PROCESS ECONOMICS PROGRAM

Transcription

1 Abstract PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Park, California Process Economics Program Report No. 129 REFORMING FOR BTX (June 1980) This report reviews the reforming of naphtha to produce benzene, toluene, and xylenes. The fundamentals of the reforming operations are discussed in detail. The economics were developed for reforming of two naphthas; a paraffinic and a naphthenic. Also, the effect of reforming severity on the economics is studied. LAC SF PEP'77 WS Fw

2 Report No. 129 REFORMING FOR BTX by FRANK B. WEST Contributions by LESLIE A. CARMICHAEL STANFORD FIELD KOON LING RING WALTER SEDRIKS May 1980 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing-in marketing research. The CHEMICAL ECONOMICS UANDROOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTCRY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

4 CONTENTS 1 INTRODUCTION SUMMARY INDUSTRY STATUS. :... 9 Production Capacity GENERAL PROCESS CONSIDERATIONS Introduction Chemistry General Feed Pretreating Reactions Reforming Reactions Isomerization and Dehydrogenation of Naphthenes Isomerization and Dehydrocyclization of Paraffins Isomerization, Dealkylation, and Disproportionation of Aromatics Isomerization Dealkylation Disproportionation and Transalkylation Hydrocracking of Paraffins and Naphthenes Coke Formation on the Catalyst Relative Reaction Rates and Computer Programs Yields Reforming Severity UOP Bimetallic Catalyst Yield Estimates Analysis of Paraffin Conversions and Selectivities Catalysts General Catalyst Supports Catalyst Dehydrogenation Activity Catalyst Acidity Mass Transfer Effects and Catalyst Size Potential Catalyst Improvements Catalyst Regeneration Feedstocks Corrosion Start-Ups Royalties ix

5 CONTENTS 5 COMMERCIAL PROCESSES Feed Pretreating Semiregenerative Reforming in General Cyclic and Continuous Reforming in General Licensed Reforming Processes Purification of Net Hydrogen Make Crude Reformate Stabilization PROCESS EVALUATIONS Introduction Process Description Case 1 Feed Pretreatment (Section 100) Case 1 Reforming (Section 200, Part 1) Case 1 Stabilization (Section 200, Part 2) Case 1 Extraction of Mixed Aromatics (Section 300) Case 1 BTX Distillation (Section 400) Other Cases Process Discussion Feedstocks and Physical Properties Section loo--hydrotreating Section 200 Part l--reforming Section 200, Part 2--Stabilization Section 300 and 400--Aromatics Extraction and Distillation Utility Estimates for Section Cost Estimates Capital Costs Production Costs Product Value Optimum Conversion Level Optimum Feedstock Continuous vs. Semiregenerative Reforming Value of Hypothetical Improved Catalyst AROMATICS OUTLOOK Introduction World Crude Oil U.S. Economic Acitivty and Energy Use NaturalGas Coal Nuclear Power X

6 CONTENTS Petroleum Synthetic Fuels Petroleum Use and Price in the United States Gasoline Demand and Quality in the United States Refinery Processing for Gasoline in the United States Benzene Supply and Demand Outlook in the United States CITED REFERENCES PATENT REFERENCES Xi

7 ILLUSTRATIONS Equilibrium Distribution for Systems n-paraffin-aromatic-hydrogen Effect of Naphtha Composition and Desired Octane Number on the Required H2/HC No1 Ratio RON-Clear of Cg+ Reformate as a Function of %v Aromatics and Source of Feed Reformer Product Distribution Selectivity of Normal Hexane to Benzene as a Function of Temperature and Pressure Temperatures to Maintain 100 RON-Clear C5+ Reformate as a Function of Time on Stream, for Various Reforming Catalysts Flow Diagram Section 200--Sheet 1 Reforming, Case 1 FlowDiagram Section LOO--Sheet 2 H2 Purification and Stabilization, Case 1 FlowDiagram Section 200--Sheet 1 Reforming, Case 2 FlowDiagram Section 200--Sheet 2 H2 Purification and Stabilization, Case 2 FlowDiagram Section 200--Sheet 1 Reforming, Case 3 FlowMagram Xiii

8 ILLUSTRATIONS 6.7 Section 200--Sheet 2 H2 Purification and Stabilization, Case 3 FlowDiagram Effect of Plant Capacity on Total Fixed Capital Effect of Plant Capacity and Operating Level on Production Cost Effect of Conversion Level on Product Value Effect of Plant Capacity and Operating Level on Product Value Arabian Light Crude Oil Price as a Function of U.S. Inflation Rate Libyan/Arabian Light Crude Oil Price Ratio Estimated U.S. Payments for Very Low Sulfur Foreign Crude Oils U.S. Passenger Car Mileage U.S. Passenger Car Gasoline Consumption U.S. Gasoline Demand U.S. Gasoline Pool Octane Number and Lead Content Catalytic Reforming and Catalytic Cracking Capacities in the United States Catalytic Reforming, Catalytic Cracking and Gasoline Production Relative to U.S. Refining Capacity Estimated Chemical Benzene Production and Capacity in the United States Percentage of U.S. Benzene Production That Was Sold xiv

9 TABLES A 6.6B 6.6C 1979 BTX Capacity and Demand... High Severity Reforming of Naphtha Composition of Reactor Effluent... Catalytic Reforming, High Severity Operation Summary of Economics... Benzene Consumption Patterns--l Toluene Consumption Pattern--l Plant Capacities for Producing Benzene, Toluene, andxylenes... References for Reforming Reactions with Pure Components.. Reforming Yields from Case 1 Through 4 Material Balances Based on UOP Estimates... Analysis of UOP Case 3 and Case 4 Mass Balances for Mol Percent Conversions of Paraffins to Aromatics and to Hydrocracking Products... Effect of Catalyst Size, from Hettinger et al.... Cases for Study--Reforming for BTX... Reformer Feed Compositions... Estimated Mid-Cycle Compositions of Net Reactor Product.. Principal Design Bases for Reactor Circuit... Principal Design Bases for Columns... Case Major Equipment... Case MajorEquipment... Case Major Equipment xv

10 TABLES 6.7 Case 1 Severe Reforming of 20,000 bpsd of Highly Naphthenic Feed Case 2 Moderate Reforming of 20,000 bpsd of Highly Naphthenic Feed Case 3 Severe Reforming of 20,870 bpsd of Highly Naphthenic Feed Case 4 Mass Balance for Moderate Reforming of 20,870 bpsd of Highly Paraffinic Feed Average Utilities Consumption for Section Summary of Capital Investments--Reforming for BTX Case 1 Capital Investment Case 2 Capital Investment Case 3 Capital Investment Related Evaluations of Semiregenerative Reforming of Paraffinic Naphthas Adjusted to 20,870 bpsd Naphtha and Pep Cost Index of Case 1 Detailed BTX Production Costs and Product Value Case 2 Detailed BTX Production Costs and Product Value Case 3 Detailed BTX Production Costs and Product Value Summary of Production Costs and Product Values-- Reforming for BTX Effect of Scale on Capital, Production Cost, and Product Value--Reforming for BTX World Petroleum Production Petroleum Demand of Major Free World Industrialized Countries xvi

11 TABLES 7.3 World Imports and Reports of Petroleum Projected Price of Arabian Light Crude Oil World Petroleum Refining Capacity U.S. Economic Activity and Primary Energy Use U.S. Petroleum Products U.S. Crude Oil Imports by Country of Origin Estimated U.S. Refiner Acquisition Cost of Crude Oil Projected U.S. Gasoline Demand ( ) U.S. Gasoline Demand and Quality ( ) Average U.S. Gasoline Quality Average U.S. Gasoline Pool Composition Octane Contributions and Octane Requirements of Major Components of the Average U.S. Gasoline Pool Contribution to Gasoline Production in the U.S. of Catalytic Cracking and Catalytic Reforming Benzene Supply and Demand BTX Supply and Demand in the United States Benzene Extraction from Reformate Production of Benzene for Chemical Use in the United States x?lii