INFO

FILTRATION IN CONTINUOUS CATALYTIC

REFINERIES
Introduction In the course of growing
demand for higher value motor fuel products, the
process of catalytic reforming has been developed
in the 1940’s and is in use since. It reforms low-
octane naphtha feed into products such as high-
octane gasoline and highly aromatic petrochemical
feedstocks. Catalytic reforming makes use of pre-
cious platinum and/or rhenium based catalysts and
it normally is the main source of the refinery’s
hydrogen production as a result of the reformer’s
various reactions, yielding hydrogen as a
by-product.
One of the key features of a Continuous Catalytic
Regeneration (CCR) unit is the circulation of its cata-
lyst between the reactor and regenerator sections.
In the reactor section, the catalyst becomes coked
while it passes through different reactors, it loses
its activity and must be re-activated, which takes
place in the regenerator section.
Overview In the proprietary reforming process of
one of the leading Octanizing and Aromizing CCR
reforming process licensors, the most fine catalyst
particles are elutriated (separated from its heavier/
more coarse particles) from the reactor and
regenerator sections and subsequently removed
from the overall process. This is achieved by
sending elutriation gas and lift gas into,
respectively, the First Upper Hopper (reaction
section) and the Upper Surge Drum (regeneration
section).
REGENERATION (CCR)
CATALYST FINES
FILTRATION
refiner rely on an efficient filtration solution for this
application.
Royal Dahlman has extensive experience with the
design and fabrication of these special high-end
automatically regenerated catalyst dust fines filters
and packaged equipment. The technology applied is
installed in refineries all over the world, in various
demanding applications and where reliability is of
the essence.
Description Royal Dahlman CCR Fines Filters/
Packages consist of a cylindrical filter vessel installed
with specially developed (proprietary) sintered
porous metal filter elements. The filters are execut-
ed with an intermediate storage capacity and a coni-
cal hopper, a cleaning system (blowback gas accu-
mulator vessel and automatic valves) and, where
necessary, the required controls, valves,
instruments, piping, assembly and installation works
can be provided.

The elutriation/lift gas containing the separated

fines is transported further into the First Upper
Hopper Fines Filter and Upper Surge Drum Fines
Filter, where the gas is filtered (99% of all particles
> 1 micron and max. 50 mg/Nm3 of dust emission).
The separated catalyst particles are collected in
drums below the CCR Fines Filters and finally
dispatched to a precious metals recovery plant. The
recovery of these metals is a means of reducing
operational costs and thus both the licensor and
INFO
During normal forward filtration mode, catalyst fines
will collect on the outside of the filter elements.
Over a period of time, a layer of catalyst will build up
on the surface of the filter elements. When reaching
a certain pre-set differential pressure over the filter
elements, the filtration system is automatically
regenerated in-situ by performing several sequential
blow back pulses in reverse direction through the
filter elements, dislodging the solids and cleaning
the filter elements. At no time during this process,
the inlet gas flow is required to be reduced; the
process design allows for maintaining flow through
the filter elements which are not being cleaned at
that moment in time. After a complete cleaning
cycle, the filter differential pressure will be restored
to its clean initial state.
Features
Use of high-efficiency filter media suitable for surface
filtration and optimal cleaning results
Highly effective in-situ element cleaning owing to
pressurized blowback cleaning
Elimination of filter plugging and consequently, ex-situ
cleaning
Non-stop operation
Full automation by PLC or DCS control system
Compactly sized, fully dressed filter packages
Full process performance guarantee
WWW.DAHLMAN.NL | T. +31 (0)10 599 1111 | E. DAHLMAN@DAHLMAN.N L
The separated catalyst can temporarily be stored
within the filter vessel and the design allows for
batches of catalyst to be unloaded without the need
for taking the filter offline.
Royal Dahlman utilizes high quality, special sintered
porous metal filter elements, which have proved to
perform excellent under a wide array of conditions.
Their features include:
 special alloy filter medium with optimal
resistance against mechanical & thermal
shock and oxidizing environment;
 excellent in-situ cleaning characteristics;
 low pressure drops compared to other filter
media;
 long element lifetime.
Royal Dahlman’s extensive know-how and expertise
on designing and fabricating assembled filtration
systems and fully dressed filter packages in
accordance with demanding specifications is
renowned in the Refining Industry.
Benefits
Maximum solids recovery & minimal
environmental exposure
Minimises blowback gas consumption -> minimized
utility costs
Enhanced operational safety & reliability, and low
OPEX
High reliability and availability (no unscheduled
downtime)
Operational cost savings and consistent
performance
Minimum floor space and low installation costs
Single point responsibility
VOLUME 3, NO. 1–JANUARY 2013