HF Alkylation Solution

8/14/2019 HF Alkylation Solution

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Industrial IT for HF AlkylationCreating value through integrated solutions

Improve HF Alkylation unit safety,environmental and economic performance


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Improve HF Alkylation unit safety,environmental and economic performance

Overview

Refiners operating H F A lk ylation uni ts are under increasing pressure tomaximize unit throughput, improve product quality and yields whileoperating safely and with low environmental impact. Ever tighteninggasoli ne quali ty legislation and increasing public and regulatory scrutinyconcerning the use of hydrofluori c acid combine to mak e reliable andefficient operation of H F Alk ylation uni ts of cri tical i mportance to theoverall reputation and profitability of petroleum refineries.

ABB offers a unique Industrial IT solution for H F Alk ylation uni tsto assist operating companies in meeting the significant challengesof this difficult operating environment.

O ur leading technology is multivariable, model-predictive controlthat exploits our unique capability for rapid and reliable on-lineanalysis of multiple H F Alk ylation uni t streams:

Recirculating acid catalyst is rapidly and precisely characterized forH F, A SO and water content by our proven technology now operatingin multiple Phi llips & U O P licensed units around the world.

Exploiting the same analyzer used for acid characterization,ABB can deliver rapid and reliable analysis of the followingH F Alk ylation unit streams: Recycle isobutane O lefin and make-up isobutane feeds Alk ylate and normal butane products Acid regenerator overheads Feed drier outlet moi sture

Caustic solution strength in acidgas relief/vent neutralization

O ur AST M approved PG C2007 and RVP4100 analyzers ensure reliableon-line measurement of sulfur i n feeds and volatili ty of alk ylaterespectively. T he PG C2007 is used in numerous refineri es for themandated measurement and reporting of fuel sulfur content and so isa proven technology for hydrocarbon sulfur analysis. T he RVP4100 isthe de-facto industry standard for on-line measurement of RV P i ngasoline blendstocks and fi ni shed products.

ABBs AC F-NT continuous emissions moni toring technology candeliver improved detection and reporting of H F stack emissionsassociated wi th ASO combustion. H F can be reliably detected over a

minimum measuring range of 0-5ppm with a limit of detection downto 0.13ppm. With over 400 installations, the technology is approvedby Germanys T U V organization and complies wi th continuousemission moni toring standards issued by the EPA, ASTM and theUKEA.

ABBs 8231 Fluoride moni tor is a proven soluti on for the rapiddetection of H F contamination of cooli ng water and condensatesystems and can prevent accelerated corrosion, alleviate safetyconcerns and decrease maintenance costs.

We offer a complete service portfolio including field services, on-linesupport and training in order to maintain the performance of yourI ndustrial I T solution.


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Industrial IT for HF Alkylation

Industrial IT for HF Alkylation

Employs our unique capability for rapid on-line characterization

of recirculating acid catalyst, a proven solution now operatingin multiple Phi llips & U O P licensed units around the world.

For the fi rst time in the industry, a technology that guarantees rapidand reliable characterization of iC 4 recycle to ensure optimum reactoroperation.

Sulfur and moisture content of unit feeds are rapidly determinedon-line leading to improved catalyst efficiency and managementof drier regeneration cycles.

O n-li ne measurement of alk ylate and n-butane quali ties ensuresmaximum product valuations.

T he commonly troublesome operation of acid regeneration can beimproved by the availability of feed and overhead compositions.

I mproved effluent management of A SO combustion and relief gas neutralization exploiting rapid on-line characterization of stack emi ssions and recirculati ng caustic ensures enhancedenvironmental compliance.

Combines these unique analytical measurements with our leadingedge multivariable control technology and extensive experience indelivering advanced process control projects leading to distinctiveclient benefits typi cally in the range of $1M - $3M per annumfor a 10,000bpd unit.

O perators can obtain an H F Alk ylation uni t process and envi ronmentalsolution from one vendor, delivering unique synergistic benefits to theoperation of these facili ties. T his leads to maxi mi zed uni t throughput,improved product quality and yields while operating safely and withlow environmental impact.

HF Alkylation Unit operations

Efficient operation of an H F Alk ylation uni t is a diffi cult task andsubject to the most testing of operating regimes. T his is due to anumber of industry specific constraints and operating issues thatstretch the processing capability of the plant.

Operating issues

H F Alk ylation uni ts must be able to deal wi th feedstocks thatroutinely vary in contaminant levels, hydrocarbon compositionand volume due to upstream operating complexities.

O perators have the diffi cult challenge of minimi zing iC 4 recycleand associated utili ty costs whi le producing alkylate of desiredquality with minimum acid consumption.

T he uni ts must be operated in a safe manner despi te the ever-present potential for acid runaway, accelerated equipment corrosionand associated H F release.

T he demands on H F Alk ylation uni ts are further increased due toongoing trends within the petroleum refining industry.


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Industry issues

Industry trends

O ngoing expansions of FCC units and implementation of newcracking catalysts to satisfy gasoline growth also results in morealk ylation feedstock.

A continuing trend towards increased residue crack ing andupgrading capacity which produces more complex and problematicalk ylation feedstocks.

I ncreasing interest i n C 5 olefin processing as a means to returnvolatile components to the gasoline pool while increasing productvolumes.

Continually tightening gasoline quality legislation mandating changesin allowable oxygenate blendstocks and drivi ng towards lower andlower sulfur content.

A ll of these scenarios result i n i ncreased demands on the H F A lk ylationuni t to be more flexible in handli ng increased and varying feedstocks,whi le maintaini ng unit efficiency and alk ylate quality. T he idealblending characteristics of alk ylate make it a criti cal element in meetingrefinery profit and legislated fuel quality compliance goals.

Health, safety and environment (HSE) issues

T he whole refining industry is subject to ever-tightening H SE legislationwi th H F Alk ylation arguably being subjected to the most stringent rulesdue to the real and perceived hazards associated with the process.

Regulations continue to drive towards minimizing air and wastewateremissions and much effort is made by operators to improve, monitor

and report environmental performance.

Penalties for non-compliance are expensive from financial as well asreputation perspectives and in some cases may result i n withdrawalof license to operate.

H F A lk ylation units continuously strive to minimi ze personnel andpublic exposure to acid with minimization of acid losses from unitcontainment.

Ever increasing public and regulatory scrutiny concerning the useof hydrofluoric acid in industrial facilities.

I ndustry trends, complex operating conditions and more stringent

H SE compli ance all contribute to the increasing diffi culties of operatingH F Alk ylation uni ts. T o meet these challenges, i t is more importantnow than ever, that these uni ts maximi ze throughput, i ncrease feedflexibility, boost product yields and volume while operating in a safeand environmentally compliant manner.


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Meeting the challenges

What are the options for HF Alkylation Unit operators?

Further technical developments and improvements in H F A lk ylationmust meet these increasing operational challenges. H F A lk ylation

technology must be highly focused on economic, safety andenvironmental compliance issues while improving operability of currentoperations. I n the last few years, the main capi tal investment for manyoperators has been the installation of acid release mitigation technologyand improved reactor configurations such as split olefin feed designs.T hese developments have been successful in solvi ng many of theoperating problems and decreasing the risk s associated with H FAlk ylation operations. H owever, despi te these improvements, a numberof historical challenges still exist that significantly hinder the optimumeconomic and safe operation of these uni ts. I n thi s respect, improvedprocess control of existing assets can further enhance unit operabilityand improve the H SE profi le of the process. Advanced process controlis always one of the most effi cient, low cost actions that is undertak enby the operators of any process uni t. M any of the ongoi ng operatingproblems and potential risk s affecting H F Alk ylation uni ts are a resultof less than opti mum process control of k ey uni t objectives.

A lthough advanced process control has been widely implementedacross the petroleum refining industry, implementations in H FAlk ylation uni ts have been few and far between. A major factorin this has been the difficulty of obtaining reliable compositional datafrom on-line analyzers due to the aggressive nature of H F acid on thesesystems. T his problem results in the following common scenarios:

A criti cal measurement i s assumed i mpossible to execute on-li neand is thus relegated to a lab measurement which is of coursetoo slow for mak ing process control decisions.

An on-line analyzer has been too unreliable or maintenanceintensive that neither the operators nor the control schemecan trust the results.

Attempts to satisfy these voi ds wi th inferenti al measurements haveresulted in mixed success.

A good example of this operating challenge is the optimum controlof isobutane:olefin ( I /O ) ratio. A lmost all operating companies havedifficulty in obtaining rapid and reliable recycle isobutane analysisbecause of the aggressive nature of trace amounts of H F on tradi tionalgas chromatographs operating i n this duty. T he lack of ti mely andreliable data for this k ey parameter can result i n significant performancedeterioration including lower product octane and higher acid

consumption, or excessive fractionation and recycle with associateduti li ty costs.

T hese and other common H F Alk ylation operating challenges that havebeen experienced for many years in the industry can now be managedby the appli cation of the ABB solution for this process - Industrial IT forH F Alk ylation. O perators that have been limi ted in their abili ty to dealwi th day to day upsets and control of k ey operating variables can nowmaintain optimum performance of H F A lk ylation operations. T he AB Bsolution delivers a robust analytical approach coupled to advancedprocess control to manage the complex multivariable interactions,high on-stream time demands and potential environmental impactof the H F Alk ylation process. T his leads to significant improvementin unit economic, safety and environmental performance.


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Industrial IT for H

2Reactor optimization

Operating challengesCalculating 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 iC 4 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 iC 4 against the benefits of improved alkylate quality, yield and

plant throughput. Optimizing iC 4 make up rate while respecting iC 4 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 arecarried out infrequently, are lengthy in execution and have historically been found to be imprecise. This poor monitoring capabilitycan lead to approaches of runaway conditions, increased corrosion, lost octane opportunities, lower alkylate yields, moreaggressive regenerator operation and higher acid losses.

Maximizing feedrates against physical operating limits across the unit while achieving product quality and energy consumptiontargets.

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 maintainingtarget local I/O ratios and reactor feed balancing.

SolutionImplementation of ABB multivariable control technology driven by our unique capability of rapid, on-line characterization of acid,recycle iC 4 and olefin/iC 4 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 nowoperating in multiple Phillips & UOP licensed units around the world. For the first time in the industry, ABB can deliver a technologythat guarantees rapid and reliable characterization of recycle isobutane by exploiting the same analyzer used for acid analysis. Theinstrument can also be configured to determine total olefin and iC 4 content of olefin feed as well as iC 4 content of make-upisobutane. The rapid and reliable availability of these measurements underpinning ABBs multivariable control approach, finallyallows operators to satisfy the long sought after goal of truly optimizing reactor I/O ratio delivering all of the documented benefitsassociated with this most key operating parameter. In addition, the APC scheme will also stabilize control of key operatingparameters such as hydrocarbon feed and acid recirculation rates, temperature and multiple reactor feed balancing.


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ylation

3Fractionation and product quality control

Operating challengesControlling nC 4 draw-off rates and internal reflux to minimize iC 4 losses while avoiding nC 4 build up in the reactor which can lead toalkylate 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 steadycolumn 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 iC 4 recycle, maximum iC 4 in the premium bottoms recycle andproduction 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 C 4 isomerate in those units that fractionate these imported streams.

SolutionImplementation of ABB multivariable control technology driven by rapid on-line characterization of iC 4 recycle, nC 4 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 iC 4 recycle byexploiting the same analyzer that delivers acid strength determination. This includes not only iC 4 content but the capability todetermine if C 3 or C 5 inerts are building up in the stream. Normal butane is also characterized by this technology for iC 4 content. ABBhas a dominant global market position in gasoline analysis via our NIR and ASTM approved RVP analyzers. This allows us to rapidlyand precisely provide on-line characterization for alkylate octane, distillation and volatility. Imported C 4 saturate streams can also becharacterized to help reject the disturbances these streams create in fractionation operations. The rapid and reliable availability of allof these measurements is a key element of ABBs multivariable control package which delivers industry leading performance for HF

Alkylation frac tionation trains.

4Acid quality management and regenerator operation

Operating challengesMaintaining acid composition ensuring high alkylate yield/quality, minimum regenerator load, minimum acid losses and extendedequipment life via reduced corrosion.

Optimizing regenerator operation to minimize energy consumption and acid losses leading to reduced acid inventory and make-upcosts while simultaneously reducing neutralization requirements.

These tasks are further complicated due to difficulties in rapidly, completely and accurately monitoring recirculating andregenerated acid qualities as off-line analysis is carried out infrequently, is lengthy in execution and has historically been found tobe 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 uniquecapability for rapid and complete on-line characterization of recirculating acidcatalyst and regenerator overheads allows these common operating problems to betruly solved for the first time.

Recirculating acid catalyst is rapidly and precisely characterized for HF, ASO andwater content by our proven NIR solution now operating in multiple Phillips & UOPlicensed units around the world. The same trusted analyzer can also be used tomonitor regenerator overhead composition. The rapid availability of both regenerator feed and overheads is integrated in the unique ABB multivariable approach tomanage the traditional problems of operating these columns.


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5Process effluent management

Operating challengesMaintaining efficient operation of acid gas relief/vent neutralization to eliminate HF breakthrough to the refinery flare system whileminimizing 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 fluor ide ionin 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 tofurther exploit the initial capital investment made in the acid analyzer. This proven application has been delivered in numerous projectsacross many industries.

In continuous emission monitoring, ABB is recognized as the global leader. Our ACF-NT technology has been installed in over 400plants for the continuous monitoring of a wide variety of components including HF. We have the lowest detection limits and sensitivityin 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 andcondensate systems to prevent accelerated corrosion, alleviate safety concerns and decrease maintenance costs.


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Benefits of Industrial IT for HF Alkylation

1 Feed quality and treatment

Successful, incident free operation of an H F Alk ylation

unit is largely related to feed composition and efficientcontaminant removal. O lefin and mak e-up i sobutanefeeds can be characterized for moisture and hydrocarboncomposition by the same analyzer that is proven for on-lineacid analysis thus helping to amortize any investmentmade in this technology. I n addi tion, ABB s PG C2007is a widely used, A STM approved technology for lowlevel sulfur analysis in hydrocarbons. Rapi d and reli ableon-line determination of hydrocarbon composition, sulfurand moisture content of feed offers several advantagesto the operator.

T he reliable determination of feed sulfur content leads to many operating benefits.

Reduced acid consumption and less aggressive operation of the acid regenerator resulting in lowervariable costs and improved equipment life.

Avoid feedrate reductions wi th coincident improvements in alk ylate quali ty and yield.

T here are fewer approaches to runaway condi tions whi ch in many units is an infrequentevent but results in significant cost penalties when experienced.

Exploiting additional measurement capabili ty of our industry standard HF acid analyzer, moisture contentcan be rapidly determi ned in olefi n and mak e-up i sobutane feeds before and after drying.

Prevent problematic moisture breakthroughs wi th opti mum management of regeneration cycles.M any plants operate wi th routine drier regeneration cycles whi ch can lead to hi gh feed moi sturelevels or conversely, unnecessarily hi gh energy costs and shortened bed li fe.

Improved control of feed moisture levels can improve alk ylate quali ty, decrease acid lossesand reduce plant corrosion.

T he acid analysis technology can also be configured to rapi dly report total olefi n and i C 4 contentof olefin feed as well as iC 4 content of mak e-up i sobutane. For both feeds, our technologycan also provide an on-line indication of C 3-C 5 content variations.

Track the quali ty of feeds deli vered by the FCC and saturated gas plant as well as thosethat are imported from external sources to allow troubleshooting and policing of upstreamunits and suppliers. O perators can be notifi ed of propylene/amylene or propane spik esin olefi n and isobutane feeds respectively.

Provide enhanced protection to those units where feed contamination incidents may be more severeas circulating acid volume is lower due to external cooling schemes.


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2 Reactor optimization

Implementation of A BB multivariable control technology underpinned by

our unique capability of rapid on-line characterization of acid, recycle iC 4,olefin/iC 4 mak e-up feeds and alk ylate delivers significant operatingimprovements to H F A lk ylation reactors.

Feedrates, alk ylate yield, and alk ylate octane are maxi mi zed to aneconomic optimum, subject to operating constraints

I /O ratio and energy consumption can be reduced while meetingalk ylate quality and yield targets wi th minimum acid consumption.

I sobutane make-up rate can be optimi zed while respecting iC 4inventory constraints.

Acid quality is maintained in the optimum operating range for H F, A SO

and water contents leading to: Less frequent approaches to runaway condi tions.

Lower acid inventory as acid mak e-up requirements are reduceddue to decreases in average operating acid strengths.

Alk ylate octane enhancements are possible as water content of thecatalyst can be i ncreased in a controlled manner. O ne of the majorlicensors 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 atan I /O ratio of 10.

Less aggressive regenerator operation and lower acid losses.

H igh quality alk ylate and yields.

Acid:hydrocarbon ratios and reactor temperature are controlledto improve product quali ty and suppress ASO production.

O peration of spli t flow and/or parallel reactor configurationsare optimized to ensure maxi mum alk ylate quality at the highestthroughput by maintaining target local I /O ratios and optimumreactor feed balancing.

Reactor conditions are optimized to manage variations in fresh feedcompositions.


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3 Fractionation and product quality control

I mplementation of A BB multivariable control technology driven by

rapid on-line characterization of iC 4 recycle, nC 4 sidedraw, depropanizerbottoms and alk ylate ensures product specifications are met wi th thelowest energy consumption.

T he optimum balance is maintained between mi nimizing iC 4 lossesin product and the build up of n-butane in recycle iC 4. Achievingsteady column performance avoids oscillations between theseoperating extremes which are common in many plants due toaggressive manual i ntervention by operators. T he reduction of i nertsin the recycle stream permits maximum fresh feed addition whilemaxi mi zing alk ylate octane-barrels. M inimi zing iC 4 losses whileavoiding alk ylate quality and yield penalties can generate annualbenefits of approxi mately $0.5M for a 10,000bpd unit.

Energy costs associated with deisobutanizer fractionation areminimized by avoiding over-purification of products and by operating the reboiler heater at maximum efficiency viapass balancing and outlet temperature control.

T ight control of the depropani zer ensures low levels of propane in i C 4 recycle, maximum iC 4 in the premium bottomsrecycle and production of propane at the highest quality.

A lk ylate draw-off rate is maxi mi zed whi le maintaining quali ty within target specifications wi th rapid and reliableon-line determination of octane, volatili ty and distillation characteristics. G iven the highly repeatable and frequentdetermination of RO N by our NI R technology, A BB s APC approach wi ll improve average alk ylate RO N qualityand so mi nimi ze those production li mi ting periods where alkylate specifi cation is the constraint.

I mported field butanes or C 4 isomerate feeds can be rapidly characterized which allows the control scheme to managethe effects of these signifi cant di sturbance variables as they impact fractionator operation.

Acid quality management and regenerator operation

ABBs multi variable control approach incorporates our dual capabili ty for rapid on-linecharacterization of recirculating acid and regenerator overhead streams. T his uniquelyintegrated approach leads to distinctive benefits for regenerator operations and acidmanagement activities.

T he lack of stream composition measurements around continuous regenerators has beena historical problem for operators. T his has now been solved allowi ng operation withminimum acid loss whi le efficiently rejecting A SO and water. Rapid and reliable measurement of H F, ASO and water in feed and overheads ( including

li ght ASO content) can be used to optimi ze column operating temperatures and iC 4stripping rates with associated energy savings.

Column overheads analysis allows mass balance calculations to be performed toestimate and control H F losses in A SO bottoms wi th associated savings in acid andneutralization costs.

Rapid k nowledge of acid quali ty means that the column can now be operated lessaggressively 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: M inimum acid strength can be now maintained i n an acceptable operating range that stil l produces the maximum

yield of hi gh quali ty alk ylate. T his lowering of average acid strength allows fresh make-up costs and overall acidinventory to be reduced making a significant contribution to improved unit safety and risk profi le.

I mproved regenerator load management for those refineries planni ng to source more feeds from resid uni ts orincrease 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. T he ABB soluti on elements for regenerator, feed characterizationand reactor control deliver signifi cant savings in operating costs, acid losses and operator attention.

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5 Process effluent management

As the global market leader i n process and envi ronmental

moni toring, A BB can help operators of H F Alk ylation uni ts meetlegislative and process operating goals under the umbrella of asingle vendor.

Exploi ting the same analyzer that is used to characterize acidcatalyst, our patented technique for rapid on-line causticanalysis can help operators maintain efficient operation of acidgas relief/vent neutralization systems leading to a number of operating benefits.

Elimi nation of H F breakthrough to the refinery flare systemwith minimum caustic consumption, associated spenteffluent neutralization and solids disposal costs.

Rapi d on-line caustic strength measurement allows detectionof non-condensable venting and helps reduce acid lossesand associated neutralization costs.

T he same analyzer can also be used to monitor upstreamM erox unit caustic strengths which in combination wi th ABBfeed sulfur analysis, will minimize contamination incidents.

M any refineries that use neutralized ASO as a fuel (eg: in mainfractionation reboi ler heater) are under increasing legislativepressure to improve, monitor and report any associated H Femissions. I n some localiti es, exceeding H F emission li mi ts wi llresult in a mandated plant shutdown. ABB can provide market

leading technology for characterization of H F stack emissionsas we are recogni zed as the global leader in conti nuousemission moni toring. O ur A CF-NT analyzer has been i nstalledin over 400 plants for the continuous monitoring of a widevariety of components. H F can be reliably detected over aminimum measuring range of 0-5ppm with a limit of detectiondown to 0.13ppm. With over 400 installations, the technologyis approved by G ermanys T U V organization and compli es wi thcontinuous emi ssion moni tori ng standards issued by the EPA,ASTM and the U K EA.

T he reliable determination of H F in A SO combustion gasesalso allows the operator to estimate H F losses in regenerator

bottoms.

Exchanger leaks can cause H F contamination of cooli ng waterand condensate systems leading to accelerated corrosion, safetyconcerns and increased mai ntenance costs. I n order to rapi dlydetect and manage these occurrences, a number of H FAlk ylation uni t operators employ the ABB 8231 Fluoridemonitor. T his analyzer is self calibrating and ensures reliableon-line measurements in this critical duty.


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Industrial IT for HF Alkylation: health, safety and environment

T here is ever increasing public and regulatory scrutiny concerning

the use of hydrofluoric acid in industrial facili ties. I n this envi ronment,H F Alk ylation processes are arguably subject to the most detailedexamination due the dual hazards of both fire and toxic releasepresented by the combi nation of LP G and H F streams. A BBsIndustrial IT for H F A lk ylation can help operators uniquely meetthe signifi cant H SE challenges encountered in the day to dayoperating activities and unit operations of their plant.

Accidental acid release: risk reduction

M inimi ze leak potential: Less aggressive regenerator operation andimproved catalyst moi sture management i s achieved by enhanced feedimpurity and catalyst water monitoring leading to reduced corrosionrates and longer equipment life.

M inimi ze quantity released: Lower acid inventory is possible bylowering average acid strengths in tandem with minimizing catalystlosses. T hese goals are achieved by rapi d feed i mpuri ty and catalystcharacterization, improved acid runaway prevention and fasterdetection, as well as optimized regenerator operation.

M inimi ze cloud forming potential: I mprove operation of modi fiedH F systems that reduce catalyst volatili ty by uti li zation of A BBs acidmonitoring technology which has been successfully applied to theConocoPhillips Revap process catalyst.

Routine acid exposure: risk reduction

M inimize exposure potential: Reduce manual acid sampling andoff-line analysis by employing ABBs rapid and reli able on-li ne acidmoni toring technology. O perator and laboratory personnel acidexposure can be significantly reduced with coincident manpowersavings of up to $40K per year being reported by exi sting cli ents.U sing the same analyzer, traditi onal hi gh maintenance G Cs can alsobe eliminated for applications such as iC 4 recycle analysis whichsignificantly reduces analyzer technician intervention and acidexposure.

Minimize process effluents

I mproved feed i mpurity and acid analysis results in reduced A SOformation and enhanced regenerator operation. T his decreases overallH F emissions associated wi th ASO combustion.

I mprove monitoring and reporting of low level H F stack emissions inASO combustion by use of our ACF-NT technology which complieswi th continuous emission moni toring standards issued by the EPA,ASTM and the U K EA.

Rapid and reliable on-line caustic strength analysis improves acidrelief/vent scrubbing and so helps prevent H F acid leakage into flaresystems as well as reduces solids disposal requi rements.

A brief history of ABB on-lineHF acid analysis

ABB began working with PhillipsPetroleum (now ConocoPhillips) todevelop an on-line acid analysissystem in 1996. Two years of testingand development followed on HF

Alkylation pilot scale units. Thisincluded sample system design,metallurgy considerations and modeldevelopment. The analyzer was theninstalled in May 1998, at the PhillipsPetroleum refinery in Sweeny, Texas.Two more years of successful on-sitetesting ensured the technology wasready for industry-wide implemen-tation. The on-line acid analyzer wasthen launched to the HF Alkylationmarket at the 2000 Phillips licenseesymposium. As of mid-2004, thesystem has been installed in over adozen HF alkylation units worldwidewith a combined operating history ofover 20 years. These systems areoperating in both ConocoPhillips & UOP licensed units in North/South

America, Europe and the Middle-Eastby operating companies includingExxonMobil, ConocoPhillips, Valero,PCK, Sunoco, Marathon-Ashlandand Pemex.


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ABB offers a unique Industrial IT solution for HF Alkylation units to assist operating companies in meeting thesignificant challenges of todays operating environment that are of critical importance from financial andreputation 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 ofthe 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 infeeds and volatility of alkylate respectively. The PGC2007 is used in numerous refineries for the mandatedmeasurement 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 gasolineblendstocks and finished products.

ABBs ACF-NT continuous emissions monitoring technology can deliver improved detection and reportingof HF stack emissions associated with ASO combustion. HF can be reliably detected over a minimummeasuring range of 0-5ppm with a limit of detection down to 0.13ppm. With over 400 installations, thetechnology is approved by Germanys TUV organization and complies with continuous emissionmonitoring 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 coolingwater and condensate systems and can prevent accelerated corrosion, alleviate safety concerns anddecrease maintenance costs.

We offer a complete service portfolio including field services, on-line support and training in order tomaintain the performance of your Industrial IT solution.

For the first time, operators can obtain a reliable multivariable control solution for H F A lk ylation uni ts, deliveringdistinctive benefits in safety, economic and environmental performance.

For more information, please visit us at www.abb.com/analytical.

ABBs 8231 Fluoride moni tor is a proven soluti on for the rapid detection of H F contamination of cooli ng water andcondensate systems and can prevent accelerated corrosion, allevi ate safety concerns and decrease mai ntenance costs.

Rapid and reliable feed and catalyst moisture monitoring permits improved drier and regenerator operation reducingconstant boiling mixture production with associated reductions in acid losses, neutralization and solids disposalrequirements.

Minimize energy consumption

Energy costs are minimi zed as ABBs integrated analytical and multi vari able control solution reduces recycle costs whi lemaintaini ng target product quali ties, avoids over-fractionation of products, ensures the highest reboi ler heater effi ciencyand optimizes stripping and vaporization rates in the regenerator column.


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Specifications subject to change without notice. Pictures, schematics and other graphics contained herein are published for illustration purposes only and donot represent product configurations or functionality. User documentation accompanying the product is the exclusive source for functionality descriptions.

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HF Alkylation Solution

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