Honeywell Technology Summit Kuwait
Mohamed Saber
October 3rd – 4th 2017OleflexTM "Light Paraffin Dehydrogenation”
UOP 8013B-0 Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Agenda
1
UOP 8013B-1
Overview of
Propane
Dehydrogenation
Technology –
C3 Oleflex
Overview of
Isobutane/
N Butane
Dehydrogenation
Technology –
C4 Oleflex
C3 Oleflex
Process
Configuration
Advantages of the
Oleflex Technology
Brief Introduction of
ISOALKYTM
Technology
Propane
Isobutane
Propylene
ContainedIsobutylene
Feedstocks Products Uses
High performance plastic
Fiber
Packaging
Gasoline Blending Components
MTBE
Iso-Octane
ETBE
Synthetic Rubbers & Acrylics
Propane
Isobutane+
Propylene
+ContainedIsobutylene
Oleflex is the best technology for Dehydrogenation
H2
UOP Oleflex Process
Why Produce Olefins from LPG?
2
UOP 8013B-2
A PDH plant converts one feed (C3 LPG) …into one primary product (propylene) …
with the option to export by-product hydrogen
C3 LPG Propylene
Hydrogen
One feed – one productSimple back integrationProven Investment
Low Capital IntensityHighest Yield of PropyleneAttractive Rate of Return
Key Features …
Why Propane Dehydro (PDH)?
3
UOP 8013B-3
• “Propylene Gap”
‒ Steam Crackers shifting to lighter feedstocks
‒ Refiners limited by low gasoline growth in many regions
• “On-Purpose Propylene” filling the gap
‒ UOP Oleflex Process
‒ UOP Advanced MTO
‒ UOP/Total Olefin Cracking
‒ UOP RxPro & PetroFCC
0
20
40
60
80
100
120
140
2001 2006 2011 2016 2021
mil
lio
n M
TA
Supply from Refinery FCCs
Supply from Steam Crackers
Demand (Polymer/Chemical Gr.)
“Propylene Gap”
Data Source: IHS Chemical
Propylene Demand Worldwide
4
UOP technologies are supplying the needs of the market!
C3 Oleflex Process
Continuous Operation Design
>250 CCR’s in Operation Today
5
Heater Cells
NetSeparatorOff Gas
To SHP
Dryer
TurboExpander
Fresh& Recycle
Feed
H2 Recycle
CCR
Rx EffluentCompressor
Regeneration Section
Reactor Section
Product Recovery Section
UOP 8013B-5
EthermaxUnit
H2
Oleflex Unit
LPG C4s
LPG C4 Processing with Recovery of MTBE or Alkylate
DIBButamer
UnitMTBE
Maximize LPG Profitability with Oleflex Dehydrogenation Technology
Butamer technology converts nC4 to iC4
Oleflex for dehydrogenation of your light paraffins
‒ Can directly process iso-butane, n-butane or mixed butane feeds
Choose your product:
‒ Ethermax™ for MTBE production (or ETBE)
‒ Alkylate production options IsoAlky™ (NEW ionic liquid alkylation technology)
AlkyPlus™ (HF alkylation) or Sulfuric Acid Alkylation
InAlk™ (indirect alkylation)
Raffinate
Methanol
Indirect or Direct
AlkylationAlkylate
UOP Solutions for LPG C4 Processing
6
UOP 8013B-6
C4 Oleflex - Way to Minimize Light Naphtha Export
• In order to maintain the octane of the
gasoline pool; some refineries might
not be able to add all light naphtha
(as isomerate) into the gasoline pool
and some of the naphtha will be
exported.
• Increasing Alkylate and MTBE
production using field butanes will
allow addition of more light naphtha as
isomerate into the gasoline pool. This
can eliminate light naphtha export.
Penex/DIH
Gasoline
Pool
Lt Naphtha
Alkylate
Isomerate
MTBE
Export X
Mixed C4
Oleflex with
Alkylate and/or
MTBE unit
Butanes
7
UOP 8013B-7
Installed & Future Oleflex Capacity
High market activity in response to end-product demand and feedstock availability
UOP has been awarded
42 out of 53 dehydro
Projects worldwide since 2011
Since first commercialized, 6 repeat customers
and 6 takeaways from competition
8
Ole
fin
Ca
pa
cit
y, k
MTA
C3 Dehydro iC4 Dehydro C3/C4 Dehydro0
1,500
3,000
4,500
Commissioned
6,000
7,500
15 Units
10 Units
4 Units3 Units
7 Units
19 Units
Award, Design or Construction
9,000
10,500
12,000
13,500
15,000
8
Global Oleflex Operating Footprint
Since 2013, 13 new units commissioned in China and 1 in USA 3 Mixed C3/C4, 6 BDH and 5 PDH
C3 Oleflex - 15
C4 Oleflex - 10
C3/C4 Oleflex - 4
9
C3 Oleflex Process Configurations
10
UOP 8013B-10
OleflexUnit
Propane
C4+
Net Gas C2-
Propylene
SHP
P-P Splitter
Deethanizer
Depropanizer
C3 Oleflex Complex
Key Advantages of the Oleflex Process
• Highest Return on Investment (ROI)
‒ Lowest Capital Cost
Small and few reactor vessels
Small process line diameters and small reactor vessels
Small (fewer stages) and simple reactor effluent compressor
Small ISBL Plot Area
‒ Lowest Operating Cost
Low propane consumption throughout catalyst life.
Platinum in the catalyst is recoverable and reusable, avoids disposal costs
Low energy usage
• Smallest Environmental Footprint
‒ Lowest energy usage
‒ Lowest CO2, NOx, SOx, VOC emissions and water usage
‒ Fully recyclable Pt based catalyst. Non-toxic catalyst system
Lo
w C
apit
al &
Pro
du
ctio
n C
ost
11
UOP 8013B-11
Lo
w C
apit
al &
Pro
du
ctio
n C
ost
Key Advantages of the Oleflex Process
• High Process Reliability / Ease-of-Operation / Design Flexibility
‒ Continuous independent reactor/regenerator sections for ease-of-operation
enabled by CCR technology
‒ Ability to change-out catalyst and perform maintenance on CCR section without
shutting unit down
‒ Easy to load and unload catalyst system
‒ Positive Pressure design
‒ Flexible utility design (green-field and brown-field sites)
• World-Class Service Organization (S/U + Post S/U); RS, FOS & TS
• Unmatched Commercial Experience
• Commitment to Continuous Innovation
‒ Significant investment in R&D year over year
‒ Oleflex Users Conferences
12
UOP 8013B-12
Honeywell Technology Summit Kuwait
ISOALKYTM - Ionic Liquid Alkylation
UOP 8013B-13 Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
New Era for an Old Process
Ionic Liquid (IL) Catalysts
• Ionic Liquids are salts that are liquid phase at low temperature
– Typically the anion and cation are both large and the cation has a low degree of symmetry
– These factors reduce the lattice energy of the crystalline form of the salt and lead to a low melting point
• Acidic ionic liquids can have acidity that is orders of magnitude higher than HF or H2SO4
• In contrast to typical liquid acids, ionic liquids are safer to handle
– Vapor pressure near zero
– Thermally stable
Comparison of the acid strength of superacid ionic liquids with those of conventional superacids
14
UOP 8013B-14
ISOALKY Simplified Flow Diagram
iC4
~90% IL Cat Recycle
Make-Up Ionic Liquid Catalyst
Organic Cl
Isobutane / HCl Recycle
nC4
Alkylate
Dryer
~10% IL Cat
DryerSHPOlefin
Feed Merox
C3
Dis
tilla
tion
Ionic Liq. CatRegeneration
Separa
tor C
hlo
rine
Reduction
Chlo
rine
Re
du
ction
Chlo
rine
Reduction
Alk
yla
tio
nR
ea
cto
r
Four Distinct Areas
• Feed Treating
• Alky Reactor & Separation
• Product Distillation and Finishing
• Ionic Liquid Catalyst Regeneration
15
UOP 8013B-15
A Better Way to Alkylate
• How ISOALKY Works
‒ Utilizes strong acid function of IL for alkylation reaction
‒ Process design similar to existing alkylation technology
‒ Small, in-situ catalyst regeneration
• ISOALKY Performance
‒ Low catalyst inventory and catalyst consumption 400 times lower
than sulfuric acid alkylation
‒ Improved feed flexibility and performance in C3-C5 range for
maximum upgrade potential
‒ No heavy oil byproduct
‒ Equivalent or better alkylate yield and octane
• ISOALKY achieves equivalent or better economic performance
relative to sulfuric acid alkylation
16
UOP 8013B-16
17
UOP 8013B-17
ISOALKY Process vs HF and Sulfuric Alkylation
H2SO4 HF ISOALKY
Temperature, °F 60 95 95
Pressure, psig 60 ~200 <200
Olefin space velocity
(vol of olefins/hr /vol of acid) 0.25 – 12
Catalyst volume in alky reactor 50% 50 - 80% 5%
Ext. isoparaffin/olefin mol ratio 8 11 7 - 10
Feed moisture requirement Not critical <10 ppm <1 ppm
Alkylate quality w C4= 95 RON 95 RON 95 RON
Alky yield w C4= per bbl olefin 1.8 bbl 1.8 bbl 1.8 bbl
Conjunct polymer formation rate, % per Olefin in feed
1 – 1.5% 0.5% 0.5%
Handling of conjunct polymer Incineration IncinerationNo conjunct polymer
bi-product
Catalyst make-up rate, lb/bbl alkylate
20 lb/bbl
Off-plot regen
0.1 lb/bbl
On-line regen
< 0.05 lb/bbl
On-line regen
Technology HS&E Issues
Acid inventory;
Acid transport for regeneration;
SOx emission for regen
Acid inventory;
Volatility of HF leads to high concern for operators and community
Reduction of hazardous material
and concerns
18
UOP 8013B-18