AlkyClean alkylation process

AlkyClean Alkylation Process A True Solid Acid Catalyst (SAC) Process... 

D Amico, V. et al. (2006) The AlkyClean alkylation process - new technology eliminates liquid acids. NPRA Spring 2006 Meeting, paper AM-06-41. 

This chapter discusses alkylation and its evolution into a modern refining process. We review the basic chemistry of alkylation, assess the properties and other merits of H F versus H2SO4, identify key drivers in the process and discuss the evolution of one particular process - the AlkyClean solid acid catalyst alkylation process. 

AlkyClean [Alkylate Clean] An alkylation process using a solid acid catalyst. Developed by CB I, Albemarle, and Neste Oil in the 1990s. 

In 1999, Akzo Nobel (which later sold its catalyst division to Albemarle) patented a new technology for alkylating hydrocarbons based on a zeolite acid catalyst [193]. This new process, AlkyClean, was then designed by ABB Lummus and Albemarle, and a 10 barrels per stream day (BPSD) demonstration unit came online in Finland in 2002. AlkyClean produces a high-quality sulfur-free alkylate (96 octane), eliminating all the drawbacks of the liquid acid catalyst technologies. There are no add-soluble oil waste streams, the reactor operates at 50-90 °C, and the catalyst is a solid, noncorrosive material, which is easily transported and stored. 

Figure4.31 A simplified design scheme ofthe AlkyClean process, using three reactors in a cyclic configuration. At any given time, two reactors are used for alkylation, while the catalyst in the third reactor is regenerated.

The AlkyClean catalyst contains no halogens, has acid sites with sufficient strength for alkylation, yields high quality alkylate with minimal side reactions, and exhibits the required activity, stability and regenerability characteristics necessary for a successful process. It is promoted with a low Pt content to assist regeneration and hydrogen transfer. 

In commercial practice, there will be significant differences in olefin feed composition. Under the AlkyClean process cyclic operation, high RON is obtained over a prolonged time period with various feeds. The use of a refinery-sourced MTBE raffinate gave similar results (alkylate yields and product quality) to a pure cis-2-butene feed (Table 12.9). The MTBE raffinate contained about 26wt% trans-2-butene, 15 wt% cis-2-butene, 12 wt% 1-butene, 2 wt% isobutene, 40 ppmw (parts per million by weight) of various oxygenates and 3 ppmw of sulfur (balance isobutane and n-butane). 

Similarly, after blending about 30vol.% of propylene with cis-2-butene, the RON loss was less than 1 number. With H2SO4 alkylation, similar amounts of propylene would lead to a RON about 1.5 lower. Table 12.10 summarizes the estimated impact of feedstock variation on RON relative to a pure cis-2-butene feedstock for the AlkyClean process and liquid acid technologies. Based on these results, it can be concluded that our new SAC technology is less sensitive to feedstock variation regarding product quality than either liquid acid technology. 

Construction of an AlkyClean process demonstration unit at Fortum s facilities in Porvoo, Finland, was completed in 2002. Figure 12.14 shows the process flow schematic of the demo unit, which contains all of the key elements of our proposed commercial design. Three reactors are included - two under cyclic operation (i.e., alternating between alkylation and mild regeneration) allowfor continuous production... 

D Amico, V.J. et al. (2002) The AlkyClean process a new solid add catalyst gasoline alkylation technology. 

A RON value of 96 is claimed for the alkylate obtained through the Allqr-Clean process. AlkyClean has been presented as a very versatile option to retrofit liquid acid processes, having up to 20% lower inside-battery-limits cost than for a H2SO4 unit and comparable to that for a HF plant. The process is also shown as attractive to revamp gasoline polymerization units, offering a short time for payback (252). 

AlkyStar Not a process but a zeolite-based alkylation catalyst claimed to be safer than the traditional acid alkylation catalysts. Used in the AlkyClean process. Developed by Albemarle, ABB Lummus Global, and Neste Oil. 

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