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Cat Tech Global Catalyst Forum  June 2011 Dubrovnik
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Cat Tech Global Catalyst Forum June 2011 Dubrovnik


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New technologies for alkylation with same reaction chemistry but smart configuration and equipment with essentially low risk as reaction chemistry as been used for 50 years

New technologies for alkylation with same reaction chemistry but smart configuration and equipment with essentially low risk as reaction chemistry as been used for 50 years

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  • 1. Enhance Refinery Economics Through C4 Chemistry & Advances Dr. Amarjit Bakshi President Refining Hydrocarbon Technologies Texas, USA. Presented at CAT-TECH Global Catalyst Technology Forum 13 & 14 June, 2011 Rixos Libertas, Dubrovnik, Croatia RHT
  • 2. Mixed Butylene Production
    • Steam Cracker
    • FCC Units
    • Other Thermal Crackers
    • For MTBE and other special use from Dehydrogenation
    2 RHT Confidential
  • 3. Uses Of Butylenes
    • Mixed Butylenes for Alkylation and ether Production
    • Mixed Butylenes for MMA
    • Pure Isobutylene for Rubber and Lubes
    • Pure 1- Butene as Monomer
    • Butene-2 for butanol and metathesis for Propylene production
    • Isobutane goes to alkylation
    3 RHT
  • 4. RHT-Alkylate Process
      • Why RHT-Alkylate
      • Paradigm Shift
      • No Major Complex Internals in the
      • Reactor
      • No Maintenance and Mechanical Problems
      • Isothermal Low Temperature Operation
      • Provides mixing with a simple Eductor providing good interfacial area .
    4 RHT
  • 5. RHT-Alkylate Process
      • Auto refrigeration vapor can be absorbed and Compressor can be deleted. A major
      • Paradigm shift and low cost option for grass root and revamps including HF units. Low maintenance option.
      • Hydrocarbon /Acid separation by low cost coalescers with optimized design.
      • No waste production.
      • Standard Process industry equipment
      • Standard Reactor internals, no proprietary internals
  • 6. RHT-Alkylate Process
      • Absorption is a low Capex option, improves system reliability. Liquid from absorber is sent to reactor which saves utilities. Compression can still be used in the existing units if so desired.
      • Lower Capex by 33 to 45 %, due to economy of scale and other improvement.
      • Depending upon the option used for vapor recovery from auto refrigeration( Absorption or Compression) lower Opex by 35 to 45 %.
    6 RHT
  • 7. RHT-Alkylate Process
      • Better Octane
      • Lower Acid Consumption
      • Easier to revamp the unit with Reactor and novel mixing Concept.
      • Vapor absorption rather than expense of compressor replacement or revamp.
      • No complex seals or proprietary internals which either require regular replacement or maintenance.
  • 8. RHT-Alkylate Process
      • Reactor can be sized to any size no scale up issues. Multiple eductor systems to provide good mixing.
      • RHT-Alkylate process uses standard equipment used in Refining or Petrochemical industry.
      • Flexible operation. No internals so no undue risk of any mishap due to internals, maintenance or replacement of internals.
      • Propylene can be fed at the motive fluid pump discharge with inline mixer, higher OSV and acid concentration, provides better efficiency.
  • 9. Alkylation Chemistry
    • Reaction Chemistry is pretty complex but same as conventional Alkylation Process chemistry though better yield observed at low temperature (US Pat. 5095068)
    • Process Selective at low temperature hence less acid soluble oil produced (US Pat. 7,652,187 )
    • Reference US Pat. 5284990
  • 10. Alkylation Chemistry Main Reactions
    • Olefins + Isobutane 2,2,4 TMP
    • 2,3,4 TMP 2,3,3 TMP
    • Other reaction products are made;
    • 2,4 and 2,3 Dimethylpentane ( DMP) , Dimethylhexanes, Isopentane and other C 9 to C 12 compounds in the alkylate.
  • 11. Figure 1 RHT-Alky: Block Flow Diagram RHT
  • 12. Figure 2 RHT Novel C4 Vapor Recovery System RHT
  • 13. RHT-Alkylate Revamp
    • Additional reactor and pumps
    • Absorption system if compression bottleneck
    • Coalescers to handle acid separation
    • Existing de-isobutaner revamp
    • Easy to convert HF alkylation
    • Vertical equipment, plot area not major constraint
    • Easy to add additional capacity
  • 14. Reactor Comparisons
      • Conventional RHT- Alkylate
    • Standard sizes Economy of scale
      • Impeller parts Simple eductors complicated seals/ as mixing device, internals no scale up issues
      • Frequent process Normal refinery maintenance equipment/low and corrosion maintenance
  • 15. Operating Variables
    • Hydrocarbon / Acid Mixing
    • Reactor temperature
    • Isobutane concentration in Reactor and Reactor effluent
    • Acid concentration
    • Olefin space velocity is olefin volume fed to Reactor per hour per volume of acid catalyst
  • 16.
    • Hydrocarbon / Acid mixing is a major variable in the alkylation reaction so that the acid interfacial area is available to olefin and isobutane to react. The eductor device provides this function very efficiently. The OSV is kept in 0.2 to 0.4 1/hr range.
    Operating Variables
  • 17.
    • Temperature, another variable which is very important for alkylation. RHT configuration provides the best results due to essentially isothermal conditions (25-27 F) in the reactor. Higher reaction temperature favors polymerization reactions, which reduces the acid concentration, increases acid consumption, corrosion and reduces Product Quality/Octane.
    Operating Variables
  • 18.
    • Isobutane concentration is kept at the optimum condition I/O ratio ranges from 6 to 15 to provide good product quality and selectivity. Optimum ratio is used so as to optimize de-isobutanizer utilities. Lower I/O ratio enhances the olefin polymerization, which is not good for quality and increases acid consumption. Isobutane in Reactor effluent is 53% to 75% by Vol.
    Operating Variables
  • 19.
    • Acid concentration is very important for alkylation reaction. At lower acid concentration, ASO increases and product quality goes down. Normal acid concentrations are kept in the range of 89% to 95%. With concentration below 86%, activity is decreased, enhancing polymerization.
    Operating Variables
  • 20.
    • Olefin Space Velocity is a measure of Olefin Volume compared to Acid Volume in the Reactor. Higher Space Velocity enhances the acid consumption and lower product quality. The Volume of acid in the Reactor is optimized in relation to olefin, providing optimum results in the range of 40% to 60%.
    Operating Variables
  • 21. RHT-Alkylate Technology Advantages
    • Lower Capex by 33% to 45% due to mixing device, economy of scale, absorption and Acid / Hydrocarbon coalescers
    • Lower Opex by >35% with absorption system application
    • Better Octane Alkylate
    • Lower acid consumption
    • Isothermal low temperature operation
    • Easier revamps
  • 22.
    • We have the answers.
    • Simple design to meet your requirements with unique eductor mixing device
    • Simple Acid/Hydrocarbon separation system
    • No special internals to be provided by single source
    • Unique absorption system instead of compression
    • Lower Capex and Opex, Higher octane and lower acid consumption
    Why RHT Alkylation Technology RHT
  • 23. C 4 Other uses
    • C 4 refinery economics enhancement
    • Isobutylene Dimerization
    • Smart Configuration
  • 24.
    • IN
  • 25. WHY RHT -Iso-octene SM
    • Novel configuration provides low cost simple catalyst system , improves conversion and catalyst life.
    • With a new Selectivator, the RHT process provides higher yield and selectivity than other processes, Isobutylene conversion of 97 to 99 % to
    • Iso-octene product.
  • 26. WHY RHT -Iso-octene SM
    • Lower codimers produced by reducing the per pass conversion in First Reactor.
    • Reduces loss of normal olefins for Alkylation.
    • Conventional catalyst and configuration lends to catalyst change while on line, hence conversions are higher on an average compared to any technology available in the market.
  • 27. Figure 1 RHT Iso-Octene Process Water wash Column Mixer Reactor Debutanizer Water Wash C 4 Feed (1) (1) 1 to 3% propylene in feed LP H 2 CW C 4 Raffinate Iso-Octene Product RHT
  • 28. Figure 2 RHT Iso-Octene Process Water wash Column Mixer Debutanizer Water Wash C 4 Feed (1) (1) 1 to 3% propylene in feed LP H 2 C 4 Raffinate Iso-Octene Product Selectivator Recycle Water to Treatment 1 st Reactor Finishing Reactor Iso-octene Column RHT
  • 29. Figure 3 RHT Iso-Octene Process Water wash Column Mixer Water Wash C 4 Feed (1) (1) 1 to 3% propylene in feed LP H 2 C 4 Raffinate Iso-Octene Product IPA Reactor (multiple) Debutanizer Iso-octene column RHT
  • 30. Figure 4 RHT Iso-Octene Process Revamp of Conventional MTBE Unit Water Wash Column Existing Mixer NEW 1 st Reactor Existing Finishing Reactor Existing Debutanizer Existing MeOH Extractor Existing Deleted MeOH Column Existing MeOH Water Wash C 4 Feed (1) (1) 1 to 3% Propylene in the feed Water to Treatment LP H 2 CW CW IPA Recycle to Reactor C 4 Raffinate Iso-Octene Product MTBE Product RHT
  • 31. Figure 6 RHT Iso-octene to Iso-octane Hydro Iso-octene H 2 CW Vent Mixer 1 st Reactor K.O.Drum 1 2 Hydrogen Cooler 3 4 Iso-octane Product Finishing Reactor Iso-octane Stripper 6 7 RHT
  • 32. WHY RHT -Iso-octene SM
    • Distillation performed at optimum conditions.
    • Easy to revamp the existing MTBE units.
    • Low cost revamp most of the equipment can be used from MTBE unit.
  • 33. WHY RHT -Iso-octane SM
    • The hydrogenation/olefin Saturation is done at lower pressure , which reduces the capital cost and utilities.
    • Conventional but high activity dual catalysts use for olefin saturation.
    • Essentially over 99 % olefin hydrogenation to Paraffins is achieved.
  • 34. RHT Portfolio
    • Please see website
    • and linkedin for other details and presentations attached to profile.
    • RHT LLC provides essentially all hydrogenation technologies ( selective hydrogenation, HDS of Naphtha and Diesel, isomerization, Benzene Saturation with Smart Configuration and enhanced economics.
    • Information provided under NDA please contact us and look up the Patents/IP.
  • 35. RHT Thank You Refining Hydrocarbon Technologies LLC 20130 Chateau Bend Drive Katy ( Houston Suburb), Texas 77450 USA Dr. Amarjit Bakshi Phone 281-398-8408/281-235-7780