Optimized reactor configuration for optimal performance of the aromax catalyst for aromatics synthesis

A naphtha reforming reactor system comprising:

• a first reactor comprising a first inlet and a first outlet, wherein the first reactor is configured to operate as an adiabatic reactor, and wherein the first reactor comprises a first naphtha reforming catalyst;
• and
• a second reactor comprising a second inlet and a second outlet, wherein the second inlet is in fluid communication with the first outlet of the first reactor, wherein the second reactor is configured to operate as an isothermal reactor, and wherein the second reactor comprises:
• a plurality of tubes disposed within a reactor furnace,
• a heat source configured to heat the interior of the reactor furnace;
• and
• a second naphtha reforming catalyst disposed within the plurality of tubes, wherein the first naphtha reforming catalyst and the second naphtha reforming catalyst are the same or different,
• wherein at least one tube of the plurality of tubes has a plurality of catalyst zones.

A naphtha reforming reactor system comprising:

• a first reactor comprising a first inlet and a first outlet, wherein the first reactor is configured to operate as an adiabatic reactor, and wherein the first reactor comprises a first naphtha reforming catalyst;
• and
• a second reactor comprising a second inlet and a second outlet, wherein the second inlet is in fluid communication with the first outlet of the first reactor, wherein the second reactor is configured to operate as an isothermal reactor, and wherein the second reactor comprises:
• a plurality of tubes disposed within a reactor furnace,
• a heat source configured to heat the interior of the reactor furnace;
• and
• a second naphtha reforming catalyst disposed within the plurality of tubes,
• wherein the first naphtha reforming catalyst and the second naphtha reforming catalyst are the same or different, wherein at least one tube of the plurality of tubes comprises a graded catalyst bed;
• and wherein the graded catalyst bed comprises an increasing amount of the second naphtha reforming catalyst disposed in the at least one tube per unit volume along a length of the at least one tube in a flow direction and wherein the balance of the material per unit volume is an insert material, a less active naphtha reforming catalyst material, or mixture of both.

A naphtha reforming reactor system comprising:

• a first reactor comprising a first inlet and a first outlet, and wherein the first reactor is configured to operate as an adiabatic reactor, and wherein the first reactor comprises a first naphtha reforming catalyst;
• and
• a second reactor comprising a second inlet and a second outlet, wherein the second inlet is in fluid communication with the first outlet of the first reactor, wherein the second reactor is configured to operate as an isothermal reactor, and wherein the second reactor comprises:
• a plurality of tubes disposed within a reactor furnace,
• a heat source configure to heat the interior of the reactor furnace;
• and
• a second naphtha reforming catalyst disposed within the plurality of tubes,
• wherein the first naphtha reforming catalyst and the second naphtha reforming catalyst are the same or different, and wherein a ratio of an amount of the first naphtha reforming catalyst in the first reactor to an amount of the second naphtha reforming catalyst in the second reactor is in the range of about 1:2 to about 1:10 by weight of fresh catalyst.

A naphtha reforming reactor system comprising:

• a first reactor comprising a first inlet and a first outlet, wherein the first reactor is configured to operate as an adiabatic reactor, and wherein the first reactor comprises a first naphtha reforming catalyst;
• and
• a second reactor comprising a second inlet and a second outlet, wherein the second inlet is in fluid communication with the first outlet of the first reactor, wherein the second reactor is configured to operate as an isothermal reactor, and wherein the second reactor comprises:
• a plurality of tubes disposed within a reactor furnace,
• a heat source configured to heat the interior of the reactor furnace;
• and
• a second naphtha reforming catalyst disposed within the plurality of tubes,
• wherein the first naphtha reforming catalyst and the second naphtha reforming catalyst are the same or different, and wherein an amount of the second naphtha reforming catalyst is configured to be substantially fully utilized when the second naphtha reforming catalyst disposed within the plurality of tubes is operating above an endothermic reaction threshold temperature.

A method comprising:

• introducing a hydrocarbon feed stream to a radial flow reactor operating under adiabatic naphtha reforming conditions, wherein the radial flow reactor comprises a first naphtha reforming catalyst, and wherein the hydrocarbon feed stream comprises a convertible hydrocarbon;
• converting at least a portion of the convertible hydrocarbon in the hydrocarbon feed stream to an aromatic hydrocarbon in the radial flow reactor to form a first reactor effluent;
• passing the first reactor effluent from the radial flow reactor to a second reactor operating under isothermal naphtha reforming conditions, wherein the second reactor comprises a plurality of tubes disposed within a reactor furnace, and a second naphtha reforming catalyst disposed within the plurality of tubes, and wherein the plurality of tubes are arranged in parallel between an inlet and an outlet of the reactor furnace;
• passing the first reactor effluent through the plurality of tubes within the second reactor;
• converting at least an additional portion of the convertible hydrocarbon in the first reactor effluent to an addition amount of the aromatic hydrocarbon in the second reactor to form a second reactor effluent, wherein the plurality of tubes is heated within the reactor furnace during the converting;
• and
• recovering the second reactor effluent form the second reactor.