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Paradip Refinery
This sulphuric acid Alkylation Unit plant is the first of its kind among all Refineries of IOCL.
Paradip Refinery
UNIT CONFIGURATION
Paradip Refinery
Paradip Refinery
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 :
Paradip Refinery
CWS
FEED HEATER
LP/MP STEAM
FG
BD = 1.3 WT%
17
SWS
DIOS STRIPPER
Temp.= 100 C Press.=17.1 kg/cm2-g
DIOS PRODUCT
To ALKYLATION UNIT
Paradip Refinery
FEED STOCK(DIOS)
Feed stock is mostly C4 molecules (97.73 wt %), consisting of 66.20 wt% olefins, 2.89 wt% butadiene (BD).
Feed Composition COMPONENT i-Butane i-Butene Butadiene Butane n-Butene-1 t-Butene-2 c-Butene-2 TOTAL
S. No. 1. 2. 3. 4. 5. 6. 7.
S. No. 1. 2. 3.
Treat Gas Composition (mol %) Contaminants PPMW H2 99.5% Methane By balance Ethylene Nil
Paradip Refinery
PRODUCT QUALITY(DIOS)
Dienes at out let of DIOS section is 200 PPMW.
i-Butane n-Butane
Isobutylene Butene-1 TR-Butene-2 CIS-Butene-2 Butadiene 2M-Butene-1 Isopentane n-Pentane
19.94 9.31
22.24 11.95 22.28 12.02 0.02 0.07 0.67 0.27
TOTAL
Paradip Refinery
100.0
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.
Paradip Refinery
0.3 kg/cm2-g
6 kg/cm2-g
DP BOTTOMS
Reflux drum
DEPROPANISER
Paradip Refinery
KO Drum
Receiver economiser
Caustic & Water Wash System
PROPANE
TO STORAGE
LP STEAM
EXCESS ISOBUTANE
TO LPG BLENDING
FEED CHILLER
FROM TRAIN -2
Reflux Drum
DEISOBUTANISER
4.4 C
18 C
BUTAMER EFFLUENT
REACTOR
SETTLER
Reflux Drum
DEBUTANISER
BUTANE
TO BUTAMER
FRESH ACID MAKE-UP NSU LPG ALKYLATE PRODUCT TO TANKS RATE = 78.1 MT/hr RON= 96.3 RVP=0.29 Kg/cm2
Fresh 98% Purity Sulphuric Acid as makeup (2100 MT for initial fill & 160 MT/Day)
Paradip Refinery
PRODUCT QUALITY(ALKYLATION)
Alkylate properties :S. No. 1. PROPERTIES Rate, m3/hr Value 111.09
2. 3.
4. 5.
0.704 96.3
93.7 0.29
Paradip Refinery
Paradip Refinery
SOR Case
OUTPUT S. No. Feed streams MT/HR Products streams MT/HR 1. Alkylation Feed ex DIOS 52.536 Alkylate 78.03 2. CCR LPG 23.027 Propane 11.13 3. SR LPG 16.02 NC4 37.79 4. Butamar product (ic4) 35.6 ASO 0.233 6. Total 127.183 127.183 INPUT
EOR Case
INPUT S. No. Feed streams 1. 2. 3. 4. 6. Alkylation Feed ex DIOS CCR LPG SR LPG Butamar product (ic4) Total MT/HR 52.55 23.03 16.03 37.39 129.00 OUTPUT Products MT/HR streams Alkylate 78.08 Propane 11.04 NC4 39.61 ASO 0.27 129.00
NOTE : ASO (acid soluble oil ) purged along with spent H2SO4
Paradip Refinery
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
CH3-CH2-CH2-CH3
Pt
Acid/PERC
CH3-CH-CH3
Paradip Refinery
ISOMERISATION REACTORS
HP STEAM
HCFE CCFE
LEAD
LAG
METHANATOR REACTOR
Temp.= 232 C Press.= 41 kg/cm2g
H2/HC = 0.03
FG
Wash water circulation pump
Stabiliser
Reflux Drum
LP STEAM
ISOMERATE
TO DIB AT ALKYLATION UNIT
Paradip Refinery
FEEDSTOCK (BUTAMER )
Composition, mole% 1.45 97.69 0.86 100.0
Hydrogen Makeup Gas Composition Stream composition units Hydrogen Volume% Methane Mole% sulfur Mole ppm Nitrogen (excluding Mole ppm N2) HCl Mole ppm CO+CO2 Volume ppm Total
Paradip Refinery
S.No.
1. 2. 3. 4. 5. 6.
Components
Propane Iso butane n-butane i-pentane n-pentane C6+(n-hexane) Total
Composition mole% SOR EOR 0.85 0.40 59.89 56.90 37.57 41.37
1.25 0.37 0.07 100.0 0.96 0.32 0.05 100.0
Paradip Refinery
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.
Paradip Refinery
Paradip Refinery
THANK YOU
Paradip Refinery