Alkylation Unit

The alkylate is a robust blending component (10-20%) due to lower RVP & sulfur, no aromatics & olefins and high octane – RON maximum 96 for C4= feed / 94 for C3=/C4+ feed and RVP under 0.5 bara. 1. HF Alkylation, not so popular anymore due to toxic aerosol formation, corrosion and HF / Fluorides need to be removed from LPG fraction. Technical info: - Reactor: shell & tube heat exchanger - Cooling by water through tubes of shell and tube heat exchanger - Reaction temperature 25 to 38°C - Reaction pressure 7.0 – 8.0 barg - Reaction phase acid continuous emulsion - Isobutane/olefin ratio 12:1 to 14:1 - Acid/hydrocarbon ratio 50% / 50% - Acid consumption rate 0.1 to 0.2 kg / m3 alkylate - Olefin space velocity 0.3 to 0.5 hr-1 - Alkylate Yield 0.25-0.28 m3 alkylate / m3 olefin (C3/C4 mix) 2. H2SO4 Alkylation, more CAPEX involved due to refrigeration, higher energy & catalyst consumption, but less corrosive and no aerosol formation, tolerates dirty feeds. Technical info: - Reactor: Multiple CSTRs in-series for CDAlky or Vertical reactor with static mixer for Exxon or shell & tube heat exchanger with mixing impeller and circulation tube by Stratco - Cooling by refrigerant mixed by static mixer or autorefrigeration or indirect effluent refrigeration – CDAlky / Exxon / Stratco - Reaction temperature to CDAlky lower than 0°C and Exxon / Stratco = 4.5-10°C - Reaction pressure 0.5 – 4.0 barg - Reaction phase acid continuous emulsion - Isobutane/olefin ratio 8:1 - Acid/hydrocarbon ratio 50% / 50% - Acid consumption rate 45 to 75 kg / m3 alkylate - Olefin space velocity 0.2 to 0.3 hr-1 - Alkylate Yield 0.28 m3 alkylate / m3 olefin (C3/C4 mix) 3. Solid Alkylation: Technical info / K-Saat: - Reactor: Multistage fixed bed reactors - Catalyst zeolite - Reaction temperature 60 to 70°C - Reaction phase liquid - Isobutane/olefin ratio 8:1 to 15:1 - Catalyst regeneration by hydrogen from Reformer - Cycle time 16-24 h - Alkylate Yield 0.30 m3 alkylate / m3 olefin - KBR states that CAPEX is 40% from a H2SO4 Alkylation Unit 4. Ionic liquid Alkylation: UOP is saying that the catalyst consumption is 400 times lower than H2SO$ Technical info / UOP: - Reactor: static mixer & settler - Catalyst Ionic liquid - Reaction temperature 1.0 to 49°C - Reaction pressure 5.1 – 18.5 barg - Reaction phase hydrocarbon continuous phase with droplets of ionic liquid catalyst - Isobutane/olefin ratio 6:10 - Catalyst regeneration: online regeneration converts conjunct polymer into saturated hydrocarbons with gasoline boiling range called “regen naphtha” and lighter hydrocarbons classified as LPG - Alkylate Yield 0.31 m3 alkylate / m3 olefin (C3/C4 mix) It is worth to mention that conversion of HF to H2SO4 could be 4500-5000 $ / BPD. eBook: - https://lnkd.in/e9-VJ6b - https://lnkd.in/evN6h_w - https://lnkd.in/eF4KWM9 - https://lnkd.in/eUcR2kk Enjoy! #innovation #sustainability #processengineering #research #energy #training #technology #business #engineering