A Sunrise Project for A Sunshine FutureParadip Refinery
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An
overview of
ALKYLATION & BUTAMER UNIT
A Sunrise Project for A Sunshine FutureParadip Refinery
This sulphuric acid Alkylation Unit plant is the first of its kind among all Refineries of IOCL.
A Sunrise Project for A Sunshine FutureParadip Refinery
UNIT CONFIGURATION
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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
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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 :
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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
A Sunrise Project for A Sunshine FutureParadip Refinery
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)
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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)
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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.
A Sunrise Project for A Sunshine FutureParadip Refinery
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
A Sunrise Project for A Sunshine FutureParadip Refinery
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 )
A Sunrise Project for A Sunshine FutureParadip Refinery
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 :-
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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 )
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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
A Sunrise Project for A Sunshine FutureParadip Refinery
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
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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
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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 )
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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)
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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.
A Sunrise Project for A Sunshine FutureParadip Refinery
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
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