How do we prevent the hf alkylation reactor from corrosion. Motor fuel markets worldwide demand gasoline with lower volatility, olefinicity, and aromaticity, while retaining high octane ratings. Development of a alkyclean solid acid catalyst solid acid. The light hydrocarbons consist of olefins such as propylene and butylene and isoparaffins such as isobutane. Inherently safer than liquid acid technologies, particularly hf. The major riskrelated differences of sulfuric acid and hf as a catalyst in the alkylation unit lies in each compounds volatility. The effluent stream is mixed with recycle stream of polypropylbenzenes and passed into transalkylation reactor where it reacts with excess benzene and convert into cumene. The hf process only creates a small amount of organofluorine side products which are continuously removed from the reactor and the consumed hf is replenished.
The design is intended to resemble the new liquidphase eb process offered by lummus crest, which uses a zeolite catalyst developed by unocal. Reactorregenerator system joint work optimization in. This course is also intended to educate personnel about the chemical properties of hf. Application of hazop, lopa and sil to the alkylation unit. Chemical kinetics is the study of rate and mechanism by which one chemical species is converted to another. And fouling dupont book pdf free download link or read online here in pdf. The introduction of a water cooled reactor takes advantage of the lighter gravity of hf catalyst and higher process operating. As of december 2006, the online acid analysis system is installed in almost 20 hf alkylation units worldwide and has a combined operating history of process collaboration hydrofluoric acid alkylation. The alkyclean process employs a zeolite catalyst coupled with a novel reactor. Fundamentals hf alkylation process implementation seminar course overview course number. When combining a selective hydrogenation process with an hf alkylation process, it is necessary to remove light gases such as ethane, methane, and hydrogen from the hydrogenation unit effluent before it is charged to the alkylation unit. Exelus has developed an innovative isoparaffin alkylation technology exsact, as an economically viable alternative to hf h2so4 processes. May 28, 2014 the publication recommends that access to an hf alkylation unit be restricted due to the potential hazards of hf.
In any manufacturing process where there is a chemical change. Cdalky breaks the lowtemperature barrier through innovative reactor design. Hf alkylation systems are licensed by both phillips petroleum co. Lecture 9 reactor sizing chemical kinetics is the study of chemical reaction rates and reaction mechanisms. Uop hf alkylation the uop hf alkylation direct alkylation process catalytically combines light olefins such as propylene, butylene or amylene with isobutane to increase their value and make an environmentally sound alkylate product for highoctane gasoline blending. This work deals with the suspension catalytic distillation scd column used for synthesis of c12 alkylbenzene with. How do we prevent the hf alkylation reactor from corrosion at. The mixture is fed to the reactor, where it is highly dispersed into an incoming stream of acid catalyst. By careful selection of the operating conditions, a high proportion of products can fall in the gasoline boiling range with motor octane. The alkylation reaction takes place combining the olefins with the isobutane to form the. The author uses the principles in his book, refinery process modeling, to present a stepwise, simulatorindependent model building procedure. Alkylation alkylation combines lowmolecularweight olefins primarily a mixture of propylene and butylene with isobutene in the presence of a catalyst, either sulfuric acid or hydrofluoric acid.
No similar specification was recommended for sulfuric acid alkylation. In the liquidphase process the alkylation reactor operates at higher pressure but lower temperature than the vaporphase alkylation process. Alkylation technology study final report south coast air. We are facing a typical problem of increased pressure drop of hf stripper feed side of hf stripper feed exchanger after the startup. Alkylate is a premium gasoline blending component alkylation capacity steadily increased annually since 1980s due to gasoline specifications high octane number isooctane. The typical hydrofluoric acid hf alkylation unit requires far less acid than a sulfuric acid unit to achieve the same volume of alkylate. Otherwise the light ends will require venting of the hf alkylation unit with resulting hf acid losses.
Stratco contactor reactor for sulfuric acid alkylation. Hydrogen fluoride gas 4000 gramton alkylate alkyclean solid acid solid design parameters and reliable scaleup demonstration unit. Mhf alkylation safe operations at the torrance refinery. Thus i wanna give it a shot to simulate this reactor using aspen custom modeler.
Commit to ending the use of hf alkylation an d replacing it with safer alternatives as soon as possible. New technology for analyzing hf alkylation processes. Hydrofluoric acid alkylation conversion and expansion. Sana alkylation alkylation combines lowmolecularweight olefins primarily a mixture of propylene and butylene with isobutene in the presence of a catalyst, either sulfuric acid or hydrofluoric acid. Olefin and isobutane feed streams are dried to remove water before they are mixed with the isobutane recycle stream.
Today, the cumene is used almost exclusively for manufacturing phenol and acetone. Alkylation reactor converts benzene and propylene to cumene. Through lecture, exercises, and discussion, participants will gain an understanding of the hf alkylation process and. Fundamentals ccr platforming process standard for cyclemax and atmospheric implementation seminar course participants will learn the principles of catalyst regeneration and the regeneration tower operation, including how to optimize catalyst performance and maximize catalyst life. The two main principles involved in establishing conditions for performing a reaction are chemical kinetics and thermodynamics. This article outlines the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to define an operating envelope. The uop hf alkylation process, created in 1941, catalytically combines light olefins propylene, butylenes and amylenes with. Fundamentals hf alkylation process implementation seminar course uop0001s. The hf alkylation reaction mixture is composed mainly of hf. Kellogg corporation cascade reactor were bubbled up through liquid hf.
Uop approved hf1, hf10, hf2, hf20, hf4, hf40, hf5, hf50. Alkylation of benzene by propylene to cumene 173 6 6. Triple offset valve tov formally approved by uop in august 2015 for hf alkylation service. Superior refinery hf alkylation unit animation duration. Alkylation reactions are catalyzed by strong acids i. A typical hf alkylation system is shown in figure 2. Alkylation and polymerization process alkene gasoline. The tov design is considered the future replacement valve for gate valves 8. Alkylation, in petroleum refining, chemical process in which light, gaseous hydrocarbons are combined to produce highoctane components of gasoline. This phenomena is seen twice after the exchanger was hydrojetted. Energy information administration in practice only isobutane is used because isopentane. Thermodynamics is an engineering fundamental having various applications for the chemical reactor design.
These compounds are fed into a reactor, where, under the influence of a sulfuricacid or. Alkylation unit processes chemical process engineering. Hydrofluoric acid hf was developed in the 1700s and has been used in manufacturing for over. A unique solidacid catalyst that converts light hydrocarbons into alkylates and 2. Reactor performance depends on important parameters such as reaction kinetics and thermodynamics, reactor configurations, production of desired products, heat transfer and materials of construction. Study on the alkylation of benzene and 1dodecene request pdf. This process can deviate from steadystate operation because of the large isobutane inventory and the asneeded addition of makeup isobutane. The failure of even a small piece of piping is a big problem when the unit is started up. Low temperature alkylation maximizes selectivity, octane value, and yield 1,2.
Petroleum refining design and applications handbook wiley. Breaks the lowtemperature barrier through innovative reactor design. Simple flowsheet for modified hf alkylation technology. Cabezas, designing sustainable processes with simulation. Invistigation on alkylation process sust repository.
The product is called alkylate and is composed of a mixture of highoctane, branchedchain paraffinic hydrocarbons. Isobutane and c 3 c 4 olefins are produced as byproducts from fcc and other catalytic and thermal conversion processes in a. Alkylate is the reactor product, isooctane or isoheptane to be separated as the isostripper bottom product. Hi guys, i am trying to simulate a sulfuric acid alkylation reactor unit in hysys but the current available reactor model is not robust enough based on the complexity of the sulfuric alkylation reaction it. Thus i wanna give it a shot to simulate this reactor using aspen custom modeler but i have to. The process occurs in the presence of an acid such as sulfuric acid h 2 so 4 or hydrofluoric acid hf as catalyst. Simulation on alkylation reactor sulfuric alkylation.
Alkylate is a premium gasoline blending component alkylation capacity steadily increased annually since 1980s due to gasoline specifications high octane number isooctane 100 low vapor pressure less volatile. The uop hf alkylation process is used in more than 150 refineries worldwide. This problem demonstrates the principles in modeling a hydrofluoric acid alkylation unit. In this method, an hf alkylation unit having an hf stripper downstream of the hf alkylation reactor is modified to a benzene rectifier. World war ii for aviation gasoline, hf alkylation and sulfuric acid alkylation, are the focus of this. Louisiana refining division if applicable hf alkylation unit training.
For hf alkylation, the reaction temperature is less significant and is between 21 and 38 c 70 and 100 f. Fundamentals engineering design seminar eds implementation course participants will learn the fundamentals of refining process design. The effect of operating conditions on corrosion in hf. Hf alkylation unit developed fel2fel3 packages and the bid package for detailed engineering for uop alkylation unit retrofitted with split olefin feed technology soft reactor for a revamp project to handle increased capacity and to handle a shift in the reactor feed composition. The study of chemical reaction engineering cre combines the study of chemical kinetics with the reactors in which the reactions occur. Simulation on alkylation reactor sulfuric alkylation posted in chemical process simulation.
For all irreversible reactions of greater than zero order, the volume of the reactor approaches. An alkylation unit alky is one of the conversion processes used in petroleum refineries. Water dissolves in hf undergoing the following dissociation reaction. Ic4 is one of the two main alkylation ingredients, supplied to the reactor in great excess and must be evaporated into the isostripper accumulator to be recycled to the reactor. The second conversion option using a novel reactor design is also suitable for both gravityflow and pumpedflow hf alkylation units. The reaction mixture is processed through the alkylation reactor at a rate to allow an average residence time therein of from about 0. By modifying the hf stripper, this invention not only makes use of the existing hf stripper but also allows the entire downstream product. Hydrofluoric acid alkylation 1 the hf alkylation unit operational objectives maximize thoughput olefin feed makeup ic4. Pdf environmental assessment of hf alkylation process using. Alkylation and isomerization advances in chemistry acs. The process combines an unsaturated light hydrocarbon with isobutane to produce alkylate. In the meantime, existing alkylation units can and must be made safer. Two hydrofluoric acid hf alkylation processes are commonly available. This included sample system design, metallurgy considerations and model development.
Uop hf alkylation the uop hf alkylation direct alkylation process catalytically combines light olefins such as propylene, butylene or amylene with isobutane to increase their value and make an environmentally sound. A method of converting an hf alkylation process into a solid catalyst alkylation process is disclosed. Concentrated hydrofluoric acid hf is then mixed in and fed to the reactor. Catalyst is separated from the organic compounds by a water wash in a separator.
Alkylation and dealkylation in industrial processes. Fixedbed alkylation using slptype catalyst in a chromatographictype reactor concept. Basic objectives in design of a reactor in chemical engineering physical operations such as fluid flow, heat transfer, mass transfer and separation processes play a very large part. A novel fixedbed reactor that is designed to enhance the performance of this. Hf alkylation and selective hydrogenation process uop inc. The louisiana refining division requires hf alkylation unit training for personnel engaged in entering the refinerys hydrofluoric acid alkylation unit hf alky unit and performing work in affiliation with equipment in hf service. Pdf alkylation process is essential for fuel upgrading via alkylate production. Alkylation reactor converts benzene and propylene to cumene and diisopropylbenzene. Alkylation reactor converts benzene and propylene to. Furthermore, there is always the risk of leaving something full of acid in a large, complex system like an entire hf alkylation unit.
I am working in a hf alkylation unit for detergent intermediates. The publication recommends that access to an hf alkylation unit be restricted due to the potential hazards of hf. Mar 11, 2015 alkylation and dealkylation in industrial processes reactor engineering class 148. Closed open dib tower light ends separation alkylation reactor no. Alkylation and dealkylation in industrial processes reactor engineering class 148. The alkylation process combines light isoparaffins, most commonly isobutane, with c 3 c 4 olefins, to produce a mixture of higher molecular weight isoparaffins i. Study on the alkylation of benzene and 1dodecene article in chemical engineering journal 933. Corrosion and fouling in hf alkylation units are closely linked to feed quality and operating conditions. Exelus has developed an innovative isoparaffin alkylation technology exsact, as an economically viable alternative to hfh2so4 processes. Alkycleans unique catalyst, reactor design and process scheme allow operation at low external isobutenetoole. Performance of alkylation process a schematic diagram of the alkylation process is shown in figure below the feed to the reactor consists of olefin v1 bpd and a fresh acid makeup of m. It is used to convert isobutane and lowmolecularweight alkenes primarily a mixture of propene and butene into alkylate, a high octane gasoline component. Sep 27, 1988 when combining a selective hydrogenation process with an hf alkylation process, it is necessary to remove light gases such as ethane, methane, and hydrogen from the hydrogenation unit effluent before it is charged to the alkylation unit.
Fouling in hf alkylation units chemical plant design. The two most commonly used reactor systems which grew out of the reactor development work for h2so4 alkylation are the stratford engineering companys stratco contactor and the m. Finally, acid cleanings leave carbon steel surfaces in a very active. Low temperature alkylationmaximizes selectivity, octane value, and yield 1,2 3050% lower acid consumption. Alkylate is a premium blending stock because it has. Invensys foxboro electrolytic conductivity sensors are a proven approach to online water determination in hf. Low temperature cd alky breaks the lowtemperature barrier through innovative reactor design. Hf alkylation unit components feed system hf alkylation reactor acid regeneration acid dump system fractionation product treating key controlled and operating variables feed flow control feed drying isobutane toolefin ratio acid strength water in acid phase reactor temperature contact time. Isoalky technology is commercially viable alternative.
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