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Copyright Notice
Case book #2
Alkylation Plant
Rev. 2 July, 2009
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2-1 Sulfuric
PRO/II Acid
Case Alkylation
Book
Plant
2-2 Sulfuric
PRO/II Acid
Case Alkylation
Book
Plant
Reactants
Vapor
Pressure at
100F
psia
Motor
Research
Isobutane
97.6
100.1
72.6
Propylene
84.9
100.2
227.6
Isobutylene
na
na
64.6
2-Butylenes
83.5*
100.0*
47.8*
1-butylene
80.8
97.4
63.2
2-Methylbutylenes
83*
99*
16.4*
20.4
Isopentane
90.3
92.3
Dimethylpentanes
88*
>100
Trimethylpentanes
98*
>100
C9s
98
*
100
approximate average
>0.5
Comparison to HF Alkylation
The relative advantages of hydrofluoric acid (HF) to H2SO4 alkylation have been vigorously debated in the open literature and in the
marketplace for years.5 From about 1960 through the 1980s, HF
alkylation was preferred to H2SO4 alkylation in new plants. The
advantages of HF include superior product when the olefin content
is high in propylene and isobutylene, and reduced catalyst cost.
Also, HF alkylation does not require refrigeration or acid regeneration so it is marginally better in that respect.
More recently, preferences have shifted toward H2SO4 alkylation.
This is due in part to the high corrosive nature of the HF acid,
which requires exotic materials of construction. The process is also
much more hazardous due to the HF acid, and is not readily
acceptable environmentally. Safety and liability considerations,
together with a reduction in isobutylene content in the olefin feed
(due to the
MTBE plant), are additional factors. Also, the more recent development of the wet sulphuric acid process (described briefly in
Appendix C) ameliorates may of the disadvantages previously
incurred by H2SO4 alkylation. Together, all these factors are changing the economics to favor H2SO4 alkylation. Several refiners, particularly those near major population centers, are considering
revamping their HF alkylation facitlities to H2SO4 alkylation.
Chemistry
The primary purpose of the alkylation reactor is to join isobutane
and a light olefin to form branched alkylates.6
acid
iC 4 + C 3 C 7 + heat
(2-1)
acid
iC 4 + C 4 C 8 + heat
Disproportionation reactions contribute to a distribution of alkylate
products from iC5 to C12+; e.g.,
2C 8 C 7 + C 9
(2-2)
12
C n H 2n + C m H 2m C n + m H 2 m + n
The polymers form acid-soluble oils that foul the sulfuric acid catalyst, resulting in excessive purge and makeup requirements. As the
acid strength weakens, an acid runaway, characterized by low
octane and increased acid consumption, may occur.
tion pair, and each olefin reacts to extinction. The REACTOR MODEL section clarifies this further.
Sulfuric acid is assumed to be 100% pure and totally
immiscible with the process hydrocarbon. In reality, circulating sulfuric acid is generally maintained at 85 to 96
weight percent.
The trace amount of hydrocarbon absorbed by the acid is
Reactor Modelling
Reaction Stoichiometry
A fixed stoichiometry for each pair of reacting components is
derived from the work of Cupit, et al.7 This reference provides
reac- tion yields on a volumetric basis. PRO/II was used to
normalize the products to mass balance with the feeds. Note that,
although it is necessary to adjust the stoichiometry to mass balance,
it is not nec- essary to normalize the stoichiometry to integer
coefficients. Table
2-2 lists the coefficients used in this simulation. Heat of reaction
data need not be supplied. PRO/II automatically accounts for reaction enthalpy via pure component heat of formation data adjusted
for temperature and pressure.
12.3008
12.3461
8.5683
10.5445
10.9924
11.3223
11.5763
9.9587
0.5541
0.5553
2.3756
5.9539
0.4574
0.0731
0.3969
0.0821
0.0594
0.6688
0.4325
0.0468
0.0315
1.2706
0.5925
0.3827
0.2638
2.5703
0.3627
2.1523
0.3998
0.2074
0.2754
0.2134
0.5173
0.0239
0.6346
0.6261
0.2832
0.1703
3.3018
0.4360
4.6514
0.1852
0.0782
0.0891
0.799
.02831
0.0000
0.6877
0.5870
0.3016
0.1730
3.1778
0.5271
4.2314
0.1686
0.0984
0.0720
0.0761
0.2674
0.0079
Products
isopentene
2,3-dimethylbutane
2,4-dimethylpentane
2,2,4-trimethylpentane
2,4-dimethylhexane
2,3-dimethylhexane
2,3,4-trimethylpentane
2,2,5-trimethylhexane
C9s (nbp=280, mw=128)
C10s (nbp=325, mw=142)
C11s (nbp=365, mw=156)
C12s (nbp=395, mw=170)
C13+ (nbp=425, mw=184)
Reactor Configurations
In the auto-refrigeration flowsheets considered by this paper, the
reaction vessel is divided into four reaction chambers. Flashing
occurs in each chamber to balance the exothermic heat of reaction.
In the flowsheet where effluent refrigeration is considered, the
reac-
tion takes place in a single reaction chamber under sufficient pressure to suppress vapor flashing. This work assumes the reaction is
maintained at 45 F. Temperatures significantly above 45 F result in
excessive acid consumption and lower octane. Temperatures significantly below 45 F increase the refrigeration load. Liquid hydrocarbon and acid phases coexist in the reactor.
The reactor could be modeled with a reactor unit operation using
conventional two phase equilibrium models, followed by a three
phase flash. This has one disadvantage in that the reactor is nested
two levels deep in controller and recycle loops, and rigorous three
phase flashes add to the calculation overhead. In this paper, a
stream calculator unit operation replaces the three-phase flash.
This allows the user to mathematically manipulate stream
separation.
One other solution for modeling a three phase reactor is to declare
the acid as a solid component. It thus carries with it a fixed heat
capacity, but no vapor pressure. This strategy is not used in the
sim- ulations presented here, but has been proven in preliminary
runs for this work.
Thermodynamic Models
The Soave modification to the Redlich?Kwong equation of state is
used for all unit operations in the flowsheet for the calculation of
equilibrium, enthalpy and entropy.8
The stream is split into four equal parts, each of which enters a
sep- arate reaction chamber. Olefin reacts to extinction with
isobutane in each chamber to form alkylate. Vaporization in each
chamber approximately compensates for the heat of reaction to
maintain the
2.0
ethane
10.1
propane
100.0
9.0
Isobutane
187.5
95.0
36.0
normal butane
100.0
50.0
9.0
propylene
9.0
isobutylene
14.0
2-butylene
75.0
2-butylene
56.0
Isopentane
5.0
399.5
413.0
45.0
Temperature, F
100
100
100
Pressure, psia
400
215
400
Total
Stream ID
Acid rate, 106 lb/hr
Temperature, F
Pressure, psig
SA1
SA1
1.00
45
40
The optimum flowsheet feed location for this stream may or may
not be the same as for the bulk of the isobutane feed. The effects of
alternate feed locations may be quickly tested via simulation.
2-12PRO/II
SulfuricCase
AcidBook
Alkylation Plant
The case study feature of PRO/II may used to study the effects of
increased propane to the refrigeration circuit, increased isobutane
recycle, and a change in feed composition to include more normal
butane. However, this must be run as a batch execution because
the PROVISION Graphical User Interface still does not fully
support all features of Casestudy.
Input Description
Appendix A lists the PRO/II keyword input file for the auto-refrigeration/isostripper batch run. This is revision 2 that is compatible
with PRO/II versions 8 and 9. An electronic copy of the file is
avail- able in the %P2Install% \manual\casebook\inputs\ directory,
where
%P2Install% is the directory where PRO/II is installed.
Results
Key operating conditions for the base case and case studies are
summarized in Table 2-5, including total reboiler duties, reactor
effluent flowrates and isobutane content, refrigeration loads, and
product flows. These parameters form the basis for calculating
operating expenses.
2-13PRO/II
SulfuricCase
AcidBook
Alkylation Plant
More C3
Recycle
More iC4
Recycle
More nC4
in Feed
50
100
50
50
2525
2525
2600
2525
50
1.00
28.24
80.69
9.09
119.02
1.00
29.02
80.69
9.08
119.79
1.00
28.40
82.73
9.10
121.23
1.00
28.46
80.36
11.73
122.05
2180
64.0
2180
64.0
2232
64.0
2214
58.4
996
2005
3001
995
2005
3000
977
2005
2982
1044
2069
2113
17.41
17.42
17.44
111.1
118.6
522.3
111.0
118.9
522.3
110.8
168.7
522.6
Observation
Conclusion
More C3 in
depropanizer
bottoms
More iC4
recycle
More nC4 in
feed
August 5 2009
2-15PRO/II
SulfuricCase
AcidBook
Alkylation Plant
2-16PRO/II
SulfuricCase
AcidBook
Alkylation Plant
Input Description
The changes required in the input file are shown in Appendix B.
Results
AutoRefrigeration
AutoRefrigeration
Effluent
Refrigeration
Deisobutanizer configuration
Isostripper
Deisobutanizer
Deisobutnaizer
1.00
28.24
80.69
9.09
119.02
1.00
27.11
80.03
9.10
117.24
1.00
27.20
80.03
9.10
117.33
2180
64.0
1131
50.7
1120
50.2
996
2005
3001
1454
2016
3470
1706
2086
3792
17.46
17.48
111.0
119.0
522.3
110.9
119.0
522.3
2-17PRO/II
SulfuricCase
AcidBook
Alkylation Plant
Observation
Conclusion
Isostripper vs.
deisobutanizer
Conclusions
References
1
2
3
4
6
7
$ OLEFIN FEED
PROP STREAM=2,TEMP=100,PRES=215, &
COMP(LV)=3,9 / 4,95 / 5,50 / 6,9 / 7,14/ 8,175 /9,56 / 10,5
$ MAKE-UP
PROP STREAM=3,TEMP=100,PRES=400,RATE(LV)=45, &
COMP(LV)=4,80 / 5,20
$ MAKEUP N-BUTANE FOR CASE STUDY ANALYSIS
PROP STREAM=1NB,TEMP=100,PRES=400,COMP(LV)=5,1,RATE=0.00001
$ ACID FEED
PROP STREAM=SA1, TEMP=45, PRES=40, COMP(WT,LB/HR)=24,1000000
$ DEIC4 FEED
PROP STREAM=253X,TEMP=110,PRES=115,REFSTREAM=251
$ DEC2 FEED
PROP STREAM=11B,TEMP=140,REFSTREAM=11A
$ RECYCLE STREAM DATA ESTIMATES
PROP STREAM=27P,NAME=RCY_SAT,PHASE=L
(100F),PRES=400, & COMP=3,80 / 4,280 / 5,50
PROP STREAM=26,NAME=SRG_DRUM,PHASE=L,PRES=73, &
COMP=3,1100 / 4,3500 / 5,620
PROP STREAM=30R,NAME=RCY_IC4,TEMP=62,PRES=200, &
COMP=3,210 / 4, 3000 / 5,300
NAME 1,SATURATED FEED/2,OLEFIN FEED/3,MAKEUP IC4/ &
10,DEC3 FEED/11,PROPANE TO DEC2/12,DEC3 BOTTOMS/ &
20, OLEFIN TO RXN/21,IC4 TO RXN/24, RXN VAPORS/&
25, RXN LIQUIDS/26, COMP SURGE DRUM LIQ/27, RCY TO DEC3/&
30, DEIC4 OVHD/ 30R, IC4 RCY/32, BUTANE/332,ALKYLATE/&
40, FUEL GAS/41B, HD5 PROPANE
OUTPUT FORMAT=VOLSUM, STREAMS=1,2,3,DESCRIPTION=FEED STREAMS
OUTPUT FORMAT=VOLSUM, STREAMS=40,41B,32,332,DESCRIPTION=PRODUCT
STREAMS
OUTPUT FORMAT=VOLSUM, STREAMS=25,DESCRIPTION=REACTOR EFFLUENT
FORMAT ID=VOLSUM, NAME, LINE, TEMP, PRES, LINE, &
LRATE(LV,1,2,BBL/DAY)=C2+,
LRATE(LV,3,BBL/DAY)=PROPANE,&
LRATE(LV,4,BBL/DAY)=I-BUTANE, LRATE(LV,5,BBL/DAY)=N-BUTANE,&
LRATE(LV,6,BBL/DAY)=PROPENE, LRATE(LV,7,9,BBL/DAY)=BUTENES,&
LRATE(LV,10,BBL/DAY)=PENTANE,
LRATE(LV,11,23,BBL/DAY)=C6+,LINE,& RATE(LV,BBL/DAY),
RATE(LV,BBL/HR), &
RATE(LV,M3/HR),
LINE, &
ARATE(LV,GAL/MIN), ARATE(LV,L/MIN), LINE,
& RATE(GV,FT3/HR),
RATE(GV,M3/HR), LINE,
& CPCT(LV,4)
RXDATA
RXSET ID=RS1
REACTION ID=RX1
$ PROPENE - ISOBUTENE REACTION
STOIC 4, -12.3461/ 6, -12.3008/ &
10, 0.5541/ 11, 0.5553/ 12, 2.3756/ 13, 5.9539/ 14, 0.4574/ &
15, 0.0731/ 16, 0.1062/ 17, 0.3969/ 18, 0.0821/ 19, 0.0594/ &
20, 0.6688/ 21, 0.4325/ 22, 0.0468/ 23, 0.0315
REACTION ID=RX2
$ ISOBUTENE - ISOBUTANE REACTION
STOIC 4, -8.5683/ 7, -10.5445/ &
10, 1.2706/ 11, 0.5925/ 12, 0.3827/ 13, 0.2638/ 14, 2.5703/ &
15, 0.3627/ 16, 0.5101/ 17, 2.1523/ 18, 0.3998/ 19, 0.2074/ &
20, 0.2754/ 21, 0.2134/ 22, 0.5173/ 23, 0.0239
REACTION ID=RX3
$ 2-BUTENE - ISOBUTANE REACTION
STOIC 4,-10.9924/ 8, -11.3233/ &
10, 0.6347/ 11, 0.6261/ 12, 0.2832/ 13, 0.1703/ 14, 3.3018/ &
15, 0.4360/ 16, 0.5566/ 17, 4.6514/ 18, 0.1852/ 19, 0.0782/ &
20, 0.0891/ 21, 0.0799/ 22, 0.2831
REACTION ID=RX4
$ 1-BUTENE - ISOBUTANE REACTION
STOIC 4,-11.5763/ 9, -9.9587/ &
10, 0.6877/ 11, 0.5870/ 12, 0.3016/ 13, 0.1730/ 14, 3.1778/ &
15, 0.5271/ 16, 0.6466/ 17, 4.2314/ 18, 0.1686/ 19, 0.0984/ &
20, 0.0720/ 21, 0.0761/ 22, 0.2674/ 23, 0.0079
UNIT OPERATION
FLASH UID=FX,NAME=OLEFIN FD
$ THIS SIMULATES THE OLEFIN FEED FROM THE BOTTOM OF THE
$ OLEFIN DEPROPANIZER (WHICH WILL BE ADDED AT A LATER
DATE FEED 2
PROD L=2A
BUBB TEMP=200
FLASH UID=HT3, NAME=PRECHILLER
$ PRECOOLS OLEFIN FEED TO 100 F
FEED 2A
PROD L=2B
ISO TEMP=100,DP=5
HX UID=FB2
OPERATION CTEMP=170
COLD FEED=1,1NB,27P,L=10
2-21PRO/II
SulfuricCase
AcidBook
Alkylation Plant
2-22PRO/II
SulfuricCase
AcidBook
Alkylation Plant
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
$
$
REACTOR SECTION
SPLITTER UID=OLSP,NAME=OLEFIN_SPLITTER
FEED 20
PROD V=20A, V=20B, V=20C, V=20D
SPEC STREAM=20A,RATE,RATIO, REFF, VALUE=0.25
SPEC STREAM=20B,RATE,RATIO, REFF, VALUE=0.25
SPEC STREAM=20C,RATE,RATIO, REFF, VALUE=0.25
CONREACTOR UID=RX1A, NAME=1ST_STAGE
FEED 20A,21,30R,SA1
PROD M=24X
OPERATION PRES=30,ADIABATIC
RXCALC MODEL=STOIC $,REFPHASE=L,REFTEMP=45
RXSTOIC RXSET=RS1
REACTION RX1
BASE COMPONENT=6
CONVERSION 1
REACTION RX2
BASE COMPONENT=7
CONVERSION 1
REACTION RX3
BASE COMPONENT=8
CONVERSION 1
REACTION RX4
BASE COMPONENT=9
CONVERSION 1
STCALC UID=F1X,NAME=3_PHASE
FEED 24X
OVHD V=24A,L=25A
BTMS STREAM=25AX
FOVHD 1,23,1.0/24,0.0
CONREACTOR UID=RX1B, NAME=2ND_STAGE
FEED 20B,25A,25AX
PROD M=24Y
OPERATION PRES=29,ADIABATIC
RXCALC MODEL=STOIC $,REFPHASE=L,REFTEMP=45
RXSTOIC RXSET=RS1
REACTION RX1
BASE COMPONENT=6
CONVERSION 1
REACTION RX2
BASE COMPONENT=7
CONVERSION 1
REACTION RX3
BASE COMPONENT=8
CONVERSION 1
2-23PRO/II
SulfuricCase
AcidBook
Alkylation Plant
REACTION RX4
BASE COMPONENT=9
CONVERSION 1
STCAL UID=F1Y,
NAME=3_PHASE FEED 24Y
OVHD V=24B,L=25B
BTMS STREAM=25BX
FOVHD 1,23,1.0/24,0.0
CONREACTOR UID=RX1C, NAME=3RD_STAGE
FEED 20C,25B,25BX
PROD M=24Z
OPERATION PRES=28,ADIABATIC
RXCALC MODEL=STOIC $,REFPHASE=L,REFTEMP=45
RXSTOIC RXSET=RS1
REACTION RX1
BASE COMPONENT=6
CONVERSION 1
REACTION RX2
BASE COMPONENT=7
CONVERSION 1
REACTION RX3
BASE COMPONENT=8
CONVERSION 1
REACTION RX4
BASE COMPONENT=9
CONVERSION 1
STCALC UID=F1Z,NAME=3_PHASE
FEED 24Z
OVHD V=24C,L=25C
BTMS STREAM=25CX
FOVHD 1,23,1.0/24,0.0
CONREACTOR UID=RX1D, NAME=4TH_STAGE
FEED 20D,25C,25CX
PROD M=24ZZ
OPERATION PRES=27,ADIABATIC
RXCALC MODEL=STOIC $,REFPHASE=L,REFTEMP=45
RXSTOIC RXSET=RS1
REACTION RX1
BASE COMPONENT=6
CONVERSION 1
REACTION RX2
BASE COMPONENT=7
CONVERSION 1
REACTION RX3
BASE COMPONENT=8
CONVERSION 1
REACTION RX4
BASE COMPONENT=9
CONVERSION 1
2-24PRO/II
SulfuricCase
AcidBook
Alkylation Plant
STCALC UID=F1ZZ,NAME=3_PHASE
FEED 24ZZ
OVHD V=24D,L=25D
BTMS L=25DX
FOVHD 1,23,1.0/24,0.0
STCALC UID=SETL,NAME=ACID_SETTLER
FEED 25D/25DX
OVHD V=24E,L=25,PRES=26
BTMS STREAM=SA2,PRES=26
FOVHD 1,23,1.0/24,0.0
MIXER UID=VAPR, NAME=RXN_VAPORS
FEED 24A,24B,24C,24D,24E
PROD V=24
CONTROLLER UID=C2
SPEC STREAM=25,TEMP,VALUE=45,ATOL=0.0002
VARY SPLITTER=S1,SPEC,MINI=1,MAXI=1000,STEP=20
CPARAMETER ITER=5
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
$ REFRIGERATION CIRCUIT
FLASH UID=MCOM
$ SIMULATED IN DETAIL OUTSIDE THE
FEED 24,29
$ RECYCLE LOOPS WITH CMP1, CMP2 AND AFTR
BUBB TEMP=100 $ PRES=73
PROD L=26
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
$ PRODUCT PURIFICATION CIRCUIT
PUMP UID=P2,NAME=EFFL_PUMP
FEED 25
PROD L=251
OPERATION PRES=120
$
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
$ After first run, substitute first insert in Appendix B for Column DIC4
COLUMN UID=DIC4, NAME=ISO-STRIPPER
PARA SURE=20, TRAYS=42
FEED 253X, 1
PROD OVHD=30, BTMS=31, 1300
DUTY 1, 42
$ The next line sets the iC4 recycle rate
SPEC STREAM=30, RATE(LV),VALUE=2525
VARY DUTY=1
ESTIMATE MODEL=CONVENTIONAL
PRESSURE 1,90 / 42,95
2-25PRO/II
SulfuricCase
AcidBook
Alkylation Plant
PRINT PROP=BRIEF
TRATE SECTION=2,42,SIEVE,PASSES=4, &
SPACING(TRAY,IN)=24,
DIAMETER(TRAY,FT)=13
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
HX UID=FT1,NAME=EFFL_RECL
COLD FEED=251,L=252,DP=5
HOT FEED=30,L=30R,DP=5
OPER HTEMP=62
CONFIG U(BTU/HR)=90
PUMP UID=P1
FEED 27
PROD L=27P
OPER PRES=400
$ THE DEBUTANIZER CIRCUIT IS SOLVED OUTSIDE THE LOOP
COLUMN UID=DEC4,NAME=DEBUTANIZER
PARA TRAYS=30,ERRINC=1.05
FEED 31,15
PROD OVHD=32,350,BTMS=33
COND TYPE=TFIX,TEMP=100,PRES=80
DUTY 1,1/2,30
SPEC STREAM=33, RVP,VALUE=12.0
SPEC STREAM=32, COMP=10, PERCENT(LV), VALUE=2.0
VARY DUTY=1,2
ESTIMATE MODEL=CONVENTIONAL
PRESSURE 2,85/30,90
PRINT PROP=BRIEF
TRATE SECTION=2,29,SIEVE,PASSES=1, &
SPACING(TRAY,IN)=24,
DIAMETER(TRAY,FT)=5
HX UID=FB4,NAME=EFFL_ALKY
COLD FEED=252,L=253,DP=5
HOT FEED=33,L=331,DP=5
OPER CTEMP=110
HX UID=CL4,NAME=ALKY_CLR
HOT FEED=331,L=332,DP=5
UTIL WATER TIN=70,TEMP=80
OPER HTEMP=100
$ THE DEETHANIZER IS SOLVED OUTSIDE THE LOOP
PUMP UID=P3
FEED 11
PROD L=11A
OPERATION PRES=600
2-26PRO/II
SulfuricCase
AcidBook
Alkylation Plant
2-27PRO/II
SulfuricCase
AcidBook
Alkylation Plant
FEED 11B,5
PROD OVHD=40,40,BTMS=41
CONDENSER TYPE=PART,PRES=420
PARA TRAY=20
SPEC TRAY=1,TEMP,VALUE=100.0
SPEC STREAM=41,TVP(PSIG),VALUE=203 $ HD5 SPEC IS 208 MAX
ESTI MODEL=CONVENTIONAL,RRATIO=2.0
DUTY 1,1/2,20
VARY DUTY=1,2
PSPEC PTOP=425,DPCOL=10
PRINT PROP=BRIEF
TSIZE SIEVE
HX UID=FB1
COLD FEED=11A,L=11B,DP=5
HOT FEED=41,L=41A,DP=5
OPERATION HOCO=5
HX UID=CL1
HOT FEED=41A,L=41B,DP=5
UTIL WATER TIN=70,TOUT=80
OPERATION HTEMP=100
$ THE COMPRESSOR REQUIREMENTS CAN BE CALCULATED AFTER
$ THE RECYCLE LOOPS ARE SOLVED
VALVE UID=SCTN, NAME=SUCTION
FEED 24
PROD V=240
OPERATION PRES=23
COMPRESSOR UID=CMP1, NAME=1ST STAGE
FEED 240
PROD V=241
OPERATION CALC=GPSA,EFF=80
DEFINE PRESSURE AS STREAM=29 PRESSURE MINUS 1
COMPRESSOR UID=CMP2, NAME=2ND STAGE
FEED 241,29
PROD V=260
OPER CALC=GPSA
DEFINE PRESSURE AS STREAM=26,PRESSURE,PLUS 5.0
FLASH UID=AFTR, NAME=AFT_COOL
FEED 260
PROD L=261
BUBB DP=5
2-28PRO/II
SulfuricCase
AcidBook
Alkylation Plant
$
----------------------------------------------------RECYCLE
2-29PRO/II
SulfuricCase
AcidBook
Alkylation Plant
2-30PRO/II
SulfuricCase
AcidBook
Alkylation Plant
Appendix B:
Input Changes for Runs 2 and 3
Keyword Input File Inserts for Run 2 (De-isobutanizer Configuration) and Run 3(Effluent Refrigeration Configuration)
Substitute these file inserts for the corresponding sections if input
listed in Appendix A.
Insert 1: Debutanizer
Original input to discard:
COLUMN UID=DIC4, NAME=ISO-STRIPPER
PARA SURE=20, TRAYS=42
FEED 253X, 1
PROD OVHD=30, BTMS=31, 1300
DUTY 1, 42
$ The next line sets the iC4 recycle rate
SPEC STREAM=30, RATE(LV),VALUE=2525
VARY DUTY=1
ESTIMATE MODEL=CONVENTIONAL
PRESSURE 1,90 / 42,95
TRATE SECTION=2,42,SIEVE,PASSES=4, &
SPACING(TRAY,IN)=24, DIAMETER(TRAY,FT)=13
PRINT PROP=BRIEF
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Appendix C:
Wet Sulfuric Acid Process
The availability of a suitable catalyst is also an important factor in
deciding whether to building an alkylation plant. When sulfuric
acid is used, significant volumes are needed. Access to a suitable
plant is required for the supply of fresh acid and the disposition of
spent acid. If a sulfuric acid plant must be constructed specifically
to support an alkylation unit, such construction will have a significant impact on both the initial requirements for capital and
ongoing costs of operation.
Alternatively it is possible to install a WSA Process unit to regenerate the spent acid. The WSA process is the ideal choice for regeneration of spent sulphuric acid. No drying of the gas takes place. This
means that there will be no loss of acid, no acidic waste material
and no heat is lost in process gas reheating. The selective
condensa- tion in the WSA condenser ensures that the regenerated
fresh acid will be 98% w/w even with the humid process gas. It will
be possi- ble to combine spent acid regeneration with disposal of
hydrogen sulphide by using hydrogen sulphide as fuel.[A1].
The wet sulfuric acid process (WSA process) is one out of many
gas desulfurization processes on the market today. Since its
introduc- tion in the 1980s, where it was patented by the Danish
catalyst com- pany Haldor Topse A/S, it has been recognised as
an efficient process for recovering sulfur from various process
gasses in the form of commercial quality sulfuric acid (H2SO4).
The WSA pro- cess is applied in all industries where removal of
sulfur is an issue.
Wet catalysis processes differ from other contact sulfuric acid processes in that the feed gas still contains moisture when it comes
into contact with the catalyst. The sulfur trioxide formed by
catalytic oxidation of the sulfur dioxide reacts instantly with the
moisture to produce sulfuric acid in the vapour phase to an extent
determined by the temperature. Liquid acid is subsequently formed
by conden- sation of the sulfuric acid vapour and not by absorption
of the sulfur trioxide in concentrated sulfuric acid, as is the case in
contact pro- cesses based on dry gases. The concentration of the
product acid depends on the H2O/SO3 ratio in the catalytically
converted gases and on the condensation temperature. [A1] [A2]
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A2
A3
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