Q&A

(2008) Question 74: Have you experienced a shortage of KOH supply for your HF alkylation unit? Are you concerned about KOH availability? What are your alternatives if KOH is unavailable?

METKA (Sunoco, Inc.) Sunoco has experienced significant shortages of KOH in both our northeast and mid-continent refinery complexes. This appears to be a universal issue. In addition, a primary supplier to the northeast claimed force majeure earlier this year.

(2008) Question 75: The butane stream from a catalytic polymerization (cat poly) unit, which contains 69% isobutene, 14% butylenes, and 17% normal butane, would appear to be an excellent alkylation unit feedstock, especially if isobutene is i

METKA (Sunoco, Inc.) We operate a cat poly and sulfuric alkylation unit within the same refinery. The configuration offers flexibility and synergies that allow various operating and business demands to be met. In our configuration, the cat poly debutanizer overhead feeds the alkylation unit to

(2008) Is your company planning to install modified HF acid capability (usage of the volatility suppressing additive)? What are the incentives for doing this? What alternatives have you considered?

In March 2006, in our continuing effort to support safe, reliable, and environmentally sound operation, we announced our plans to apply for a permit to independently initiate an alkylation process improvement project in our Philadelphia HF alkylation unit.

(2008) Question 70: How frequently do you have fires on reformer reactor flanges? What bolting techniques and gasket types do you use to prevent leaks? What other fixes, such as flange resurfacing, have you employed? Do you use steam ri

GRUBB (Chevron USA, Inc.) Chevron has had some experience with flange fires in the past, so I’ve consulted with Dave Reeves, our corporate expert and also our Best Practice that we’ve developed for this. I know that I said temporary fixes up on the slide, but it’s not really a temporary fix.

(2008) Question 71 Is your company planning to install modified HF acid capability (usage of the volatility suppressing additive)? What are the incentives for doing this? What alternatives have you considered?

METKA (Sunoco, Inc.) In March 2006, in our continuing effort to support safe, reliable, and environmentally sound operation, we announced our plans to apply for a permit to independently initiate an alkylation process improvement project in our Philadelphia HF alkylation unit.

(2008) Question 76 The regeneration of feed dryers/sulfur guard beds on butane isomerization units generates a butane slop stream. Will processing this butane slop stream in an HF or sulfuric acid alkylation unit cause any problems? If so, what else may be done with this slop stream?

QUINTANA (Valero Energy Corporation) The spent Isom regenerant will contain butanes that are attractive to recover. They can come from generally any of three sources: either the treated normal butane feed downstream of the on-stream dryer, the fractionated isobutene from the Deisobutanizer fractionator overhead, or the isomerate product is used as the regenerant source. The spent regenerant also contains all of the sulfur and oxygenate impurities that were previously accumulated on the sieve; and after the spent regenerant coalescer, it will also be saturated with water.

(2008) Question 77 What is your experience with cooling water exchangers in an HF alkylation unit? How long do you go between cleanings? Do you have a special water treatment program for cooling towers dedicated to the alkylation unit?

KAISER (Delek Refining Ltd.) In my experience, the cooling water exchangers in an HF alkylation unit are really no more problematic than any other exchanger in the refinery when you’re looking at the waterside only. If you have an exchanger in the HF alkylation unit that suffers from low flow or it’s at the end of a header, trapped scale, and there are certainly critical exchangers inside the alkylation unit that you want to keep clean, it’s really no different if it’s in the alkylation unit or in some other unit in the refinery. You’re going to have water problems and that’s going to generate issues for you.

(2008) Question 78 For HF alkylation units, have you changed your criteria for materials given the low availability of low carbon/non-recycled steel? Are you heat treating welds? Can you control Brinell Hardness with welding procedures? For small bore pipe, do you recommend using flanges or threaded pipe?

KAISER (Delek Refining Ltd.) Again, just to re-emphasize, I’m not currently on an HF unit so part of this response will rely on some former colleagues of mine. I would not make a blanket recommendation to change the material specification for carbon steel in HF alkylation units. To me, the risk is too great. I understand that there are certain times when things are tight and you might need immediate material delivery and there’s no other option, but I would not make a blanket relaxation in the material specifications.

(2008) Question 79 It has been reported that diisobutylene (isooctene) causes a stability problem when blended in gasoline. Do you have experience blending diisobutylene in gasoline? And if so, were there stability or other problems?

GRUBB (Chevron USA, Inc.) I consulted our corporate experts for this, Shingou Lou and Dave Kohler. We built one in Pascagoula and their basic response was that there’s really no reason to expect any more instability problems than you would have with normal olefins. And as with the other olefins, if you let them go unchecked, they could lead to an insoluble gum residue. These can be mitigated effectively with some antioxidants—the phenylenediamine-hindered phenol. They do recommend that you inject them very close to the source unit. Like I said, Pascagoula converted an MTBE plant and we had no instability issues at our plant. Corporate-wide, we actually have experience with two ion exchange resin-type catalyst units, two solid phosphoric acids distributed on solid support-type catalyst units, and we have experience with Dimersol-type units.

(2008) Question 80: Where in the isomerization reactor catalyst bed does the hydrogenation of benzene (exothermic) occur? How does this affect the other isomerization reactions? What concentration of benzene in the isomerization feed is acceptable?

ZMICH (UOP LLC) This question refers to or asks about benzene hydrogenation and how it affects to isomerization reactions, maximum levels in the feed, and where does it happen in the reactors. So what I thought we would do is start out with what am I talking about: benzene saturation.

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