Process for reforming a hydrocarbon feedstock comprising paraffins and naphthenes. A hydrocarbon feedstock is contacted with a first reforming catalyst in a first reactor at a temperature and pressure that facilitates conversion of naphthenes to aromatics while converting less than 50 wt. % of paraffins in the feedstock to olefins, thereby producing a first effluent that is separated into a first fraction that is enriched in aromatics and a second fraction that is enriched in paraffins. The second fraction is contacted with a second reforming catalyst in a second reactor at a temperature and pressure that converts at least 50 wt. % of paraffins in the second fraction to olefins. The process produces a liquid hydrocarbon reformate product suitable for use as a blend component of a liquid transportation fuel.

Process for reforming a hydrocarbon feedstock comprising paraffins and naphthenes. A hydrocarbon feedstock is contacted with a first reforming catalyst in a first reactor at a temperature and pressure that facilitates conversion of naphthenes to aromatics while converting less than 50 wt. % of paraffins in the feedstock to olefins, thereby producing a first effluent that is separated into a first fraction that is enriched in aromatics and a second fraction that is enriched in paraffins. The second fraction is contacted with a second reforming catalyst in a second reactor at a temperature and pressure that converts at least 50 wt. % of paraffins in the second fraction to olefins. The process produces a liquid hydrocarbon reformate product suitable for use as a blend component of a liquid transportation fuel.

Systems and methods are provided for performing multistage naphtha reforming with intermediate separation of aromatics using a swing adsorption process. Use of a swing adsorption process can allow aromatics to be selectively removed from the intermediate reforming effluent while reducing or minimizing the energy costs for cooling and subsequent reheating of the intermediate reforming effluent. The resulting aromatics-rich stream generated from swing adsorption can have a substantially higher aromatics content than an aromatics-rich stream generated by conventional separation methods during multi-stage naphtha reforming. In some aspects, selective thermal purging (either hot or cold) can be used to further facilitate adsorption or desorption of components by the adsorbent in the swing adsorption vessel.

A process for operating a reforming system by operating a reforming section containing a plurality of reactors, wherein each of the plurality of reactors containing a reforming catalyst capable of catalyzing the conversion of at least a portion of the hydrocarbons in a treated hydrocarbon stream into a reactor effluent comprising aromatic hydrocarbons, and operating a sulfur guard bed (SGB) to remove sulfur and sulfur-containing hydrocarbons from a hydrocarbon feed to provide the treated hydrocarbon stream, where the SGB contains at least a layer of a SGB catalyst comprising the same catalyst as the reforming catalyst, and where each reactor of the plurality of reactors within the reforming section may be operated at a higher operating temperature than an operating temperature of the SGB. A system for carrying out the process is also provided.

The invention provides a process for producing hydrogen for a hydrogen consuming process comprising obtaining a net gas stream containing hydrogen, compressing the gas stream to a pressure of 20.7 to 68.9 bar (300 to 1000 psig) to produce a compressed gas stream; sending the compressed gas stream to a pressure swing adsorption unit to be separated into a hydrogen stream and a fuel gas stream; purging the pressure swing adsorption unit with an external purge gas stream from a hydroprocessing unit off gas; treating the off gas with a thermal swing adsorption unit to remove water and other impurities prior to purging the pressure swing adsorption unit, and using a protective adsorbent layer in the pressure swing adsorption unit to adsorb impurities from the external purge gas.

The invention provides a process for producing hydrogen for a hydrogen consuming process comprising obtaining a net gas stream containing hydrogen, compressing the gas stream to a pressure of 20.7 to 68.9 bar (300 to 1000 psig) to produce a compressed gas stream; sending the compressed gas stream to a pressure swing adsorption unit to be separated into a hydrogen stream and a fuel gas stream; purging the pressure swing adsorption unit with an external purge gas stream from a hydroprocessing unit off gas; treating the off gas with a thermal swing adsorption unit to remove water and other impurities prior to purging the pressure swing adsorption unit, and using a protective adsorbent layer in the pressure swing adsorption unit to adsorb impurities from the external purge gas.

Spent aromatization catalysts containing a transition metal and a catalyst support are selectively poisoned in the disclosed reforming methods, resulting in improvements in overall aromatics yield and selectivity.

Spent aromatization catalysts containing a transition metal and a catalyst support are selectively poisoned in the disclosed reforming methods, resulting in improvements in overall aromatics yield and selectivity.

A naphtha reforming reactor system comprising a first reactor comprising a first inlet and a first outlet, wherein the first reactor is configured to operate as an adiabatic reactor, and wherein the first reactor comprises a first naphtha reforming catalyst; and a second reactor comprising a second inlet and a second outlet, wherein the second inlet is in fluid communication with the first outlet of the first reactor, wherein the second reactor is configured to operate as an isothermal reactor, and wherein the second reactor comprises a plurality of tubes disposed within a reactor furnace, a heat source configured to heat the interior of the reactor furnace; and a second naphtha reforming catalyst disposed within the plurality of tubes, wherein the first naphtha reforming catalyst and the second naphtha reforming catalyst are the same or different.

A naphtha reforming reactor system comprising a first reactor comprising a first inlet and a first outlet, wherein the first reactor is configured to operate as an adiabatic reactor, and wherein the first reactor comprises a first naphtha reforming catalyst; and a second reactor comprising a second inlet and a second outlet, wherein the second inlet is in fluid communication with the first outlet of the first reactor, wherein the second reactor is configured to operate as an isothermal reactor, and wherein the second reactor comprises a plurality of tubes disposed within a reactor furnace, a heat source configured to heat the interior of the reactor furnace; and a second naphtha reforming catalyst disposed within the plurality of tubes, wherein the first naphtha reforming catalyst and the second naphtha reforming catalyst are the same or different.