Optimization Approach for Continuous Catalytic Regenerative Reformer Processes

Abstract

The new approach for simulation and optimization of a continuous catalytic regenerative (CCR) reformer process is proposed. Typical CCR reforming processes consist of three to four reactors with recycle. The reaction patterns and reactors are typically modeled using a system of partial differential equations (PDEs). The numerical simulation solution of the entire model for a process system consisting of multiple reaction zones with recycle is extremely time-consuming and, thus, impractical in optimization studies. That is why we proposed a more efficient simulation and optimization scheme based on quasi-steady-state assumptions. We define criteria for reactor fragmentation to avoid the introduction of large errors in the quasi-steady-state calculations. The optimization problem is formulated with the objective of minimizing fuel consumption. The employed objective function constitutes a combined measure for economic and environmental performance. It is shown that the proposed approach identifies considerable improvements for the process.