Alkylation Technology

Transcription

1 Alkylation Technology Sulfuric Acid Alkylation Unit (SAAU) Refining Gas Processing Petrochemicals Gas Chemicals 2016

2 RUSSIAN PATENDTED TECHNOLOGY LIGHT OLEFINS (PROPYLENE, BUTYLENE, AMYLENE) TO REACT WITH ISOBUTANE IN THE PRESENSE OF A STRONG ACID CATALYST SULFURIC ACID ALKYLATION TECHNOLOGY ON A BASIS OF REACTOR-SET INCLUDING JET REACTOR AND HYDROCYCLONE

3 STATISTICS Secondary Petroleum Refining Processes Share (Primary Processes = 100%) Alkylation, Алкилирование Oxygenates Bitumen Битум ГидроОчистка Hydrotreatment Риформинг Reforming Коксование Coking ГидроКрекинг Hydrocracking Thermo ТермоПроцессы Processes КаталитическийКрекинг Catalytic Cracking США USA РФ RUSSIA 0,0 10,0 20,0 30,0 40,0

4 С3 С3-С4 TYPICAL SCHEMATIC OF FUEL ORIENTED REFINERY С3-С4 С5-С6 ISOMERIZATION ISOMERIZATE LPG NAPHTA Г MTBE ALKYLATE REFORMATE GASOLINE EURO-5 DHT REFORMING DO MTBE DO i-c4 ALKYLATION VGO LGO FCC LPG ББФ CATALYTIC GASOLINE DO EURO-5 CATALYTIC GASOLINE GASOLINE HYDROTREATMMENT HEAVY FCC OIL HEAVY NAPHTA VACUUM RESID NAPHTA. Feedstock % Crude oil 100 Product % LPG 5,6 Euro-5 Gasoline 43,7 Euro-4 Diesel Oil 40,8 Heavy Fuel Oil 4,4 HYDROCRACKING DO HYDROCRACKING RESID HFO

5 BBF PROCESSING BBF CONTENTS PRODUCED ON FCC UNIT capacity 120 ktpa Component Contents, Volume, % mass ktpa propylene 0,5 % propane 1,5 % n-butane 10 % i-butane 35 % 42,0 i-butylene 16 % n-butene 12 % t-butene 14 % 62,4 z-butene 10 % pentene 0,3 % i-pentane 0,6 % n-pentane 0,1 % Total:

6 BBF PROCESSING COMPARISON OF BBF PROCESSING METHODS PROCESS SELECTIVITY, % FINAL PRODUCT, tpa 1 Oligomerization Alkylation* Alkylation + MTBE** Selective oligomerization + Alkylation * - in presence of additional volume of isobutane ** - in presence of additional volume of methanol

7 BBF PROCESSING OCTANE-TON PARAMETER COMPARISON TABLE Component Volume, ktpa RON MON (RON+M ON)/2 Octane-ton, thousand per year 1. Alkylate 85, MTBE 29, Oligomerizate

8 BBF PROCESSING Oligomerizate 53 thousand ton Option 1 Option 2 Ballast (C3-C4) BBF 120 ktpa Alkylate + 85 ktpa MTBE 30 ktpa

9 ALKYLATION CHEMICAL REACTIONS SCHEME butylene i-butane СН 3 CH 3 - С - СН 2 - СН - СН 3 СН 3 СН 3 2,4,4-trimethylpentane CH 2 = СН - СН 2 - СН 3 CH 3 H 2 SO 4 or HF СН 3 СН - СН 3 CH 3 - СН - С - СН 2 - СН 3 СН 3 СН 3 СН 3 CH 3 - СН = СН - СН 3 2,3,3-trimethylpentane СН 3 CH 3 - СН - СН - СН - СН 3 СН 3 СН 3 2,3,4-trimethylpentane

10 ALKYLATE ALKYLATE PROPERTIES Saturated hydrocarbons mixture contains mainly trimethylpentanes (60 to 80% mass) with low reid vapour pressure Contains no aromatics, no unsaturated hydrocarbons, no sulfur, no lead, manganese and ferrum Motor octane number Stable chemical, ideal blend for clean burning gasoline

11 ALKYLATION REACTORS Contactor 50 cbm Jet Reactor 10 cbm Cascade reactor 200 cbm

12 PATENT No ALKYLATION PROCESS AND REACTOR

13 JET REACTOR KEY FEATURES Weight 10 ton Volume 10 cmb Operation pressure 8 atm Product retention period 60 sec Olefins space velocity 3 hr -1 Operation temperature 14 0 С Internal olefines:isobutane ratio 1:35 Capacity 200 t/day

14 dispersiveness JET REACTOR OPERATION SCHEME Re active emulsion internal recirculation ratio (К EJ. = 2 ) retention period max 60 sec inlet ejection ejection Reaction mass Feedstock: i-bu, (BBF) t (l) Sulfuric Acid H 2 SO 4 Reactor Products

15 EMULSION DISPERSITY Jet Reactor Cascade Reactor 900 rpm 35 micron 135 micron

16 IN-OPERATION REACTOR DETAILS compact size high process flow speed enhanced reliability no mixers inside the reactor propylene feed operation option no internal tube bundle easy maintenance combined reactor-hydrocyclone operations YANOS Refinery / capacity 16 mtpa Alkylation unit in operation since 2000

17 ALKYLATION UNIT / FLOW CHART Isobutane JR HC sludge tank cooler To compressor Feedstock (BBF) To rectification buffer Н-2 Reaction Product Н-1 Sulfuric Acid JR jet reactor HC hydrocyclone

18 HYDROCYCLONE HYDROCYCLONE DETAILS enhanced reliability regulated separation compact size separation process flow speed increase

19 HYDROCYCLONE OPERATION SCHEME

20 3-D MODEL / ALKYLATION UNIT

21 MATH MODELLING OF HYDRODINAMICS IN JET REACTOR Reactor geometry Model mesh fragment Sectional controls Flow structure in sectional controls

22 MATH MODELLING OF HYDRODINAMICS IN JET REACTOR FLOW STRUCTURE (lines of fluid flow is some sectional controls) Longitudal cyclone Transverse cyclone Corkscrew flow in ring clamp Turbulence area Pressure area

23 COMPARISON TABLE FOR TECHNICAL AND ECONOMICAL EVALUATION OF ALKYLATION TECHNOLOGIES IN THE MARKET Рабочая температура, ºC max Объем производства алкилата т/сутки Октановое число Количество реакторов Количество отстойников Энергопотребление, расходные показатели Компрессор, КВт Встроенные мешалки, КВт Насосы, КВт Всего, КВт Вода для охлаждения м3/ч 96.3 RON RON RON Пар, т/ч Свежая кислота тонн в сутки

24 TURN-KEY SOLUTION FOR ALKYLATION UNIT 1. License and Basic Design 2. Detail Engineering Project duration, years months 2 months 12 months 12 months 3. Design Engineering of equipment 4. Procurement 6 months 3-16 months 6 months 3-16 months 5. Construction 26 months 6. Commissioning 26 months 3 months. 3 months Detailed construction plan is prepared in MS Project format and can be modified according to Client s demand Time saving year

25 CONCLUSIONS A new type of reactor for Alkylation process has been developed and implemented New alkylation technology has proven design and in operation currently Quality of final Alkylate product is matching with other Licensor s product characteristics Our technology provides cost savings in both CAPEX and OPEX and also easier equipment access and maintainability comparing with other Licensors units

26 OUR CONTACTS Address: 6 bld. 5, Barklaya str., Moscow , Russia HEAD OFFICE Barklay Plaza Business Center 6-5, Barklaya str., Moscow Phone / Fax: +7 (495) , +7 (495) , +7 (495) , info@rangroup.ru