Chemical reaction and reactor design begins with a discussion of chemical reactions, emphasizing chemical equilibrium and rate of reaction and proceeds to the theory and practice of heat and mass transfer, and important considerations in the design of chemical reactors. Petroleum refining design and applications handbook wiley. Vice president operations jonathan bayhi 225 7479565 email protected learn more. Fundamentals of petroleum refining pages 251 300 text.
A method of converting an hf alkylation process into a solid catalyst alkylation process is disclosed. The typical hydrofluoric acid hf alkylation unit requires far less acid than a sulfuric acid unit to achieve the same volume of alkylate. Materials selection in hfalkylation units is mostly based on long time experience. 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. Fouling in hf alkylation units chemical plant design. Pdf modelling and simulation of benzene alkylation process. Procedia chemistry 10 2014 547 a 554 551 as each har molecule can deactivate 2 moles of acid, catalyst relative activity dependence on har content in the reactor is linear and is written as follows. Cenco refining licenses phillips revap alkylation technology.
Furthermore, there is always the risk of leaving something full of acid in a large, complex system like an entire hf alkylation unit. Once in the alkylation unit, the alkenes react to the isobutane while in the presence of a catalyst, causing the two substances to combine, creating the alkylates. Phillips is a major licensor of hf alkylation technology and numerous other technologies. Low temperature cd alky breaks the lowtemperature barrier through innovative reactor design. Exelus has developed an innovative isoparaffin alkylation technology exsact, as an economically viable alternative to hfh2so4 processes. 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. By true sac we mean that the catalytic acid function is intrinsic to the solid itself rather than being a separate species, such as an immobilized liquid deposited on a solid substrate. Invistigation on alkylation process sust repository. 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. In this method, an hf alkylation unit having an hf stripper downstream of the hf alkylation reactor is modified to a benzene rectifier.
Modelling and simulation of benzene alkylation process reactors for production of ethylbenzene article pdf available in petroleum and coal 461 january 2004 with 5,582 reads. Alkylate is the reactor product, isooctane or isoheptane to be separated as the isostripper bottom product. Alkylation reactions are catalyzed by strong acids i. Motor fuel markets worldwide demand gasoline with lower volatility, olefinicity, and aromaticity, while retaining high octane ratings. 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. In the meantime, existing alkylation units can and must be made safer. Application of hazop, lopa and sil to the alkylation unit. May 28, 2014 the publication recommends that access to an hf alkylation unit be restricted due to the potential hazards of hf. Superior refinery hf alkylation unit animation duration. The equipment is a stack of 3 aeu exchangers, with the stripper feed in the tubes. Shutting down a sulfuric acid alkylation unit reactor. Materials selection in hf alkylation units is mostly based on long time experience.
Concentrated hydrofluoric acid hf is then mixed in and fed to the reactor. Exelus has developed an innovative isoparaffin alkylation technology exsact, as an economically viable alternative to hf h2so4 processes. Because of the chemical burn hazard present with hf, refineries have incorporated many or all of the following engineering controls at hf alkylation units. The hazop technique is a structured process hazards. In the liquidphase process the alkylation reactor operates at higher pressure but lower temperature than the vaporphase alkylation process. The second conversion option using a novel reactor design is also suitable for both gravityflow and pumpedflow hf alkylation units. Construction of concrete containment curbs around reactor and hf storage vessels. Materials performance in hfalkylation units book osti. Low temperature alkylation maximizes selectivity, octane value, and yield 1,2. An improved reactor for an hf alkylation unit of the shellandtube heat exchanger type has an axial tube bundle to provide cooling for the reactor and a centrallylocated axial sparger system for injecting and dispersing the hydrocarbon reactants into the flow path in the reactor. Simulation on alkylation reactor sulfuric alkylation. For the conversion of a gravityflow hf alkylation unit, the existing vertical acid settler will be retrofitted with proprietary internals for mixing and will perform the function of an alkylation reactor, acid. Results of alkylation unit hazard, operability study are.
Kellogg corporation cascade reactor were bubbled up through liquid hf. For hf alkylation, the reaction temperature is less significant and is between 21 and 38 c 70 and 100 f. The light hydrocarbons consist of olefins such as propylene and butylene and isoparaffins such as isobutane. The effect of operating conditions on corrosion in hf. Louisiana refining division if applicable hf alkylation unit training. 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. Hf alkylation process with internal acid regeneration.
Mar 11, 2015 alkylation and dealkylation in industrial processes reactor engineering class 148. Design of the chemical reactor critical manifoldsdistance to the critical. In hf alkylation units, hydroflouric acid is used as the catalyst. 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.
Triple offset valve tov formally approved by uop in august 2015 for hf alkylation service. Alkylation, in petroleum refining, chemical process in which light, gaseous hydrocarbons are combined to produce highoctane components of gasoline. How do we prevent the hf alkylation reactor from corrosion at. The alkyclean process employs a zeolite catalyst coupled with a novel reactor. Installation of segregated sewer systems designed to contain spills and runoff from hf acid areas. The most widely used material in the station units is standard carbon steel, because it is capable to form a thick protective fefsub 2 layer in concentrated or anhydrous hydrofluoric acid. 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. Isoalky technology is commercially viable alternative.
Reactor performance depends on important parameters such as reaction kinetics and thermodynamics, reactor. This is especially true for the hf alkylation process. Dobis, materials and corrosion director at the equity engineering group, inc. The two main principles involved in establishing conditions for performing a reaction are chemical kinetics and thermodynamics. Alkylation and dealkylation in industrial processes reactor engineering class 148.
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. Uop approved hf1, hf10, hf2, hf20, hf4, hf40, hf5, hf50. Apr 22, 2020 after prescreening of potential candidates in a laboratory alkylation micro reactor, a true sac was selected as the preferred prototype. Develop reactor internals for optimizing reactor design. A unique solidacid catalyst that converts light hydrocarbons into alkylates and 2. The uop hf alkylation process, created in 1941, catalytically combines light olefins propylene, butylenes and amylenes with.
The publication recommends that access to an hf alkylation unit be restricted due to the potential hazards of hf. Solidacid alkylation process development is at a crucial stage osti. Alkylation processes alkylation is catalysed by a strong acid, either sulphuric h2so4 orhydrofluoric hf. 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 mixture is fed to the reactor, where it is highly dispersed into an incoming stream of acid catalyst.
The sparger comprises an axiallyextensive tube with outlet nozzles for the hydrocarbon reactants arranged around. Reactorregenerator system joint work optimization in benzene. 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. Commit to ending the use of hf alkylation an d replacing it with safer alternatives as soon as possible. Hf alkylation conversion is finally within reachpart 1. Fundamentals hf alkylation process implementation seminar course overview course number. The worldwide capacity for alkylate production by these two processes over the past 50 years has shown a decline in hf alkylation since 1990 beall et al. 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.
Refineries without alkylation capabilities are becoming rarer and typically can only produce conventional gasoline, i. Hf alkylation and selective hydrogenation process uop inc. Through lecture, exercises, and discussion, participants will gain an understanding of the hf alkylation process and. Hydrofluoric acid alkylation conversion and expansion.
Simulation on alkylation reactor sulfuric alkylation posted in chemical process simulation. Williams at marathon ashland petroleum llc, and david l. Thermodynamics is an engineering fundamental having various applications for the chemical reactor design. The design is intended to resemble the new liquidphase eb process offered by lummus crest, which uses a zeolite catalyst developed by unocal. The uop hf alkylation process is used in more than 150 refineries worldwide. No similar specification was recommended for sulfuric acid alkylation. 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. Thus i wanna give it a shot to simulate this reactor using aspen custom modeler but i have to. A process for removing polymeric byproduct aso acid soluble oil from the circulating hf alkylation acid in an hf alkylation unit used for the production of gasoline boiling range alkylate product by alkylation of an isoparaffin with an olefin, which comprises. The alkylation process itself generates a significant amount of heat. Chemical kinetics is the study of rate and mechanism by which one chemical species is converted to another.
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. 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. Alkylation and dealkylation in industrial processes. Revap is compatible with existing hf alkylation reactor systems, which are used to meet increasing demand for alkylate as a clean highoctane blending component in reformulated gasoline. The effect of operating conditions on corrosion in hf alkylation units part 1 by jonathan d. A case study of the alkylation unit at the delaware city refining company dcrc involving equipment maintenance incident petroleum refining design and applications handbook, volume 1. The alkylation reaction takes place combining the olefins with the isobutane to form the. By careful selection of the operating conditions, a high proportion of products can fall in the gasoline boiling range with motor octane. These compounds are fed into a reactor, where, under the influence of a sulfuricacid or. Otherwise the light ends will require venting of the hf alkylation unit with resulting hf acid losses. How do we prevent the hf alkylation reactor from corrosion at the design stage. Our team our dedicated team of professionals are on a mission to provide the highest level of service and support to hf units worldwide. A novel fixedbed reactor that is designed to enhance the performance of this.
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. Cdalky breaks the lowtemperature barrier through innovative reactor design. The failure of even a small piece of piping is a big problem when the unit is started up. Low temperature alkylationmaximizes selectivity, octane value, and. The conversion options for the reaction section include. Olefin and isobutane feed streams are dried to remove water before they are mixed with the isobutane recycle stream.
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