System and method for on stream catalyst replacement

A method comprising:

• operating a reforming reactor system comprising a plurality of reactors connected in a first order until a first reactor of the plurality of reactors is deemed to contain a spent catalyst, wherein each of the plurality of reactors contains a catalyst comprising a zeolite capable of converting at least a portion of a hydrocarbon stream to aromatic hydrocarbons, wherein the plurality of reactors comprises three or more serially connected reactors, wherein the hydrocarbon stream flows along a first flow path through the plurality of reactors in the first order, wherein at least one reactor of the plurality of reactors is downstream of both the first reactor and a second reactor in the first order;
• isolating the first reactor containing the spent catalyst from the remaining reactors, wherein the remaining reactors continue to operate to convert at least the portion of the hydrocarbon stream to aromatic hydrocarbons when the first reactor is isolated from the remaining reactors;
• restoring the ability of the first reactor containing the spent catalyst to convert at least a portion of the hydrocarbon stream to aromatic hydrocarbons;
• returning the first reactor to the remaining reactors at a new location to form a second flow path of the hydrocarbon stream through the plurality of reactors, wherein the hydrocarbon stream flows along the second flow path through the plurality of reactors in a second order, and wherein the first reactor is the last reactor in the second flow path of the hydrocarbon stream through the plurality of reactors;
• resuming operations of the reforming reactor system until the second reactor of the plurality of reactors is deemed to contain a spent catalyst;
• isolating the second reactor containing the spent catalyst from the remaining reactors, wherein the remaining reactors continue to operate to convert at least the portion of the hydrocarbon stream to aromatic hydrocarbons when the second reactor is isolated from the remaining reactors;
• restoring the ability of the second reactor containing the spent catalyst to convert at least a portion of the hydrocarbon stream to aromatic hydrocarbons;
• and
• returning the second reactor to the remaining reactors at a new location a third flow path of the hydrocarbon stream through the plurality of reactors, wherein the hydrocarbon stream flows along the third flow path through the plurality of reactors in a third order, and wherein the second reactor is the at least reactor in the third flow path of the hydrocarbon stream through the plurality of reactors.

A process for operating a reforming reactor system comprising:

• operating a plurality of reactors until at least one reactor is deemed to have an operational issue, wherein each of the plurality of reactors contains a catalyst capable of converting at least a portion of a hydrocarbon stream to aromatic hydrocarbons, wherein a sulfur removal system is not located upstream of the plurality of reactors, and wherein the hydrocarbon stream fed to the plurality of reactors comprises sulfur, wherein the plurality of reactors comprises three or more serially connected reactors, wherein the hydrocarbon stream flows along a first flow path through the plurality of reactors in a first order, wherein the at least one reactor is adjacent to a second reactor of the plurality of reactors in the first flow path, and wherein a low activity reactor is downstream of at least one reactor of the plurality of reactors in the first flow path through the plurality of reactors in the first order;
• isolating the at least one reactor deemed to have the operational issue from a remaining plurality of reactors that continue to operate to convert at least the portion of the hydrocarbon stream to aromatic hydrocarbons while the at least one reactor deemed to have the operational issue is isolated from the plurality of remaining reactors;
• addressing the operational issues;
• reconnecting the at least one reactor to the remaining plurality of reactors at a new location to form a second flow path of the hydrocarbon stream through the plurality of reactors, wherein the low activity reactor is the first reactor in the second flow path wherein the low activity reactor comprises a catalyst with the lowest activity of the plurality of reactors in the second flow path, and wherein the at least one reactor is not adjacent to the second reactor in the second flow path;
• resuming operations of the reforming reactor system to convert at least the portion of the hydrocarbon stream to aromatic hydrocarbons;
• and
• absorbing the sulfur in the hydrocarbon stream in the low activity reactor before passing the hydrocarbon stream to a downstream reactor.