators are in operation with others in design and construction.二十二個加壓再生器在投入使用，還有其它

23、一些正在設(shè)計和建造中。lContinuing Innovation - The CycleMax Regeneratorl持續(xù)創(chuàng)新- CycleMax再生器UOP has continued its regeneration technology innovations. In 1996 UOP licensed and commercialized its newest“CycleMax”regenerator design. This design features new catalyst transfer systems and improved internals design fo

24、r optimized coke burning capability.UOP一直以來堅持其再生技術(shù)的創(chuàng)新。1996年UOP取得專利并商業(yè)化其其最新的“CycleMax”再生器設(shè)計。這個設(shè)計的特點是新催化劑的傳輸系統(tǒng)和為優(yōu)化燒焦能力而改進的內(nèi)部設(shè)計。The new design has eliminated the lock hopper vessel and has moved the reduction zone to the top of the reactor stack. This has combined to reduce installation costs by as muc

25、h as 25% and has significantly reduced the height of the regenerator structure. The new“CycleMax”design combines the best features of the atmospheric and pressurized regenerators into a single design.新的設(shè)計去除了閉鎖料斗而且把還原區(qū)放到了疊置式反應(yīng)器的頂部。這種組合減少了大約25%的安裝成本并且大幅度降低了再生器的建造高度。新的 CycleMax再生器設(shè)計融合了常壓再生和加壓再生的優(yōu)點到單一的設(shè)

26、計中。lReliable Catalyst Transferl可靠的催化劑輸送Quick turnover of the catalyst inventory minimizes the effects of process upsets.The standard“two-lift”catalyst transfer system moves catalyst reliably through the reactor stack and regenerator with minimum catalyst attrition.催化劑快速周轉(zhuǎn)減小了工藝波動的影響。標(biāo)準(zhǔn)的 二段提升 催化劑輸送系統(tǒng)使

27、得催化劑以最小的磨損在疊置式反應(yīng)器和再生器之間可靠輸送。lSimplified Catalyst Handlingl催化劑處理簡單化CCR Platforming catalyst remains free flowing at all times. Catalyst can be withdrawn from the unit, added, or totally replaced if desired, without having to shut down the unit. Many refiners have found the“on-the-fly catalyst loading

28、 feature to be very useful in maintaining uninterrupted production of high octane reformate and high purity hydrogen. On-the-fly loading contributes to the reliability and flexibility of UOP CCR Platforming technology, and is a unique feature in the industry. Also, catalyst disposal is not a problem

29、 since all spent catalyst is routed to a platinum recovery facility.催化重整催化劑實時保持自由流動。催化劑可以從裝置卸出、裝入，或根據(jù)意愿全部更換而不需停車。很多煉油廠發(fā)現(xiàn)這一性能對不間斷生產(chǎn)高辛烷值重整生成油和高純氫氣十分有用。在線催化劑裝填使得CCR技術(shù)既可靠又靈活，是UOP工藝的獨有特性。并且，催化劑的處理也不是問題，所有的失效催化劑送到鉑回收設(shè)備。UOP CCR Platforming catalyst is not toxic to plant operators or the surrounding area an

30、d poses no environmental problems.UOP的重整催化劑對操作工和環(huán)境沒有毒性，不會產(chǎn)生任何環(huán)境問題。lFeedstock Flexibilityl進料彈性UOPs design philosophy of operational flexibility without excessive cost, together with Continuous Catalyst Regeneration, combines to give CCR Platforming units unparalleled ability to recover quickly from f

31、eedstock upsets or to accommodate feedstock changes with minimum penalty. For example, process upsets caused by transient high end point feed stocks are easily handled by a CCR Platforming unit, while they would undoubtedly shorten the run length of fixed bed reformers.UOP對于操作彈性的設(shè)計理念使得裝置無須額外投資，與連續(xù)催化

32、劑再生系統(tǒng)賦予連續(xù)重整裝置可以以最小代價迅速從進料造成的工藝波動中恢復(fù)的無與倫比的能力。例如，由于高終餾點進料造成的暫時工藝波動CCR重整裝置可以很容易的得到處理，而對于固定床重整來說，這將無疑會縮短運行周期。Quick turnover of the catalyst inventory in a CCR Platforming unit also minimizes the effects of process upsets.在催化重整裝置中催化劑總量的快速移動也使工藝波動的影響最小化。lLow Pressure Dropl低壓降Minimum pressure drop in the r

33、eactor section is critical for efficient low pressure operation. Low pressure drop minimizes recycle gas compressor differential pressure and horsepower, resulting in lower utility consumption. Minimum pressure drop also permits operation at the lowest possible average reactor pressure which increas

34、es reformate and hydrogen yields. UOPs use of either a Vertical Combined Feed/Effluent exchanger (VCFE) or a Packinox welded plate type exchanger maximizes thermal efficiency while minimizing pressure drop. UOPs fired heaters are also designed for minimum pressure drop. Both of these design features

35、 help to increase yields and profits from a CCR Platforming unit.反應(yīng)部分的最小壓降對于高效的低壓操作是至關(guān)重要的。低壓降可降低循環(huán)氣壓縮機的出口壓力和功率，這可使得消耗降低。低壓降可以允許在低反應(yīng)壓力下操作，這將提高生成油和氫氣產(chǎn)率。UOP應(yīng)用立式組合進料/流出物換熱器(VCFE)或Packinox板焊式換熱器使得在低壓降下傳熱效率最大化。這兩項特色設(shè)計將幫助催化重整裝置提高產(chǎn)率和效益。lMinimum Plot Area，Simplified Catalyst Transferl最少占地簡化的催化劑輸送UOPs stacked

36、 reactor design requires the smallest plot area of any licensed reforming process. Besides offering minimum plot area, the stacked reactor design concept allows catalyst to flow gently downward from reactor to reactor by gravity, simplifying catalyst transfer and minimizing attrition. The catalyst t

37、ransfer operation between the reactor and regenerator sections is trouble-free, requiring no operator intervention. Catalyst is lifted pneumatically only twice during each cycle, from the bottom of the reactor stack to the top of the regenerator and then from the bottom of the regenerator back to th

38、e top of the reactor stack.UOP的疊置式反應(yīng)器在所有催化重整技術(shù)中需要最小的占地面積。除了最少占地，疊置式反應(yīng)器的設(shè)計理念使得催化劑在重力作用下從一個反應(yīng)器流向另一個反應(yīng)器，從而簡化了催化劑輸送并使得磨損最小化。催化劑在反應(yīng)器和再生器之間的輸送沒有任何障礙，不需操作員干預(yù)。催化劑在每次循環(huán)中被氣體提升兩次，從疊置式反應(yīng)器底部到再生器頂部，然后從再生器底部返回反應(yīng)器頂部。1.2Reaction Section Process Description反應(yīng)部分工藝描述The CCR Platforming unit utilizes a single stack of f

39、our reactors. UOPs stacked reactor system requires the smallest plot space of any licensed catalytic reforming process. The reactors are easy to fabricate and easy to maintain. Dozens of fabricators worldwide are experienced in the fabrication of these reactors.CCR催化重整裝置采用四合一疊置式反應(yīng)器。UOP疊置式反應(yīng)器需要的占地面積在

40、獲取專利的催化重整技術(shù)中最小。反應(yīng)器容易制造和維護。在世界上有數(shù)十個制造商對此反應(yīng)器有著豐富的制造經(jīng)驗。In principle stacked reactors eliminate the cost and maintenance associated with the additional inter-reactor catalyst lift systems that would be required if the reactors were placed side-by-side on the ground. The stacked reactors allow for the el

41、imination of the inter-reactor catalyst transfers. The stacked reactors are also more reliable than side-by-side reactors since catalyst flows simply by gravity.總體上說疊置式反應(yīng)器由于沒有并列式反應(yīng)器所必需的反應(yīng)器間提升系統(tǒng)，從降低了投資和維護費用。由于催化劑只是依靠重力流動，疊置式反應(yīng)器可以取消反應(yīng)器間催化劑輸送系統(tǒng)。而因為催化劑只是簡單的依靠重力流動，所以疊置式反應(yīng)器比并列式反應(yīng)器更加可靠。Hydrotreated naphtha

42、 feedstock from the bottom of the Hydrotreater Stripper Column is combined with recycle hydrogen, preheated by exchange with reactor effluent, heated to reaction temperature by the fired Charge Heater and passes to Reactor 1. As combined feed passes through the catalyst bed in Reactor 1, endothermic

43、 reactions cause the temperature to decrease. The effluent from Reactor 1 is then reheated to reaction temperature by Interheater 1 and sent on to Reactor 2. Effluent from Reactor 2 is again reheated to reaction temperature by Interheater 2, and so on through Reactors 3 and 4. Effluent from Reactor

44、4 is cooled first by exchange against the combined feed and then by the Product Condenser before passing to the Separator Drum.加氫精制石腦油進料從加氫處理分離器底部出來和循環(huán)氫混合進入換熱器與反應(yīng)流出物換熱，后被反應(yīng)加熱爐加熱到反應(yīng)溫度后進入第一反應(yīng)器。當(dāng)混合進料通過第一反應(yīng)器床層，由于吸熱反應(yīng)使反應(yīng)溫度下降。第一反應(yīng)器流出物被第一中間加熱爐加熱到反應(yīng)溫度然后進入第二反應(yīng)器，第二反應(yīng)器流出物再一次被第二中間加熱爐加熱到反應(yīng)溫度，如此通過第三和第四反應(yīng)器，第四反應(yīng)器流出

45、物先在換熱器中被混合進料換熱后冷卻，然后經(jīng)過產(chǎn)品冷卻器后進入分離器。Recycle gas, rich in hydrogen, is taken from the Separator, compressed by the Recycle Compressor, and combined with fresh feed to the unit. The net gas is compressed by the Net Gas Compressor and recontacted in a counter-current fashion with Separator liquid at a lo

46、w temperature. LICENSORs patented counter-current net gas recontacting scheme recovers most of the valuable C3+ material which would otherwise be lost in the net gas. The net gas is then typically sent to the Net Gas Chloride Treater where residual levels of chlorides are removed. The net gas is the

47、n sent to the hydrogen system of the refinery and is usually as make-up hydrogen to hydroprocessing units.循環(huán)的富氫氣體在分離器中分離出來后被循環(huán)氫壓縮機壓縮，然后和新鮮進料混合進入裝置。凈化后氣體經(jīng)氫壓縮機壓縮經(jīng)逆流再接觸在較低溫度下進行氣液分離。擁有專利的逆相凈化再接觸設(shè)計可以最大量回收C3+物料，否則這些將物料將會凈化氣中而損失掉。然后凈化氣體常規(guī)上要被送到凈化氣脫氯罐，在那里脫除殘留的氯化物。高純氫氣被送到煉廠的加氫裝置來補充氫氣。Unstabilized reformate fr

48、om the Products Separator after recontacting and recovered hydrocarbons from the net gas chiller are preheated by exchange with Debutanizer Column bottoms before being fed to the Debutanizer Column. The Debutanizer Column is reboiled by a steam reboiler or fired heater. Overheads from the column are

49、 partially condensed in the Debutanizer Condenser and collected in the Debutanizer Receiver.Uncondensed vapors are recycled to the recontact section and some of the liquid is returned to the column as reflux. The remaining overhead liquid product is sent to the battery limits for recovery of LPG.從產(chǎn)品

50、分離器分離出的未經(jīng)穩(wěn)定處理的重整生成油經(jīng)再接觸從氣體冷卻器回收烴類，然后與進脫丁烷塔底換熱器換熱后進入脫丁烷塔。脫丁烷塔由蒸汽或加熱爐加熱再沸。在脫丁烷塔頂冷凝器中部分冷凝進入脫丁烷塔回收罐。未液化的油氣循環(huán)進入再接觸部分，一部分液體做為塔頂回流。剩余的塔頂液體送出界區(qū)做為液化氣回收。The stabilized reformate product bottoms is cooled against the column feed and then by the Products Cooler before being sent to the battery limits. A Process

51、 Flow Diagram of the Reactor Section of a typical CCR Platforming unit can be found at the end of Appendix I.穩(wěn)定生成油產(chǎn)品經(jīng)與塔進料換熱冷卻再經(jīng)產(chǎn)品冷卻器送出裝置區(qū)。典型的重整反應(yīng)部分工藝流程圖見附件1末尾。I.3Regeneration Section Process Description再生部分工藝描述The CCR Regenerator section performs the following functions to return the catalyst to“as

52、new”conditions:CCR再生器部分具有以下功能使得返回的催化劑達到“新鮮”狀態(tài)。1. Burns off the accumulated coke1.燒掉累積的焦炭2. Adjusts chloride balance, oxidizes and disperses metals2.調(diào)整氯平衡，氧化和分散金屬3. Removes the moisture produced by combustion3.除去燃燒產(chǎn)生的濕氣4Reduces the oxidized catalyst metals4還原被使氧化的催化劑金屬The first three regeneration ste

53、ps occur in the Regeneration Tower. The fourth step occurs in the Reduction Zone at the top of the reactor stack in the CycleMax design。 Although these steps appear to be relatively simple, only careful design and control of the regenerator will return the catalyst to“as new”performance.在CycleMax設(shè)計中

54、，再生的前三個步驟發(fā)生在再生區(qū)，第四步發(fā)生在反應(yīng)器頂部的還原區(qū)。雖然這些步驟只是簡單關(guān)聯(lián)，但通過精細的設(shè)計和控制使得返回的催化劑性能就和新鮮催化劑一樣。Spent catalyst flows by gravity from the bottom of the last reactor to the Catalyst Collector, which is an integral part of the last reactor. Catalyst flows downward and is lifted by the lift gas into the Disengaging Hopper

55、above the Regeneration Tower. Catalyst fines are separated from undamaged catalyst in the Disengaging Hopper and are carried out the top of the hopper by elutriation gas. The fines are removed in the Dust Collector and the recycle gas flows back to the Separator. The catalyst drops to the bottom of

56、the Disengaging Hopper and then, under a nitrogen purge, flows by gravity into the Regeneration Tower. Removal of catalyst fines prior to regeneration is important to avoid blockage of the distributor screens which would limit on-stream time and optimum performance of the regenerator.失活催化劑在重力作用下從最后反

57、應(yīng)器底部流出進入催化劑收集器，這個收集器已經(jīng)集成到末反中。催化劑向下流動然后被提升器提升進入再生器上部的分離料斗。催化劑細粉被淘析氣從分離料斗中分離出來與未損催化劑分開，粉塵進入粉塵收集器，循環(huán)氣體返回分離器。催化劑向下流入底部分離料斗，在重力作用下進入再生器。去除催化劑對再生非常重要，它可以避免阻塞，保證再生系統(tǒng)的流化性能。As mentioned above, three functions are carried out in the Regeneration Tower: coke burn, chlorination, and drying依上所述，再生器中執(zhí)行了三個功能。燒焦、氯化

58、和干燥。In the burn zone, the catalyst flows downward through an annulus between two vertical, cylindrical screens. Hot, recirculating, regeneration gas, consisting of nitrogen with a low concentration of oxygen, is used to burn off the accumulated coke. The regeneration gas flows radially from the outside to the inside of the catalyst bed, is withdrawn from the centerpipe, compressed, and then cooled in the Regeneration Cooler before being returned to the Regeneration Tower. The oxygen content of the regeneration gas is known at any