Modeling and Application of Response Surface Methodology in Optimization of a Commercial Continuous Catalytic Reforming Process

A kinetic model based on five groups of 26 lumped pseudo-components, including C-6 to C-9 carbon atoms in categories of paraffins, isoparaffins, cyclohexanes, cyclopenthanes, and aromatics was developed for modeling and optimization of a commercial continuous catalytic naphtha reformer in Bandar Abbas Refinery. The reaction network consisted dehydrogenation, hydrogenation, ring expansion, paraffin and isoparaffin cracking, naphthene cracking, paraffin isomerization, and hydrodealkylation of aromatics as well as coke formation. The product compositions, temperature profile, pressure drop, and coking profiles were determined in the four radial-flow moving bed reactors. The kinetic parameters were derived from the literature and used without tuning the parameters in the CCR model. The outlet temperature, reformate yield, and research octane number (RON) were compared and validated with the outlet results of the commercial CCR. Optimization of operational conditions was carried out using the CCR model and response surface methodology (RSM) based on the statistical analysis. The influence of inlet feed temperature, bed pressure, inlet hydrogen to feed ratio, and the number of adiabatic beds was analyzed simultaneously on the yield and research octane number of the reformate product, and the optimal results were calculated and discussed to approach to the highest RON and reformate yield.