Yield and energy optimization of the continuous catalytic regeneration reforming process based particle swarm optimization

Yield and energy optimization based particle swarm optimization of the reforming process was carried out to maximize the reformate and energy saving in order to perform the process improvement. Data from the existing process was extracted, and then a development of the mathematical model that represented the full process was investigated. The analysis showed two enormous opportunities for enhancing productivity via the improvement of the reactions network and separation process, and for energy saving at the heat exchangers network via pinch analysis approach. Improvements analyses of the existing process to achieve the optimum yield of reformate included modifications of inlet temperature, inlet pressure and molar ratio hydrogen to hydrocarbon according to enhancement in the process from 93.91% to 94.46%. The maximum energy savings of heat exchangers network indicated that reduction of utilities around 16.20%, which led to an addition to an incremental area according to the reduction in ΔTmin from 80.3 K to 65 K to the existing heat exchangers. The final evaluation of yield-energy optimization of the modified process indicated an enhancement of productivity by 8700 t/y and the energy saving around 99.81 GJ/h, which led to a process profit increment of approximately USD$ 6.03 M/y. •Yield and energy optimization of the CCRRP were conducted as a new method.•Particle swarm optimization coupled with pinch analysis approach was implemented.•Maximum yield reached to 94.51% and maximum energy savings was around 16.20%.•Optimal modifications of pressure, temperature and molar ratio H/HC were estimated.•Evaluation of the CCRRP indicated the profit of approximately USD$ 6.03 million/year.