Alkylation & butamer .pptx

A Sunrise Project for A Sunshine FutureParadip Refinery

Presented by:

An

overview of

ALKYLATION & BUTAMER UNIT

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This sulphuric acid Alkylation Unit plant is the first of its kind among all Refineries of IOCL.



UNIT CONFIGURATION



LICENSOR : M/s EXXON MOBILE, USA.

LSTK contractor : M/s Punj Lloyd

DETAIL ENGG. : M/s Aker power gas Pvt. Ltd

CAPACITY : DIOS unit design capacity 442 KTPA i.e. 53.1 MT per hour

Alkylation unit design capacity 650 KTPA i.e. 78.1 MT per hour

On stream factor: 8320 HRS./YR

OBJECTIVE :

For maximisation of MS production as well as to improve its quality in line with premium Euro-IV grade, having high RON , low RVP & low benzene (< 0.1 wt%).

PROCESS CHEMISTRY :

Olefin & isobutane are mixed with the sulfuric acid catalyst in the reactor and chemically combine to form iso-octane rich alkylate.

BRIEF DESCRIPTION OF THE ALKYLATION UNIT



OBJECTIVE (DIOS SECTION)

To selectively hydrogenate >99% of butadiene (BD) in C4 olefinic stream.

Reduces the butadiene in its feed stream from 2.89 wt% to 200 wppm, since dienes cause high acid consumption in the Alkylation Unit.

The fresh feed is blended with recycled product from the bottom of the stripper to maintain the reactor inlet butadiene concentration at 1.30 wt%.

PROCESS CHEMISTRY :



PFD OF DIOS SECTION

FEED SURGE DRUM

Reflux Drum

DIOS REACTOR

DIOS FEED FROM PRU SWS

FG

CWS

LP STEAM

To ALKYLATION UNIT

Excess DIOS Prod. To LPG Blending

SWS

LP/MP STEAM

CWS

FEED HEATER

HYDROGEN GASTreat gas rate = 968/1290Nm3/hr

H2/BD= 1.5/2.0

STATIC MIXER

DIOS UNIT RECYCLERECYCLE RATIO= 1.25

FEED RATE= 89.5 m3/hrBUTADIENE = 2.89%SULPHUR= 25 wppm

BD = 1.3 WT%

DIOS PRODUCT(BUTADIENE <= 200wppm)

Reactor EIT= 66.3/92.2 °CPressure=35.2 kg/cm2-g

ΔT= 14 °CΔP= 0.95 kg/cm2-g

DIOS STRIPPER

21

17

1

Temp.= 100 °CPress.=17.1 kg/cm2-g



Feed CompositionS. No. COMPONENT WT %

1. i-Butane 19.982. i-Butene 22.273. Butadiene 2.894. Butane 9.245. n-Butene-1 14.36. t-Butene-2 17.337. c-Butene-2 11.72

TOTAL 100.0

Treat Gas Composition (mol %)S. No. Contaminants PPMW

1. H2 99.5%2. Methane By balance3. Ethylene Nil

Feed stock is mostly C4 molecules (97.73 wt %), consisting of 66.20 wt% olefins, 2.89 wt%

butadiene (BD).

FEED STOCK(DIOS)



Product Composition (WT %)S. No. COMPONENT Wt%

1. Propylene 0.49

2. Propane 0.74

3. i-Butane 19.944. n-Butane 9.315. Isobutylene 22.24

6. Butene-1 11.95

7. TR-Butene-2 22.28

8. CIS-Butene-2 12.02

9. Butadiene 0.02

10. 2M-Butene-1 0.07

11. Isopentane 0.67

12. n-Pentane 0.27

TOTAL 100.0

Dienes at out let of DIOS section is 200 PPMW.

PRODUCT QUALITY(DIOS)



PROCESS VARIABLES (DIOS)

Reactor Temperature : SOR 57 deg. C , EOR 83 deg. C

Hydrogen : Butadiene Ratio : Unit is operated between 1.5 at SOR and 2.0 at EOR on molar basis.

Space Velocity : Unit is operated at 8.07 hr -1 LHSV

Reactor Pressure and Bed Pressure Drop : Reactor operates at 35.2 kg/cm2(g).

Catalyst Type / Volume : Pd catalyst-25 m3

Catalyst Activity : Sulfur is the main contaminant expected in the fresh feed that will inhibit the performance of the palladium catalyst.



PFD of ALKYLATION UNIT

REACTOR SETTLER

DEISO

BU

TAN

ISER

DEB

UTA

NISER

Reflux Drum

Reflux Drum

KO D

rum

Receiver

Reflux drum

FEEDCHILLER

DEPR

OP

AN

ISER

PROPANETO STORAGE

Caustic & Water Wash

System

Caustic & Water Wash

System

economiser

DIOS STRIPPER BOTTOM

M

EXCESS ISOBUTANETO LPG BLENDING

CCR LPG

BUTAMER EFFLUENT

LP STEAM

SPENT ACID TO SARU

ALKYLATE PRODUCT TO TANKS

NSU LPG

BUTANETO BUTAMER

FRESH ACID MAKE-UP

40 ºC

6 kg/cm2-g0.3 kg/cm2-g

18 ºC4.4 ºC

RATE = 78.1 MT/hrRON= 96.3

RVP=0.29 Kg/cm2

REFERIGERATION COMPRESSOR

ISOBUTANE RECYCLE

FEED EFFLUENT H.E.

DP BOTTOMS

TO TRAIN -2

FROM TRAIN -2



S. No. Components Olefins from

DIOS Stripper

CCR LPG NSU LPG Butamer product

1. Propane --- 42.27 1.70%2. Isobutane 19.94% 21.39% 21.67% 59.56% SOR,

56.76% EOR3. n-Butane 9.31 % 32.88 % 74.97 % 37.81% SOR,

41.27% EOR4. Isobutylene 22.24 %5. Butene-1 11.95 %6. TR-Butene-2 22.28 %7. CIS-Butene-2 12.02 %

Fresh 98% Purity Sulphuric Acid as makeup

(2100 MT for initial fill & 160 MT/Day)

Fresh 20% Caustic as makeup (NaOH)

(179 Sm3 for initial fill & 9.51 MT/Day )

FEED STOCK (ALKYLATION )



PRODUCT QUALITY(ALKYLATION)

S. No. PROPERTIES Value

1. Rate, m3/hr 111.09

2. Specific Gravity(15/15) 0.704

3. RON, clear 96.3

4. MON, clear 93.7

5. RVP, kg/cm2 0.29

Alkylate properties :-



Reaction Temperature : Operating range is between 2-5.7 Deg C

Acid Strength : Best alkylate quality and highest alkylate yields are obtained 92 to 95 wt% acid strengths.

Isobutane Concentration : Design isobutane concentration is 62.7 LV% in the reactor product stream.

Olefin Space Velocity : Overall olefin space velocity is 0.090 m3/hr olefin/m3 acid inventory.

Percent Acid-in-Emulsion (Acid/Hydrocarbon Ratio) : Most desirable range is 60 to 65%.

Reactor Mixing : Mixing is important in sulfuric acid alkylation because the iso-butane solubility is low and the acid catalyst is viscous at the low operating temperatures employed.

Olefin Feed Injection : To minimize the polymerization reactions, the feed is “jetted” into the reactor emulsion through feed rings , each having 86 feed jets at a high velocity(30 m/s)

PROCESS VARIABLES (ALKYLATION )



MATERIAL BALANCES (ALKYLATION) Alkylation unit (Butamar yield design case)

INPUT OUTPUTS. No. Feed streams MT/HR Products

streamsMT/HR

1. Alkylation Feed ex DIOS 52.55 Alkylate 78.082. CCR LPG 23.03 Propane 11.043. SR LPG 16.03 NC4 39.614. Butamar product (ic4) 37.39 ASO 0.27

6. Total 129.00 129.00

INPUT OUTPUTS. No. Feed streams MT/HR Products streams MT/HR

1. Alkylation Feed ex DIOS 52.536 Alkylate 78.032. CCR LPG 23.027 Propane 11.133. SR LPG 16.02 NC4 37.794. Butamar product (ic4) 35.6 ASO 0.233

6. Total 127.183 127.183

SOR Case

EOR Case

NOTE : ASO (acid soluble oil ) purged along with spent H2

SO4



LICENSOR : M/s UOP, USA.

LSTK contractor : M/s Punj Lloyd

DETAIL ENGG . : M/s Aker power gas Pvt. Ltd

CAPACITY : 35621 kg/hr (iC4 = 59.60 mol%) of isomerate at SOR and 37382 kg/hr of isomerate (iC4 = 56.90 mol%) at EOR .

On stream factor : 8320 HRS./YR

OBJECTIVE :

The unit purpose is to produce isobutane from n-butane ex-alkylation unit to balance the requirement of isobutane within the Alkylation unit.

PROCESS CHEMISTRY :

CH3

PtCH3-CH2-CH2-CH3 CH3-CH-CH3 Acid/PERC

BRIEF DESCRIPTION OF BUTAMER UNIT



PFD of BUTAMER UNIT

COALESCER

Feed Surge Drum

Stabiliser

Reflux Drum

METHANATOR REACTOR

ISOMERISATION REACTORS

HP steam

FG

MUG K.O. Drum

cws

BUTAMER FEED

FROM ALKYLATION

UNIT

MAKE UP GAS DRIERS

LIQUID FEED DRIERS

LEAD LAG

CCFE

HCFE

CHARGE HEATER

HP STEAM

CHLORIDE INJECTION

ISOMERATETO DIB AT ALKYLATION

UNIT

FRESH CAUSTIC MAKE-UP

FLOW= 35453 / 37389 kg/hr(iC4 = 1.45 %,nC4= 97.7 %)

FLOW= 35621 / 37382 kg/hr(iC4 = 56.90 %,nC4= 41.37 %)

FLOW=45 kg/hr(CO+CO2= 20 ppm)

(CO+CO2= 10w ppmCO = 1wppm)Temp.= 232 º C

Press.= 41 kg/cm2g

Temp.= 93-174/120.156 º CPress.= 31.8 kg/cm2gLHSV = 4

H2/HC = 0.03

H2 MAKE-UP GAS

LP STEAM

NET GAS CHILLER

NET GAS PREHEATER

NET G

AS

SCR

UB

BER

Caustic circulation pump

Wash water circulation pump



Components Composition, mole%

Isobutane 1.45

n-butane 97.69

Isopentane 0.86

Total 100.0

Feed Composition

Hydrogen Makeup Gas Composition

Stream composition units valueHydrogen Volume% 99.5Methane Mole% Balancesulfur Mole ppm NilNitrogen (excluding N2)

Mole ppm 0.00

HCl Mole ppm 1CO+CO2 Volume ppm 20Total 100.0

FEEDSTOCK (BUTAMER )



S.No. Components Composition mole%

SOR EOR

1. Propane 0.85 0.40

2. Iso butane 59.89 56.903. n-butane 37.57 41.37

4. i-pentane 1.25 0.965. n-pentane 0.37 0.326. C6+(n-hexane) 0.07 0.05

Total 100.0 100.0

PRODUCT QUALITY (BUTAMER)



PROCESS VARIABLES(BUTAMER)

REACTOR TEMPERATURE

Minimum inlet temperature=105oC

Maximum bed temperature=205oC

LIQUID HOURLY SPACE VELOCITY : Units are operated at 4 1/hr LHSV

HYDROGEN TO HYDROCARBON RATIO : Units are designed to operate at a 0.03 H2 mole ratio at the reactor outlet.

PRESSURE :Typical operating pressure is 31.6 kg/cm2 g.



MATERIAL BALANCE (BUTAMER)

Stream UOM Start of Run End of Run

Feed ex Alkylation kg/hr 35948 37643Make up Hydrogen kg/hr 45 45Total kg/hr 35993 37688

Feed

Product

Stream UOM Start of Run End of Run

Isomerate kg/hr 35621 37382

Fuel Gas kg/hr 360 294Water kg/hr 12 12Total kg/hr 35993 37688



THANK YOU


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Alkylation & butamer .pptx