2. Alkylation, continued
The auto-refrigeration vapor is first enhanced by the ejector and
then absorbed in a heavy liquid—alkylate, which provides a low-cost
option and then condensed. Some liquid is sent to depropanizer (6);
propane and light ends are removed. The bottoms are recycled to C4
system and sent to the reactor.
The major advances of RHT process are threefold: eductor mixing
device, advance coalescer system to remove acid from hydrocarbon (dry
system), and C4 autorefrigeration vapors recovery by absorption, mak-
ing compressor redundant.
Economics: For a US Gulf Coast unit 1Q 2006 with a capacity of 10,000
bpd alkylate unit
CAPEX ISBL, MM USD 29.5
Power, kWh 2,800
Water, cooling, m3/ h 1,750
Steam, kg / h 25,600
FCC Feed (about 15% isobutelene in C4 mixed stream)
Product properties: Octane (R+M)/2:94.8–95.4
Commercial units: Technology is ready for commercialization.
References:
US patent 5,095168.
US Patent 4,130593.
Kranz, K., “Alkylation Chemistry,” Stratco, Inc., 2001.
Branzaru, J., “Introduction to Sulfuric Acid Alkylation,” Stratco, Inc.,
2001.
Nelson, Handbook of Refining.
Meyers, R. A., Handbook of Refining, McGraw Hill, New York, 1997.
Licensor: Refining Hydrocarbon Technologies LLC contact
4. Biodiesel, continued Economics: The normal utilities for continuous biodiesel unit based on
heterogeneous catalyst for tph of biodiesel capacity are listed. This does
of methanol react with the triglyceride to produce 3 moles of methyl not include the glycerine purification utilities. The capital cost for the
ester oil (biodiesel) and one mole of glycerine. The transesterfication re- ISBL Biodiesel plant on Gulf coast site basis based on 1Q 2006 is pro-
actor uses a highly alkaline heterogeneous catalyst and provides essen- vided below.
tially 100% conversion. The transesterification reactor effluent is sent
CAPEX ISBL plant: USD/ton Biodiesel 235–265
to gravity separator/settler. The biodiesel product is taken from the top
Steam, lb/h 368
of the separator, and is water washed. The washed biodiesel product is
Water, cooling gpm 64
taken from the top of the drum. Water washing removes excess metha-
Power, kWh 9
nol from the reaction products, which is recovered by normal distillation;
the pure methanol is recycled back to the reactor. The bottoms from the Licensor: Refining Hydrocarbon Technologies LLC contact
separator/settler are sent to the purification unit to remove impurities
and residual methanol, which is recycled back. Pure glycerine product is
sent to storage.
Fig. 2 is an alternate flow scheme; a spare transesterification reactor
is added to remove glycerine from the reactor to sustain reaction rates.
Once the reaction rates are reduced the reactor is switched and washed
with hot solvent to remove residual glycerine and biodiesel. This extra
reactor patented mode of operation provides higher reactions rates and
onstream capability while enhancing yield and productivity. Glycerine
purity can exceed 99.8% after distillation.
Reaction chemistry: Transesterification reactions:
Triglycerides + 3 Methanol ➞ Methyl Ester of the oil (biodiesel) + Glycerol
Comparision of the Diesel/Biodiesel Properties
Fuel Property Diesel Biodiesel
Fuel standard ASTM D 975 ASTM P S 121
Fuel composition C10–C21 HC C12–C22 FAME
Lower heating value, Btu/gal 131 117
Kinemetic Vis @ 40°C 1.3–4.1 1.9–6
SG at 60°F 0.85 0.88
Water, wppm 161 500
Carbon 87 77
Hydrogen 13 12
Oxygen 0 11
Sulfur, wppm 15–500 0
Bp, °F 380–650 370–340
Flash Pt, °F 140–175 210–140
6. Hydrogenation/hydrodesulfurization, continued The catalyst used for first reactor for selective hydrogenations are Pt/
Pd, Pd, Ni, Ni//W or Ni/Mo depending upon the feed and operating con-
for the process/olefins or saturation. The process uses lower pressure ditions selected. Catalyst required for HDS include Co/ Mo, Ni/W or Ni/
than conventional processes and can work in single phase or two phase Mo. RHT processes do not use any internals. Additionally, if the capacity
reactor operation. must be increased for future processes with special internals become a
RHT-HDS: FCC Gasoline: The RHT- HDS process (flow diagram B) bottleneck and one has to install complete additional train, which is very
can be used for FCC gasoline. Processing scheme for straight-run naph- expensive.
tha, heavy gasoil and diesel is similar to conventional schemes. The FCC RHT-HDS: Gasoil/diesel: RHT has a configuration to desulfurize the
gasoline is mixed with hydrogen and is heated to moderate tempera- crude and vacuum unit pumparound and main fractionators side draws
ture. The feed is sent to the selective hydrogenation reactor to remove at the location with staggered pressures so that hydrogen can be spilled
diolefins to prevent the formation of gums and polymers and coking into lower pressure unit, gasoil, diesel/kerosine/naphtha in that order.
on the HDS catalyst. The reactor operates in two phases or single phase The flow schemes are similar to conventional processes with reactor
down-flow reaction mode. Reactor effluent is sent to the splitter where internals designed to meet high-distribution efficiency. The catalyst is
light cut naphtha (LCN) is taken as side-draw overhead and heavy cut same as mentioned above earlier, e.g., Co/Mo, Ni/W, Ni/Mo. Zeolite/Pt
naphtha (HCN) is taken from the bottom and medium cut naphtha catalyst and Ni is used for light cycle oil (LCO) aromatic saturation and
(MCN) is taken as side draw. The LCN is almost sulfur-free and contains ring opening.
less than 3 to 5 wppm mercaptans and other sulfur compounds. DMS is
essentially eliminated or minimized. Economics: 1Q 2006 Gulf coast Basis;
The HCN is taken from bottom of the splitter and is mixed with RHT-Hydrogenation:
hydrogen required for HDS and is heated to the desulfurization tem- CAPEX (ISBL facility only), $/bbl 517
perature in the furnace. The feed is fed to the HDS reactor in down- Utilities and catalyst, $/bbl 0.25
flow mode. The HDS occurs in the catalyst zone at high temperatures RHT-HDS:
to support high desulfurization rates HCN, which contains the maxi- Capex (ISBL facility only), $/bbl 980
mum sulfur level and is the most refractory. The MCN is also mixed with Utilities and catalyst, $/bbl 1.26
hydrogen and heated to the reactor temperature and is sent the HDS
reactor around the middle of reactor. The space velocity for HCN and
Product properties: Hydrogenation stream meets the diolefin specifica-
tion as required with high selectivity. For HDS, the product sulfur speci-
MCN depends on the total sulfur concentration in both streams and the
fications are met below 10 wppm.
sulfur-containing species. Another consideration for the catalyst quan-
tity is based on the product specifications required. The reactor effluent Installation: Technology is ready for commercialization.
is sent to stabilizer, where residual sulfur is driven from the MCN and
HCN product and is taken as the bottom product from stabilizer. Licensor: Refining Hydrocarbon Technologies LLC.
8. Isooctene/isooctane, continued
If isooctane is to be produced the debutanizer bottom, isooctene
product is sent to hydrogenation unit. The isooctene is pumped to the
required pressure (which is much lower than conventional processes),
mixed with recycle stream and hydrogen and is heated to the reaction
temperature before sending it the first hydrogenation reactor. This reac-
tor uses a nickel (Ni) or palladium (Pd) catalyst.
If feed is coming directly from the isooctene unit, only a start-up
heater is required. The reactor effluent is flashed, and the vent is sent
to OSBL. The liquid stream is recycled to the reactor after cooling (to
remove heat of reaction) and a portion is forwarded to the finishing
reactor—which also applies a Ni or Pd catalyst (preferably Pd catalyst) —
and residual hydrogenation to isooctane reaction occurs. The isooctane
product, octane (R+M)/2 is >98.
The reaction occurs in liquid phase or two phase (preferably two
phases), which results in lower pressure option. The olefins in isooctene
product are hydrogenated to over 99%. The finishing reactor effluent is
sent to isooctane stripper, which removes all light ends, and the product
is stabilized and can be stored easily.
Economics:
Isooctene Isooctane1
CAPEX ISBL, MM USD
(US Gulf Coast 1Q 06, 1,000 bpd) 8.15 5.5
Utilities basis 1,000-bpd isooctene/isooctane
Power, kWh 65 105
Water, cooling, m 3/h 154 243
Steam, HP, kg/h 3,870 4,650
Basis: FCC feed (about 15–20% isobutelene in C4 mixed stream)
1These utilities are for isooctene / isooctane cumulative.
Installation: Technology is ready for commercial application.
Licensor: Refining Hydrocarbon Technologies LLC ContACt
10. Olefin etherification, continued Economics:
CAPEX ISBL, MM USD (US Gulf Coast 1Q06,
By installing multiple reactors, it is possible to extinct the olefins 1,000-bpd ether product) 9.1
within the raffinate. The cost of side draws and reactors can achieve Utilities Basis 1,000 bpd ether
pay-off in 6 to 18 months by the higher catalyst cost as compared to Power kWh 45.0
Water, cooling m 3/ h 250
other processes. This process could provide 97–99.9% isobutene con-
version in C4 feed (depending on the configuration) and 95–98+% of Steam MP, Kg / h 6,000
isoamylenes in C5 stream. Basis: FCC Feed (about 15–20% isobutylene in C4 mixed stream)
The ether product is taken from the bottom, cooled and sent to the
storage. The raffinate is washed in extractor column (6) with and is sent Commercial units: Technology is ready for commercialization.
to the OSBL. The water/alcohol mixture is sent to alcohol recovery col- Licensor: Refining Hydrocarbon Technologies LLC contact
umn (7) where the alcohol is recovered and recycled as feed.
For ETBE and TAEE, ethanol dehydration is required for most of the
processes, whereas for RHT process, wet ethanol can be used providing
maximum conversions. If need be, the TBA specification can be met by
optimum design with additional equipment providing high ETBE yield
and conversion. Cost of ethanol dehydration is much more than the
present configuration for the RHT wet-ethanol process.
The total capital cost /economics is lower with conventional catalyst
usage, compared to other technologies, which use complicated struc-
ture, require installing a manway (cumbersome) and require frequently
catalyst changes outs.
The RHT ether processes can provide maximum conversion as com-
pared to other technologies with better economics. No complicated or
proprietary internals for the column including single source expensive
catalyst. Distillation is done at optimum conditions. Much lower steam
consumption for alcohol recovery. For example, the C5 feed case requires
less alcohol with RHT configuration (azeotropic alcohol is not required)
and lowers lower steam consumption.