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No / In this paper, a model of catalytic naphtha reforming process of commercial catalytic reforming unit of Kaduna Refining & Petrochemical Company (KRPC) is adopted and simulated using the gPROMS software, an equation-oriented modelling software. The kinetic and thermodynamic parameters and properties were obtained from literature. The model was used to monitor the behaviour of the temperature and concentrations of parafins, naphthenes and aromatics with respect to the changing heights of the reactors. A comprehensive sensitivity analysis of the product quality (Aromatics) and product yield, reformate, lighter gases and hydrogen yields is performed by varying the operating conditions of the reaction and the following conclusions were made. It was found that the production of aromatics, hydrogen yield, lighter gases and coke on catalyst increase with increasing temperature of the reaction while the reformate yield decreases with the increasing temperature and vice versa. The aromatics, hydrogen yield, coke on catalyst and lighter gases decrease with increasing pressure while the reformate yield decreases with decreasing pressure and vice versa. Hydrogen-hydrocarbon ratio (HHR) affects the product quality slightly by increasing the reformate and hydrogen yield and decreasing the aromatics slightly as well decreasing the coke on catalyst.

This dissertation includes two accounts of rigorous modeling of petroleum refinery modeling using rigorous reaction and fractionation units. The models consider various process phenomena and have been extensively used during a course of a six-month study to understand and predict behavior. This work also includes extensive guides to allow users to develop similar models using commercial software tools. (1) Predictive Modeling of Large-Scale Integrated Refinery Reaction and Fractionation Systems from Plant Data: Fluid Catalytic Cracking (FCC) Process with Planning Applications: This work presents the methodology to develop, validate and apply a predictive model for an integrated fluid catalytic cracking (FCC) process. We demonstrate the methodology by using data from a commercial FCC plant in the Asia Pacific with a feed capacity of 800,000 tons per year. Our model accounts for the complex cracking kinetics in the riser-regenerator and associated gas plant phenomena. We implement the methodology with Microsoft Excel spreadsheets and a commercial software tool, Aspen HYSYS/Petroleum Refining from Aspen Technology, Inc. The methodology is equally applicable to other commercial software tools. This model gives accurate predictions of key product yields and properties given feed qualities and operating conditions. This work differentiates itself from previous work in this area through the following contributions: (1) detailed models of the entire FCC plant, including the overhead gas compressor, main fractionator, primary and sponge oil absorber, primary stripper and debutanizer columns; (2) process to infer molecular composition required for the kinetic model using routinely collected bulk properties of feedstock; (3) predictions of key liquid product properties not published alongside previous related work (density, D-86 distillation curve and flash point); (4) case studies showing industrially useful applications of the model; and (5) application of the model with an existing LP-based planning tool. (2) Predictive Modeling of Large-Scale Integrated Refinery Reaction and Fractionation Systems from Plant Data: Continuous Catalyst Regeneration (CCR) Reforming Process: This work presents a model for the rating and optimization of an integrated catalytic reforming process with UOP-style continuous catalyst regeneration (CCR). We validate this model using plant data from a commercial CCR reforming process handling a feed capacity of 1.4 million tons per year in the Asia Pacific. The model relies on routinely monitored data such ASTM distillation curves, paraffin-napthene- aromatic (PNA) analysis and operating conditions. We account for dehydrogenation, dehydrocyclization, isomerization and hydrocracking reactions that typically occur with petroleum feedstock. In addition, this work accounts for the coke deposited on the catalyst and product recontacting sections. This work differentiates itself from the reported studies in the literature through the following contributions: (1) detailed kinetic model that accounts for coke generation and catalyst deactivation; (2) complete implementation of a recontactor and primary product fractionation; (3) feed lumping from limited feed information; (4) detailed procedure for kinetic model calibration; (5) industrially relevant case studies that highlight the effects of changes in key process variables; and (6) application of the model to refinery-wide production planning. / Ph. D.

Biomass gasification offers the chance to produce carbon neutral, renewable fuels. One of the main problems facing the commercialization of biomass gasification technology is the presence of large quantities of methane and carbon dioxide in the biogas. Catalytic reforming of these wastes allows for effective utilization of biomass derived syngas. In most reforming studies, impregnation methods are the primary synthesis technique. Impregnation methods often lead to poor dispersion and are un-reproducible from batch to batch. In the development of a novel catalyst for reforming applications, another preparation method is implemented, controlled adsorption (CA). Ni/Al2O3 and Co/Al2O3 prepared by CA are compared against catalysts that were prepared by a more traditional method, dry impregnation (DI). It is found that controlling the metal deposition provides catalysts with higher dispersion and consequently higher activity for methane dry reforming. NiAl2O4 catalysts prepared by Pechini synthesis were also studied for catalytic conditioning of biomass derived syngas. Physicochemical characterization revealed unique structural properties, indicated a high degree of mobility of nickel in the aluminate structure, and demonstrated the regeneration properties of nickel aluminates under harsh reaction conditions, which will be important at extended reaction times when catalyst regeneration becomes necessary. Fourfold coordinated nickel species are believed to be responsible for high, stable methane dry reforming activity and metallic nickel is believed to be the active site that allows for high, stable conversion during methane dry reforming.

This work presents a techno-economic analysis of multiple direct hydrogen production technologies using different blends of Arabian crude oil and natural gas as feedstock: Auto thermal reforming, steam reforming, and combined reforming technologies are thermodynamically and technically evaluated through development of process flowsheets. Comparative analysis indicates that combined reforming using Arabian light crude oil achieves a 22.69 % of hydrogen recovery with carbon capture, which is higher than auto thermal reforming and steam reforming by 0.7 %. At the same time, auto thermal reforming achieves a 26.70 % of hydrogen recovery without carbon capture, which is higher than steam reforming and combined reforming by 4 %. Arabian heavy, medium, light, and extra light are evaluated using auto thermal reforming technology to estimate hydrogen recovery values. A wide range of crude oil and natural gas prices are included in the analysis to calculate hydrogen production cost. With crude oil price at 90 USD/bb, the hydrogen production cost is 2.9 USD/kg, and natural gas prices at 30 USD/MMBtu (Europe), 20 USD/MMBtu (Japan), and 2.5 USD/MMBtu (GCC region), the hydrogen production cost is 4.5, 3.0, and 0.4 USD/kg respectively.

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Although current trends in global warming are of great concern, energy demand is still increasing, resulting in increasing pollutant emissions. To address this issue, we need reliable renewable energy sources, lowered pollutant emissions, and efficient and profitable processes for energy conversion. We also need to improve the use of the energy, produced by existing infrastructure. Consequently, the work presented in this thesis aims at investigating current scientific and technological challenges in energy conversion through biomass gasification and the alternative use of fossil fuels, such as diesel, in the generation of cleaner electricity through auxiliary power units in the transport sector. Production of chemicals, syngas, and renewable fuels is highly dependent on the development and innovation of catalytic processes within these applications. This thesis focuses on the development and optimization of catalytic technologies in these areas. One of the limitations in the commercialization of the biomass gasification technology is the effective catalytic conversion of tars, formed during gasification. Biomass contains high amounts of alkali impurities, which pass on to the producer gas. Therefore, a new material with alkali tolerance is needed. In the scope of this thesis, a new catalyst support, KxWO3 – ZrO2 with high alkali resistance was developed. The dynamic capability of KxWO3 – ZrO2 to store alkali metals in the crystal structure, enhances the capture of alkali metals "in situ". Alkali metals are also important electronic promoters for the active phase, which usually increases the catalysts activity and selectivity for certain products. Experimental results show that conversion of 1-methylnaphathalene over Ni/KxWO3 – ZrO2 increases in the presence of 2 ppm of gas-phase K (Paper I). This support is considered to contribute to the electronic equilibrium within the metal/support interface, when certain amounts of alkali metals are present. The potential use of this support can be extended to applications in which alkali "storage-release" properties are required, i.e. processes with high alkali content in the process flow, to enhance catalyst lifetime and regeneration. In addition, fundamental studies to understand the adsorption geometry of naphthalene with increasing temperature were performed in a single crystal of Ni(111) by STM analyses. Chapter 9 presents preliminary studies on the adsorption geometry of the molecule, as well as DFT calculations of the adsorption energy. In relation to the use of clean energy for transport applications, hydrogen generation through ATR for FC-APUs is presented in Papers II to V. Two promoted RhPt bimetallic catalysts were selected in a previous bench scale study, supported on La2O3:CeO2/d – Al2O3 and MgO : Y2O3/CeO2 – ZrO2. Catalyst evaluation was performed in a fullscale reformer under real operating conditions. Results showed increased catalyst activity after the second monolithic catalyst due to the effect of steam reforming, WGS reaction, and higher catalyst reducibility of the RhxOy species in the CeO2 – ZrO2 mixed oxide, as a result of the improved redox properties. The influence of sulfur and coke formation on diesel reforming was assessed after 40 h on stream. Sulfur poisoning was evaluated for the intrinsic activity related to the total Rh and Pt area observed after exposure to sulfur. Sulfur concentration in the aged catalyst washcoat was observed to decrease in the axial direction of the reformer. Estimations of the amount of sulfur adsorbed were found to be below the theoretical equilibrated coverage on Rh and Pt, thus showing a partial deactivation due to sulfur poisoning. / <p>QC 20150213</p>

published_or_final_version / abstract / Chemistry / Doctoral / Doctor of Philosophy

Carbon dioxide reforming, or drying reforming, of methane can now be used in new applications such as landfill gas utilization where CO and CH need to be converted to a mixture of CO and H, called synthesis gas or syn-gas. A novel Ni-Co/AlMgO bimetallic powder catalyst was developed in previous research for dry reforming of methane (DRM) process which can eliminate carbon deposition. But it is difficult242x to apply this loose-powder catalyst in industrial scale. The procedure of making spherical Ni-Co/AlMgOx bimetallic catalyst supported on BASF CSS-350 alumina balls (BASF Catalysts LLC) using impregnation method with different impregnation steps and calcination steps is explained in this thesis. For every batch of preparation, the concentration of metal solution was calculated based on different impregnation steps. BET (Brunauer-Emmett-Teller) analysis, compressive strength test, XANES (X-ray Absorption Near-Edge Structure) measurement and ICP-MS (Inductively Coupled Plasma Mass Spectrometry) analysis are conducted to understand the physical and chemical properties of the catalyst. It is found that both impregnation steps and calcination steps have great influence on the performance of the prepared catalyst samples. Among all the catalysts prepared, BF-4-0.25(MgNiCo)-C, which was made by using 4 impregnation-calcination cycles, shows the best activity and stability for 160 h time-on stream (TOS) under the reaction condition of 0.10 g catalyst loading, 750 oC, ambient pressure, GHSV=100,000 ml/gc·h, and CH4/CO2/N2 = 1/1/1. The CH4 conversion started at 66.7% and slowly dropped to 52.8% after 160 hours. I I BF-4-0.25(MgNiCo)-C spherical catalyst shows lower reaction rate compared to the loose powder format but shows compatible or higher activity to other two reported catalysts in similar compositions. Most importantly, it is a shaped catalyst ready for industrial use.