ppPLUS: Technologies and more


Go to Homepage to browse companies and process data

ppPLUS-Solutions providing Services and Support

Register creating your own models

Name
UOP CCR Platforming
Owner
/ Honeywell UOP
Brand
UOP CCR Platforming™
Process
Fuel Processes
Type
Catalytic Reforming
Available
Description

The CCR Platforming™ process is a continuous catalytic reforming technology developed by Honeywell UOP to convert low-octane naphtha into high-octane gasoline blending components and aromatics for petrochemical production, while generating hydrogen as a byproduct. This process enabled lead-free gasoline production through its innovative continuous catalyst regeneration system.

Process Overview (illustration)

  1. Feed Preparation

    Hydrotreated naphtha feed (C6-C11 hydrocarbons) is combined with recycled hydrogen gas and preheated in a combined feed exchanger using reactor effluent heat.
     
  2. Reactor Section
     
    • Uses 3-4 vertically stacked radial-flow reactors with platinum-based catalyst
    • Endothermic reactions require interheaters between reactors to maintain 480-525°C reaction temperatures
    • Key reactions occur through dual-function catalyst (acid and metal sites) — Fig. 1:
      • Dehydrogenation of naphthenes to aromatics
      • Isomerization of paraffins
      • Dehydrocyclization of paraffins to aromatics
         
  3. Product Separation

    Reactor effluent is cooled and separated in a gas-liquid separator:
    • Vapor phase: Hydrogen-rich gas (65-90% purity) partially recycled, remainder sent to refinery hydrogen network
    • Liquid phase: Sent to stabilizer column to remove light ends, producing high-octane reformate (RON 100-106)

Figure 1 - UOP CCR Platforming Generalized Reaction Scheme.

Continuous Catalyst Regeneration (CCR) System

The defining feature enabling continuous operation:

  • Spent catalyst (0.5-1.5% coke) flows by gravity from reactor stack to regenerator
  • Regeneration steps:
    1. Coke combustion (500-550°C)
    2. Oxychlorination to redisperse platinum
    3. Drying and reduction
  • Regenerated catalyst (0.02% residual coke) returns to top reactor
  • Maintains constant activity with <0.1 RON octane drop over 10+ years

Key Advantages

  • Operational Efficiency
    "98% on-stream factor vs 90-92% for semi-regenerative units"
  • Yield Optimization
    3-5% higher liquid yield and 30-50% more hydrogen vs semi-regenerative systems
  • Feed Flexibility
    Processes paraffinic and cracked naphthas that would rapidly deactivate conventional catalysts
  • Environmental Impact
    Enabled elimination of lead additives from gasoline through high-octane reformate production

Technical Specifications

Parameter Value/Range
Operating pressure 3-10 bar(g)
Reactor temperature 480-525°C
Catalyst circulation 100-600 kg/h
Hydrogen production 300-600 Nm³/ton feed
Reformate yield 82-86 wt%


Commercial Experience

First commercialized in 1971, over 380 CCR Platforming units have been licensed globally, processing more than 6 million barrels per day. Recent advancements include improved chloride management systems and R-234 catalyst introduced in 2020, achieving 99% of theoretical maximum reforming efficiency.

References

  1. Edward R. Morgan, Jan 2021, Fifty years of CCR platforming, Honeywell UOP.
  2. UOP4523-2b, Sep 2016, UOP CCR Platforming Motor Fuel Datasheet, Honeywell UOP.
  3. Dorr Dikora, 14th May 2013 (last published), CCR Platforming PDF, retrieved via the Web Archive.
Link
System Info

Updated by
UserPic  Kokel, Nicolas
Updated
4/25/2025 8:31 AM
Added by
UserPic  Kokel, Nicolas
Added
11/24/2024 2:14 PM
Solutions
Solutions

Solution-Reference:

#T280

No Services yet available. Go to Solutions to enquire how we can help you or how you can market your own expertise.
Enquire in Solutions how we can help you.

Copyright
CCR Platforming Process