# US 11,028,328 B2 · Systems and processes for catalytic reforming of a hydrocarbon feed stock

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- Number: US 11,028,328 B2
- Document ID: US11028328B2
- Status: Granted
- Kind: B2
- Application number: 16/594,275
- Filed: 2019-10-07
- Published: 2021-04-08
- Granted: 2021-06-08
- Earliest claimed: 2019-10-07
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Ali H. Alshareef; Mohammad A. Al-Rebh
- Web page: https://patentgrep.com/patent/US11028328B2

## CPC

- C10G 59/02: plural serial stages only
- B01J 38/30: in gaseous suspension, e.g. fluidised bed
- C10G 35/04: Catalytic reforming
- C10G 35/06: characterised by the catalyst used
- C10G 2300/1044: Heavy gasoline or naphtha having a boiling range of about 100 - 180 °C
- C10G 2300/70: Catalyst aspects
- C10G 2300/701: Use of spent catalysts
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

Processes for catalytic reforming of a hydrocarbon feedstock may include contacting the hydrocarbon feedstock with catalyst in a first reforming unit to produce a first effluent and used catalyst. The method may further include passing a portion of the first effluent directly to a second reforming unit and contacting the first effluent with catalyst to produce a second effluent and used catalyst. The method may also include passing a portion of the second effluent directly to a third reforming unit and contacting the second effluent with catalyst to produce a reformate effluent and used catalyst. Additionally, the method may include regenerating at least a portion of the used catalyst to produce regenerated catalyst. The catalysts may each include regenerated catalyst.

## Claims

### Claim 1

A process for catalytic reforming of a hydrocarbon feedstock, the process comprising:
contacting the hydrocarbon feedstock with a first catalyst in a first reforming unit, the contacting causing reaction of at least a portion of the hydrocarbon feedstock to produce a first reforming effluent and a used first catalyst;
passing a first portion of the first reforming effluent directly to a second reforming unit;
contacting the first portion of the first reforming effluent with a second catalyst, the contacting causing reaction of at least a portion of the first reforming effluent to produce a second reforming effluent and a used second catalyst;
passing a first portion of the second reforming effluent directly to a third reforming unit;
contacting the first portion of the second reforming effluent with a third catalyst, the contacting causing reaction of at least a portion of the second reforming effluent to produce a reformate effluent and a used third catalyst; and
regenerating at least a first portion of the used first catalyst, at least a first portion of the used second catalyst, and at least a first portion of the used third catalyst to produce a regenerated catalyst,
where the first catalyst, the second catalyst, and the third catalyst each comprise the regenerated catalyst.

### Claim 2 (depends on 1)

The process of claim 1, where the hydrocarbon feedstock comprises one or more of paraffins, naphthenes, aromatics, olefins, or combinations of these.

### Claim 3 (depends on 1)

The process of claim 1, where the hydrocarbon feed comprises a heavy naphtha stream.

### Claim 4 (depends on 1)

The process of claim 1, further comprising:
heating a second portion of the first reforming effluent; and
passing the second portion of the first reforming effluent to the second reforming unit.

### Claim 5 (depends on 1)

The process of claim 1, further comprising:
heating a second portion of the second reforming effluent; and
passing the second portion of the second reforming effluent to the third reforming unit.

### Claim 6 (depends on 1)

The process of claim 1, where the second catalyst further comprises a second portion of the used first catalyst that has not been regenerated.

### Claim 7 (depends on 6)

The process of claim 6, further comprising passing the second portion of the used first catalyst directly to the second reforming unit without regenerating.

### Claim 8 (depends on 1)

The process of claim 1, where the third catalyst further comprises a second portion of the used second catalyst that has not been regenerated.

### Claim 9 (depends on 8)

The process of claim 8, further comprising passing the second portion of the used second catalyst directly to the third reforming unit without regenerating.

### Claim 10 (depends on 1)

The process of claim 1, where the at least a first portion of the used first catalyst, the at least a first portion of the used second catalyst, and the at least a first portion of the used third catalyst are each regenerated in a separate catalyst regenerator.

### Claim 11

A process for catalytic reforming of a hydrocarbon feed stream, the process comprising:
introducing the hydrocarbon feedstock to a first reforming unit operable to contact the hydrocarbon feedstock with a first catalyst, the contact causing reaction of at least a portion of the hydrocarbon feedstock to produce a first reforming effluent and a used first catalyst;
passing a first portion of the first reforming effluent directly to a second reforming unit operable to contact the first portion of the first reforming effluent with a second catalyst, the contact causing reaction of at least a portion of the first reforming effluent to produce a second reforming effluent and a used second catalyst;
passing a first portion of the second reforming effluent directly to a third reforming unit operable to contact the first portion of the second reforming effluent with a third catalyst, the contact causing reaction of at least a portion of the second reforming effluent to produce a reformate effluent and a used third catalyst;
passing at least a portion of the used first catalyst, the used second catalyst, and the used third catalyst to at least one catalyst regenerator operable to regenerate the portions of the used first catalyst, the used second catalyst, and the used third catalyst to produce a regenerated catalyst; and
recycling at least a portion of the regenerated catalyst to one or more of the first reforming unit, the second reforming unit, the third reforming unit, or combinations of these, such that the first catalyst, the second catalyst, and the third catalyst each comprise at least a portion of the regenerated catalyst.

### Claim 12 (depends on 11)

The process of claim 11, further comprising:
passing a second portion of the first reforming effluent to a heating unit to heat the second portion of the first reforming effluent; and
passing the second portion of the first reforming effluent from the heating unit to the second reforming unit.

### Claim 13 (depends on 11)

The process of claim 11, further comprising:
passing a second portion of the second reforming effluent to a heating unit operable to heat the second portion of the second reforming effluent; and
passing the second portion of the second reforming effluent from the heating unit to the third reforming unit.

### Claim 14 (depends on 11)

The process of claim 11, where the second catalyst further comprises a second portion of the used first catalyst that has not been regenerated.

### Claim 15 (depends on 11)

The process of claim 11, where the third catalyst further comprises a second portion of the used second catalyst that has not been regenerated.

### Claim 16 (depends on 11)

The process of claim 11, where the at least a first portion of the used first catalyst, the at least a first portion of the used second catalyst, and the at least a first portion of the used third catalyst are each regenerated in a separate catalyst regenerator.

### Claim 17 (depends on 16)

The process of claim 16, comprising:
passing the first portion of the used first catalyst to a first catalyst regenerator operable to regenerate the first portion of the used first catalyst to produce a regenerated first catalyst; and
recycling at least a portion of the regenerated first catalyst to the first reforming unit such that the first catalyst comprises at least the regenerated first catalyst.

### Claim 18 (depends on 16)

The process of claim 16, comprising:
passing the first portion of the used second catalyst to a second catalyst regenerator operable to regenerate the first portion of the used second catalyst to produce a regenerated second catalyst; and
recycling at least a portion of the regenerated second catalyst to the second reforming unit such that the second catalyst comprises at least the regenerated second catalyst.

### Claim 19 (depends on 16)

The process of claim 16, comprising:
passing the first portion of the used third catalyst to a third catalyst regenerator operable to regenerate the used third catalyst to produce a regenerated third catalyst; and
recycling the regenerated third catalyst to the third reforming unit such that the third catalyst comprises the regenerated third catalyst.

### Claim 20 (depends on 14)

The process of claim 14, where a weight average inlet temperature of the first reforming unit, the second reforming unit, the third reforming unit, or combinations of these is from 500 degrees Celsius (° C.) to 560° C.