Technology

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

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, 14^th May 2013 (last published), CCR Platforming PDF, retrieved via the Web Archive.