CCR PlatformingTM Technology:

Advancing the State of the Art

Mike Salem
UOP Limited
Guildford England

2005 UOP LLC. All rights reserved. UOP 4474F-01

 Agenda
Market Drivers
Process: UOP has unique design advantages
and is continuously improving the
technology.
Regeneration: UOP regeneration capability is
unmatched in the industry. New advances
move the technology forward even further.
New catalyst option for increased
profitability: R-264 catalyst for increased
capacity, activity, or yield in your reforming
unit.

UOP 4474F-02
 Market Drivers
Product demand:
Tight supply for gasoline in the US
Benzene and Xylene
Specification drivers:
Desulfurization in transportation fuels
Increased octane for gasoline in Asia
Efficiency:
Improve feed utilization
Reduce costs per BBL

UOP 4474F-03
 191 Operating CCR Platforming Units
37 in Design and Construction
Commissioned CCRTM
Regenerators Types
First generation Atmospheric
Pressurized
Second Generation Pressurized
24 Sequential
CycleMaxTM 1 Current state of the art high
41 capacity regeneration
CyclceMaxTM
Newest small capacity regenerator
Sequential

Atmospheric
125

Vast experience base

UOP 4494B-08
 191 Operating CCR Platforming Units
37 in Design and Construction
CCR Platforming unit
Design Capacities, BPD
5 units operating > 60,000 BPD Less than 10,000
9 units
3 units operating > 80,000 BPD 10,000 20,000
72 units
at high severity Greater than 30,000
36 units

20,000 30,000
74 units

Unmatched experience with large

capacity units UOP 4474F-05
 CCR Platforming Process
Customers Experience
Number of repeat technology selections after having
a first CCR Platforming unit in operations.
85
Many companies license exclusively from UOP
All world scale companies have only CCR
Platforming units
There are more than 15 companies around the world
which only license from UOP
Why? Proven performance. Best service.
Best technology
UOP 4474F-06
 Reactor Configuration
UOP offers both side-by-side and stacked
reactor designs. UOP has designed and has in
operation Platforming units with 3+1, 2+1, and
2+2 stacked reactor configuration. Most
customers prefer a single stacked reactor.
Stacked reactors result in:
Lower capital cost
Fewer pieces of equipment
Smaller plot space
Lower catalyst attrition
Lower operating maintenance costs

UOP has designed many

different reactor configurations
UOP 4474F-07
Upflow Centerpipe Reactor Advantages
Vapor Flow

Higher velocity head

Downflow centerpipes
are obsolete
The upflow centerpipe
is a UOP unique design
Vapor flow distribution
is optimized in an
upflow design

Optimized vapor
distribution results in best
catalyst utilization UOP 4494B-13
 Improved Reactor Upflow Centerpipe

Benefits of Upflow Centerpipe

Easy socket assembly
Less maintenance
Assured catalyst containment
Uniform catalyst withdrawal
at base of centerpipe.

Machine Socket
Most reliable mechanical assembly. (Female End)
Ensures best utilization
of catalyst

UOP 4474F-09
 Reduction
Zone Smooth Catalyst Movement
Only 2 lifts
Straight upward lift lines
Horizontal flow only at
downward slope
Last No operating valves in
Reactor
catalyst lines
Catalyst
Smooth flow control with
Collector
Lock
unique L-valve
Hopper
Impactless elbows
Booster
N2 Gas H2

Fewer lifts, bends and valves result

in lower catalyst attrition UOP 4494B-16
Market Trends Toward Large Units
Largest CCR Platforming Units
Design by Decade
Units in operation from
6000 BPD to 85,000 BPD
Current design ranges are
12,000 to 95,000+ BPD
Careful attention to
design is critical

UOP has the most experience and expertise

for design of large units
UOP 4474F-12
Examples of Recent Design
Improvements
Redesigned
Scallops D style and
Optimizers
Centerpipes
Internal heads
Improved seal ventilation
Virtually eliminated heel
catalyst
Cooldown mode - increased
reliability during startup
and shutdown
Continuous innovation particularly
important for super-sized units
UOP 4474F-13
 CycleMax Regenerator
Feature
Superior catalyst reconditioning
Low fines make
Fewer pieces of equipment
No waste liquid or solids
Low maintenance requirements
Premier regenerator
Benefit
- Best catalyst performance
- Ultra-long catalyst life
- Less catalyst makeup
- Higher reliability
- Easier and cheaper to
construct and maintain
- No disposal costs
- Can match desire for 3 to 5
year turnaround schedule
on reactors
UOP 4474F-14
 CycleMax Regenerator Burn Zone
Feature Benefit
Tapered screen : Maintains good Pt
Shorter residence time at dispersion
peak temperature Ultra-long catalyst life
Low O2 concentration: Ultra-low fines production
Low peak burn Special
Thermocouples
temperature

UOP catalyst with good burn Complete coke removal in

characteristics single burn zone
Stable catalyst performance Minimal equipment
Simple operating scheme No waste liquid or solid
disposal

Long catalyst life is achieved with

UOP catalyst in simple to operate
CycleMax regenerator UOP 4474F-15
 CycleMax Regenerator Experience
through Year 2005 Commissioning
Catalyst life is a function of operating severity + ability
to successfully rejuvenate the catalyst

2nd Load 3rd Load Few units have reloaded

0%
17% with catalyst since
commissioning.
First unit commissioned is
operating with its original
catalyst after >9 year
operation at high severity.
Because so many units are
1st Load still on first load of catalyst
83%
it is impossible to report
average life
UOP catalyst and the CycleMax regenerator produce
the longest catalyst life in the industry
UOP 4474F-16
Long Catalyst Life with Constant Yields

Over 8 years

Stable yields for more than 8 years

At 103 to 105 RONC
UOP 4474F-17
Reduction Zone Advantages
Catalyst In

Reduced Catalyst

Reactor No. 1 Feed

Reactor No. 1 Effluent

Catalyst
Transfer Pipes

UOP reduction zone results in better Pt

dispersion and catalyst performance UOP 4474F-18
 CCR TM
Regenerator
with ChlorsorbTM System

Disengaging
Vent Gas Caustic scrubbing is
Hopper
< 30 ppm HCl outdated
Catalyst
Chlorsorb system
Chlorsorb results in:
Vessel
No waste water
Minimal chloride
Regeneration Burn Zone injection due to
Tower Gas extensive chloride
recycle

>99% Chloride removal efficiency

with no waste products or moving parts
UOP 4474F-19
Chlorsorb System Performance Data
100
99
98
Percent Reduction

97
96
95
94
93
92
91
90
TCDD I-TEF CL-BZ PCB HCL Total
CCR Regenerator Vent Gas Compounds

Excellent commercial performance

UOP 4474F-20
 Chlorsorb Experience

Operating
Design and
construction
Successfully Operating
4 CycleMax regenerators
11 Atmospheric regenerators

22 more in design and construction

UOP 4474F-21
 R-264 Catalyst
for the CCR Platforming Process
R-264 catalyst performance
Catalyst yields
Catalyst comparisons
Physical characteristics
R-264 catalyst commercialization
Commercial status
Commercial data

High Density, Highest Activity, Low Coke,

High Hydraulic Capacity
UOP 4474F-23
 R-264 Catalyst Benefits
One Catalyst Two Operating Modes
Maximum Yield Mode
~0.6 wt% yield advantage
~ 7 Nm3/m3 Hydrogen
Same activity as R-134 catalyst

Relative to R-134 Catalyst

Maximum Activity Mode

~2-4 oC activity advantage
Same yields as R-134 catalyst

18% less coke make than R-134 catalyst in either mode

UOP 4474F-24
R-264 Catalyst Breakthrough Performance
R-264 catalyst flexibility -
Higher yield or greater activity

R-274 R-264 High Yield Mode

Yield

R-234 R-264 catalyst

performance line

Yield
R-264 High
R-134 Activity
Activity Mode
Activity
UOP 4474F-25
 Third Party Catalyst Testing
R-264, R-134, Competitor Catalyst
Catalyst A has poorer selectivity to H2, C5+, and
aromatics than R-264 or even R-134 catalyst
R-264 catalyst exhibits better selectivity
R-264 catalyst has a large selectivity advantage
over competitors catalyst A
Selectivity advantage increases with lower
pressure and higher severity
R-264 catalyst shows
More C5+
More aromatics and hydrogen
Less A6 and more A8+
UOP 4474F-26
 3rd Party Evaluation
R-264, R-134, Competitor Catalyst

Cat. A R-134 R-264

C5+, wt% - 0.5 + 1.2
H2, wt% -0.05 +0.12
Total A, wt% - 0.4 +1.1
Bz SAME
Base -0.1
Tol SAME SAME
Xyl - 0.2 +0.6
A 9+ -0.2 +0.6
Coke make, +8% -26 %
% Kg/hr change
UOP 4474F-27
R-264 Catalyst Physical Properties
More open pore structure higher throughput
operation
Low coke
Faster burning rate
Higher density
Higher pin margin for more throughput
Higher strength
Lower fines make
Surface area stability
Catalyst life equal to the best in the industry
(R-134)
UOP 4474F-28
 R-264 Commercial Status
8 refiners have selected R-264
6 are in operation
1 more will load 4th quarter 2005
1 will load 1st quarter 2006
A commercial example
Switched from R-134 ( nearly 10 years old)
Wanted flexibility for high selectivity or activity
Immediate need for more reformate

UOP 4474F-29
 R-264 Catalyst
Feed & Operating Conditions
P/N/A, lv% 43/36/21
IBP / 50% / EP, C 99/127/179
RONC Typical 99-100
R-264 Catalyst Mode High Activity

Relatively consistent feed rate, PNA, distillation

and RONC before and after catalyst change-out

UOP 4474F-30
R-264 Catalyst Commercial Performance
Improved Yields
C5+ Yield H2 Yield
90 1400
C5+ Yield, LV%
89 H2 Yield
1300
C5+ Yield, LV%

H2 Yield, SCFB
88
R-134 1200
87
86 1100
85
1000 R-264
84 R-134
83 R-264 900
82
12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05 800
12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05
Date Date
C5+ yield increased by 1-2 LV%
Hydrogen yield up by ~20 Nm3/m3

R-264 catalyst delivers higher yield

UOP 4474F-31
 R-264 Catalyst Commercial Performance
WAIT and LHSV
1000 2.20

995

11 C more active 990

2.15

LHSV, 1/hr
WAIT, F
985 R-264 Catalyst
R-134 Catalyst 2.10
980

975 WAIT, deg F 2.05

Fines Make, Lbs/Day LHSV
50 970
45 Fines Make, Lbs/Day 965 2.00
40 12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05
Date
Fines, Lbs/Day

35
30
R-134 Catalyst
25
20
15
R-264 Catalyst 50% less fines make
10
5
0
12/9/04 12/19/04 12/29/04 1/8/05 1/18/05 1/28/05 2/7/05 R-264 catalyst is more active with
lower fines make!
UOP 4474F-32
 R-264 Catalyst Commercial
Performance Summary
Activity increased by ~ 11C
C5+ yield increased by ~ 1-2 lv %
Hydrogen yield increased by ~ 20 NM3/m3
Chloride use reduced by ~70%
Fines make reduced by 50%

R-264 catalyst meeting

process objectives.
Customer delighted with
performance
UOP 4474F-33
 Commercialization Summary
Eight customers have selected
R-264 catalyst
R-264 catalyst has provided
Higher activity key requirement
allowing for :
Increased throughput
Increased octane-barrels
Lower coke
Lower catalyst makeup

Successful Commercialization of R-264 Catalyst

UOP 4474F-34
 Summary
UOP continues to innovate and improve
the Platforming process
UOP has unique design advantages in
CCR Platforming
CCR Platforming process is being
continuously improved
UOP regeneration capability is
unmatched in the industry

UOP 4474F-35
 Summary Contd
UOP continues to innovate and improve
the Platforming process
UOP has the skill and experience to design
CCR Platforming units to meet the needs
of all markets
R-264 catalyst is the highest performance
catalyst available today

UOP 4474F-36
UOP 4474B-37