IndustrialIT for HF Alkylation

Creating value through integrated solutions

Improve HF Alkylation unit safety, environmental and economic performance

Improve HF Alkylation unit safety, environmental and economic performance

Overview Refiners operating HF Alkylation units are under increasing pressure to maximize unit throughput, improve product quality and yields while operating safely and with low environmental impact. Ever tightening gasoline quality legislation and increasing public and regulatory scrutiny concerning the use of hydrofluoric acid combine to make reliable and efficient operation of HF Alkylation units of critical importance to the overall reputation and profitability of petroleum refineries. ABB offers a unique IndustrialIT solution for HF Alkylation units to assist operating companies in meeting the significant challenges of this difficult operating environment. Our leading technology is multivariable, model-predictive control that exploits our unique capability for rapid and reliable on-line analysis of multiple HF Alkylation unit streams: Recirculating acid catalyst is rapidly and precisely characterized for HF, ASO and water content by our proven technology now operating in multiple Phillips & UOP licensed units around the world. Exploiting the same analyzer used for acid characterization, ABB can deliver rapid and reliable analysis of the following HF Alkylation unit streams: Recycle isobutane Olefin and make-up isobutane feeds Alkylate and normal butane products Acid regenerator overheads Feed drier outlet moisture Caustic solution strength in acid gas relief/vent neutralization Our ASTM approved PGC2007 and RVP4100 analyzers ensure reliable on-line measurement of sulfur in feeds and volatility of alkylate respectively. The PGC2007 is used in numerous refineries for the mandated measurement and reporting of fuel sulfur content and so is a proven technology for hydrocarbon sulfur analysis. The RVP4100 is the de-facto industry standard for on-line measurement of RVP in gasoline blendstocks and finished products. ABBs ACF-NT continuous emissions monitoring technology can deliver improved detection and reporting of HF stack emissions associated with ASO combustion. HF can be reliably detected over a minimum measuring range of 0-5ppm with a limit of detection down to 0.13ppm. With over 400 installations, the technology is approved by Germanys TUV organization and complies with continuous emission monitoring standards issued by the EPA, ASTM and the UKEA. ABBs 8231 Fluoride monitor is a proven solution for the rapid detection of HF contamination of cooling water and condensate systems and can prevent accelerated corrosion, alleviate safety concerns and decrease maintenance costs. We offer a complete service portfolio including field services, on-line support and training in order to maintain the performance of your IndustrialIT solution.

Industrial IT for HF Alkylation

IndustrialIT for HF Alkylation Employs our unique capability for rapid on-line characterization of recirculating acid catalyst, a proven solution now operating in multiple Phillips & UOP licensed units around the world. For the first time in the industry, a technology that guarantees rapid and reliable characterization of iC4 recycle to ensure optimum reactor operation. Sulfur and moisture content of unit feeds are rapidly determined on-line leading to improved catalyst efficiency and management of drier regeneration cycles. On-line measurement of alkylate and n-butane qualities ensures maximum product valuations. The commonly troublesome operation of acid regeneration can be improved by the availability of feed and overhead compositions. Improved effluent management of ASO combustion and relief gas neutralization exploiting rapid on-line characterization of stack emissions and recirculating caustic ensures enhanced environmental compliance. Combines these unique analytical measurements with our leading edge multivariable control technology and extensive experience in delivering advanced process control projects leading to distinctive client benefits typically in the range of $1M - $3M per annum for a 10,000bpd unit. Operators can obtain an HF Alkylation unit process and environmental solution from one vendor, delivering unique synergistic benefits to the operation of these facilities. This leads to maximized unit throughput, improved product quality and yields while operating safely and with low environmental impact. HF Alkylation Unit operations Efficient operation of an HF Alkylation unit is a difficult task and subject to the most testing of operating regimes. This is due to a number of industry specific constraints and operating issues that stretch the processing capability of the plant. Operating issues HF Alkylation units must be able to deal with feedstocks that routinely vary in contaminant levels, hydrocarbon composition and volume due to upstream operating complexities. Operators have the difficult challenge of minimizing iC4 recycle and associated utility costs while producing alkylate of desired quality with minimum acid consumption. The units must be operated in a safe manner despite the everpresent potential for acid runaway, accelerated equipment corrosion and associated HF release. The demands on HF Alkylation units are further increased due to ongoing trends within the petroleum refining industry.

Industry issues

Industry trends Ongoing expansions of FCC units and implementation of new cracking catalysts to satisfy gasoline growth also results in more alkylation feedstock. A continuing trend towards increased residue cracking and upgrading capacity which produces more complex and problematic alkylation feedstocks. Increasing interest in C5 olefin processing as a means to return volatile components to the gasoline pool while increasing product volumes. Continually tightening gasoline quality legislation mandating changes in allowable oxygenate blendstocks and driving towards lower and lower sulfur content. All of these scenarios result in increased demands on the HF Alkylation unit to be more flexible in handling increased and varying feedstocks, while maintaining unit efficiency and alkylate quality. The ideal blending characteristics of alkylate make it a critical element in meeting refinery profit and legislated fuel quality compliance goals. Health, safety and environment (HSE) issues The whole refining industry is subject to ever-tightening HSE legislation with HF Alkylation arguably being subjected to the most stringent rules due to the real and perceived hazards associated with the process. Regulations continue to drive towards minimizing air and wastewater emissions and much effort is made by operators to improve, monitor and report environmental performance. Penalties for non-compliance are expensive from financial as well as reputation perspectives and in some cases may result in withdrawal of license to operate. HF Alkylation units continuously strive to minimize personnel and public exposure to acid with minimization of acid losses from unit containment. Ever increasing public and regulatory scrutiny concerning the use of hydrofluoric acid in industrial facilities. Industry trends, complex operating conditions and more stringent HSE compliance all contribute to the increasing difficulties of operating HF Alkylation units. To meet these challenges, it is more important now than ever, that these units maximize throughput, increase feed flexibility, boost product yields and volume while operating in a safe and environmentally compliant manner.

Meeting the challenges

What are the options for HF Alkylation Unit operators? Further technical developments and improvements in HF Alkylation must meet these increasing operational challenges. HF Alkylation technology must be highly focused on economic, safety and environmental compliance issues while improving operability of current operations. In the last few years, the main capital investment for many operators has been the installation of acid release mitigation technology and improved reactor configurations such as split olefin feed designs. These developments have been successful in solving many of the operating problems and decreasing the risks associated with HF Alkylation operations. However, despite these improvements, a number of historical challenges still exist that significantly hinder the optimum economic and safe operation of these units. In this respect, improved process control of existing assets can further enhance unit operability and improve the HSE profile of the process. Advanced process control is always one of the most efficient, low cost actions that is undertaken by the operators of any process unit. Many of the ongoing operating problems and potential risks affecting HF Alkylation units are a result of less than optimum process control of key unit objectives. Although advanced process control has been widely implemented across the petroleum refining industry, implementations in HF Alkylation units have been few and far between. A major factor in this has been the difficulty of obtaining reliable compositional data from on-line analyzers due to the aggressive nature of HF acid on these systems. This problem results in the following common scenarios: A critical measurement is assumed impossible to execute on-line and is thus relegated to a lab measurement which is of course too slow for making process control decisions. An on-line analyzer has been too unreliable or maintenance intensive that neither the operators nor the control scheme can trust the results. Attempts to satisfy these voids with inferential measurements have resulted in mixed success. A good example of this operating challenge is the optimum control of isobutane:olefin (I/O) ratio. Almost all operating companies have difficulty in obtaining rapid and reliable recycle isobutane analysis because of the aggressive nature of trace amounts of HF on traditional gas chromatographs operating in this duty. The lack of timely and reliable data for this key parameter can result in significant performance deterioration including lower product octane and higher acid consumption, or excessive fractionation and recycle with associated utility costs. These and other common HF Alkylation operating challenges that have been experienced for many years in the industry can now be managed by the application of the ABB solution for this process - IndustrialIT for HF Alkylation. Operators that have been limited in their ability to deal with day to day upsets and control of key operating variables can now maintain optimum performance of HF Alkylation operations. The ABB solution delivers a robust analytical approach coupled to advanced process control to manage the complex multivariable interactions, high on-stream time demands and potential environmental impact of the HF Alkylation process. This leads to significant improvement in unit economic, safety and environmental performance.

ABBs unit-wide advanced process control approach for HF Alkylation will stabilize plant operation, improve profitability by maximizing throughput against equipment and operating constraints, increase octane-barrels and reduce acid and energy consumption. Our integrated solution provides rapid and reliable on-line analyses, in tandem with control and constraint enforcement for key process variables targeted in unit operating objectives. The ABB solution will reject feed disturbances via rapid feed characterization, stabilize control of key reactor operating parameters, manage acid regeneration and control the fractionation of key products. IndustrialIT for HF Alkylation can deliver distinctive benefits to operators and some aspects of this uniquely integrated analytical and process control approach are described below.
Feed quality and treatment
Operating challenges Varying feedstock compositions are common due to upstream operating complexities in the FCC complex or by importation of externally purchased feeds. This can lead to poor alkylate quality from low I/O ratio in the reactor. Acid and isobutane consumption can also increase as the C3-C5 olefins content of the feed changes. Rapid and frequent variations in feed contaminant levels, especially sulfur compounds, can lead to high acid consumption, throughput reduction, poor product quality, aggressive regenerator action, equipment fouling and approaches to runaway conditions. Feed moisture breakthroughs can result in increased acid losses and accelerated plant corrosion. Conversely, drier regeneration cycles can be too frequent with associated penalties in energy costs and shortened bed life. Solution The implementation of ABB analytical technology for on-line analysis of sulfur, moisture and other common contaminants in tandem with rapid hydrocarbon composition characterization allows these common operating problems to be solved. Using our proven ASTM approved PGC2007 sulfur analyzer, this most common and troublesome feed contaminant can be reliably detected on-line down to the low levels demanded by the process. Exploiting additional measurement capability of our industry standard HF Acid analyzer, moisture content as well as hydrocarbon composition can be determined in olefin and makeup isobutane feeds. Moisture content can be measured before and after the drier(s) to allow optimum management of regeneration cycles for these unit operations. In addition, total olefin and iC4 content of olefin feed can be determined as well as iC4 content of make-up isobutane. For both feeds, our technology can also provide an on-line indication of C3-C5 content variations. eg: This can help notify operators of propylene or propane spikes in olefin and isobutane feeds respectively.

Industrial IT for HF
2
Reactor optimization
Operating challenges Calculating and maintaining optimum I/O ratio continues to be a difficult challenge for many operating companies due to: Frequently varying composition of olefin and make-up isobutane feeds further complicated by slow feedback from traditional GC methods whether on-line or in the laboratory. Problems maintaining reliable performance of the recycle iC4 GC due to trace HF acid breakthrough causing plugging and corrosion. Many operators report discontinued use of this analyzer due to unacceptable maintenance costs or performance. Achieving minimum I/O ratio while meeting alkylate quality and yield targets in tandem with acceptable acid consumption. Balancing fractionation costs of better inerts removal in recycle iC4 against the benefits of improved alkylate quality, yield and plant throughput. Optimizing iC4 make up rate while respecting iC4 inventory constraints. To produce high yields of quality alkylate, acid composition must be maintained in a target operating range for HF, ASO and water contents. Many operators are limited in their capability to rapidly and accurately monitor catalyst quality as off-line methods are carried out infrequently, are lengthy in execution and have historically been found to be imprecise. This poor monitoring capability can lead to approaches of runaway conditions, increased corrosion, lost octane opportunities, lower alkylate yields, more aggressive regenerator operation and higher acid losses. Maximizing feedrates against physical operating limits across the unit while achieving product quality and energy consumption targets. Maintaining target acid:hydrocarbon ratios and reactor temperature to improve product quality and suppress ASO production. Optimizing split flow or parallel reactor configurations to ensure maximum alkylate quality at the highest throughput by maintaining target local I/O ratios and reactor feed balancing. Solution Implementation of ABB multivariable control technology driven by our unique capability of rapid, on-line characterization of acid, recycle iC4 and olefin/iC4 make-up allows these common operating problems to be solved. Recirculating acid catalyst is rapidly and precisely characterized for HF, ASO and water content by our proven NIR solution now operating in multiple Phillips & UOP licensed units around the world. For the first time in the industry, ABB can deliver a technology that guarantees rapid and reliable characterization of recycle isobutane by exploiting the same analyzer used for acid analysis. The instrument can also be configured to determine total olefin and iC4 content of olefin feed as well as iC4 content of make-up isobutane. The rapid and reliable availability of these measurements underpinning ABBs multivariable control approach, finally allows operators to satisfy the long sought after goal of truly optimizing reactor I/O ratio delivering all of the documented benefits associated with this most key operating parameter. In addition, the APC scheme will also stabilize control of key operating parameters such as hydrocarbon feed and acid recirculation rates, temperature and multiple reactor feed balancing.

Alkylation
3
Fractionation and product quality control
Operating challenges Controlling nC4 draw-off rates and internal reflux to minimize iC4 losses while avoiding nC4 build up in the reactor which can lead to alkylate octane and yield loss as well as fresh feed throughput limitations. This difficult balance is further exacerbated by slow or non-existent measurement of key compositions which can lead to aggressive overcorrection by operators. Achieving steady column performance to avoid oscillating between these common extremes. Minimizing the high energy costs associated with deisobutanizer fractionation by avoiding over-purification of products. Operating the depropanizer to ensure low levels of propane in iC4 recycle, maximum iC4 in the premium bottoms recycle and production of propane with the highest quality. Maximizing alkylate draw-off rate while maintaining quality within target specifications. Managing the frequent quality variations of field butanes or C4 isomerate in those units that fractionate these imported streams. Solution Implementation of ABB multivariable control technology driven by rapid on-line characterization of iC4 recycle, nC4 sidedraw, depropanizer bottoms and alkylate streams allows these common operating problems to be solved. For the first time in the industry, ABB can deliver a technology that guarantees rapid and reliable characterization of iC4 recycle by exploiting the same analyzer that delivers acid strength determination. This includes not only iC4 content but the capability to determine if C3 or C5 inerts are building up in the stream. Normal butane is also characterized by this technology for iC4 content. ABB has a dominant global market position in gasoline analysis via our NIR and ASTM approved RVP analyzers. This allows us to rapidly and precisely provide on-line characterization for alkylate octane, distillation and volatility. Imported C4 saturate streams can also be characterized to help reject the disturbances these streams create in fractionation operations. The rapid and reliable availability of all of these measurements is a key element of ABBs multivariable control package which delivers industry leading performance for HF Alkylation fractionation trains.

Acid quality management and regenerator operation

Operating challenges Maintaining acid composition ensuring high alkylate yield/quality, minimum regenerator load, minimum acid losses and extended equipment life via reduced corrosion. Optimizing regenerator operation to minimize energy consumption and acid losses leading to reduced acid inventory and make-up costs while simultaneously reducing neutralization requirements. These tasks are further complicated due to difficulties in rapidly, completely and accurately monitoring recirculating and regenerated acid qualities as off-line analysis is carried out infrequently, is lengthy in execution and has historically been found to be imprecise. This is especially true for ASO and water components which are critical to optimizing regenerator operations. Solution Implementation of ABB multivariable control technology underpinned by our unique capability for rapid and complete on-line characterization of recirculating acid catalyst and regenerator overheads allows these common operating problems to be truly solved for the first time. Recirculating acid catalyst is rapidly and precisely characterized for HF, ASO and water content by our proven NIR solution now operating in multiple Phillips & UOP licensed units around the world. The same trusted analyzer can also be used to monitor regenerator overhead composition. The rapid availability of both regenerator feed and overheads is integrated in the unique ABB multivariable approach to manage the traditional problems of operating these columns.

Process effluent management

Operating challenges Maintaining efficient operation of acid gas relief/vent neutralization to eliminate HF breakthrough to the refinery flare system while minimizing caustic consumption, spent effluent neutralization and solids disposal costs. Ensuring that neutralized ASO used as a fuel meets compliance limits for HF stack emissions. Minimizing HF contamination of cooling water and condensate systems to prevent corrosion and improve safety. Solution ABB provides proven analytical technology for on-line analysis of caustic strength, low levels of HF in stack emissions and fluoride ion in water streams to allow these common operating challenges to be addressed. On-line caustic strengths can be rapidly determined using the same analyzer used for HF catalyst analysis. This permits the operator to further exploit the initial capital investment made in the acid analyzer. This proven application has been delivered in numerous projects across many industries. In continuous emission monitoring, ABB is recognized as the global leader. Our ACF-NT technology has been installed in over 400 plants for the continuous monitoring of a wide variety of components including HF. We have the lowest detection limits and sensitivity in the industry for analysis of HF in stack emissions. We also offer our leading 8231 Fluoride monitor as a proven solution for the rapid detection of HF contamination of cooling water and condensate systems to prevent accelerated corrosion, alleviate safety concerns and decrease maintenance costs.

Benefits of Industrial IT for HF Alkylation

Feed quality and treatment

Successful, incident free operation of an HF Alkylation unit is largely related to feed composition and efficient contaminant removal. Olefin and make-up isobutane feeds can be characterized for moisture and hydrocarbon composition by the same analyzer that is proven for on-line acid analysis thus helping to amortize any investment made in this technology. In addition, ABBs PGC2007 is a widely used, ASTM approved technology for low level sulfur analysis in hydrocarbons. Rapid and reliable on-line determination of hydrocarbon composition, sulfur and moisture content of feed offers several advantages to the operator. The reliable determination of feed sulfur content leads to many operating benefits. Reduced acid consumption and less aggressive operation of the acid regenerator resulting in lower variable costs and improved equipment life. Avoid feedrate reductions with coincident improvements in alkylate quality and yield. There are fewer approaches to runaway conditions which in many units is an infrequent event but results in significant cost penalties when experienced. Exploiting additional measurement capability of our industry standard HF acid analyzer, moisture content can be rapidly determined in olefin and make-up isobutane feeds before and after drying. Prevent problematic moisture breakthroughs with optimum management of regeneration cycles. Many plants operate with routine drier regeneration cycles which can lead to high feed moisture levels or conversely, unnecessarily high energy costs and shortened bed life. Improved control of feed moisture levels can improve alkylate quality, decrease acid losses and reduce plant corrosion. The acid analysis technology can also be configured to rapidly report total olefin and iC4 content of olefin feed as well as iC4 content of make-up isobutane. For both feeds, our technology can also provide an on-line indication of C3-C5 content variations. Track the quality of feeds delivered by the FCC and saturated gas plant as well as those that are imported from external sources to allow troubleshooting and policing of upstream units and suppliers. Operators can be notified of propylene/amylene or propane spikes in olefin and isobutane feeds respectively. Provide enhanced protection to those units where feed contamination incidents may be more severe as circulating acid volume is lower due to external cooling schemes.

Benefits of Industrial IT for HF Alkylation

Reactor optimization

Implementation of ABB multivariable control technology underpinned by our unique capability of rapid on-line characterization of acid, recycle iC4, olefin/iC4 make-up feeds and alkylate delivers significant operating improvements to HF Alkylation reactors. Feedrates, alkylate yield, and alkylate octane are maximized to an economic optimum, subject to operating constraints I/O ratio and energy consumption can be reduced while meeting alkylate quality and yield targets with minimum acid consumption. Isobutane make-up rate can be optimized while respecting iC4 inventory constraints. Acid quality is maintained in the optimum operating range for HF, ASO and water contents leading to: Less frequent approaches to runaway conditions. Lower acid inventory as acid make-up requirements are reduced due to decreases in average operating acid strengths. Alkylate octane enhancements are possible as water content of the catalyst can be increased in a controlled manner. One of the major licensors reports that an increase in water content from 1.0 - 2.0 wt% can deliver over $1M in benefits for a 10,000bpd unit operating at an I/O ratio of 10. Less aggressive regenerator operation and lower acid losses. High quality alkylate and yields. Acid:hydrocarbon ratios and reactor temperature are controlled to improve product quality and suppress ASO production. Operation of split flow and/or parallel reactor configurations are optimized to ensure maximum alkylate quality at the highest throughput by maintaining target local I/O ratios and optimum reactor feed balancing. Reactor conditions are optimized to manage variations in fresh feed compositions.

Benefits of Industrial IT for HF Alkylation

Fractionation and product quality control

Implementation of ABB multivariable control technology driven by rapid on-line characterization of iC4 recycle, nC4 sidedraw, depropanizer bottoms and alkylate ensures product specifications are met with the lowest energy consumption. The optimum balance is maintained between minimizing iC4 losses in product and the build up of n-butane in recycle iC4. Achieving steady column performance avoids oscillations between these operating extremes which are common in many plants due to aggressive manual intervention by operators. The reduction of inerts in the recycle stream permits maximum fresh feed addition while maximizing alkylate octane-barrels. Minimizing iC4 losses while avoiding alkylate quality and yield penalties can generate annual benefits of approximately $0.5M for a 10,000bpd unit. Energy costs associated with deisobutanizer fractionation are minimized by avoiding over-purification of products and by operating the reboiler heater at maximum efficiency via pass balancing and outlet temperature control. Tight control of the depropanizer ensures low levels of propane in iC4 recycle, maximum iC4 in the premium bottoms recycle and production of propane at the highest quality. Alkylate draw-off rate is maximized while maintaining quality within target specifications with rapid and reliable on-line determination of octane, volatility and distillation characteristics. Given the highly repeatable and frequent determination of RON by our NIR technology, ABBs APC approach will improve average alkylate RON quality and so minimize those production limiting periods where alkylate specification is the constraint. Imported field butanes or C4 isomerate feeds can be rapidly characterized which allows the control scheme to manage the effects of these significant disturbance variables as they impact fractionator operation.

Acid quality management and regenerator operation

ABBs multivariable control approach incorporates our dual capability for rapid on-line characterization of recirculating acid and regenerator overhead streams. This uniquely integrated approach leads to distinctive benefits for regenerator operations and acid management activities. The lack of stream composition measurements around continuous regenerators has been a historical problem for operators. This has now been solved allowing operation with minimum acid loss while efficiently rejecting ASO and water. Rapid and reliable measurement of HF, ASO and water in feed and overheads (including light ASO content) can be used to optimize column operating temperatures and iC4 stripping rates with associated energy savings. Column overheads analysis allows mass balance calculations to be performed to estimate and control HF losses in ASO bottoms with associated savings in acid and neutralization costs. Rapid knowledge of acid quality means that the column can now be operated less aggressively and with less energy consumption, helping to reduce corrosion and extending equipment life. Rapid and accurate acid analysis in tandem with acid level controls means that: Minimum acid strength can be now maintained in an acceptable operating range that still produces the maximum yield of high quality alkylate. This lowering of average acid strength allows fresh make-up costs and overall acid inventory to be reduced making a significant contribution to improved unit safety and risk profile. Improved regenerator load management for those refineries planning to source more feeds from resid units or increase amylene content of feed. For those plants that operate regenerators on a campaign basis, the frequency of required start-ups and the duration of the regeneration period can be significantly reduced. The ABB solution elements for regenerator, feed characterization and reactor control deliver significant savings in operating costs, acid losses and operator attention.

Benefits of Industrial IT for HF Alkylation

Process effluent management

As the global market leader in process and environmental monitoring, ABB can help operators of HF Alkylation units meet legislative and process operating goals under the umbrella of a single vendor. Exploiting the same analyzer that is used to characterize acid catalyst, our patented technique for rapid on-line caustic analysis can help operators maintain efficient operation of acid gas relief/vent neutralization systems leading to a number of operating benefits. Elimination of HF breakthrough to the refinery flare system with minimum caustic consumption, associated spent effluent neutralization and solids disposal costs. Rapid on-line caustic strength measurement allows detection of non-condensable venting and helps reduce acid losses and associated neutralization costs. The same analyzer can also be used to monitor upstream Merox unit caustic strengths which in combination with ABB feed sulfur analysis, will minimize contamination incidents. Many refineries that use neutralized ASO as a fuel (eg: in main fractionation reboiler heater) are under increasing legislative pressure to improve, monitor and report any associated HF emissions. In some localities, exceeding HF emission limits will result in a mandated plant shutdown. ABB can provide market leading technology for characterization of HF stack emissions as we are recognized as the global leader in continuous emission monitoring. Our ACF-NT analyzer has been installed in over 400 plants for the continuous monitoring of a wide variety of components. HF can be reliably detected over a minimum measuring range of 0-5ppm with a limit of detection down to 0.13ppm. With over 400 installations, the technology is approved by Germanys TUV organization and complies with continuous emission monitoring standards issued by the EPA, ASTM and the UKEA. The reliable determination of HF in ASO combustion gases also allows the operator to estimate HF losses in regenerator bottoms. Exchanger leaks can cause HF contamination of cooling water and condensate systems leading to accelerated corrosion, safety concerns and increased maintenance costs. In order to rapidly detect and manage these occurrences, a number of HF Alkylation unit operators employ the ABB 8231 Fluoride monitor. This analyzer is self calibrating and ensures reliable on-line measurements in this critical duty.

Benefits of Industrial IT for HF Alkylation

A brief history of ABB on-line HF acid analysis

ABB began working with Phillips Petroleum (now ConocoPhillips) to develop an on-line acid analysis system in 1996. Two years of testing and development followed on HF Alkylation pilot scale units. This included sample system design, metallurgy considerations and model development. The analyzer was then installed in May 1998, at the Phillips Petroleum refinery in Sweeny, Texas. Two more years of successful on-site testing ensured the technology was ready for industry-wide implementation. The on-line acid analyzer was then launched to the HF Alkylation market at the 2000 Phillips licensee symposium. As of mid-2004, the system has been installed in over a dozen HF alkylation units worldwide with a combined operating history of over 20 years. These systems are operating in both ConocoPhillips & UOP licensed units in North/South America, Europe and the Middle-East by operating companies including ExxonMobil, ConocoPhillips, Valero, PCK, Sunoco, Marathon-Ashland and Pemex.

IndustrialIT for HF Alkylation: health, safety and environment There is ever increasing public and regulatory scrutiny concerning the use of hydrofluoric acid in industrial facilities. In this environment, HF Alkylation processes are arguably subject to the most detailed examination due the dual hazards of both fire and toxic release presented by the combination of LPG and HF streams. ABBs IndustrialIT for HF Alkylation can help operators uniquely meet the significant HSE challenges encountered in the day to day operating activities and unit operations of their plant. Accidental acid release: risk reduction Minimize leak potential: Less aggressive regenerator operation and improved catalyst moisture management is achieved by enhanced feed impurity and catalyst water monitoring leading to reduced corrosion rates and longer equipment life. Minimize quantity released: Lower acid inventory is possible by lowering average acid strengths in tandem with minimizing catalyst losses. These goals are achieved by rapid feed impurity and catalyst characterization, improved acid runaway prevention and faster detection, as well as optimized regenerator operation. Minimize cloud forming potential: Improve operation of modified HF systems that reduce catalyst volatility by utilization of ABBs acid monitoring technology which has been successfully applied to the ConocoPhillips Revap process catalyst. Routine acid exposure: risk reduction Minimize exposure potential: Reduce manual acid sampling and off-line analysis by employing ABBs rapid and reliable on-line acid monitoring technology. Operator and laboratory personnel acid exposure can be significantly reduced with coincident manpower savings of up to $40K per year being reported by existing clients. Using the same analyzer, traditional high maintenance GCs can also be eliminated for applications such as iC4 recycle analysis which significantly reduces analyzer technician intervention and acid exposure. Minimize process effluents Improved feed impurity and acid analysis results in reduced ASO formation and enhanced regenerator operation. This decreases overall HF emissions associated with ASO combustion. Improve monitoring and reporting of low level HF stack emissions in ASO combustion by use of our ACF-NT technology which complies with continuous emission monitoring standards issued by the EPA, ASTM and the UKEA. Rapid and reliable on-line caustic strength analysis improves acid relief/vent scrubbing and so helps prevent HF acid leakage into flare systems as well as reduces solids disposal requirements.

Benefits of Industrial IT for HF Alkylation

ABBs 8231 Fluoride monitor is a proven solution for the rapid detection of HF contamination of cooling water and condensate systems and can prevent accelerated corrosion, alleviate safety concerns and decrease maintenance costs. Rapid and reliable feed and catalyst moisture monitoring permits improved drier and regenerator operation reducing constant boiling mixture production with associated reductions in acid losses, neutralization and solids disposal requirements. Minimize energy consumption Energy costs are minimized as ABBs integrated analytical and multivariable control solution reduces recycle costs while maintaining target product qualities, avoids over-fractionation of products, ensures the highest reboiler heater efficiency and optimizes stripping and vaporization rates in the regenerator column.

ABB offers a unique IndustrialIT solution for HF Alkylation units to assist operating companies in meeting the significant challenges of todays operating environment that are of critical importance from financial and reputation perspectives. Our leading technology is multivariable, model-predictive control that exploits our unique capability for rapid and reliable on-line analysis of multiple HF Alkylation unit streams: Recirculating acid catalyst is rapidly and precisely characterized for HF, ASO and water content by our proven technology now operating in multiple Phillips & UOP licensed units around the world. Exploiting the same analyzer used for acid characterization, ABB can deliver rapid and reliable analysis of the following HF Alkylation unit streams: Recycle isobutane Olefin and make-up isobutane feeds Alkylate and normal butane products Acid regenerator overheads Feed drier outlet moisture Caustic solution strength in acid gas relief/vent neutralization Our ASTM approved PGC2007 and RVP4100 analyzers ensure reliable on-line measurement of sulfur in feeds and volatility of alkylate respectively. The PGC2007 is used in numerous refineries for the mandated measurement and reporting of fuel sulfur content and so is a proven technology for hydrocarbon sulfur analysis. The RVP4100 is the de-facto industry standard for on-line measurement of RVP in gasoline blendstocks and finished products. ABBs ACF-NT continuous emissions monitoring technology can deliver improved detection and reporting of HF stack emissions associated with ASO combustion. HF can be reliably detected over a minimum measuring range of 0-5ppm with a limit of detection down to 0.13ppm. With over 400 installations, the technology is approved by Germanys TUV organization and complies with continuous emission monitoring standards issued by the EPA, ASTM and the UKEA. ABBs 8231 Fluoride monitor is a proven solution for the rapid detection of HF contamination of cooling water and condensate systems and can prevent accelerated corrosion, alleviate safety concerns and decrease maintenance costs. We offer a complete service portfolio including field services, on-line support and training in order to maintain the performance of your IndustrialIT solution. For the first time, operators can obtain a reliable multivariable control solution for HF Alkylation units, delivering distinctive benefits in safety, economic and environmental performance. For more information, please visit us at www.abb.com/analytical.

IndustrialIT Solutions from ABB

IndustrialIT solutions from ABB blend the industrys broadest portfolio of compatible knowledge components with a proven architecture for real-time enterprise automation and information.

Visit us at: www.abb.com/analytical Email: analyzeit@us.abb.com

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