UOP Processing Guide
IMAGINATION, INNOVATION AND DISCOVERY
INSPIRED BY EXPERIENCE
Empowering customers to maximize profitability
UOP Processing Guide
UOP processes have changed the world. Since the ground-breaking introduction
of the Dubbs Process in 1914, UOP’s engineers and chemists have excelled in
turning laboratory science into industrial reality, helping to solve many of the
world’s energy challenges. Today more than 60% of the world’s gasoline and
85% of its bio-degradable detergents are made using UOP technology. As the
needs of the world’s refining, petrochemical and natural gas industries continue
to evolve, we are committed to developing technologies, products and services
that allow our customers to profit in a highly-competitive marketplace.
The UOP Processing Guide is a valuable tool to introduce many of the
processes, products and services that we offer to help our customers meet
challenges of a changing demand in product mix, environmental and regulatory
requirements, and production efficiency needs. We look forward to working
with you to develop tailored solutions for the challenges you face.
UOP PROCESSING GUIDE
Table of Contents
REFINING PROCESSES
1
GASOLINE UPGRADING
UOP CCR PlatformingTM Process
UOP PenexTM and Par-IsomTM Processes
UOP PenexTM Process
UOP Par-IsomTM Process
UOP BenSatTM Process
6
6
8
8
9
10
GASOLINE FROM LPG
UOP HF Alkylation Process
UOP ReVapTM Modified HF Process
UOP InAlkTM Process
UOP ButamerTM Process
11
11
13
14
16
CONVERSION
UOP UnicrackingTM Process
UOP Fluid Catalytic Cracking Process
UOP LCO-XTM Process
18
18
20
22
HYDROPROCESSING
UOP UnionfiningTM Process
UOP MQD UnionfiningTM Process
UOP Distillate UnionfiningTM Process
UOP VGO UnionfiningTM Process
UOP RCD UnionfiningTM Process
UOP SelectFiningTM Process
23
23
23
24
24
26
27
TREATING
UOP MeroxTM Process
Liquid-Liquid Extraction Merox
Sweetening Merox
28
28
28
29
RESIDUE UPGRADING
UOP UniflexTM Process
UOP Catalytic Crude UpgradingTM Process
UOP/FWUSA Solvent Deasphalting Process
SYDEC Delayed CokingTM Process
30
30
31
32
33
PETROCHEMICAL PROCESSES
35
AROMATICS
UOP ParexTM Process
UOP Sinco Solid State Polycondensation Process
UOP SulfolaneTM Process
UOP TatorayTM Process
UOP IsomarTM Process
UOP MX SorbexTM Process
UOP PX-PlusTM Process
40
40
42
44
45
46
47
48
AROMATIC DERIVATIVES
Lummus/UOP EBOneTM Process
Lummus/UOP Classic SMTM Process
Lummus/UOP Smart SMTM Process
UOP Q-MaxTM Process
Sunoco/UOP Phenol Process
49
49
50
51
52
53
OLEFINS
UOP OleflexTM Process
UOP/HYDRO MTO Process
Total Petrochemicals/UOP Olefin Cracking Process
UOP MaxEneTM Process
Hüls UOP Selective Hydrogenation Process
Hüls Butene-1 Recovery Process
UOP Propylene Recovery Unit
54
54
56
57
59
60
61
62
DETERGENTS
UOP Linear Alkylbenzene (LAB) Complex
UOP MolexTM Process
UOP PacolTM Process
UOP DeFineTM Process
UOP PEPTM Process
UOP/CEPSA Detal Process
64
64
64
64
64
64
64
HYDROGEN
UOP PolybedTM PSA System
UOP PolysepTM Membrane System
Hydrogen Management Services
GAS PROCESSING
NATURAL GAS TREATING
UOP Amine Guard FSTM Process
UOP BenfieldTM Process
De-hydration and Sulfur Removal
Mercury Removal
Ortloff Technologies
UOP SelexolTM Process
Integrated LNG Feed Pre-treatment
UOP SeparexTM Membrane System
FLNG and FPSO Feed Pre-treatment
Syngas Treating
RENEWABLES
UOP/Eni EcofiningTM Process
UOP Renewable JetTM Process
The Envergent RTPTM Process
ADSORBENTS
Molecular Sieve Adsorbents
Aluminas
67
71
72
73
75
79
79
80
81
82
84
87
89
90
92
93
95
99
101
102
105
109
110
EQUIPMENT
UOP Distillation Technology
UOP Heat Transfer Technology
UOP High FluxTM Tubing
UOP High CondTM Tubing
Raschig Packings
Raschig Super-RingTM Packing
Raschig Super-PakTM
Reactor Internals
Inlet Diffuser
Rough Liquid Distribution Tray
Vapor/Liquid Distribution Tray
Catalyst Support Grid
Quench Zone
Outlet Collector
SERVICES
Services We Offer
Training
Inspection
Process Transformation
Field Operating Services
Regional Services
Technology Services
Performance Optimization
Optimization Services
Strategic TIPS
Energy and CO2 Management
Tactical TIPS
113
116
118
118
119
120
120
120
121
121
122
122
122
123
123
125
129
129
129
130
130
130
131
131
132
132
132
133
UOP PROCESSING GUIDE
Glossary of terms
UOP PROCESS
COMMON INDUSTRY TERM
Envergent RTP Process
Hüls Butene-1 Recovery Process
Lummus/UOP Classic SM Process
Lummus/UOP EBOne Process
Lummus/UOP Smart SM Process
Ortloff Technologies
Sunoco/UOP Phenol Process
SYDEC Delayed Coking Process
Total Petrochemicals/UOP Olefin Cracking Process
UOP Amine Guard FS Process
UOP Benfield Process
UOP BenSat Process
UOP Butamer Process
UOP Catalytic Crude Upgrading Process
UOP CCR Platforming Process
UOP/Eni Ecofining Process
UOP Fluid Catalytic Cracking Process
UOP/FWUSA Solvent Deasphalting Process
UOP HF Alkylation Process
UOP/HYDRO Methenol to Olefins Process
UOP InAlk Process
UOP Isomar Process
UOP LCO-X Process
UOP Linear Alkybenzene (LAB) Complex
UOP MaxEne Process
UOP Merox Process
UOP MX Sorbex Process
UOP Oleflex Process
UOP Par-Isom Process
UOP Parex Process
UOP Penex Process
UOP Polybed PSA System
UOP Polysep Membrane System
UOP PX-Plus Process
UOP Q-Max Process
UOP Renewable Jet Process
UOP ReVAP Process
UOP SelectFining Process
UOP Selective Hydrogenation Process
UOP Selexol Process
UOP Separex Membrane System
UOP Sinco Solid State Polycondensation Process
UOP Sulfolane Process
UOP Tatoray Process
UOP Unicracking Process
UOP Uniflex Process
UOP Unionfining Process
Bio-mass conversion
Butene-1 production
Styrene monomer
Toluene dis-proportionation
Styrene monomer
NGL recovery and elemental sulfur production
Phenol (from cumene)
Delayed coking
Olefin cracking
Gas treating
Gas treating
Gasoline benzene reduction
Butane isomerization
Stranded crude upgrading
Catalytic reforming
Renewable diesel fuel
Octane enhancement and propylene production
Residue solvent deasphalting
Motor fuel alkylation
Methanol to olefins
Motor fuel alkylation (indirect)
Xylene isomerization
FCC light cycle oil conversion
Bio-degradable detergent intermediate production
Naphtha separation
Hydrocarbon treating
Meta-xylene adsorptive separation
Propane dehydrogenation
Light naphtha (LN) isomerization
Para-xylene adsorptive separation
Light naphtha (LN) isomerization
Hydrogen purification
Hydrogen purification
Toluene dis-proportionation
Cumene
Renewable oil hydrogenation
Motor fuel alkylation mitigation system
Olefinic naphtha selective hydroprocessing
Selective hydrogenation
Natural/synthesis gas treating
Gas treating
PET resin production
Aromatics extraction
Aromatics dis-proportionation
Conversion
Slurry residuum hydrocracking
Hydrotreating
REFINING PROCESSES
REFINING PROCESSES
We can transfer UOP technology to your refinery
through a unique collection of products and services.
REFINING PROCESSES
Through the decades, the marketplace has required that refiners meet the difficult technical challenges of
changing product slates, increasingly strict fuel specifications and higher environmental stewardship while
maintaining profitability for their stakeholders. In the present and in the future, these challenges will remain,
and will likely intensify. UOP offers refiners a full portfolio of innovative process technology, adsorbents and
catalysts, specialized equipment, engineering and technical services, and operational support services to
allow them to successfully address those challenges.
ur customers employ UOP’s
Hydrogen is a major focus in refining
licenses, basic design and front-end
technical capabilities for
today because of the drive toward
engineering services, adsorbent and
operational improvements, revamps
low-sulfur gasoline and diesel fuels.
catalyst supply, and training and technical
of existing equipment and major
UOP is focused on managing hydrogen
support at unit commissioning. UOP also
expansions, as well as grassroots refinery
networks more efficiently and maximizing
transfers technology in the form of
projects. With UOP acting as a single
hydrogen production from existing
equipment, either skid-mounted process
source, you receive fully-integrated and
producers, while minimizing consumption
modules or individual process- and
optimized solutions, resulting in lower
in hydroprocessing units. The UOP
catalyst-related equipment items.
investment cost and shorter project
PolybedTM PSA and UOP PolysepTM
timing, and ensure maximum
Membrane Systems are integral to
UOP's post-start up technical services
project profitability.
efficient hydrogen generation and
include process- and catalyst-related
management.
consulting and refinery-wide optimization
O
services. Recognizing the dynamic nature
UOP has a long history of industry
UOP is also dedicated to making the
of our customers’ business environment,
technologies with the UOP Platforming ,
world a better place to live, work and
UOP provides services such as
UOP Penex , UOP Butamer
play by focusing a large portion of our
configuration studies to assist you with
efforts on developing clean and efficient
maintaining your competitive edge in an
as the UOP Fluid Catalytic Cracking
new technologies, including those for
ever-changing world.
process. UOP has also developed
renewable fuels and chemicals. The
leadership in gasoline production
TM
TM
TM
UOP HF Alkylation
TM
and
processes, as well
TM
newer technologies such as the
UOP SelectFining
TM
and UOP InAlk
TM
processes to meet changing
outcome is not only cost-effective, but it
After more than a century of developing
will make it easier for you to meet current
innovative technology, UOP remains
and future environmental regulations.
committed to helping the world’s refiners
address their evolving operating challenges.
gasoline needs.
The UOP Fluid Catalytic Cracking, UOP
Unicracking
TM
and UOP Unionfining
TM
processes provide flexible solutions to
gas oil conversion for ultra-low-sulfur
diesel fuel, kerosene and gasoline
production.
UOP offers crude and vacuum
distillation, coking, visbreaking and
solvent deasphalting, and the UOP
Merox process for product treating,
as part of a full refinery solution.
4
UOP transfers its technology to your
In the following pages, you’ll find descrip-
refinery through a unique collection of
tions of our refining processes, as well as
products and services, including process
diagrams that illustrate how they fit together.
Refining Process Flow
Gas
Concentration
Hydrogen
Purification
H2 Plant
Amine Treating
Hydrogen
Sulfur
Treating
LPG
from FCC
Treating
Treating
Light
Naphtha
To Black Oil
Hydrocracking
Crude
Distillation
Hydrotreating
Light Naphtha
Isomerization
Hydrotreating
Reforming
Gasoline
Treating
Kerosene
& Jet Fuel
Heavy
Naphtha
Kerosene
Middle Distillate
Hydrotreating
Diesel
Desalted
Crude Oil
Catalytic
Condensation
Atmospheric
Gas Oil
C4
Isomerization
Treating
FCC
Cycle Oils
Hydrotreating
Alkylation
SHP
Treating
Selective
Hydrotreating
Hydrocracking
Lube Oils
Vacuum
Distillation
Black Oil
Fuel Oil
Coke
Asphalt
5
REFINING PROCESSES
GASOLINE UPGRADING
UOP CCR PlatformingTM Process
Catalytic reforming
Used throughout the petroleum and petrochemical industries, the UOP CCR
Platforming process utilizes naphtha feedstocks boiling in the range of 180-400°F to
produce high-octane gasoline blending components or petrochemical precursors.
n petrochemical applications, the
semi-regenerative Platforming technology.
catalytic reforming, has more than 200
CCR Platforming process upgrades
And, 40 years ago, UOP again
units on stream with the continual
naphtha into aromatics-rich product for
revolutionized catalytic reforming with the
addition of newly-licensed units bringing
downstream petrochemicals processing.
introduction of the Platforming process with
UOP's latest innovations in design,
In gasoline applications, it produces
CCRTM catalyst regeneration. The new
catalysts and equipment to market.
high-octane reformate for unleaded
technology enabled Platforming units to
Commercial CCR Platforming units
gasoline blending. In reformulated
operate continuously by eliminating the need
routinely achieve on-stream efficiencies
gasoline applications, the low-pressure,
to shut down for catalyst regeneration.
of more than 97%. The first CCR
low-severity (LPLS) CCR Platforming
UOP, the market and technology leader in
Platforming unit is still operating today.
I
process restores a refinery’s hydrogen
balance by maximizing the yield of
hydrogen, even at the required
low-octane severities. With appropriate
pre-fractionation, the process produces
the low-benzene, low-vapor-pressure
material required to produce
reformulated gasoline.
Over 60 years ago, UOP introduced the
semi-regenerative Platforming process,
the first catalytic reforming process to
use a platinum-based catalyst. Frequent
advances in process and catalyst
technology continually improved the
6
REFINING PROCESSES
GASOLINE UPGRADING
CCR Platforming Process
Stacked Reactors
Naphtha Feed
from Hydrotreating
CCR
Regenerator
Net Gas
Compressor
Net H2-Rich Gas
Recovery
Section
Combined
Feed
Exchanger
H2-Rich
Light Ends
Separator
Stabilizer
Regenerated
Catalyst
Fired Heaters
Aromatics-Rich
Reformate
Spent
Catalyst
Hydrotreated naphtha feed is combined
liquid to the product recovery section.
made over the last two decades in
with recycled hydrogen gas and heat-
Liquid from the recovery section is
optimizing operating conditions with
exchanged against reactor effluent. The
sent to a stabilizer, where the light
continually-improving catalysts. In
combined feed is then raised to reaction
hydrocarbons are removed from the
addition, UOP has made dramatic
temperature in the charge heater and
aromatics-rich reformate product.
progress toward closing the actual-to-
sent to the reactors. The reaction occurs
theoretical yield gap. Selectivities now
as the charge flows radially across the
Over time at reaction conditions, coke
range from 80% to 100% for heavier
annular catalyst beds. The circulating
builds up on the Platforming catalyst.
paraffin species and heavy five- and
catalyst, including the UOP R-100 and
Partially-deactivated catalyst is continually
six-membered naphthene ring species.
R-200 series catalysts, flows vertically
withdrawn from the last reactor and
downward, by gravity, through the reactor
transferred to the CCR Regenerator
The CCR Platforming process has a
stack. The pre-dominant reactions are
Section. Spent catalyst from the bottom
minimal environmental impact with
endothermic, so an interheater is used
of the reactor stack flows to the
high-energy efficiency. In all applications,
between each reactor to reheat the
regeneration tower, where the
the Platforming unit is a reliable,
charge to reaction temperature. Flue gas
catalyst is completely regenerated.
continuous source of high-purity
from the fired heaters is typically used to
Regenerated catalyst is then lifted with
hydrogen, with a guarantee of no yield
generate high-pressure steam, but other
hydrogen and returned to the top of the
decline (C5+ reformate and hydrogen)
heat generation options are available.
reactor stack. An automated, computer-
over the life of the catalyst.
controlled system ensures trouble-free
The effluent from the last reactor is
operation of the catalyst transfer.
heat-exchanged against the combined
feed, then cooled and split into vapor
The UOP Platforming process with
and liquid products in a separator.
CCR catalyst regeneration provides
A portion of the gas is compressed
refiners with proven, ultra-low-pressure
and recycled back to the reactors.
operation (50-psig reactor pressure)
The hydrogen-rich net gas is compressed
and, therefore the highest reforming
and charged together with the separator
yields. Major advances have been
7
REFINING PROCESSES
GASOLINE UPGRADING
UOP PenexTM and Par-IsomTM Processes
Light naphtha isomerization
In the world's established and growing gasoline markets, new and evolving specifications present refiners
with processing challenges, but also potential profitability gains through targeted strategies. For decades, the
isomerization of light naphtha (LN) streams has contributed significant octane-barrels to the world's gasoline
pools. With more strict specifications, light naphtha isomerization's high-octane gasoline blending component,
which is also low in sulfur, benzene and olefins, is increasingly valuable. UOP's portfolio of LN isomerization
technologies, including the UOP Penex and Par-Isom processes, provides important options to suit a refiner's
specific operating objectives and site conditions.
U
OP has decades of global
In commercial isomerization processes,
experience with isomerization
reactions take place over a fixed-bed of
technologies. The first commercial
catalyst in the presence of hydrogen.
Penex process unit, built for the
The amount of hydrogen required
isomerization of light straight-run
depends on the feedstock composition
naphtha, went on-stream in the late
and the catalyst. The three types of
1960's. And, in the 50+ years since
isomerization catalysts that are used
the startup of the first UOP Butamer
commercially are differentiated by the
unit, over 300 units using UOP's light
materials that provide the catalyst
paraffin isomerization technologies
acidity: Zeolite, sulfated-metal oxide
have been placed on stream at
and chlorided alumina.
refineries around the world.
Penex Process
Penex Process
The Penex process is a fixed-bed
process that uses high-activity, chloride-
Stabilizer
Reactors
Make-up Hydrogen
promoted catalysts to isomerize C5/C6
paraffins to higher-octane branched
components. The reaction conditions
promote isomerization and minimize
Dryer
hydrocracking. UOP currently offers the
I-80 catalyst series. These catalysts
represent the most active and longest-life
catalysts available on the market today.
The Penex process is currently operating
in more than 120 units worldwide. The
Dryer
Isomerate
process has a wide range of recycle
configurations for optimum design flexibility.
8
Feed
Off Gas
GASOLINE UPGRADING
Par-Isom Process
REFINING PROCESSES
recycle compressor and back to the
The Par-Isom process is an innovative
application of a UOP-developed,
non-chlorided alumina catalyst for light
paraffin isomerization. In this process,
the fresh C5/C6 feed is combined with
make-up and recycle hydrogen and
reaction section. The liquid product is
sent to a stabilizer column where
the light ends and any dissolved
hydrogen are removed. The stabilized
isomerate product can be sent directly
to gasoline blending.
then directed to a heat exchanger,
where the reactants are heated to
reaction temperature. The heated
combined feed is then sent to the
reactor. Conversion is accomplished
across UOP’s PI-200 series catalysts,
an extremely robust, fully-regenerable,
noble-metal (platinum), light paraffin
More refineries are utilizing UOP
isomerization technologies because
light naphtha isomerate is an excellent
gasoline-blending component, due to
its high-octane, low-sulfur, low-olefin
and low-benzene properties. Light
paraffin isomerization can offset octane
loss from lead phase-out or from
isomerization catalyst.
de-sulfurization of FCC naphtha. In
The reactor effluent is cooled, and then
sent to a product separator where
recycle hydrogen is directed to the
addition, the process can provide a
cost-effective solution to benzene
management in motor fuels.
Par-Isom Process
Make-up Hydrogen
Stabilizer
Off
Gas
Reactor
Product
Separator
Feed
Isomerate
9
REFINING PROCESSES
GASOLINE UPGRADING
UOP BenSatTM Process
Gasoline benzene reduction
In both established and growing markets the gasoline pools face tightening benzene limits that cannot be met
by naphtha reformer feed pre-fractionation alone. The UOP BenSat process is designed to efficiently remove
benzene from light reformate or light straight-run naphtha streams to meet those benzene specifications.
Benzene is saturated to cyclo-hexane using a highly-selective catalyst.
M
ost refiners achieve benzene
The technology is based on years
reduction by managing benzene
of experience with the UOP HB UnibonTM
production from the catalytic reformer.
process, which converts benzene to
The two primary strategies to accomplish
high-purity cyclo-hexane for petrochemical
this goal are the minimization of benzene
use. High space velocity in the reactor
and benzene precursors in the catalytic
contributes to the unit’s cost-effective
reformer feed, or the elimination of
design. For refiners who do nort require
benzene from the reformate after it is
additional octane to meet their blending
formed. The BenSat process can be
requirements, a BenSat unit is the most
applied equally well in either of these
effecient benzene management option.
strategies as a stand-alone,
For those who require additional octane-
cost-effective option to treat C5/C6
barrels, the UOP Penex-PlusTM and UOP
feedstocks that are high in benzene.
TIP-PlusTM processes provide both
octane upgrading and benzene reduction.
BenSat Process
Make-up
Hydrogen
Feed
Light Ends
to Fuel Gas
Reactor
Stabilizer
Product
10
GASOLINE FROM LPG
REFINING PROCESSES
UOP HF Alkylation Process
Motor fuel alkylation
Motor fuel markets worldwide demand gasolines with lower volatility, olefinicity and aromaticity while retaining high
octane ratings. The UOP HF Alkylation process catalytically combines light olefins (propylene, butylenes and/or
amylenes) with iso-butane to produce a premium gasoline blending component. Reacting these light hydrocarbons
increases their value, making an environmentally-sound alkylate product characterized by low RVP and high octane.
L
ight olefins are important
by-products of heavy oil conversion
processes, such as fluid catalytic
cracking (FCC) and coking units.
A refinery’s gasoline output and quality
significantly increase when an HF
alkylation unit is placed downstream
of the FCC unit. And, alkylate continues
to become a more important blending
component as gasoline pool
requirements progressively tighten.
The UOP HF Alkylation process is
the culmination of over 60 years of
research and development, engineering
innovation and commercial experience.
In addition, UOP acquired
ConocoPhillips’ suite of HF alkylation
technologies in 2007. The integration of
all these technologies brings together
the best in HF alkylation, enhancing
customer value by providing flexible
technical support, independent of the
existing unit's heritage, and grassroots
and revamp designs aimed at the
specific concerns of each refiner.
In the UOP HF Alkylation process,
Iso-butane reacts under mild operating
conditions with propylene, butenes
and/or amylenes in the presence of
hydrofluoric acid to produce a highoctane alkylate blending component
for motor gasoline. There are several
technology options that can be
11
REFINING PROCESSES
GASOLINE FROM LPG
UOP HF Alkylation Process continued
incorporated into new unit designs, as
injection points throughout the reactor
fugitive emissions. The iso-paraffin
well as in the revamp of existing units,
that can take advantage of un-reacted
composition of the alkylate further
that will enhance intrinsic safety,
iso-butane, maximizing alkylate yield
reduces the olefin and aromatic
decrease environmental impact and
from an existing alkylation unit with
contents of the overall gasoline pool.
improve reliability. One such
minor capital investment.
The low RVP of alkylate lessens the
technology is a passive mitigation
impact of gasoline volatility issues for
system that will reduce aerosol formation
Alkylate product from the UOP HF
refiners who are trying to meet
from any leak that occurs, and a system
Alkylation process sets the quality
renewable fuels targets by blending
that can quickly transfer the catalyst
standard for environmental gasoline.
ethanol into the gasoline pool. The
inventory from the operating unit in an
Its high octane level places alkylate in
UOP HF Alkylation process remains an
emergency. An additional option
the range of a premium blending
economically-viable method for the
employs a system of multiple feed
component, while the low RVP reduces
production of alkylate.
HF Alkylation Process
Feed Dryer
Settler
Iso-butane
Olefin
Feed
Main
Fractionator
Motor Fuel
Butane
HF
Stripper
KOH
Treater
Propane
De-fluorinator
and KOH Treater
Accumulator
Alkylate
12
GASOLINE FROM LPG
REFINING PROCESSES
UOP ReVAPTM – Modified HF Process
Motor fuel alkylation mitigation system
The ReVAP process is used with hydrofluoric (HF) alkylation technology to reduce the potential of HF
aerosol formation in the event of an HF release, while maintaining unit operability and product quality.
This passive mitigation system, in which an additive is used to alter the properties of the HF acid phase,
requires no specific operator interaction.
T
he ReVAP process was developed
The additive forms a complex with the
in the mid-1990’s, and was first
HF, which is recovered from the
proven at the Torrance refinery in
hydrocarbon phase in the additive
California, U.S.A. The technology has
recovery section of the plant. Polymer
since been commissioned in several
is separated from the HF-additive
HF alkylation units.
complex and sent for neutralization.
The HF-additive complex is recycled
The ReVAP process provides a variety
back to the reactor section. The HF
of benefits, including a significant
acid regenerator column is still used
reduction of HF vapor pressure,
for the removal of water and light
demonstrated aerosol reduction and
polymer from the process.
improved plant safety. The process
also offers potential for alkylate
octane improvement.
ReVAP Process
Additive
Recovery Section
Feed Dryer
Settler
Additive
Storage
Iso-butane
Olefin
Feed
Main
Fractionator
Motor Fuel
Butane
HF
Stripper
KOH
Treater
Propane
De-fluorinator
and KOH Treater
Accumulator
Alkylate
Additive
Extraction Column
Recovered Additive
13
REFINING PROCESSES
GASOLINE FROM LPG
UOP InAlkTM Process
Motor fuel alkylation (indirect)
Alkylate is a key gasoline blending component in the modern oil refinery. Many refiners would be unable to
produce an acceptable slate of gasoline products without this valuable gasoline stream. Traditional alkylation
processes react light olefins (C3 - C5) with iso-butene to produce a high-octane, low-vapor pressure, paraffinic
blending component that is ideal for refiners in need of premium gasoline, octane or reformulated gasoline.
D
irect alkylation processes use
extension of UOP's catalytic
The InAlk process makes premium
HF or sulfuric liquid acids as the
condensation and olefin saturation
alkylate using a combination of
technologies.
commercially-proven technologies.
catalytic medium. UOP has developed
a unique approach to produce an
Iso-butene reacts with itself or with other
indirect alkylation gasoline-blending
The InAlk process improves gasoline
C3-C5 olefins via polymerization. The
component similar in quality to traditional
quality by increasing the availability of
resulting mixture of higher molecular
motor alkylate. This technology is the
clean-burning, mid-boiling-range
weight iso-olefins is then hydrogenated
InAlk (indirect alkylation) process,
iso-paraffins with high-octane, low RVP
to form a high-octane, paraffinic gasoline
which uses solid catalysts for reacting
and low-sulfur content, while reducing
blendstock that is similar to alkylate,
iso-butene with light olefins to produce
gasoline pool olefin content by the
but usually higher in octane. Control of
a high-octane, paraffinic gasoline
conversion of C4 and C5 olefin
the polymerization conditions minimizes
component. The InAlk process is an
components to alkylate.
low-octane isomer production. The
Inalk Process with SPA Catalyst
Polymerization
Reactor
Paraffinic and
Olefinic LPG
Stabilizer
Make-up
Hydrogen
Hydrogenation
Reactor
Light Ends
Steam Cracker
or FCC C4
Separation
Alkylate
14
GASOLINE FROM LPG
REFINING PROCESSES
InAlk process is more flexible than the
The InAlk process is based on proven
than 200 hydrogenation units in olefin
traditional alkylation processes. Using a
technology and light hydrocarbon
and di-olefin saturation service.
direct alkylation process, refiners must
chemistry well-known in the industry.
Commercialized in the early 2000's,
match the iso-butane requirement with
UOP has licensed and designed over
InAlk units based on both the SPA and
olefin availability. InAlk does not require
400 catalytic polymerization units using
the resin catalyst systems are now
a set amount of iso-butane to produce
SPA catalysts producing poly-gasolines
providing refiners a valuable solution to
a high-quality product.
and petrochemical olefins, and more
their gasoline pool challenge.
The flexibility of the InAlk process is in
both the polymerization and saturation
sections. Each section has different
catalyst options to suit a refiner’s
specific operating objectives and
site conditions. Either resin or solid
phosphoric acid (SPA) catalysts are
used to polymerize the olefins. Resin
catalysts primarily convert iso-butene.
SPA catalysts also convert normal
butenes. The saturation section uses
either a base-metal or noble-metal
catalyst. Base-metal catalysts are less
sensitive to feed contaminants than
noble-metal catalysts, but require a
higher capital investment.
The InAlk process is designed to
minimize capital and operating costs,
while producing a premium alkylate
product. In addition, of all commerciallyavailable alkylation technologies, the
InAlk process requires the least capital
investment. The SPA catalyst system
offers the best revenue potential
because of its greater ability to convert
normal butene to alkylate.
15
REFINING PROCESSES
GASOLINE FROM LPG
UOP ButamerTM Process
Butane isomerization
The petroleum industry has witnessed a significant shift to environmentallysuperior gasoline blending components. Motor fuel alkylate is one blending
component that has seen a substantial increase in demand because of its
paraffinic, high-octane, low-vapor pressure blending properties. Iso-butane
is a primary feedstock for producing motor fuel alkylate.
T
he Butamer process is a high-
reaction is equilibrium-limited, and the
efficiency, cost-effective means of
production of iso-butane is favored by
meeting the demands for the production
lower temperature (see graph).
of iso-butane by isomerizing normal
butane (n-C4) to iso-butane (i-C4). The
High-activity, chlorided-alumina
Butamer process has reliably served
catalysts, such as UOP I-12TM catalyst
UOP’s innovative hydrogen-once-through
as the primary technology for iso-butane
and UOP I-120TM catalyst, are used in
(HOT) Butamer process flowscheme
production since the late 1950's.
the Butamer process. These catalysts
results in substantial savings in capital
Design, operation and catalyst
are capable of converting normal
equipment and utility costs by eliminating
innovations have kept this process a
butane to iso-butane with a close
the need for a product separator or
state-of-the-art technology.
approach to equilibrium. Volumetric
recycle gas compressor.
selectivity to i-C4 exceeds 99%. In
The Butamer process is a fixed-bed
almost all applications, unconverted
Typically, two reactors in series flow
catalytic process that uses high-activity,
normal butane is eliminated through
are used to achieve high on-stream
chloride-promoted catalysts to isomerize
the use of a de-isobutanizer column
efficiency. The catalyst can be replaced
normal butane to iso-butane. The
(DIB) or an iso-stripper column
in one reactor while operation continues
associated with an alkylation unit.
in the other. The stabilizer separates the
light gas from the reactor effluent.
Because of the low temperature and
Iso-butane Equilibrium
dry operating environment, Butamer
unit design can take advantage of
i-C4/Total C4, mol%
Isobutane/ΣButanes, mol%
100
economical carbon steel construction.
80
60
40
20
0
200
(93)
300
(149)
400
(204)
Temperature, °F (°C)
16
500
(260)
600
(316)
REFINING PROCESSES
GASOLINE FROM LPG
Virtually-complete conversion of normal
butane to iso-butane can be achieved
Butamer Process
when the Butamer unit is integrated with
an alkylation unit. In this application, the
Butamer unit feed is a side-cut from the
Reactor
iso-stripper column, and the stabilized
isomerate is returned to the iso-stripper
Gas to
Scrubbing
and Fuel
Stabilizer
column. Unconverted normal butane is
recycled to the Butamer unit, along
with normal butane from the fresh feed.
Dryer
n-Butane
The best feeds for a Butamer unit
Dryer
contain the highest practical normal
butane content and only small
Isomerate
Make-up
Hydrogen
amounts of iso-butane, pentanes and
heavier material. Natural gas liquids
(NGL) from a UOP NGL recovery unit
can be processed in a Butamer unit.
To provide a Butamer feed that is rich
in normal butane, streams with large
amounts of iso-butane or pentanes
should be processed first through an
Alkylation Butamer Integration
iso-stripper or DIB column.
LPG
The stabilized isomerate is a nearequilibrium mixture of iso-butane and
Iso-stripper
i-C4
normal butane with small amounts of
Isomerate
heavier material. The light-ends yield
Light Ends
from cracking is less than 1 Wt% of
the butane feed.
Olefin
Feed
Alkylation
Reactor
Section
n-C4
With more than 70 Butamer units on
stream with feed capacities ranging
from 800 to more than 35,000 BPSD
Saturated
Butanes
Make-up
Hydrogen
(74 to 3,250 T/D), the Butamer process
provides refiners the design flexibility
Butamer
Unit
Alkylate
and operational reliability to meet their
specific processing needs.
17
REFINING PROCESSES
CONVERSION
UOP UnicrackingTM Process
Conversion
Distillate demand is expected to grow significantly over the coming years.
Refiners must increase yields of these fuels while meeting specifications, but
also need flexibility in their production slate to meet regional market demands.
The Unicracking process is the most versatile hydrocracking process for
selectively upgrading a variety of feedstocks to high-quality lighter products.
T
his critical technology can produce
contents can be optimized based on
LPG, naphtha, kerosene and diesel,
their end users.
as well as high-quality unconverted oil
for lube base-stocks or FCC feedstock
There are several Unicracking processes
by conversion of heavier feedstocks
presently offered to meet a refiner's
and the addition of hydrogen. The
needs and project objectives. The basic
Unicracking process operates at
flowschemes utilize a single-stage or
elevated hydrogen partial pressures
two-stage design options.
in the presence of a catalyst, which
selectively produces products in the
desired boiling range. Selection of unit
configuration, catalysts and process
conditions, such as space velocity and
pressure, are a function of the desired
operating cycle life and required
product qualities.
Feedstocks can range from naphtha
to light gas oils to non-distillable
components such as de-metallized oil.
Depending on the refiner’s need,
Unicracking products can include LPG,
naphtha, kerosene, diesel, high-quality
unconverted oils (UCO), or virtually
any combination of these materials. In
general, the process chemistry favors
highly-saturated products. However,
the combination of the Unicracking
• The single-stage Unicracking
process can be a once-through flow
scheme for partial conversion, or a
flowscheme, the first stage provides
recycle flowscheme for full conver-
hydrotreating and partial conversion
sion. These flowschemes are simple
of the feed. Products from this stage
and cost-effective designs widely
are then separated by fractionation.
used in refineries. The once-through
The second stage of the two-stage
Unicracking process produces
design provides the remaining high
hydrocracked products, as well as
conversion of recycle oil. These
high-quality unconverted oil that can
flowschemes offer several advantages
be excellent feed for FCC or ethylene
in processing heavier and highly-
cracking units. The UCO can also
contaminated feeds. The two-stage
be used as a high-quality lube
flowscheme is also economical when
base-stock. When high conversion
the throughput of the unit is relatively
is desired, the single-stage recycle
high, regardless of feed properties.
flowscheme offers a simple and
cost-effective design for moderate
In a typical refining situation, a Unicracking
capacity hydrocracking designs.
unit can be used as a stand-alone
conversion process to produce
• The two-stage Unicracking process
high-quality distillate products for direct
process and innovative catalysts targets
can be configured either as a separate
blending into the product pool. This
hydrogen addition to specific high-value
hydrotreat or a two-stage flowscheme.
technology may also be used to produce
products. As a result, distillates have
In the separate hydrotreat flowscheme,
low-sulfur naphthas for reforming into
high cetane number and smoke point,
the first stage provides only
gasoline, or to upgrade FCC products
while naphtha and UCO hydrogen
hydrotreating, while in the two-stage
through aromatic saturation for additional
distillate production or sulfur removal.
18
REFINING PROCESSES
CONVERSION
UOP has developed several Unicracking
catalyst families that offer flexibility to
Single-Stage Unicracking Process
achieve product objectives within the
reaction environment, depending on
Make-up
Hydrogen
the level of severity created by the
flowscheme employed. Catalyst
selection within these families is
Reactors
Cold
Separator
Feed
Vent Gas
HT
dependent upon the required product
HC
Product
Separation
quality, product selectivity, and the
Butanes
Wash
Water
process conditions required to
achieve them.
Cold
Flash
Drum
Light
Naphtha
Heavy
Naphtha
As market needs have evolved, UOP
has continually adapted Unicracking
Hot
Separator
technology to address these changes.
Hot
Flash
Drum
Distillate
One such area is in catalyst selection
Recycle Oil (If Required)
and in performance optimization.
Traditionally, catalysts were viewed simply
by selectivity and activity. As catalysts
have become more sophisticated and
performance needs more varied,
catalyst selection requires
multi-dimensional considerations.
Two-Stage Unicracking Process
In addition to selectively and activity,
a third dimension, hydrogenation, has
Make-up
Hydrogen
Reactors
been added to describe catalyst
formulations. The catalysts developed
Cold
Separator
Feed
Vent Gas
will be able to better meet the needs of
refiners that encounter critical hydrogen
HT
HC
Product
Separation
management issues.
Butanes
Flash
Drum
Hot
Separator
Since hydrocracking technology was
Naphtha
offered by UOP in the late 1950's, UOP
has continually improved both the
Hot
Flash
Drum
process and catalyst systems. With more
than 200 units awarded in over 40
countries, UOP delivers the capabilities
and experience necessary to help you
improve your bottom line.
Jet
Distillate
HC
UCO
Recycle Oil
19
REFINING PROCESSES
CONVERSION
UOP Fluid Catalytic Cracking Process
Octane enhancement and propylene production
Whether meeting a regional transportation fuel market demand, or pursuing an integrated
refinery/petrochemical strategy to meet the developing world's rapidly growing use of synthetic
materials, the UOP Fluid Catalytic Cracking (FCC) process can help refiners maximize their
profitability by enabling them to achieve refining and petrochemical objectives effectively and efficiently.
T
he UOP FCC process and its
but have developed emission- and
related processes can enable
yield-selective additives. Technology
refiners to convert straight-run atmos-
licensors have continued to make
pheric gas oils, vacuum gas oils, certain
advances in feed distribution
atmospheric residues and heavy stocks
systems, riser termination devices
recovered from other refinery operations,
and spent-catalyst stripping. Each
into high-octane gasoline, light fuel oils
advancement has contributed to
and olefin-rich light gases such as
improved operability and product
propylene. Integrated refining/
selectivity; in combination, they have
petrochemical complexes utilize
dramatically increased the value of
unique UOP solutions to ensure
the technology.
RxCAT Design
availability of petrochemical feedstocks
and create new revenue sources.
Of the more than 400 FCC units
worldwide, nearly 40% operate under
Over the past 20 years, FCC technology
a UOP license. UOP maintains
has seen significant improvements in
its position as an industry leader in
catalyst, equipment and process
FCC technology through continued
design. Catalyst companies have not
technological development and
only advanced basic catalyst design,
constant process-design evolution.
Based on conventional, proven
technology, UOP's FCC process
FCC Process
features elevated UOP OptimixTM feed
Regenerator
Reactor
Main
Column
Overhead Vapors
and Unstablized
Gasoline
To
Flue Gas System
Fuel Gas to
Treating
Gas
Concentration
Unit
Heavy Naphtha Product
Light Cycle Oil Product
Heavy Cycle Oil Product
C3-C4 to Treating,
Alkylation
or Polymerization
Debutanized
Gasoline
to Treating
distributors, UOP VSSTM (Vortex
Separation System) riser termination
device, and a combustor-style
regenerator or a two-stage regenerator
in cases where full combustion would
result in excessive regenerator
temperatures.
Additional technological features include
catalyst coolers, UOP RxCatTM design,
Air
20
Fresh Feed
Main Column
Bottoms Product
UOP AFTM spent catalyst stripper
technology, selective recycle, power
CONVERSION
REFINING PROCESSES
recovery and unmatched catalyst
circulation. Beyond its conventional
FCC process, UOP offers several related
processes: the UOP Resid FCC (RFCC)
process, the UOP Petro FCCTM process,
and the UOP RxProTM process.
The PetroFCC and RxPro processes
convert gas oils and heavier streams
selectively to lighter, more-valuable
products, including propylene. The
PetroFCC process produces over 15 Wt%
propylene on a fresh feed basis and
the RxPro process over 20 Wt%. The
technology utilized in the FCC process
provides a number of benefits, including
reduced dry gas, lower delta coke,
decreased clarified oil yield and increased
olefinicity and gasoline yield. The UOP AF
spent catalyst stripper technology increases
hydrocarbon displacement efficiency, even
at very high flux rates. Catalyst coolers can
reduce the regenerated catalyst
temperature and increase the catalyst/oil
ratio. The coolers also allow the processing
of heavy feeds and improved yields.
UOP’s combustor regenerator is
considered the most efficient design in
the industry. It provides full combustion
without the use of promoter, minimum
afterburn, the lowest possible carbon on
regenerated catalyst, no possibility of
spent catalyst bypassing the regeneration
zone and lower catalyst inventory.
Benefits of the two-stage regenerator
include coke-free catalyst from the
second stage, and the ability to process
heavy and contaminated residues.
21
REFINING PROCESSES
CONVERSION
UOP LCO-XTM Process
FCC light cycle oil conversion
Clean fuel regulations have further complicated refiners' choices for profitable use of the FCC light cycle oil
(LCO). LCO has conventionally been blended into diesel or fuel oil, because of LCO's high levels of sulfur,
nitrogen and aromatics, those uses have become less attractive. These changes have created an opportunity
for refiners. The high level of aromatics in LCO make it suitable to be economically converted into high-value
aromatics feedstocks – benzene, toluene and xylenes.
U
OP developed the LCO-X process,
operation, reducing construction costs
utilizing catalyst and process
and risk associated with high-pressure
systems to maximize the yield of
operation. The pressure requirement
aromatics from LCO. This process
will be somewhat higher than
uses elements of hydrocracking and
high-severity hydrotreating, but
aromatics production, and is an
significantly lower than a conventional
economic approach to getting the most
partial-conversion and full-conversion
value out of the FCC process. The
hydrocracking unit design. The upgraded
feedstock is processed over a
middle distillate product makes a suitable
pre-treatment catalyst, and then
ultra-low sulfur diesel (ULSD) blending
hydrocracked in the same stage. The
component. The naphtha product has
products are subsequently separated
ultra-low sulfur, high octane and high
without the need for liquid recycle. The
aromatics content which can be further
advantage of the LCO-X process is that
processed for aromatics recovery.
it can be designed for lower-pressure
Commercialized in the late 2000's,
the LCO-X process provides refiners
a novel and profitable solution to an
old problem.
LCO-X Process
Reactor
LCO
Feed
Make-up
Hydrogen
Stabilizer
HT
LPG
Fractionator
Light
Naphtha
HC
Off Gas
HPS
Aromatics
Maximization
LPS
ULSD
Blendstock
22
Benzene
Mixed
Xylenes
REFINING PROCESSES
HYDROPROCESSING
UOP UnionfiningTM Process
Hydrotreating
Hydrotreating is one of the most mature technologies found in refineries today, rivaling the history and
longevity of the thermal processes. The Unionfining technology suite is designed to remove contaminants such
as sulfur, nitrogen, condensed-ring aromatics and metals. Feedstocks range from naphtha to vacuum residue.
The Unionfining technologies are used to upgrade feed to meet strict product quality specifications, or for use
as feedstocks elsewhere in the refinery.
T
here are several Unionfining
processes offered to meet a refiners
Single-Stage MQD Unionfining Process
needs and project objectives. The basic
flow schemes are fixed-bed catalytic
hydrotreating technologies that operate
Recycle Gas
Compressor
Fresh
Feed
at elevated pressure and temperature
and consume hydrogen, reducing the
Quench
Gas
Reactor
contaminant content of the feedstock.
Separation
Maximum Quality Distillate
(MQD) Unionfining Process
The UOP MQD Unionfining process is
Light
Ends
Hydrogen
Makeup
Stripper
a family of technologies that offers
Steam
Sour
Water
completely-integrated solutions to upgrade
Diesel
Product
difficult, refractory, distillate-range feeds
to high-quality distillate that meets stringent
requirements for sulfur and aromatics
content, cetane number and cold-flow
Two-Stage MQD Unionfining Process
properties. The process is based on a
number of multi-functional catalysts that
are optimized to achieve varying product
1st Stage
Reactor
Recycle Gas
Compressor
quality objectives. Process configuration
Amine
Scrubber
Lean Amine
Rich
Amine
Makeup
Gas
and catalyst choice depend on the desired
product quality improvement and existing
refinery configuration.
Quench
Gas
High Pressure
Cold Separator
The MQD Unionfining process uses a
Stripping
Gas
single- or two-stage configuration. The
single-stage design is used with most
base-metal catalyst applications. The
Oil to
Low Pressure
Cold Separator
Hot
Stripper
Water
2nd Stage
Reactor
two-stage scheme is designed to achieve
the highest-quality diesel by employing a
noble-metal catalyst in the second stage.
Quench Gas
23
REFINING PROCESSES
HYDROPROCESSING
UOP Unionfining Process Continued
Distillate Unionfining Process
Distillate Unionfining Process
Adding hydrogen to the feed while
The UOP Distillate UnionfiningTM
removing sulfur enables a refiner to
process improves the quality of distillate
achieve higher yields and improved
boiling-range feedstocks – kerosene, jet
quality distillate-range material to
fuel and diesel oils. This process uses
better meet stringent fuel regulations.
state-of-the-art catalysts and
The product can be blended directly
carefully-selected processing conditions
into fuel, and can facilitate the blending
to achieve the customer's product
of other streams, depending on the
sulfur requirements, as well as desired
refiner’s processing objectives.
Fresh
Feed
Make-up
Hydrogen
Lights
Ends
improvements in other properties such
as cetane number, smoke point for
Separator
Fractionator
jet fuels, stability, color, odor or
aromatics content.
Desulfurized
Product
VGO Unionfining Process
VGO Unionfining Process
Recycle Gas
Compressor
The feeds processed in the UOP VGO
Unionfining
TM
process are vacuum gas
oil boiling range feedstocks, including
Fresh
Feed
Reactor
Make-up
Hydrogen
straight-run vacuum gas oil, heavy
coker gas oil and visbreaker gas oil.
Amine
Scrubber
The typical application of this technology
Lean Amine
is in FCC feed pre-treatment. This
Rich Amine
processing provides higher yields and
Cold
Separator
a better quality of FCC gasoline, and
lower yields of FCC light and heavy
cycle oils. Product from the VGO
Hot
Separator
Fractionation Section
Wild
Naphtha
Unionfining process can also be used
as low-sulfur fuel oil.
Cold
Flash
Drum
Hot
Flash
Drum
Flash
Gas
Diesel
Product
Sour Water
FCC
Feed
24
25
REFINING PROCESSES
HYDROPROCESSING
UOP Unionfining Process continued
RCD Unionfining Process
The OP RCD UnionfiningTM process is a
fixed-bed catalytic residue hydrotreating
technology that uses base-metal
catalysts to remove contaminants such
as sulfur, nitrogen, organo-metallics
and asphaltenes in heavy feedstocks,
such as atmospheric residue, vacuum
residue and de-asphalted oil (DAO).
Because of the typically high contaminant
new-generation reactor internals,
levels, a guard bed reactor is used to
innovative separation and process
control pressure drop associated with
schemes, minimizing the capital
large particles and solids that might be
investment required to revamp existing
in the residue feed. Several reactors in
assets. Combining the Unicracking and
series are often required because of
Unionfining processes, UOP offers
the low reactivity and high contaminant
refiners a number of integrated solutions
levels of the feedstocks.
that take into account changing crude
slates, feed segregation, diesel blending
Hydroprocessing technology
and hydrogen management to help
The most common application of
The relative processing severity of the
minimize the cost of regulatory
the RCD Unionfining process is
Unionfining technologies is dependent
compliance. Additionally, these solutions
FCC/RFCC feed pre-treatment, in which
on feedstock type and processing
can provide flexibility for future increases
approximately 90% of the sulfur and
objectives. As a result of collaboration
in production rates.
organo-metallics are removed. The
within the Hydroprocessing Alliance,
process is also used for production
UOP is able to offer refiners a unique
Hydrotreating technology has been
of low-sulfur fuel oil and partial
combination of processes and catalysts
offered by UOP since the early 1950's.
conversion of non-distillables to
to provide optimum performance. Many
Our partnerships and technology
distillables.
Unionfining process features include
developments have changed over
the years to continually deliver innovation
and options to refiners. Based on UOP's
continued technology development,
more than 120 Unionfining process
RCD Unionfining Process
licenses have been issued in the
Fixed Bed Reactors
last decade. UOP is a leading
hydroprocessing licensor with more
than 600 Unionfining units in
operation worldwide.
Hot
Separator
Residue
Feed
Make-up
Hydrogen
Fractionator
H2
Recovery
Gas
Naphtha
Purge
H2S
Scrubber
To
Fuel Gas
Cold
Separator
Cold
Flash
Drum
26
Hot
Flash
Drum
Distillate
Hydrotreated
Residue
HYDROPROCESSING
REFINING PROCESSES
UOP SelectFiningTM Process
Olefinic naphtha selective hydroprocessing
The SelectFining process is the latest addition to UOP’s family of
gasoline desulfurization technologies, designed to produce
ultra-low-sulfur gasoline by removing more than 99% of the sulfur in
olefinic naphtha, while minimizing octane loss and hydrogen consumption,
maximizing liquid yield and eliminating re-combination sulfur.
T
he SelectFining process provides
gasoline-blending components and
refiners with a simple, flexible
the types and amounts of olefinic and
solution to help meet sulfur specifications.
sulfur species in the feed.
The SelectFining process can hydrotreat
The configuration and operating
full boiling-range (FBR) olefinic naphtha
conditions of a single-stage
or, when used in conjunction with a
SelectFining unit processing FBR
Because FBR olefinic naphtha contains
naphtha splitter, any fraction of the
olefinic naphtha is similar to that of a
highly-reactive di-olefins which can
FBR naphtha. This flexibility allows the
conventional hydrotreater, enabling
polymerize and foul equipment and
feed to the SelectFining unit to be
refiners to implement SelectFining
catalyst beds, the SelectFining process
optimized based upon refinery-specific
technology by re-use of existing idle
can incorporate a separate reactor for
factors, such as the final gasoline
hydroprocessing equipment.
di-olefin stabilization. The fresh feed
sulfur specification, the available
naphtha is first mixed with a small
stream of heated hydrogen-rich recycle
gas and then directed to this reactor
for stabilization. The stabilized naphtha
SelectFining Process
is then sent to the unit’s main reactor
containing SelectFining catalyst for
Make-up
Hydrogen
sulfur removal.
Recycle
Compressor
Lean
Amine
Fresh
Feed
Recycle Gas
Scrubber
SelectFining
Reactor
Rich
Amine
Stabilization
Reactor
Product
Separator
Light Ends
De-butanizer
Low
Sulfur
Naphtha
27
REFINING PROCESSES
TREATING
UOP MeroxTM Process
Hydrocarbon treating
In addition to many required product properties, the markets for distillates, gasoline and light gases have
increasingly-stringent specifications for sulfur and sulfur species. For the refiner, meeting these specifications
is an absolute necessity in order to remain in operation. The Merox process was introduced to the refining
industry more than 50 years ago as a means of treating gasoline and diesel product specifications. It quickly
became one of UOP's most successful processes, and it remains a key technology because it enables refiners
to meet those more stringent sulfur specifications while reducing project capital costs.
T
he Merox process is an efficient,
mercaptan sulfur with resultant reduction
low-cost, low-maintenance
of total sulfur. In this flowscheme,
mercaptan control technology. All
the hydrocarbon is counter-currently
versions of the Merox process are
contacted with Merox caustic in a
characterized by the Merox catalysts'
multi-stage, high-efficiency Merox
ability to promote the direct oxidation of
extractor column. The caustic-extracted
mercaptans (RSH) to di-sulfides (RSSR)
mercaptans are then efficiently oxidized
in an alkaline environment. The process
catalytically to di-sulfides in the Merox
Merox Process for
Mercaptan Extraction
Treated Product
Regeneration Section
Oxidizer
Spent Air
Extractor
is broadly divided by application into
regeneration section of the unit.
Air
Di-sulfide
H2S-Free
Feed
Di-sulfide
Separator
“Extraction” and “Sweetening”.
The mercaptan content of light FCC
Liquid-Liquid Extraction
Merox Process
naphtha can be reduced by more than
Merox extraction is used with light
liquid extraction Merox process with no
hydrocarbon streams, such as gas,
yield or octane loss.
95% through application of the liquid-
Caustic
Catalyst
Injection
Lean Merox
Caustic
Intermittent Use
The hydrocarbon section of the
LPG and light gasoline, for removal of
liquid-liquid extraction Merox unit
consists of three basic operations: H2S
removal (when required), mercaptan
Merox Process for Gas Extraction
extraction and caustic coalescing.
UOP’s process innovations have
Combination Column
Water Wash
Section
combined these operations into a single
Treated
Gas Product
Water
vessel. Due to this improved design,
refiners can benefit from a reduction in
Regeneration Section
Extraction
Section
Oxidizer
cost-savings are achieved due to the
reduced number of vessels required, and
the corresponding plot space reduction.
Caustic
Air
Prewash
Section
Di-sulfide
Oil
To De-gassing
Drum
Gas
Feed
28
the unit capital cost of up to 30%. The
Spent
Air
Di-sulfide
Separator
REFINING PROCESSES
TREATING
Sweetening Merox Process
usage, greatly reducing spent caustic
Merox sweetening is used with heavier
disposal concerns. With the development
hydrocarbon streams for direct, in-situ
of the caustic-free Merox process for
conversion of the mercaptans to
gasoline treating, UOP has eliminated the
di-sulfides, with no reduction in total
use of caustic and its disposal concerns.
Merox Process for
Fixed-Bed Sweetening
Air
H2S-Free
Feed
sulfur. The Merox sweetening process
is offered in various versions depending
Benefits associated with the Minalk
on the hydrocarbon stream to be
process include:
treated: conventional fixed-bed, UOP
• Production of a “doctor negative”
Reactor
Sweetened
Product
Caustic
Settler
MinalkTM fixed-bed and caustic-free
product, while minimizing removal
fixed-bed flowschemes.
of phenols from the naphtha
Caustic
Circulation
• Long catalyst life
• Minimal operator attention
Minalk Process for
Fixed-Bed Sweetening
• A small continuous discharge of
spent caustic
Air
• Low capital and operating costs
For more difficult-to-sweeten feedstocks
Continuous
Alkali
Injection
such as heavy straight-run gasolines,
FCC gasolines, gasolines, light
visbreaker and coker light naphthas,
straight-run gasolines and condensate
and kerosenes, UOP offers its
gasolines typically contain easy-to-
conventional fixed-bed Merox
sweeten mercaptans and can be treated
sweetening process which utilizes a
in either the Minalk or caustic-free
fixed-bed reactor with a caustic settling
version of the process. The Minalk flow
section, and periodic caustic circulation.
scheme was developed to minimize
For certain kerosenes, UOP also offers a
equipment requirements and caustic
caustic-free version of Merox sweetening.
Reactor
H2S-Free
Naphtha
Sweetened
Naphtha
Product
Drain
Interface Pot
Spent Alkali
and Water
Caustic-Free Merox Process
for Kerosene/Jet Fuel Sweetening
Salt
Filter
Water Air
Clay
Filter
Reactor
Kerosene/
Jet Fuel
Feed
Water
Wash
Ammonia
Merox
CF
Additive
Water
Sweetened
Kerosene/
Jet Fuel
Product
29
REFINING PROCESSES
RESIDUE UPGRADING
UOP UniflexTM Process
Slurry residuum hydrocracking
High crude oil prices require that refiners get the maximum value from every barrel of oil processed. Residue
by-products are of low value and can be difficult to market. The Uniflex process is a high-conversion residue
hydroprocessing technology for the production of gas oil conversion unit feedstocks, naphtha and distillates.
The Uniflex process contains elements of the UOP Unionfining and Unicracking processes and Natural
Resources Canada’s CANMET Hydrocracking process.
T
he most common feedstock to
In the Uniflex process, the feed, make-up
Product and catalyst leave the top
a Uniflex process unit is vacuum
hydrogen and a portion of the recycle
of the reactor, and are immediately
residue, although atmospheric residue
gas are heated to the desired
quenched to terminate the reaction
and other streams, such as solvent
temperature in a devoted heater. The
before flowing to the hot separator
deasphalting (SDA) pitch, can also be
bulk of the recycle gas is heated
(HHPS). The overhead stream from the
processed. The Uniflex process achieves
separately to an elevated temperature
HHPS is heat exchanged with the feed
a very high conversion of vacuum residue
above the desired mix temperature.
and recycle gas streams, and then sent
through the injection of a dispersed-
This controlled heating ensures the
to the cold, high-pressure separator
phase catalyst into the feed under
feed does not start to crack until it is
(CHPS). The vapor stream from the
elevated temperatures and pressures in
in the reactor. Small particulate catalyst
CHPS is recycled back to the reactor
a hydrogen atmosphere. An upflow
is added continuously in the feed just
after combining with makeup hydrogen.
reactor, with unique operating conditions
before the feed heater. The recycle gas
CHPS and HHPS liquids are flashed
specific to the Uniflex process, is used to
and the feed are mixed in the bottom
and then sent to fractionation. The
obtain the desired conversion levels and
zone of the reactor (an upflow reactor
products are sent to downstream
control the natural tendency of vacuum
with continuous backmixing).
hydrotreating processes or hydropro-
residues to become thermally unstable at
cessing technologies to meet product
high conversion levels.
quality objectives.
Because of the high conversion and
selectively to produce distillates, naphtha
Uniflex Process
and VGO conversion unit feedstock,
the Uniflex process can provide very
Recycle H2
Make-up
Hydrogen
H
H
P
S
CHPS
high refinery margins, especially in
comparison with traditional residue
Flash Gas
conversion processes, such as
C4-
Uniflex
Reactor
delayed coking.
CFD
Naphtha
H
F
D
The Uniflex process also enables
upgrading of several other refinery
Diesel
systems. For example, co-processing
LVGO
conversion of the slurry oil to distillate
Feed
HVGO
Catalyst
30
of FCC slurry oil will result in very high
Pitch
and lighter streams.
REFINING PROCESSES
RESIDUE UPGRADING
UOP Catalytic Crude UpgradingTM Process
Stranded crude upgrading
The Catalytic Crude Upgrading (CCU) process is a stand-alone upgrading process based on UOP FCC
technology. The CCU process offers a unique solution to enable the recovery of stranded crudes that do
not meet pipeline specifications without the need for an external light-diluent source. This is achieved by
producing a cutter stock within the CCU unit that is used as a diluent. To maximize liquid volume recovery
from well to pipeline, the CCU unit is designed to process the minimum quantity of crude required to
make a blended synthetic crude product that meets pipeline specifications.
he CCU process can be adapted
coking-based facility and higher overall
the RVP specification, recovered as an
to meet the needs of a variety of
liquid product recovery than conventional
LPG product, or fired with fuel gas from
stranded oil projects where natural gas
upgrading technologies. Because the
the Gas Con to general steam.
and electricity supplies are limited or
CCU process is an FCC process
unavailable. The CCU proccess is
derivative, the coke that is produced
This auxiliary firing of off-gas, coupled
applicable to heavy crudes or bitumens
is burned off of the catalyst in the
with the heat and energy available in
that do not meet pipeline specifications
regenerator. This coke burning provides
the regenerator flue gas, results in an
for API or viscosity, as well as light waxy
the heat required by the reactor.
opportunity to produce large quantities
T
of both steam and electrical power.
crudes that cannot be pipelined
Light cycle oil (LCO) from the main
The CCU unit is capable of generating
column and naphtha from the gas
more steam and electricity than
The key to the CCU process is the
concentration unit (Gas Con) are blended
required to meet the utility demands
benefit of better yield and selectivity
together to form the cutter stock. Slurry
of the upgrading complex. Excess
associated with a catalytic conversion
oil can either be blended into the cutter
power and steam can be exported to
system over a thermal process. This
stock or used as fuel oil. Recovered
support the surrounding oil field
results in a higher API liquid cutter
LPG can be blended into the cutter
infrastructure. Excess steam can also
stock, less coke make than a traditional
stock, up to the maximum allowed by
be integrated with a steam assisted
because of pour point restrictions.
gravity drainage (SAGD) complex.
Catalytic Crude Upgrading Process
LCO
Raw
Crude
Main
Column
Slurry
Oil
The CCU process offers many benefits
Naphtha
LPG
Synthetic
Crude
Product
critical to liberate stranded crudes,
including self-sufficiency with regard to
utilities, minimized crude processing,
low capital cost, increased product
Pre-Fractionator
margin due to API gravity improvement,
higher volume recovery than other
upgrading technologies and no
Reactor/
Regenerator
Steam
hydrocarbon waste by-products.
Power
Gas Con
LPG
Steam Power
Fuel Oil
or SAGD
31
REFINING PROCESSES
RESIDUE UPGRADING
UOP/FWUSA Solvent Deasphalting Process
Residue solvent deasphalting
The UOP/Foster Wheeler USA Corporation (FWUSA) Solvent Deasphalting Process (SDA) is a unique separation
process in which residue is separated by density and molecular weight instead of by boiling point, as in the
vacuum distillation process. The SDA process produces a low-contaminant, deasphalted oil (DAO) rich in
paraffinic-type molecules and a high-viscosity residue by-product (pitch).
T
he DAO can be further processed
precipitate out of the mixture. Separation
stripping of any entrained solvent.
in conventional conversion units,
of the DAO phase from the pitch phase
The DAO and pitch product are then
such as FCC or hydrocracking units.
occurs in the extractor. The extractor is
sent to battery limits.
The pitch contains the majority of the
designed to separate the two phases
residue’s contaminants (metals,
efficiently and minimize contaminant
The solvent recovered under low
asphaltenes and condradson carbon),
entrainment in the DAO phase.
pressure from the pitch and DAO
and is rich in aromatic compounds and
strippers is condensed and combined
asphaltenes. A three-product unit, in
The DAO phase is heat exchanged with
with the solvent recovered under high
which a resin stream can be recovered,
the recovered solvent and then heated
pressure from the DAO separator. The
is also available. This design allows
to conditions where the solvent becomes
solvent is then recycled back to be
for a range of asphalts (bitumens)
super-critical. Under these conditions,
mixed with the feed.
to be manufactured from various
the separation of the solvent from the
resin/pitch blends.
DAO is very efficient. This occurs in the
The SDA process allows efficient
DAO separator. Any entrained solvent
separation of vacuum residue into
In the SDA process feed is mixed
from the DAO separator is then
high-quality conventional VGO
with a light paraffinic solvent – typically
stripped out at low pressure. Likewise,
conversion unit feedstock from the
butane – where the soluble oils are
the pitch effluent from the extractor is
lowest-quality components in vacuum
dissolved. The insoluble pitch will
heated and then flashed, followed by
residue. This significantly increases
the potential transportation fuels from
a refinery.
UOP/FWUSA Solvent Deasphalting Process
Because the SDA process is a
moderate-pressure and mild-temperature
process and does not require hydrogen
Extractor
addition, capital and operating costs
Vacuum
Residue
Charge
DAO
Separator
are relatively low compared to conversion
technologies such as delayed coking
and residue hydrotreating technologies.
Pitch
Stripper
DAO
Stripper
Pitch
32
DAO
RESIDUE UPGRADING
REFINING PROCESSES
SYDECTM Delayed Coking Process
Delayed coking
Delayed coking is a total residue-conversion process that produces gas oil
conversion unit feedstocks, distillates, naphtha and petroleum coke. The
normal feedstock to a delayed coker is vacuum residue, although atmospheric
residue and other streams (solvent deasphalting pitch) can be processed.
T
he chemical reactions of delayed
The Selective Yield Delayed Coking
coking are intricately complex
(SYDEC) technology, licensed by Foster
with three distinct reactions occurring:
• Partial vaporization and mild cracking
(visbreaking) of the feed as it passes
through the coker’s furnace
Wheeler USA Corporation (FWUSA), is
a low-pressure, low-recycle design for
maximum liquid yields. In most parts of
the world, UOP has exclusive marketing
rights for the technology when the delayed
coker is part of a multi-unit project.
• Cracking of the reactants in the
• Anode grade
vapor phase as it passes through
the coke drum
• Successive cracking and
polymerization of the liquid trapped
in the coke drum until it is converted
to vapor and coke
Coker types are defined by the types
Anode grade coke is produced
of coke produced.
from low-sulfur and low-metals type
• Fuel grade
feedstocks. It is used for anodes
The most common type of coker is
the fuel grade. Here the objective is to
in the aluminum industry.
• Needle coke
maximize liquid yields because the
Needle coke is produced from
coke has a relatively low value.
highly-aromatic feedstocks, such as
FCC slurry oils and thermal tars. It
is used for electrodes in the steel
SYDEC Delayed Coking Process
Coke Drums
Fuel Gas
Coke Drums
Product
Recovery
Butane/Butene
Light Coker Naphtha
Heavy Coker Naphtha
Light Coker Gas Oil
Heavy Coker Gas Oil
industry and garners a high price.
Consequently, coke yield is more
important than liquid yield. When
producing high-value needle coke,
the feedstock must be highly
aromatic, with low asphaltene, sulfur
and ash contents.
Switch
Valve
Switch
Valve
FWUSA has licensed more than 140
delayed coking plants over the past
50 years. FWUSA has designed and
constructed the maximum size coke
drums permissible under current
hydraulic limitations. In addition, the
company has designed the world’s
tallest delayed coker structure.
Fired Heater
Fired Heater
Vacuum Residue
33
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
PETROCHEMICAL PROCESSES
PETROCHEMICAL PROCESSES
Along with its rich 60-year history of commercializing
innovative technologies supporting the aromatics, aromatic
derivatives and detergent intermediates industries, UOP has
become the leader in supplying technology, products and
services to olefin producers worldwide.
PETROCHEMICAL PROCESSES
Worldwide petrochemical growth continues to be strong, particularly in developing economies. UOP's industryleading technologies provide producers with proven solutions to meet this demand for aromatics, aromatic
derivatives, olefins and linear alkyl-benzene (LAB). UOP’s association with the petrochemical industry began in
the late 1940's with the introduction of the Platforming process, which revolutionized the production of aromatics
with catalytic reforming of naphthas. It was soon followed by the development of the classic Udex technology for
extracting and recovering high-purity benzene, toluene and xylenes from broad boiling range reformates.
A
major milestone came with the
development of the UOP Sorbex
of available feedstocks and consuming
process in the 1960’s, and in particular
less energy to produce ever-increasing
the early 1970's commercialization of
quantities of higher-quality products.
the UOP ParexTM process for the
A modern aromatics complex using
selective purification and recovery of
UOP’s latest technologies can produce
para-xylene from a mixture of C8
para-xylene for significantly lower
aromatic isomers. With the Parex
capital and operating cost relative to
process, UOP re-defined the concept
what was available as recently as the
of high-purity para-xylene, with
1990’s. It is no wonder that two-thirds
improvements in design and adsorbent
of the current world capacity for
technology over the years, presently
para-xylene production uses UOP
enabling purity in excess of 99.9 Wt%
technology. UOP has expanded its
Growth in demand for laundry
at recoveries not achievable by
portfolio in aromatics processing over
detergents, in particular in developing
conventional crystallization or other
the last 15 years with the successful
economies, is driving demand for linear
adsorptive separation processes.
introduction of the UOP MX Sorbex
alkyl-benzene (LAB) produced from
UOP created the modern “aromatics
process for meta-xylene purification
kerosene-derived normal paraffins.
complex” by developing the UOP
and recovery and the UOP PX-Plus
UOP is the global LAB technology
IsomarTM and UOP TatorayTM processes,
process for the selective conversion of
leader, with over 80% of the world's
enabling the full range of compounds
toluene to enriched para-xylene and
LAB being produced using the UOP
contained in reformate to be exhaustively
benzene products. The introduction of
Detergents technologies including the
converted to high-value products
the UOP Oleflex
para-xylene and benzene, as well as
1990's provided the industry a new,
PacolTM process, UOP DeFineTM
ortho-xylene and toluene. Advances
effective and efficient route to on-purpose
process, UOP PEPTM process and
in extraction technology have led to the
polymer-grade propylene production
UOP MolexTM process.
wide acceptance of an extractive
from propane to meet the accelerating
distillation flowscheme for the UOP
demand growth for propylene-derived
Moderate growth in polystyrene demand,
TM
TM
TM
process in the early
UOP/CEPSA DetalTM process, UOP
materials. In recent years, UOP has
but greater demand growth for
purify benzene and toluene in the
introduced technologies for on-purpose
polycarbonate and phenolic resins, are
modern aromatics complex flowscheme.
ethylene and propylene production from
driving growth in aromatic derivatives.
alternate feedstocks, including synthesis
UOP, together with our alliance partners,
Improvements in catalyst and adsorbent
gas, coal and other hydrocarbons.
offers world-class technologies to
performance, as well as the process
The portfolio includes the UOP/HYDRO
produce these benzene derivatives,
design of these technologies over the
methanol to Olefins (MTO) process,
focusing on high efficiency and low
years, have resulted in each of UOP’s
the Total Petrochemicals/UOP Olefin
energy consumption for minimum
processes for aromatics production
Cracking (OCP) process and the UOP
investment cost.
becoming more efficient – requiring less
MaxEneTM process.
TM
Sulfolane
38
investment to install, making better use
TM
process, generally used to
Petrochemicals Process Flow
Feedstocks
Olefins
Coal
Petroleum Coke
Bio-mass
Methanol
Synthesis
Methane
Methanol
Ethylene
Methanol
to Olefins
Propylene
C3/C4
Dehydrogention
MTBE
C4
Processes
Mixed Butenes
Steam
Cracking
Ethane
Butene-1
1,3 Butadiene
Olefin
Cracking
Propane
Butanes
Naphtha
n-Paraffin
Recovery
Propylene
Recovery
High
Severity FCC
Gas Oil
Heptenes
Octenes
Nonenes
Dodecenes
Catalytic
Condensation
Gasoline & Aromatics
Aromatics
Pressure Swing
Adsorption
Ethylene
High Purity
Hydrogen
Ethylbenzene
EB
Dehydrogenation
Alkylation
Styrene
Propylene
Cumene
Alkylation
Oxidation
& Cleavage
Phenol
Acetone
Benzene
Hydrogenation
Naphtha
Reforming
Cyclo-hexane
Aromatics
Recovery
Isomerization
& Transalkylation
PX
PTA
Melt
Poly
SSP
Benzene
Toluene
o-Xylene
m-Xylene
PET
Resin
Detergents
Normal
Paraffins
Normal
Paraffins
Kerosene
n-Paraffin
Recovery
Olefin
Recovery
Linear
Mono-Olefins
Alkylation
Linear
Alkyl-benzene
(LAB)
Paraffin
Dehydrogenation
Benzene
39
PETROCHEMICAL PROCESSES
AROMATICS
UOP ParexTM Process
Para-xylene adsorptive separation
The growth in worldwide demand for polyester fibers, films and resins continues to outpace the broader economic
growth benchmarks. When this occurs, capacity additions for the key precursor, para-xylene, often cannot keep
pace with the surging demand. Producers have an opportunity to enhance their bottom-line performance.
The Parex process was commercialized in the early 1970's and today is the most important and commonly-used
process to recover high-purity para-xylene.
T
he Parex process relies on
operate continuously, remaining
combined benefits of the latest adsorbent
innovative technology that operates
on stream for many years between
technology and engineering features
infrequent planned maintenance events.
enable new designs at much higher
in liquid-phase and uses counter-
capabilities. The world’s first one million
current adsorptive separation, employing
a simulated moving bed to efficiently
Throughout its history, the Parex
metric ton-per-year single adsorption
recover high-purity para-xylene from its
process has been improved by a
train Parex unit, started up in 2010, is
C8 aromatic isomers. Its use has
steady stream of innovations. Improved
just one of the many milestones for the
become so common that its simplicity
generations of higher-performing
Parex process. Further optimizations in
granted today.
adsorbents have, through the years,
process design to identify additional
resulted in lower capital and energy
operating cost savings are continually
The key piece of equipment that
requirements that are applied to existing
being developed.
enables the efficiency and reliability of
plants, as well as new facilities.
the Parex process is the UOP Rotary
Innovation in process design has
The Parex process offers a combination
Valve. The staged movement of the net
allowed the Parex process to continue
of advantages – low operating cost,
liquid streams to different points in the
to set the standard for para-xylene
operational simplicity and unmatched
adsorbent chambers facilitates simulation
purity. Modern plants can be designed
on-stream availability – making it a
of a moving bed of adsorbent. That this
to achieve 99% para-xylene purity
highly attractive process for
can be accomplished with a single
at recoveries exceeding 97%. The
para-xylene production.
device, with minimal piping and without
additional control valves, ensures the
most efficient use of the adsorbent and
results in the lowest-cost method for
Parex Process
para-xylene production. Experience with
Concentrated
Extract
(Para-xylene)
the rotary valve is vast, with more than
t
en
of 2010. The high reliability of the rotary
rb
operation in commercial Parex units as
so
De
110 rotary valves having been placed in
Ext
Rotary
Valve
Extract
Extract
Column
rac
valve is well documented, with greater
t
Desorbent
than 99.9% process availability being
process, and a design that has been
refined through vast commercial
experience, ensure Parex units can
d
Fee
Concentrated
Raffinate
Ra
ffi
na
te
commonplace. The nature of the
Adsorbent
Chamber
Raffinate
Feed
40
Raffinate
Column
41
PETROCHEMICAL PROCESSES
AROMATICS
UOP Sinco Solid State PolycondensationTM Process
PET resin production
The UOP Sinco Solid State Polycondensation (SSP) process was
developed to meet the PET producer’s objective of making the highest
quality resin at the lowest possible cost, maximizing profit potential.
U
OP Sinco SSP units in operation
With UOP Sinco’s precise control of
around the globe are producing
critical process parameters, the final
over 7.5 million metric tons of resin
product will be within target specification
per year, producing bottle-grade chips
more than 99% of the time.
that are certified by major bottled
beverage producers.
UOP Sinco’s simple processing scheme
and equipment design make for
Product chips have consistent intrinsic
extremely robust, trouble-free
viscosity, excellent resin color, low
operation. Maintenance is simple
UOP Sinco has been involved with over
acetaldehyde and carboxyl end group
and infrequent.
90 SSP projects since the mid-1980's
content, minimal dust content and no
agglomerates. These and other quality
parameters are backed up by UOP’s
performance guarantee.
The process accommodates feed chips
from every major melt polymerization
process and can change product
grade (IV) rapidly.
The UOP Sinco SSP offers a choice of
flowschemes using either gravity or a lift
system (to minimize height), both of
providing basic design, detailed design,
equipment and material supply, unit
construction and startup services.
Projects range from pilot plant scale to
the largest commercial production
units, including new and retro-fit units.
Pre-crystallizer
which are designed to offer very low
Amorphous chips are introduced
operating costs.
into the SSP plant from storage or
directly from the melt phase plant, and
The patented nitrogen purification unit
subsequently fed to the pre-crystallizer.
(NPU) safely and efficiently converts all
The pre-crystallizer is a high-efficiency,
hydrocarbon waste to CO2 and H2O,
fluid-bed heat exchanger which
using premium catalysts and molecular
de-dusts the incoming PET chips
sieves developed and manufactured
and initiates the crystalization. The
by UOP.
use of nitrogen affords high flexibility
in the selection of process temperature
and eliminates the possibility of chip
color change.
42
AROMATICS
Crystallizer
Nitrogen Purification Unit (NPU)
The crystallizer completes the
The entire process is performed under
crystallization under process conditions
an inert nitrogen atmosphere to ensure
optimized to the behavior of the feed
production of the best quality chips.
polymer. Crystallization is performed in
UOP Sinco’s patented NPU purifies
a moist nitrogen environment, one
the recirculating nitrogen gas and a
feature of UOP Sinco’s patented flow
catalytic reactor converts the organic
PETROCHEMICAL PROCESSES
impurities from the SSP reactor to
carbon dioxide and water — the only
waste materials from the entire SSP
unit. Both the catalyst and molecular
sieves are UOP formulations designed
to minimize consumption of utilities and
promote optimum process conditions.
scheme to reduce acetaldehyde in
the product.
SSP polycondensation reactor
The desired intrinsic viscosity (IV) is
achieved in the mass-flow SSP
polycondensation reactor, where its
patented low gas-to-solids ratio ensures
optimum process performance.
Cooling section
The chips exit the SSP reactor and flow
to the cooling section where the final
cooling and de-dusting of the polymer
chips is performed. Product chips exiting
the cooling section are ready for
injection molding, bagging or spinning.
1. Precrystallizer
2. Crystallizer
3. SSP Reactor
4. Nitrogen
purification unit
5. Cooling section
43
PETROCHEMICAL
REFINING PROCESSES
PROCESSES
AROMATICS
UOP SulfolaneTM Process
Aromatics extraction
Since its introduction in the 1960’s, the Sulfolane process has been widely
used for recovering high-purity aromatics, particularly benzene, toluene
and xylenes, from a variety of feedstocks. Producing high-purity aromatics
reliably at low cost is the hallmark of the Sulfolane process. It has an
important role in a modern aromatics complex where high-purity benzene
is produced, in addition to purified xylene isomers. For refiners, the
importance of the Sulfolane process has grown in recent years due to
the increased need to reduce the benzene content in gasolines.
key feature of the Sulfolane
grades for cyclohexane and other
and extractive distillation. Strictly
process is its solvent system,
petrochemical uses. It can also be
extractive distillation applications offer the
which has the highest aromatic
used to meet ASTM specifications for
advantage of being the most cost-effective.
selectivity and capacity of any
nitration-grade toluene and xylenes, as
commercially-available solvent, and it
well as xylene feed for para-xylene
UOP is the pre-eminent licensor of the
is extremely flexible in its capability to
production.
Sulfolane process, and has developed
A
efficiently recover aromatics over a
design features and operating techniques
broad range of feed compositions. The
The process can be used in both
which have enabled process performance
Sulfolane process has set the standard
liquid-liquid extraction and extractive
improvements in modern units. There are
for purity and recovery of aromatics,
distillation applications, so it can be
more than 140 UOP-licensed Sulfolane
while requiring very low investment and
retro-fitted into existing extraction units
units throughout the world.
operating cost. It is routinely used to
regardless of the vintage. Conventional
produce benzene to meet ASTM
units have elements of both liquid-liquid
Sulfolane Process
Raffinate
Product
to Storage
Extractor
Extract to Clay
Treaters in
Benzene/Toluene
Fractionation Unit
Recovery
Column
Stripper
Feed
44
Raffinate
Wash
Column
Solvent
Regenerator
AROMATICS
PETROCHEMICAL PROCESSES
REFINING PROCESSES
UOP TatorayTM Process
Aromatics dis-proportionation
The Tatoray process, originally developed by Toray Industries of Japan, is a key processing step in a modern
aromatics complex. Through a single reaction step where catalytic dis-proportionation and transalkylation reactions
take place, toluene, C9 aromatics and C10 aromatics, which have been produced in the upstream catalytic
reforming unit, are converted into more valuable xylenes and benzene. The result is a substantial increase in the
overall yield of xylenes and benzene from a given quantity of naphtha. In fact, in a modern aromatics complex,
the yield of para-xylene can be more than doubled when the Tatoray process is included in the flowscheme.
he Tatoray process offers several
need for regeneration. Higher conversion
conditions are similar to those for a
key advantages that make it the
results in smaller recycle streams, and
variety of refining and petrochemical
most economical way to increase xylene
along with less recycle hydrogen, this
processes, allowing for more
and benzene yields in an aromatics
also means substantial improvement in
economical revamps.
complex. Modern catalyst technology
overall energy costs associated with
has resulted in a great reduction in both
para-xylene production. Increased time
capital and operating costs, as well as
spans between regenerations ensures
improved process reliability. Yields
maximum process availability. Modern
from modern Tatoray catalysts are
Tatoray catalysts are capable of achieving
substantially higher than those achieved
continuous operating cycles of several
with earlier catalyst generations, resulting
years, improving the economics of the
in significantly-reduced feed costs.
aromatics complex substantially.
Due to their robustness and inherently
The Tatoray process is also extremely
higher stability, modern catalysts are
flexible, capable of processing feeds
also capable of operating at higher
ranging from 100% toluene to
conversions, with less recycle hydrogen,
approximately 30% toluene and 70%
and for much longer cycles prior to the
A9+. Its flowscheme and operating
T
Tatoray Process
Separator
Purge Gas to
Isomar Unit
Stripper
Overhead
Liquid
Reactor
Toluene from
Toluene Column
C9 Aromatics
from A9 Column
Toluene from
Parex Unit
Recycle Gas
Product
Make-up
Hydrogen
45
PETROCHEMICAL PROCESSES
AROMATICS
UOP IsomarTM Process
Xylene isomerization
The Isomar process is used primarily in para-xylene production facilities to aid in the economic
production of one or more desired isomers from C8 aromatic-rich feedstocks. In a para-xylene complex,
it enables maximum yield of para-xylene from the available C8 aromatics.
P
arex unit raffinate, typically depleted
Two different types of Isomar catalysts
to less than 1% para-xylene, is
are used, depending on the target
mainly composed of a mixture of
production of para-xylene and benzene.
ortho-xylene, meta-xylene and
EB-isomerization catalysts, used to
ethylbenzene (EB). Fed to the Isomar
maximize the yield of para-xylene from
unit, Parex raffinate is isomerized to
naphtha, convert ethylbenzene to
near-equilibrium concentrations,
xylenes and ultimately para-xylene.
thereby raising the para-xylene
Modern EB-isomerization catalysts offer
concentration to 21-24 Wt%. This
considerably higher activity, selectivity
enables the stream to be fed back to
and stability relative to earlier generations.
the Parex unit for additional para-xylene
These advantages result in a lower
recovery. In a similar way, the Isomar
capital requirement and the need for
process can be used in conjunction
less catalyst, as well as lower feedstock
with the UOP MX Sorbex
TM
process to
costs and longer operating cycles.
maximize yield of meta-xylene from
EB-dealkylation catalysts convert
C8 aromatics.
ethylbenzene to benzene. These catalysts
offer a highly efficient and economic
means of producing para-xylene, as well
Isomar Process
as increased levels of benzene. Due
Purge
Gas
Benzene to
Benzene
Recovery
Reactor
to their very high activity and close
approach to equilibrium per pass, these
catalysts allow for smaller equipment
throughout the aromatics complex,
lowering capital and energy costs. With
Separator
Deheptanizer
Parex
Raffinate
the commercialization of its UOP I-350TM
catalyst, providing the same EBdealkylation performance and stability of
the previous generation UOP I-300TM
catalyst, the Isomar process can now
Makeup
Hydrogen
offer the added benefit of a high-purity
To Xylene
Splitter
benzene by-product that does not
require extraction. As a result, I-350
catalyst offers a significant reduction in
capital and operating costs in a new
facility, while providing considerable
opportunity to debottleneck an existing
facility that is extraction-capacity limited.
46
PETROCHEMICAL PROCESSES
AROMATICS
UOP MX SorbexTM Process
Meta-xylene adsorptive separation
The MX Sorbex process recovers meta-xylene from mixed xylene feedstocks, where separation by conventional
distillation is impractical. MX Sorbex technology has been developed to meet increased demand for Purified
Isophthalic Acid (PIA) and meta-xylene diamine. The growth in demand for PIA is linked to the co-polymer
requirements for PET bottle resin applications, a rapidly growing market.
S
ince the mid-1990's, all
meta-xylene capacity added
MX Sorbex Process
worldwide uses MX Sorbex technology.
Adsorbent Chambers
The MX Sorbex process has become
the industry standard due to its
reduced environmental impact, inherent
Rotary Valve
safety and improved economics. The
process is highly flexible and can
process a variety of C8 aromatic feeds,
Feed
including UOP ParexTM raffinate or
Extract
Raffinate
mixed xylenes derived from reformate,
hydrotreated pyrolysis gasoline or a
UOP TatorayTM unit. The MX Sorbex
Extract
Column
Raffinate
Column
process can be integrated into an
existing UOP aromatics complex that
includes a Parex unit.
Raffinate to Storage
or Isomerization
m-Xylene
Product
Desorbent
The process is part of the family of UOP
The MX Sorbex adsorptive separation
SorbexTM adsorptive separation processes.
mechanism does not use hydrofluoric
Sorbex technology is UOP’s innovative
acid to purify the meta-xylene product.
adsorptive separation method for highly
For this reason, the MX Sorbex has
efficient and selective recovery of
much less environmental impact than
high-purity chemicals that cannot be
does HF-BF3 technology.
separated by conventional fractionation.
Unlike conventional-batch chromatog-
The conditions for the process are
raphy, the Sorbex process simulates a
mild, allowing for safe, energy-efficient
moving bed of adsorbent with continuous
designs. And the selective adsorbent
counter-current flow of a liquid feed over
can produce meta-xylene with a 99.5+
a solid bed of adsorbent. Feed and
Wt% purity at 95% recovery per pass,
products enter and leave the adsorbent
allowing for efficient production of a
bed continuously, at nearly constant
high-purity product.
compositions.
47
PETROCHEMICAL PROCESSES
AROMATICS
UOP PX-PlusTM Process
Toluene dis-proportionation
The PX-Plus process offers an alternative low-cost route to producing high-purity para-xylene and benzene.
It uses toluene as feedstock, and with a single reaction step produces a xylene stream with a para-xylene
concentration of about 90%, in addition to a significant yield of benzene.
D
ue to the high para-xylene
The PX-Plus process converts toluene
concentration in the product, the
to benzene and xylenes by selective
PX-Plus process offers para-xylene
disproportionation. The key feature of
producers an inexpensive way to
the catalyst used is its high selectivity
increase capacity without the need
to para-xylene. In addition, a high
to increase the size of the existing
selectivity to benzene makes this
Parex unit. It can also be used in
technology valuable in times when
conjunction with single-stage
benzene is an attractive by-product.
crystallization to produce high-purity
para-xylene from toluene without
One advantage of the PX-Plus process
the need for a fully-integrated
is its simplicity. Like the Tatoray
aromatics complex.
process, its flowscheme and operating
conditions are similar to those of a
variety of refining and petrochemical
processes, allowing existing equipment
PX-Plus Process
to be easily revamped and put into
PX-Plus service. The PX-Plus process
Separator
Purge
Gas
can also be integrated into new
large-scale grassroots para-xylene
Overhead Liquid
to Platforming Unit
Debutanizer
Reactor
Stripper
Toluene
To Benzene/Toluene
Fractionation
Recycle Gas
Make-up
Hydrogen
48
complexes when relatively high
benzene production is desired.
PETROCHEMICAL PROCESSES
AROMATIC DERIVATIVES
Lummus/UOP EBOneTM Process
Toluene dis-proportionation
The Lummus/UOP EBOne process is a liquid-phase alkylation process that uses a zeolite-based
catalyst system to produce ethylbenzene (EB) from ethylene and benzene. This latest generation of
Lummus/UOP alkylation technology represents a major step-change from older vapor-phase technologies.
U
OP’s EBZ series of catalysts
• Low benzene-to-ethylene (B/E)
provide for exceptional run
lengths (three to five years), eliminating
the need for frequent regenerations
and the Lummus/UOP Smart SM
requirements
styrene monomer technology for
• Carbon steel construction with no
and change outs.
fired heaters resulting in lower
investment costs
The process provides a number of
features and benefits, including:
product from ethylbenzene feedstock,
operations for reduced utility
cost-effective revamps and expansions.
An EBOne unit combined with a Classic
SM or Smart SM unit provides a highly
heat-integrated complex that results in
• Long-term catalyst stability for
significant savings in operating costs.
lower production costs
• High EB yield for lower feedstock
Since the introduction of the
consumption and production cost
• High EB product purity for increased
purity styrene monomer production
UOP also offers the Lummus/UOP
Lummus/UOP EBOne process in the
Classic SM process for the
early 1990's, Lummus and UOP have
manufacture of styrene monomer
been awarded over 39 projects
worldwide.
EBOne Process
Alkylation Transalkylation Benzene
Reactor
Reactor
Column
Ethylbenzene Poly-ethylbenzene
Column
Column
Ethylbenzene
(to SM Unit)
Heavy
Ends
Ethylene
Recycle Benzene
Benzene
Recycle Poly-ethylbenzene
49
PETROCHEMICAL PROCESSES
AROMATIC DERIVATIVES
Lummus/UOP Classic SM Process
Styrene monomer
The Lummus/UOP Classic Styrene Monomer (SM) process (Classic SM)
is a deep-vacuum, adiabatic ethylbenzene (EB) dehydrogenation technology,
well known for its efficient heat integration and exceptional mechanical
integrity. The unique dehydrogenation reactor system is designed to operate
at a very cost-effective, minimal operating pressure to achieve the highest
SM selectivities at high conversions.
U
OP’s on-going program of catalyst
• Low equipment pressure drop which
and process development
permits the reactor to operate at
provides clients with technologies that
high vacuum, resulting in higher
have significant capital and operating
product quality and lower EB feed
cost advantages.
consumption
The Classic SM process provides a
number of features and benefits, including:
• High styrene monomer purity
• Low steam-to-hydrocarbon ratios,
• Minimum pressure-drop radial
bed reactors for lower operating
resulting in lower steam imports
pressure, resulting in lower EB
and production costs
feed consumption and reduced
(at least 99.95%)
Since its introduction the 1970's,
by-product formation
Classic SM technology has been
• High per-pass EB conversion for
lower operating costs
• Energy savings from a highly-efficient
selected for more than 60 major
heat recovery scheme that does not
• High product yields resulting in lower
projects throughout the world.
require compression equipment
EB feed consumption
Classic SM Process
Ethylbenzene Benzene/
Recycle
Toluene
Column
Splitter
Benzene
Recycle Ethylbenzene
Ethylbenzene
(from EB Plant)
Off Gas
Toluene
Inhibitor
Steam
Superheated Steam
Dehydrogenation
Reactors
Off Gas
Recovery
Dehydrogenated
Mixture
Separator
Ethylbenzene
Styrene
Splitter
Styrene
Styrene
Finishing
Column
Condensate
Tar
50
PETROCHEMICAL PROCESSES
AROMATIC DERIVATIVES
Lummus/UOP Smart SMTM Process
Styrene monomer
The Lummus/UOP Smart SM process combines oxidative reheat technology
with adiabatic dehydrogenation technology to economically produce styrene
monomer (SM) from ethylbenzene (EB). It uses specially-designed reactors
to achieve the oxidation and de-hydrogenation reactions. Revamping
existing SM plants with Smart SM technology can realize significant
capacity expansions without the need of an additional train.
I
n the oxidative reheat section of the
The process provides a number of
reactors, hydrogen is oxidized to
features and benefits, including:
supply the heat for the dehydrogenation
reactions. The oxidation is accomplished
using UOP’s OC series of catalysts
• High styrene monomer purity
• High per-pass EB conversion for
which are highly selective. This
increased throughput
eliminates the costly interstage
Since the introduction of the
Lummus/UOP Smart SM process
• Reduced superheated steam
reheater and reduces superheated
steam requirements. For existing SM
producers, revamping to the Smart
requirements, resulting in lower
in the mid-1990's, SM producers
production costs
worldwide have a cost-effective route
to high capacity.
SM process is a cost-effective route
• No interstage heater, resulting in
to increased capacity.
lower investment costs
Smart SM Process
Ethylbenzene Benzene/
Toluene
Recycle
Splitter
Column
Benzene
Recycle Ethylbenzene
Ethylbenzene
(from EB Plant)
Off Gas
Toluene
Inhibitor
Steam
Oxidation/
Dehydrogenation
Reactors
Superheated Steam
Off Gas
Recovery
Dehydrogenated
Mixture
Separator
02/Air
Ethylbenzene
Styrene
Splitter
Styrene
Styrene
Finishing
Column
Condensate
Tar
51
PETROCHEMICAL PROCESSES
AROMATIC DERIVATIVES
UOP Q-MaxTM Process
Cumene
The Q-Max process produces high-quality cumene via the
alkylation of benzene with propylene using a zeolitic catalyst
system developed by UOP.
T
he Q-Max process represents
a substantial improvement over
older cumene technologies, and is
characterized by its exceptionally-high
yield, superior product quality and low
investment costs. UOP’s QZ series of
catalysts exhibit outstanding stability,
even when operating at low benzeneto-propylene (B:P) ratios.
• High catalyst stability, resulting in
fewer unit turnarounds
• Carbon steel construction keeping
investment costs low
The Q-Max process can be designed
to handle refinery-, chemical- or
polymer-grade propylene. The quality
of the cumene product produced in a
The process provides a number of
features and benefits, including:
Q-Max unit is strongly influenced by
the specific contaminants present in
the feedstocks.
• High cumene purity (at least
99.95 Wt%)
• High cumene yields (at least 99.7
Wt%), resulting in lower feedstock
consumption
• Low B:P operations, as low as
A majority of cumene units are integrated
Since the introduction of the Q-Max
with a downstream phenol unit.
process in the mid-1990's, with over
Combining the Q-Max process with the
4 million MTA cumene capacity
Sunoco/UOP Phenol process results in
licensed, it has provided a significant
higher phenol yields, improved product
portion of capacity additions worldwide.
quality and lower utility consumption.
2.0 molar, resulting in lower
utility requirements
Q-Max Process
Alkylation
Reactor
Benzene
Propylene
De-propanizer
Transalkyation
Reactor
Benzene
Column
Cumene
Column
Poly-iso-proplbenzene
Column
Recycle Benzene
Propane
Cumene
Recycle DIPB
Heavies
52
PETROCHEMICAL PROCESSES
AROMATIC DERIVATIVES
Sunoco/UOP PhenolTM Process
Phenol (from cumene)
The Sunoco/UOP Phenol process represents state-of-the-art technology for phenol production. The process
is the result of the merging of UOP’s and Allied's (now Sunoco's) phenol technologies in the mid-1980's. It is
based on the auto-catalytic oxidation of cumene, and the subsequent dilute acid cleavage of the intermediate
cumene hydroperoxide (CHP) into phenol and acetone. The Sunoco/UOP Phenol process produces the highest
quality phenol and acetone at the lowest feedstock and utility requirements and the lowest capital investment.
T
he Phenol process features
low-pressure oxidation for
Phenol Process
improved product yield and safety,
advanced CHP cleavage for high
Spent Air
Acid
Neutralizing
Agent
Phenol and
Acetone
Purification
product selectivity, an innovative direct
product neutralization process that
minimizes process waste, and an
Cumene
Air
Oxidation
Concentration
Decomposition
Neutralization
Acetone
Phenol
Residue
improved, low-cost product recovery
H2
scheme. The result is a very lowcumene feed consumption ratio that is
Recycle Cumene
AMS
Hydrogenation
or
AMS Refining
AMS
achieved without acetone recycle to
cleavage or tar cracking. By-product
alpha-methylstyrene (AMS) can be
refined for sale or hydrogenated back
to cumene in order to reduce feedstock
consumption. Integration of the
Sunoco/UOP Phenol process with the
Q-Max process can result in a further
reduction in utility costs.
The high quality of the phenol and
acetone products meets the most
stringent feed specifications required
for bisphenol-A/polycarbonate (phenol)
and food/pharmaceutical (acetone)
applications.
The Sunoco/UOP Phenol process is
a pre-dominant technology producing
over 40% of the world's 7.4 million
MTA of licensed capacity since the
early 1990's.
53
PETROCHEMICAL PROCESSES
OLEFINS
UOP OleflexTM Process
Propane dehydrogenation
With worldwide petrochemical growth remaining strong, particularly in developing economies, demand for
propylene presents producers with both challenges and opportunities. By 2020, 20% of worldwide propylene
production is expected to come from on-purpose propylene technologies. The UOP C3 Oleflex process produces
polymer-grade propylene from a propane feedstock. This highly-selective process provides an opportunity to
participate in the growing propylene market, independent of a steam cracker or FCC unit.
leflex technology can be applied
A by-product of this reaction is coke
The reactor effluent is then sent to a
to C4 olefin production by
that is formed on the catalyst, which
recovery/fractionation section in which
processing an iso-butane feed or
suppresses the catalyst activity and
polymer-grade propylene or high-purity
by co-processing iso-butane with
selectivity. The catalyst is slowly
iso-butylene is produced. Within this
propane. For a producer interested
circulated to a Continuous Catalyst
section, there is an option to recover
in both propylene and MTBE,
Regeneration (CCR) section where the
high-purity hydrogen using a PSA unit.
co-processing provides the dual
coke on the catalyst is removed by high
economic benefits of reduced feedstock
temperature oxidation, thereby restoring
Among the unique benefits of the
consumption and reduced investment
catalyst activity and selectivity. The
Oleflex process design is the separate
cost, compared to equivalent
regenerated catalyst is then circulated
reaction and regeneration sections
stand-alone units.
back to the reaction section. As a
which allow operational flexibility,
result, activity and selectivity are
including the ability to reload fresh
The Oleflex reactor section uses a highly
essentially constant during the life
catalyst without a unit shutdown. Also,
selective, platinum-based catalyst system
of the catalyst.
operating at positive pressure minimizes
O
to dehydrogenate propane to propylene,
capital and operating costs, while the
or iso-butane to iso-butylene.
reactor and CCR section designs
minimize land requirements. The Oleflex
process incorporates several important
pieces of UOP equipment, including
Oleflex Process
UOP PolybedTM PSA, modular CCR
Reactor Section
CCR Section
Product Separation Section
regenerators, UOP Catalyst
Regeneration Control Systems, UOP
MDTM distillation trays and UOP High
FluxTM tubing, all of which help optimize
Turbo
Expander
the techno-economic performance
C
C
R
of the unit.
Reactor Effluent
Compressor
Beginning in the 1990's, Oleflex units
for propylene production, iso-butylene
Dryer
production and C3/C4 production
To Propylene
Recovery
H2 Recycle
have been commissioned worldwide.
A significant portion of on-purpose
propylene demand growth continues
Fresh and
Recycle Feed
54
Net Separator
Off Gas
to be met by the Oleflex process.
55
PETROCHEMICAL PROCESSES
OLEFINS
UOP/HYDRO Methanol to Olefins Process
Methanol to olefins
With an increasing portion of the fast-growing demand for light olefins expected to come from cost-advantaged
alternative feedstocks, select producers will have unique and strategic investment opportunities. The UOP/HYDRO
Methanol to Olefins (MTO) process was jointly developed by UOP and Norsk Hydro (now Ineos) for the selective
production of propylene and ethylene from crude or refined methanol. The MTO process is a vital link in the
production of light olefins from cost-advantaged alternative feedstocks such as natural gas or coal via methanol.
N
atural gas or gasified coal is first
The process combines proven process
converted to methanol, and then
technologies used in Fluid Catalytic
the methanol is sent to the MTO unit.
Cracking (FCC) complexes and ethylene
In the UOP/HYDRO MTO process,
plants with a catalyst from UOP –
methanol is converted primarily to
containing silico-aluminophosphate, or
propylene and ethylene, with a small
SAPO-34. The unit consists of two main
amount of C4 olefinic by-product. The
sections: the reactor/regenerator section
MTO process has a minimal production
and the product recovery section. The
of by-products compared to a steam
methanol is converted in an exothermic
cracker, which means a simplified
reaction to olefins at high temperature in
product recovery section. Easy
the fluidized bed reactor. Coke accumulates
integration with the Olefin Cracking
on the catalyst during the reaction and
Process (OCP) achieves a light olefin
must be removed to maintain catalyst
yield of up to 90%. The process also
activity. To accomplish this, a portion of
the coke is removed by combustion
provides flexibility to operate at
the catalyst is continuously circulated from
with air. The regenerated catalyst is
propylene-to-ethylene product ratios
the reactor to the regenerator, in which
then circulated back to the reactor.
+
over a wide range.
The reaction section product is sent to
MTO Process
the product recovery section in which
CO2 R
C1
WR
polymer-grade propylene and ethylene
are produced via treatment and
fractionation. This fractionation is
H2O
D
DE
AS
basically the same as in a steam
DM
Flue
Gas
cracker. In addition to the polymer-grade
98+% Purity
Ethylene
Reactor
Regenerator
98+% Purity Propylene
ethylene and propylene, a small C4+
olefinic stream is produced. The olefins
in this stream can be easily converted
into propylene and ethylene by integration
with the Total Petrochemicals/UOP
DP
Crude
MeOH
OCP. This boosts the overall olefin
Air
Product Recovery Section Legend
WR = Water Removal
DE = De-ethanizer
CO2 R = CO2 Removal
AS = Acetylene saturator
C = Compressor
DM = De-methanizer
D = Dryer
DP = De-propanizer
56
yield, while eliminating a by-product.
C4+ Product
PETROCHEMICAL PROCESSES
OLEFINS
Total Petrochemicals/UOP Olefin CrackingTM Process
Olefin cracking
The combination of increasing demand for petrochemical-derived materials, high feedstock costs and a competitive
global market favors maximizing the production and recovery of light olefins from the available feedstock. Total
Petrochemicals, in France, and UOP developed the Total Petrochemicals/UOP Olefin Cracking Process (OCP) to
meet the increasing demand for propylene by converting low-value olefins in mixed by-product streams to propylene
and ethylene at high propylene-to-ethylene ratios. The OCP technology is capable of processing a wide range of
C4-C8 olefins from steam crackers, refining FCC complexes and methenol-to-olefin (MTO) plants.
O
CP uses fixed-bed reactors that
system. The Olefin Cracking process
operate at moderate temperatures
can be integrated with several different
and low pressure. The process utilizes a
technologies:
zeolitic catalyst and provides high yields
of propylene. The catalyst exhibits little
Steam cracker integration
sensitivity to common impurities such as
Low-value C4-C6 olefin by-product streams
dienes, oxygenates, sulfur compounds
produced in naphtha cracker furnaces
and nitrogen compounds. The reactor
can be used as feed to an OCP unit to
size and operating costs are minimized
produce additional light olefins. The OCP
by operating at high space velocities and
light olefin product streams are sent to the
high conversions and selectivities without
naphtha cracker recovery section, while the
the use of an inert diluent stream, such
C4-C6 streams, now depleted in olefins and
as steam. A swing reactor system allows
paraffin-rich, are recycled to the naphtha
catalyst regenerations without taking the
cracker furnaces. Case studies of olefin
unit offstream. The design of the separa-
cracking integration with naphtha
tion facilities depends upon how the unit
crackers have shown significant
is integrated into the overall processing
increase in propylene production.
Steam Cracker Integration
Olefin Cracking Process
C2= /C3=
Olefinic
C4-C8
Naphtha
OCP
Reactor Section
Furnace
Section
C2=
C3=
Fuel Gas
PyGas
C4
By-product
De-butanizer
C5+
By-products
De-propanizer
Product
Recovery &
Purification
Section
Paraffin-rich
C4-C6
C4-C6
Olefin-rich
By-product
OCP
Unit
57
PETROCHEMICAL PROCESSES
OLEFINS
UOP Olefin Cracking (OCP) Process continued
FCC refinery integration
MTO integration
When integrated within refining FCC
MTO reactions are quite selective,
complexes, the OCP converts C4-C8
however they produce a small C4+
olefins in olefin-rich by-product streams
by-product stream that is rich in olefin.
from the FCC and coker units to
The OCP unit can be used to convert
high-value light olefins which are
C4+ olefin to propylene and ethylene.
recovered as products. The by-product
By integrating OCP into an MTO
of the OCP is a gasoline stream low in
complex, the overall propylene and
olefins, with virtually the same octane
ethylene yield in the complex can be
number as the feed to the OCP due
greatly increased, approaching 90%
to small amount of aromatics which
(carbon basis). In this integration, the
are formed.
advanced MTO olefin recovery section
is also used to recover the OCP unit
FCC Refinery Integration
Gasoline
Cycle Oils
FCC
Unit
Gas Oils
C2=
C3=
C5+
C4-C8
Olefin-Rich
By-product
Olefin
Recovery
LPG
OCP
Unit
Light
Olefins
MTO Integration
light olefins.
MeOH
C2=
MTO
Unit
C4-C5
Olefin-Rich
By-product
C3=
Light
Olefins
OCP
Unit
C4+
In addition to its role upgrading
to propylene and ethylene the C4+
by-product streams from steam
crackers and FCC units, OCP can be
used to up-grade by-products from
delayed cokers.
58
PETROCHEMICAL PROCESSES
OLEFINS
UOP MaxEneTM Process
Naphtha separation
The MaxEne process is an innovative method of increasing the yield of ethylene from naphtha crackers
by 30% or more by increasing the quality of the feed to the cracker. The increase in ethylene yield is
achieved by raising the concentration of normal paraffins in the naphtha cracker feedstock. This is achieved
by utilizing adsorptive separation to recover C5-C11 normal paraffins from naphtha.
shape-selective adsorbent to simulate
is recovered from this stream by
moving-bed, counter-current adsorptive
fractionation and sent to the naphtha
process is a continuous process that
separation. The separation process
cracker, while the recovered desorbent
extracts normal paraffins from
consists of selective adsorption of
is recycled.
non-normal paraffins in straight-run
normal paraffins, followed by desorption
naphtha. The naphtha is first
using a specific desorbent. The rotary
hydrotreated and is then sent to the
valve, which is used periodically to
MaxEne unit. The extraction of
switch the position of the liquid feed,
normal paraffins takes place in an
desorbent and withdrawal points in
adsorption chamber that is divided into
the adsorbent chamber, creates four
discrete beds. Each bed contains
major streams:
T
he latest application of the UOP
Sorbex
TM
technology, the MaxEne
shape-selective adsorbent, as well as a
specialized grid to support the
adsorbent. The grids are designed to
provide highly-efficient flow distribution in
the chamber. Each bed in the chamber
• The raffinate stream, which contains
non-normal paraffins and the liquid
desorbent. Naphtha depleted in
normal paraffins is recovered from
this stream by fractionation and
sent to a refinery or an aromatics
complex, while the recovered
• The feed stream, which is the
naphtha feed containing a mixture
of hydrocarbons
desorbent is recycled.
• The desorbent stream, which is the
liquid desorbent that is recycled
• The extract stream, which contains
is connected to a UOP Rotary Valve.
normal paraffins and the liquid desorbent.
The rotary valve is used along with the
Naphtha that is rich in normal paraffins
from the fractionation section to
the chamber
The UOP Rotary Valve has been
engineered for ruggedness and reliability,
qualities proven in nearly 200 Sorbex
MaxEne Process
process units worldwide. UOP rotary
valves typically operate for several
Adsorbent
Chamber
1
2
3
4
5
6
7
8
years without the need for maintenance.
Extract
Column
Desorbent
On-stream availability for a Sorbex
Rotary
Valve
process unit is very high, with minimal
Normal
Paraffins
Desorbent
Extract
maintenance required, the result of the
mild operating conditions.
Feed
te
Raffina
Raffinate
Column
Straight Run Naphtha
Non-normal
Hydrocarbons
59
PETROCHEMICAL PROCESSES
OLEFINS
UOP Selective HydrogenationTM Process
Selective hydrogenation
UOP offers several technologies, used in various services, for the
selective hydrogenation of acetylenes, dienes and mono-olefins.
F
or all these processes, the reaction
takes place at low temperatures
• The Hüls Complete Saturation
Process (CSP) converts essentially
and pressures. The hydrogenation
100% of olefins to the corresponding
technology is highly selective with
paraffin with minimal isomerization.
minimum loss of olefins by saturation.
In the CSP, olefins can be reduced
• The Hüls Selective Hydrogenation
to the lower limit of detection.
Process (SHP) is a low-cost, highly
Employing an economical process
selective process for the hydrogenation
design and catalyst system, the Hüls
of dienes and acetylenes to their
SHP processes are well-established
corresponding mono-olefins. The
technologies, processing feedstocks of
process can be applied to streams
a wide range of compositions in various
containing C3, C4 or C5 fractions,
process applications worldwide.
and in all these carbon ranges, the
di-olefin content of the product is less
than 10 ppm.
• The Hüls Selective Hydrogenation
Selective Hydrogenation Process
Process-Concentrated Butadiene
(SHP-CB) is a variant of the SHP
Light Ends
Recovery
used to convert C4 dienes and
acetylenes in a naphtha cracker
crude C4 stream, which contains
Reactor
high concentrations of butadiene,
to mono-olefins. The SHP-CB can
Stripper
be configured for either maximum
butene-1 (B-1) production or
maximum butene-2 (B-2) production.
Typical di-olefins in the product are
less than 10 ppm.
Alkylation
Unit
Make-up
Hydrogen
Olefin Feed
60
PETROCHEMICAL PROCESSES
OLEFINS
Hüls Butene-1 Recovery Process
Butene-1 production
UOP licenses the Hüls Butene-1 Recovery process, which is designed
to recover high-purity butene-1 (B-1), as well as other technologies for
the production of high-purity B-1 from crude C4 streams.
T
• If BD is not a desired product, B-1
echnology selection for the
is then sent to two super-fractionators
production would require an SHP-CB
for the recovery of 99.5% B-1. This
depends on the producer's needs for
unit, an MTBE unit and the B-1
separation requires ~200 trays in each
butadiene (BD). Typically multiple
Recovery unit.
fractionator. The close spacing of UOP
production of high-purity butene-1
MDTM distillation trays makes it possible
technologies, including B-1 recovery, are
required to accomplish the production
In either the SHP or SHP-CB unit,
to use only two towers for this
of high purity B-1. BD constitutes
di-olefins and acetylenes are selectively
fractionation, decreasing capital and
40-50% of the crude C4 cut from a
hydrogenated to the corresponding
operating costs, as well as plot space.
steam cracker, and can either be
mono-olefin. Because iso-butylene and
recovered via extraction or be converted
B-1 cannot be separated efficiently by
Commercial operations of Huls Butene-1
to mono-olefins (butene-1 and butene-2)
fractionation, the effluent is then sent
Recovery units have allowed producers
by selective hydrogenation. The process
to an MTBE unit (UOP EthermaxTM
to meet their B-1 and BD requirements
flow for the production of B-1 from a
process) where the iso-butylene present
with cost effectiveness and high
crude C4 stream depends on which
is reacted to near-completion with
process efficiency.
products are desired:
methanol to form MTBE. It is necessary
to react at least 99.9% of the
• If BD is first extracted as a desired
iso-butylene in order to produce
product, B-1 production would
high-purity B-1. The Ethermax process
require an SHP unit, a Methyl
employs Reaction with Distillation
tertiary-Butyl Ether (MTBE) unit
(RWD) to do this in a cost-effective
(UOP Ethermax process) and the
manner. The effluent from the MTBE unit
B-1 Recovery unit.
Butene-1 Production Process
B-1 Recovery Unit
Methanol
Make-up
Hydrogen
C4 Stream
from Cracker
C4/C4=
Butene-2
Column
Butene-1
Column
Light Ends
& Iso-butane
Ethermax
SHP-CB
MTBE
Butene-2 & Butene-1
Normal Butane
61
PETROCHEMICAL PROCESSES
OLEFINS
UOP Propylene Recovery Unit
Propylene recovery
The UOP Propylene Recovery Unit (PRU) produces chemical- or polymer-grade propylene from refinery
by-product streams. Additionally, the PRU can be used to upgrade existing refinery-grade and chemical-grade
propylene to polymer-grade. To meet polymer-grade specifications, the stream must be concentrated to a
minimum of 99.5% propylene and be essentially free of di-olefins and acetylenic species. Incorporating UOP
process equipment and adsorbents, the PRU allows the refiner to recover polymer-grade propylene in the
most economic manner available.
he PRU configuration depends
The propane-propylene fractionation
on the feed expected to be
is a difficult separation, historically
functions as the reboiler and
processed in the unit. Assuming the
requiring two towers to accommodate
condenser, reducing the overall
feed is the C3/C4 by-product from an
the high reflux and large number of
equipment count and lowering
FCC unit, the feed is first de-propanized
distillation trays. However, the UOP
fractionation pressure.
and then de-ethanized. De-ethanizer
PRU utilizes three proven technological
overhead is typically sent to the refinery
advances that allow the fractionation to
The combination of these three proven
fuel gas system, while the destination
be accomplished in a single tower.
PRU technologies – UOP’s MD trays,
T
of the de-propanizer bottoms is refineryspecific. The C3 splitter then fractionates
propane and propylene. Propane is
• UOP’s MDTM multiple-downcomer
distillation trays reduce tower height
and diameter without sacrificing
sent from the bottom of the column to
product purity.
storage, while the propylene is taken
overhead and sent downstream for
High Flux tubing and the heat pump
system, together with UOP adsorbents
– results in the most economic
separation of propylene from
propane available.
• UOP’s High Flux
TM
further treating.
• A heat pump compressor system
tubing reduces
the size of the reboiler/condenser
With over 100 propane/propylene
exchanger by promoting greater
splitters using MD trays, as well as
heat transfer efficiency.
multiple PRUs worldwide, UOP is
the leader in the technologies for
high-purity propylene recovery.
Propylene Recovery Unit
C3/C4 Splitter
Propane/Propylene
Splitter
Solvent
System
De-ethanizer
Mixed
C3/C4 Feed
Sand
Filter
C4
By-product
62
Propane
Product
Dryers
Treater
Propyl
Produ
63
PETROCHEMICAL PROCESSES
DETERGENTS
UOP Linear Alkylbenzene Complex
Bio-degradable detergent intermediate production
Population growth worldwide and economic growth in the developing regions drive the increase demand for
household detergents. Linear alkylbenzene (LAB) is the most commonly-used raw material in the manufacture
of bio-degradable household detergents. LAB is produced via the alkylation of benzene with normal olefins.
Normal olefins are derived from normal paraffins, which are typically obtained from straight-run kerosene.
U
OP's LAB processes are the most
the UOP PEPTM process and the
economical technologies available
UOP/CEPSA Detal
TM
process.
range of molecular weight, is produced.
The Distillate Unionfining process
today, providing LAB producers with
hydrotreats kerosene to remove sulfur,
low production costs and high product
The typical UOP LAB complex consists
nitrogen, olefins and oxygenate
quality. More than 80% of the world’s
of two sections: the front end, which
compounds that might otherwise
LAB is produced using UOP
focuses on the recovery of normal
poison the Molex adsorbent.
technologies. UOP offers an array of
paraffins from kerosene, and the back
processes, catalysts, adsorbents and
end which focuses on the production of
The Molex process is a liquid-state
equipment for the production of LAB.
LAB from normal paraffins and benzene.
separation of normal paraffins from
The processes can be used in
branched and cyclic components using
Recovery of normal paraffins
from kerosene
UOP Sorbex technology. It operates in
The UOP LAB complex consists of a
Kerosene prefractionation is often
bed in a fixed-bed system by use of
combination of several UOP process
used to tailor the kerosene feed to the
the UOP Rotary Valve. The Molex
technologies, including kerosene
desired carbon range. Kerosene is
process combines low operating
prefractionation, the UOP Distillate
stripped of light ends and heavier
costs with attention-free operational
UnionfiningTM process, the UOP
components so that the heart cut,
simplicity, making it the most attractive
containing the desired normal paraffins
normal paraffin separation process
for the production of LAB with a certain
available commercially.
combination for new complexes, or
retro-fitted into existing complexes.
Molex
TM
process, the UOP Pacol
TM
process, the UOP DeFineTM process,
liquid phase and simulates a moving
Integrated LAB Complex
Kerosene
Benzene
Prefractionation
& Hydrotreating
UOP Molex
Process
Return Kerosene
64
n-Paraffins
Hydrogen Light Ends
Aromatics
UOP Pacol/
DeFine Processes
UOP PEP
Process
Recycle n-Paraffins
Heavy
Alkylate
UOP/CEPSA
Detal Process
LAB
DETERGENTS
PETROCHEMICAL PROCESSES
Production of LAB from
normal paraffins and benzene
The PEP process allows for the
commercialization in 1995, over 75% of
selective removal of aromatics in the
new LAB capacity has been based on
In the Pacol process, normal
olefin/paraffin feed to the Detal unit.
Detal process technology.
paraffins are dehydrogenated to their
Removal of the aromatics results in a
corresponding mono-olefins using
3-5% increase in LAB yield and improved
UOP began offering alkylbenzene
UOP’s DeH series of catalysts which
stability of the Detal alkylation catalyst.
technology in the 1940’s. UOP's
continuing stream of innovations driven
are highly active and selective. The
de-hydrogenation reaction is achieved
The final step in making LAB is to
by environmental, safety, economic
under mild operating conditions, with
alkylate the linear mono-olefins produced
and technological needs has
minimal loss of feedstock to by-products.
in the upstream processes with benzene
strengthened UOP's position as the
to produce linear alkylbenzene. This is
primary supplier of LAB technology to
The DeFine process is a liquid-phase,
accomplished in the Detal process,
producers worldwide, with well over
selective hydrogenation of the di-olefins
jointly developed by UOP and CEPSA.
100 operating units. UOP's LAB
contained in the Pacol reactor effluent
The process uses a solid, heteroge-
technologies provide a proven and
to corresponding mono-olefins over a
neous catalyst and has replaced HF
reliable route to produce high-quality
catalyst bed. The addition of a DeFine
alkylation as the technology of choice
LAB in a cost-effective manner.
unit after the Pacol unit in a LAB
for LAB production. The principal
complex results in a 5% yield increase
benefits of the Detal process are lower
of LAB product by reducing heavy
unit investment and operating costs,
alkylate and regenerator bottoms
resulting from the use of a solid,
by-products.
non-corrosive catalyst system. Since its
65
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
HYDROGEN
HYDROGEN
Producing, recovering and purifying hydrogen for
use in downstream processes is critical for profitability.
HYDROGEN
Today's refineries continually face the challenge of producing cleaner fuels, increasing
the demand for hydrogen. Creative solutions are needed to address hydrogen demand
and improve profitability. UOP offers innovative proven solutions, ensuring reliable supply
of pure hydrogen for your downstream processing needs.
OP uses a unique methodology
waste streams is often an important
PolysepTM Membrane systems. These
and approach to analyze a
strategy to improve hydrogen network
technologies are provided in the form
refinery’s hydrogen system. The
efficiency. Producing, recovering and
of equipment, typically skid-mounted
approach focuses on meeting new fuel
purifying hydrogen for downstream use
process modules which allow expedited
specifications, addressing hydrogen
is critical for profitability. The purification
project execution for the earliest
demands and improving the refinery’s
technologies we use to recover hydrogen
realization of those benefits.
U
bottom line. Recovering hydrogen from
70
TM
include UOP Polybed
PSA and UOP
HYDROGEN
UOP PolybedTM PSA System
Hydrogen purification
Polybed pressure swing adsorption (PSA) is a cyclical process in which all of the impurities in a
hydrogen-containing stream are adsorbed at high pressure and subsequently rejected at low pressure.
The hydrogen product is typically upgraded to 99.9+% purity to meet downstream processes' requirements,
with hydrogen recoveries of 80 to 90%.
T
o meet refiners' and petrochemical
producers' increasing need for
reliable, high-purity hydrogen for their
downstream processing, UOP offers
the PSA system. Polybed PSA systems
are used in many applications to recover
and purify hydrogen. The hydrogen
from a steam reformer is typically purified
by a PSA system. The PSA system
produces high-purity hydrogen to meet
downstream process requirements.
In addition, Polybed PSA systems are
the technology-of-choice for recovering
and purifying hydrogen that otherwise
would be wasted to fuel.
The Polybed PSA system:
• Provides a reliable, low-maintenance
and very cost-effective alternative to
replace complex wet scrubbing
• Controls the variation of the tail gas
stream’s Wobbe index
• Offers reduced plot requirements,
fast delivery times and low installation
costs based on the modular design
Since the Polybed PSA system’s
commercialization in the 1960’s, UOP has
installed more than 900 PSA systems in
more than 70 countries. The system has
of hydrogen from gasification syngas,
demonstrated exceptional economic
purification of helium for industrial gas
value in many applications, including
use, adjustment of synthesis gas for
recovery of hydrogen from refinery
ammonia production, purification, of
off-gases, purification of hydrogen from
methane for petrochemicals production,
ethylene plant off gas, recovery of
and H2/CO ratio adjustment for syngas
monomers in polyolefin plants, extraction
used in the manufacture of oxo-alcohols.
Polybed PSA Process Steps
Gas Product
Gas to Re-pressurize
purification systems
Gas to Purge & Equalize
• Simplifies plant configuration
• Produces hydrogen with higher purity
levels than traditional wet scrubbing
Re-pressurization
minimal feed pre-treatment and utility
requirements
Adsorption
to automatic operation, as well as
Purge
Co-Current De-pressurization
• Requires minimal manpower due
Counter Current De-pressurization
and operation
systems
• Provides valuable heat input to the
reformer furnace
Feed Gas
Step 1
Step 2
Step 3
Step 4
Step 5
Tail
Gas
H2
Impurities
Time
The same process steps apply to a PSA unit with any number of adsorbers.
71
HYDROGEN
UOP PolysepTM Membrane System
Hydrogen purification
The Polysep membrane system combines state-of-the-art composite membrane
technology with advances in polymer science, a pairing that results in membranes
that are fundamentally different from other options. To allow today's producers
to meet the challenges of increasingly-stringent specifications on fuels and
petrochemical products, the Polysep family offers a complete selection of
separation polymers featuring a versatile range of separation characteristics –
permeability, selectivity and contaminant resistance – that allows the design
of an optimum hydrogen purification system to fit a given process need.
P
olysep membrane systems are
modular units containing hollow
Automatic operation features require
• Future expandability by adding
modules or skids
fiber spiral-wound membrane elements.
no special operator consideration.
The membranes are well-supported by
The system's design permits easy
In their primary application, Polysep
the element structure, resulting in
turn-up and turn-down without
systems produce high-purity hydrogen
excellent mechanical integrity and flow
on-going operator attention to
from a variety of feed sources, such as
distribution. The elements are housed
capacity
high-pressure vents and purge streams
in pressure tubes that are mounted on
a skid in series or parallel configurations,
depending upon feed-gas volume and
product requirements. High membranepacking density minimizes system size
and cost.
Polysep membrane systems offer:
• Ease of installation and maintenance
Modular design and shop fabrication
allow for compact design, but
membrane elements are carefullyoriented for ease of maintenance
72
• Minimal manpower requirements
• High reliability
Historical operating data indicates
minimal unscheduled shutdowns,
with an on-stream factor
exceeding 99.8%
from hydroprocessing, methanol and
ammonia plants. UOP has supplied
more than 70 units, including installations
providing more than 55,000 Nm3/h of
enriched hydrogen.
HYDROGEN
UOP Hydrogen Management Services
Refiners' and petrochemical producers' increasing demands for pure hydrogen can sometimes
be met by optimization of hydrogen use throughout their entire network. UOP Hydrogen
Management Studies employ a rigorous methodology which analyzes the refinery hydrogen
balance as a network problem, utilizing hydrogen pinch analysis. Minimum hydrogen requirements
are set and network improvements are defined using refinery-wide hydrogen network models,
and hydrogen generation and purification process models. The UOP methodology relies on
detailed process models and refinery-wide LP economic models to optimize the use of
hydrogen. Significant bottom-line impact is possible.
H
ydrogen – specifically hydrogen
improvements can be made. It can
partial pressure – has a strong
• Consider impact on process units
lower refinery operating costs or new
UOP combines analyses of hydrogen
impact on profitability because of its
hydrogen plant capacity by reducing
network and purification systems,
effect on throughput, product quality,
overall hydrogen needs.
with a thorough understanding of the
role of hydrogen partial pressure, to
conversion, yield and catalyst life.
UOP uses a four-stage approach:
By combining hydrogen network
analysis with an in-depth understanding
of the role that hydrogen plays in
• Analyze refinery hydrogen balance
A systematic methodology is used
hydrogen-consuming processes, UOP
to set the minimum hydrogen
can help open opportunities for
requirements and identify where
increased refinery profitability far
network improvements can be made.
beyond the benefit realized by simply
reducing hydrogen costs.
• Improve/add hydrogen purification
Improvements to existing hydrogen
UOP’s approach provides a means of
purification units are evaluated, as
setting minimum consumption targets
well as various alternatives for new
and direction on where network
purification.
$MM/yr Profit Improvement
changes require re-design of the
hydrogen network, the analysis
becomes iterative.
• Sustain the benefits
The full benefits of hydrogen
management can only be realized
if network optimization becomes an
integral part of refinery operations.
A UOP hydrogen network model
allows optimization and what-if
analyses on a routine basis.
H2 savings only
UOP Hydrogen Management Studies
H2 savings plus process improvements
10
the process units. Because process
running on the engineer’s desktop
Benefits of UOP H2 Management Studies
12
identify hidden profit potential in
have been successfully employed in
dozens of refineries ranging in size from
8
90,000 to 810,000 BPD, and involving
6
as few as four and as many as 32
4
hydrogen-consuming units, to meet U.S.,
European and Asian fuel specifications.
2
0
A
B
C
D
E
Project
F
G
H
I
73
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
GAS PROCESSING
GAS PROCESSING
UOP technologies treat and condition natural gas streams
for the removal of multiple acid gases and contaminants.
GAS PROCESSING
Natural gas and synthesis gas (Syngas) streams contain acid gases
(carbon dioxide and hydrogen sulfide) and/or water that must be removed
before the gas is sent to downstream processing units or put into a
pipeline. UOP is unique in the gas processing industry, having the
capability to deliver acid gas removal processing solutions based
on solvent, adsorption and membrane technologies.
U
OP’s broad and overlapping
The diagram below shows where these
technical solutions ensure that we
technologies fit based on the acid gas
can provide the right technology for
partial pressure in the feed and product
every treating need. UOP can also tailor
gas streams.
a solution to meet complex performance
targets by integrating several processes
In addition, UOP has a cooperative
into a systems package.
marketing alliance with Ortloff Engineers,
Ltd. for processes to recover natural
The acid gas removal technologies
gas liquids (NGL) from natural gas
UOP offers include:
streams and produce elemental sulfur
• UOP Amine GuardTM FS process
from acid gas streams.
• UOP BenfieldTM process
process
• UOP SeparexTM Membrane systems
• UOP MOLSIVTM adsorbents
• UOP GBTM adsorbents
1000
Partial Pressure of Acid Gas in Feed, psia
• UOP Selexol
TM
1000
Selexol
Process
Benfield Process
100
10
1.0
Separex
Membrane
Systems
100
Polybed
PSA
Systems
Amine Guard FS
Process
10
MOLSIV Adsorbents
1.0
UOP GB
Adsorbents
0.1
0.001
0.01
0.1
1.0
10
Partial Pressure of Acid Gas in Product, psia
78
0.1
100
GAS PROCESSING
NATURAL GAS TREATING
UOP Amine GuardTM FS Process
Gas treating
The Amine Guard FS process technology combines the high-performance,
formulated, UCARSOL® family of solvents produced by The Dow Chemical
Company with UOP's reliable Amine Guard process technology. The
Amine Guard FS process can be tailored for either bulk, selective or trace
acid gas removal for CO2 and H2S. It is typically used to treat natural gas
streams for pipelines, or NGL or LNG applications or synthesis gas
streams in ammonia plants.
A
cid gas (AG) partial pressure is
an important parameter for
selection of the best Amine Guard FS
process flowscheme. Feed conditions
Amine Guard FS Process with
Low Energy Option for CO2 Removal
can range between 25 and 1800 psia
Sweet Gas
total pressure, with acid gas
compositions of 0.5% to 20% by volume.
The process is capable of achieving
Amine
Absorber
Acid
Gas
very low product gas specifications, to
1 ppmv of H2S and 50 ppmv of CO2.
UOP employs either the thermal- or
Acid Gas
Knock-Out
Drum
Flash Gas
to Fuel
Header
Feed
Gas
Amine
Stripper
Rich Flash
Drum
flash-regenerated Amine Guard FS
process to selectively remove H2S and
other sulfur components from the feed
Rich Flash
Column
gas stream or to achieve bulk removal
Make-up
Water
of CO2. Hydrocarbon, H2 and CO losses
Amine
Reboiler
are minimal in the Amine Guard FS
Lean/Rich
Exchanger
process due to their low solubility in
the UCARSOL solvent.
Amine Guard FS process technology
Amine Guard FS Process with
Selective H2S Removal Option
was introduced over 20 years ago.
Treated Gas
UOP has licensed over 400 Amine
Guard units for commercial service
throughout the world.
Amine
Absorber
Acid Gas
Amine
Stripper
Make-Up
Water
Feed
Gas
79
GAS PROCESSING
NATURAL GAS TREATING
UOP BenfieldTM Process
Gas treating
The UOP Benfield process is a thermally-regenerated, cyclical solvent
process that uses an activated, inhibited hot potassium carbonate
solution to remove CO2, H2S and other acid gas components.
T
here are a variety of Benfield
flowschemes available that permit
process optimization and energy
reduction with this near-isothermal
unit operation. Existing plants can be
• Lowers the CO2 in product gas
by 25-85%
• Lowers the carbonate solvent solution
circulation by 5-15%
revamped for capacity increases and/or
• Lower regeneration energy
The Benfield process can be tailored for
heat savings through the use of UOP’s
requirements by 5-15%
either bulk or trace acid gas removal. It is
LoHeatTM technology and/or UOP high
performance packings.
• Increases feed gas throughput by
5-15%
UOP’s Benfield ACT-1TM activator is a
promoter for the absorption of carbon
dioxide (CO2) by hot potassium
carbonate solution. ACT-1 activator can
do one or more of the following in
comparison with DEA activation:
• Reduces the consumption of
anti-foam and other chemicals
• Reduces or eliminates the reduction
of vanadium valence state from V+5 to
inactive V+4 in ammonia or hydrogen
purification service
typically used in the following applications
and markets:
• Synthesis gas treating for CO2
removal in ammonia plants
• Synthesis gas treating for CO2 removal
in direct iron ore reduction plants
• Natural gas treating to achieve either
LNG product or pipeline specifications
• Recycle gas purification in an
Benfield Process
Product Gas
ethylene oxide facility
Acid Gas
Acid gas partial pressure is an important
parameter in the design of the Benfield
process. Typical feed conditions range
Benfield
Absorber
between 150 and 1800 psia total
pressure, with acid gas compositions
Benfield
Regenerator
of 5% to more than 35% by volume.
The product specifications achievable
depend on the application, and can
Feed
Gas
Hydraulic
Turbine
(optional)
range from a few hundred ppmv to few
percent of CO2.
The Benfield process was introduced
over 35 years ago and over 700 Benfield
units are in commercial service worldwide.
80
NATURAL GAS TREATING
GAS PROCESSING
Dehydration and Sulfur Removal
Whether to meet final product specifications, to protect downstream
catalysts and equipment or for environmental compliance, UOP offers
molecular sieve adsorbents to remove contaminants from natural gas,
syngas and other streams.
M
olecular sieves are adsorbents
UOP manufactures molecular sieve
composed of aluminosilicate
products in various UOP MOLSIV
crystalline polymers (zeolites). They
forms: beads, granules and extrudates,
efficiently remove low concentrations of
including standard pellets and UOP
polar or polarizable contaminants such
TRISIVTM pellets. The type, size and
as H2O, methanol, H2S, CO2, COS,
particle shape of molecular sieve
mercaptans, sulfides, ammonia,
selected for a particular customer are
aromatics and mercury down to
determined by the application. An
trace concentrations.
extensive and exclusive database
allows us to select the optimum
products on a case-by-case basis.
The natural gas processing industry
uses molecular sieves for:
• Natural gas dehydration
• Natural gas mercury removal
• Natural gas/LPG desulfurization
• Natural gas CO2 removal for
Open Cycle Molecular Sieve Dehydration System
Feed Gas
Separator
Molecular Sieve
Adsorbers
“peak shaving”
Spent
Regeneration
Gas
Regeneration
Gas Separator
• Ammonia synthesis gas purification
Number of operating units,
worldwide:
Natural gas dehydration
1,000+
Dehydration with regenerative
Wet Feed
Gas
Condensed
Liquid
mercury removal
Natural gas treating (sulfur, CO2)
50+
200+
CO2 removal for
Regeneration
Gas Heater
“peak shaving” LNG facilities
100+
LPG combined
Condensed
Liquid
dehydration/desulfurization
Regeneration Gas
Synthesis gas purification
100+
100+
Product
81
GAS PROCESSING
NATURAL GAS TREATING
Mercury Removal
UOP offers regenerable molecular sieve adsorbents and non-regenerable metal-oxide
adsorbents to remove mercury from natural gas, LPG and other light hydrocarbon streams.
U
OP HgSIVTM adsorbents are
silver-laden molecular sieves
Mercury Removal Unit Upstream of the Amine and Dryer Units
specially formulated to remove mercury.
Regen Off Gas
The adsorbent can be loaded into an
UOP GB MRU
existing molecular sieve de-hydration
unit to simultaneously remove mercury,
Spent
Regeneration
Gas
water and other impurities. HgSIV
adsorbents are regenerated with a
clean gas stream. The mercury is
rejected with the regeneration gas and,
if desired, can be captured on a bed of
non-regenerable GB series adsorbent.
Natural Gas
UOP MOLSIV
Adsorbents
The GB series are spherical, metal
oxide adsorbents designed for the
Feed Gas Separator
Dehydration
CO2 Removal
non-regenerative removal of mercury.
Mercury from the process stream is
tightly bound to the material as it flows
over the bed. Spent mercury-laden
Mercury Removal Unit on the Regeneration Gas Off the Dryers
adsorbent must be disposed of
properly when it is unloaded from the
Regen Off Gas
vessel. Mercury removal units may
Spent
Regeneration
Gas
include one or more absorber vessels,
depending on the application.
UOP GB MRU
UOP can provide new mercury removal
units as packaged equipment systems.
This option enables a customer to
obtain the process unit, adsorbent
and performance warranty from a
UOP MOLSIV
Adsorbents
and
UOP HgSIV
Adsorbents
Natural Gas
single supplier, generally resulting in
cost savings.
Feed Gas Separator
Product Gas
CO2 Removal
82
Dehydration
83
GAS PROCESSING
NATURAL GAS TREATING
Ortloff Technologies
NGL recovery and elemental sulfur production
Orloff Engineers, Ltd. is a leading engineering and consulting company with a portfolio of process technologies,
know-how and patents in the natural gas liquids (NGL and LPG) recovery, sulfur recovery, CO2 fractionation
and liquified natural gas (LNG) markets. Orloff's technologies are designed to increase yields of high-value
components of the natural gas stream in various process applications and otherwise optimize process yields.
Orloff's technologies have been utilized worldwide.
Single Column Overhead
Recycle Process
the stream. With appropriate design
The Ortloff Single Column Overhead
process can also be switched to operate
REcycle (SCORE) process is a state-of-
in an ethane recovery mode utilizing the
the-art gas processing technology suited
Ortloff Gas Subcooled Process (GSP).
features, a plant using the SCORE
to the recovery of propane and heavier
The SCORE process is applied to:
• Achieving high propane recovery
from natural gas or refinery off-gas
streams with minimum compression
requirements, while rejecting lighter
components to meet liquid product
hydrocarbons from a natural gas stream.
GSP typically achieves ethane recovery
The SCORE process is one of many
of greater than 85%, with propane
Ortloff technologies capable of extremely
recovery greater than 98%. Although
high propane recovery with high efficiency.
switching the SCORE plant to GSP
moderate ethane recovery without
requires additional piping and several
the need for additional equipment
Propane recovery typically exceeds
valves, additional major equipment is
97%, with 99% or higher easily
not required in most cases.
achievable, while rejecting all ethane in
specifications
• Allow gas processing plants to realize
• Providing flexibility to gas processing
plants where varying economic
conditions may favor operating in
either ethane recovery or ethane
rejection modes for extended periods
The SCORE process can accommodate
Ortloff SCORE Process
a wide range of natural gas compositions
Heat Exchanger
and inlet conditions. Inlet pressures
above 600 psi are generally preferred
Residue
Gas
for natural gas streams, but lower
pressures can be accommodated.
Richer gas compositions may require
Residue Gas
Compressor
Inlet Gas
the addition of a refrigeration system.
Expander/
Compressor
In normal operation, the SCORE process
produces a mixed LPG product stream,
Heat
Exchanger
De-ethanizer
typically meeting a maximum ethanein-propane liquid product specification.
When converted to GSP mode, a mixed
NGL product stream is produced,
typically meeting a maximum methanein-ethane liquid product specification.
NGL or LPG Product
84
GAS PROCESSING
NATURAL GAS TREATING
Recycle Split Vapor Process
The Ortloff Recycle Split Vapor (RSV)
process is an enhancement of Ortloff’s
original Gas Subcooled Process (GSP)
technology. The RSV process can
• Provide gas processing plants
operational flexibility where varying
economic conditions may favor
operating in either ethane recovery
or ethane rejection mode
provide ultra-high ethane and/or propane
RSV technology can be installed in a
recovery from natural gas streams.
new facility or retro-fitted into an existing
It can also be operated to recover only
facility where ultra-high recoveries,
a portion of the ethane.
increased throughput and/or plant
operational flexibility are desired.
The RSV technology is extremely
flexible and can operate as either an
The RSV process can accommodate
ethane recovery or a propane recovery
most natural gas compositions. Richer
process. This flexibility allows a producer
gas compositions may require the
to maximize plant profits based on
addition of a refrigeration system. Inlet
ethane economics. In addition, an RSV
pressures above 600 psi are generally
plant can operate at throughputs
preferred.
significantly different than design. In the
stream is produced, typically meeting the
case of lower rates higher recoveries
In ethane recovery mode, the RSV
maximum ethane-in-propane liquid
can be achieved; for rates higher than
process produces a mixed NGL product
product specification. The residue gas
design, high product recoveries can
stream, typically meeting the required
product stream will contain methane, or
be maintained.
maximum methane-in-ethane liquid
methane and ethane, depending on the
product specification. In propane
mode of operation.
Another important feature of the RSV
recovery mode, a mixed LPG product
technology is the ability to tolerate
increased CO2 inlet gas concentrations.
Because it employs a leaner top reflux
Ortloff RSV Process
feed, the tower pressure can be
Heat
Exchanger
increased while still providing high
recovery. This provides a greater
margin of safety from CO2 freezing.
Residue
Gas
De-methanizer/
De-ethanizer
The RSV process can be applied to:
• Achieve high- to ultra-high ethane
recovery from natural gas streams,
with essentially no loss of propane
and heavier components
Residue Gas
Compressor
Inlet Gas
Expander/
Compressor
Heat
Exchanger
• Achieve high propane recovery from
natural gas streams while rejecting
lighter components to meet liquid
product specifications
NGL or LPG Product
85
GAS PROCESSING
NATURAL GAS TREATING
Sulfur Recovery Processes
Ortloff offers Claus sulfur recovery
processes based on the Amoco
process for both natural gas and
refinery applications. Amoco's patented
ammonia destruction technology for
use in refinery sulfur recovery plants is
combined with the know-how Ortloff
has developed from the design and
operation of sulfur recovery plants.
Amoco's technology has been licensed
for use in more than 400 sulfur recovery
plants worldwide.
For applications requiring an intermediate
level of sulfur recovery, Ortloff has
Sulfur recovery systems designed by
maintenance cost and with considerably
employed Amoco's Cold Bed
Ortloff Engineers Ltd. include many
greater ease of operation and flexibility
Adsorption (CBA) sulfur recovery
special design features which allow
than is commonly experienced in other
process (98-99.5%). The application of
them to operate for longer periods of
sulfur recovery plants. The following are
Ortloff's know-how and design featured
time between shutdowns, with reduced
some of the features that enhance
in key areas of these plants has allowed
for improved sulfur recovery plant
operation. Ortloff's Sulfur Vapor Line
Valve Assemblies are provided to meet
the demanding cyclic process and
mechanical requirements for sulfur
vapor service.
For applications where a high level of
overall sulfur recovery is required (more
than 99.5%), Ortloff provides Shell's
their quality and reliability:
• Robust waste heat boiler design
• Indirect re-heat for higher conversion
• Cold catalyst bed startup
• Reliable sulfur valve assemblies
• Superior sulfur-conversion catalyst
performance
• Reliable sulfur drain seal assembly
SCOT tail gas clean-up process. This
process is the best-proven technology
available in the industry and can
achieve overall sulfur recovery
performance in excess of 99.9%.
86
• Extended turn-down range
• Enhanced sulfur condenser design
GAS PROCESSING
NATURAL GAS TREATING
UOP SelexolTM Process
Natural/synthesis gas treating
The demand for energy with a low carbon footprint is increasing around
the world, while new technologies are enabling development of previously
hard-to-reach energy sources. This energy demand has increased the
need for natural gas and synthesis gas processing.
T
he Selexol process is a well-proven
The Selexol process can be tailored and
commercial process that uses a
optimized for either bulk or trace acid
physical solvent to remove acid gases
gas removal. The Selexol process can
from synthetic or natural gas streams.
be applied to the selective removal of:
It is ideally suited for the selective
removal of H2S and COS and/or CO2
to very low levels in the treated gas,
providing on-spec products, protection
of catalysts as well as equipment, and
environmental compliance. Sulfur levels
below 1 ppmv can be achieved with
variable and optimized CO2 capture
levels. The process uses The Dow
• The selective removal of H2S and
COS in an integrated gasification
combined cycle (IGCC), with high
CO2 slippage to the treated product
gas and high sulfur levels in the acid
gas to downstream sulfur recovery
systems
• H2S and COS achieve bulk removal
Chemical Company's Selexol solvent
of CO2 in gasification for high purity H2
made of a mixture of di-methyl ethers
generation for refinery, fertilizer,
of poly-ethylene glycol. The solvent is
chemical or liquid fuels production;
chemically inert, and is not subject to
total sulfur levels to less than 1 ppmv
degradation. The solvent can be
are achievable
®
regenerated thermally by flashing or
using a stripping gas, dependent on
application and processing severities.
Selexol Process for Acid Gas Removal
The Selexol process can also be used
to remove mercaptan sulfur. The solvent will remove the minor amounts of
H2S
Stripper
Treated Gas
Acid Gas
XXXX
Reflux
Accumulator
ammonia, HCN, metal carbonyls and
other contaminants that are typically
found in synthetic gas streams.
Make-up
Water
Sulfur
Absorber
Compressor
H2S
Concentrator
Feed
Gas
Packinox
Exchanger
87
GAS PROCESSING
NATURAL GAS TREATING
UOP Selexol Process continued
• Generate high purity H2 for refinery,
fertilizer, chemical or liquid fuels
Selexol Process for Sulfur Removal and CO2 Capture
production.
Treated Gas
A Selexol unit can be initially designed to
CO2
Absorber
remove sulfur, with a CO2 capture section
added as a second-phase project.
Acid gas partial pressure is the key
driving force for the Selexol process.
CO2
Typical feed pressure is greater than
H2S
Stripper
Acid Gas
XXXX
350 psia with an acid gas composition
Reflux
Accumulator
of CO2 plus H2S of 5% or greater by
Make-up
Water
volume. The product specifications
achievable depend on the application
Sulfur
Absorber
H2S
Concentrator
and feed characteristics and can be as
low as 1 ppmv total sulfur with greater
than 95% CO2 capture.
The Selexol process was introduced
over 30 years ago and over 60 Selexol
units have been put into commercial
service. The most recent applications
have focused on treating of synthetic
gas from gasification complexes for
power and hydrogen production.
Extensive optimization can be brought
to the gasification project through the
study of integration possibilities inside
and outside the Selexol battery limits.
88
Feed
Gas
Packinox
Exchanger
GAS PROCESSING
NATURAL GAS TREATING
Integrated LNG Feed Pre-treatment
Gas treating
Natural gas streams are typically treated for control and removal of
multiple acid gas contaminants, and in most cases these compounds
cannot be removed cost-effectively by a single technology.
W
hen confronted with a
strength while maximizing integration to
highly-contaminated natural
minimize capital and operating costs.
gas stream containing both H2S and
The flowscheme minimizes the number
mercaptan sulfurs, the treating solution
of required units, and the optimized
can be complex. The presence of
integration results in a very cost-
mercaptan sulfur as a contaminant
effective and technically-comprehensive
recovery unit (SRU). The de-sulfurized
makes the acid gas control a more
solution.
regeneration gas is either compressed
technically-challenging project. The
technology units required, and how
and recycled back to the Amine unit
An integrated flowscheme is shown in
and/or used as fuel for a gas turbine
they are integrated, will significantly
the graphic below. Complete H2S and
for facility power generation. In this
impact overall project economics
CO2 removal, and bulk COS removal,
flowscheme, the C2 and higher
and success.
are done in an Amine Guard FS unit.
hydrocarbon fractions are also
Water, mercaptan sulfur and mercury
separated in an Ortloff NGL recovery
UOP has designed and implemented
removal are accomplished via a
and fractionation unit. The C3 and C4
a unique flowscheme to effectively
multi-adsorbent molecular sieve desul-
fractions are treated in liquid-phase
remove and control all acid gas
furization unit. The spent regeneration
molecular sieve units for sulfur
components prior to liquid product
gas from the molecular sieve unit is
polishing to ensure all product
recovery. The flowscheme takes
treated in a Selexol unit with the acid
specifications are met.
advantage of each technology’s
gas stream sent to a Claus sulfur
The integrated flowscheme results in
lower utility requirements, lower waste
Gas Phase RSH Removal
disposal costs, higher hydrocarbon
recovery and higher sulfur recovery
than a conventional flowscheme. The
Acid Gas
(H2S, CO2, COS)
NG
Feed
Acid Gas Recovery
(UOP Amine
Guard FS Process)
Dehydration RSH
and Hg Removal
(UOP MOLSIV
Adsorbents)
Acid Gas
(RSH, H2S, COS)
integrated flowscheme has been
NGL
Recovery
(Ortloff)
RSH Removal
(UOP Selexol
Process)
implemented in several operating LNG
complexes in the Middle East.
C2
Product
C3
Treated
Regeneration
Gas
Treated Gas
(To pipeline,
LNG, GTL)
C4
COS, RSH Removal
(UOP MOLSIV
Adsorbents)
C3 Product
C4 Product
Regeneration
Gas
89
GAS PROCESSING
NATURAL GAS TREATING
UOP SeparexTM Membrane System
Gas treating
Floating platforms allow access to deep-water energy reserves and the
liquefaction of offshore gas. Shale gas and the gasification of various
solids are opening up new onshore energy production.
T
hese new energy sources
The advantages of Separex membrane
increase the need for natural gas
systems over conventional processes
processing. Separex membrane systems
are used for the removal of acid gas
are site-specific, but may include:
• Lower capital and energy costs
and water from natural gas streams.
The systems are modular, skid-mounted
• Reduced space requirements,
units containing spiral-wound membrane
faster delivery time, and lower
UOP offers complete membrane system
elements. The elements are housed in
installation costs
design, including comprehensive feed
pressure tubes in various configurations,
depending on process requirements.
gas pre-treatment to extend membrane
• Lower operating costs and manpower
requirements
Separex membrane systems are
typically used in the following
applications and markets:
• Increased flexibility to meet product
with the continuing development of
advanced membranes, has further
gas specifications as feed flow and
enhanced the performance and reliability
composition change over time
of membrane technology. Separex
• Natural gas upgrading
systems operate with high on-line
• Elimination of dehydration equipment
efficiencies. As with other UOP processes,
• Shorter, easier startup and shutdown
engineering services are readily available
• Remote and offshore locations
• Enhanced oil recovery (EOR)
operations
life. Improved pre-treatment, combined
through our worldwide Gas Processing
• Higher permeate gas pressure,
technical service organization.
which reduces re-injection
• Bio-gas methane recovery
• Debottlenecking of existing acid gas
removal units
compression requirements
The combination of extensive
engineering design experience,
innovative research and development
and world-class technical service has
made Separex the technology of choice
for CO2 removal for a wide variety of
processing conditions.
More than 130 UOP membrane
systems have been put into service.
Most customers report downtime at less
than 0.5% per year. UOP produces
membrane elements for Separex systems
at its manufacturing plants.
90
91
GAS PROCESSING
NATURAL GAS TREATING
FLNG and FPSO Feed Pre-treatment
Natural gas treating
New technologies have allowed the development of previously hard-to-reach offshore energy sources. Floating
Production, Storage and Offloading (FPSO) systems have been in use for a number of years. More recently, the
market for Floating Liquefied Natural Gas (FLNG) systems is starting to develop. Both types of systems will
become even more important in the future as producers increasingly monetize offshore and deepwater oil and
gas resources.
C
ompact and lightweight natural
Footprint and weight are of vital
gas treating systems are critical to
concern in FPSO, FLNG and platform
cost-effective gas production and rapid
applications. The MultiTube system
project implementation for hard-to-reach
is a recent development designed to
offshore energy sources. Gas with a
reduce the footprint and weight of a
high CO2 concentration may require
Separex membrane system.
bulk CO2 removal before the gas is
sent by undersea pipeline to shore,
re-injected for enhanced oil recovery
or sent to the downstream polishing
unit. Depending on the application,
mercury removal, amine treating and
dehydration may also be required. UOP
can provide all of these technologies as
equipment packages for FPSO and
FLNG systems.
One of Three Potential Integrated FLNG Pre-treatment Schemes
UOP GB-562
Adsorbent
Mercury Removal Unit
UOP Separex
Membrane System
UOP Amine Guard
FS Process Unit
UOP MOLSIV
De-hydration Unit
Treated Gas to
Liquefaction
Technology
Feed
Gas
Sour Gas
(CO2 + H2S)
92
Water
GAS PROCESSING
SYNGAS TREATING
Syngas Treating
Gas treating
Gasification of hydrocarbons is becoming more common, but these hydrocarbons are often of low value and
frequently have a high sulfur content. In addition, the presence of acid gases (COS, H2S, CO2) and other
impurities require gas treatment processes to make the syngas suitable for downstream use.
OP’s portfolio of technologies
U
gas removal processes. The capability
These processes include:
and expertise in gas processing
have been combined to provide gas
purification complexes that can
• CO shift or COS hydrolysis, or both
re-process the Claus tail gas contribute
• Claus sulfur recovery
ratio-adjusted syngas for chemicals
in the acid gas for the Claus plant and
the ability of the Selexol unit to
• Acid gas removal
produce clean syngas for power
generation or hydrogen, and
to produce a high concentration of H2S
to such effective results.
• Claus tail gas treating
The flexibility of the Selexol process to
production.
• Hydrogen extraction and purification
As a leading technology supplier, UOP
• H2/CO and H2/N2 ratio adjustment
accommodate recycle of hydrogenated
Claus tail gas not only improves
process economics, but also:
has developed unique expertise in
project definition as well as optimization,
For a sulfur complex of an IGCC flow
engineering and technical support.
scheme (defined as COS hydrolysis,
During project definition, UOP selects
acid gas removal, Claus sulfur plant,
the processes and flowscheme that
and tail gas treating), use of the UOP
will yield the most cost-efficient gas
SelexolTM process for acid gas removal
• Reduces the overall sulfur emissions
purification complex within the economic
yields overall combined plant economics
from the entire complex as a result
and technical requirements of the specific
equivalent or lower than non-UOP acid
of higher overall sulfur recovery
gasification plant being designed.
• Eliminates additional processing units
(tail gas treater and off-gas incinerator)
with their added complexity
• Enables the plant to easily tolerate
periodic breakthroughs of SO2
UOP Optimized Syngas Purification Complex
UOP can develop a gas purification
TGCU
complex to produce syngas that meets
SRU
Tail gas
the specifications required for specific
downstream chemicals manufacturing.
Sulfur
Product
SRU
PSA Tail gas
CO2
Product
Acid Gas
Using a combination of UOP Polybed
PSA and UOP PolysepTM membrane
systems, the syngas composition can
PolyBed PSA
H2
Product
IGCC
Power
The syngas composition can also be
Methanation
SNG
Product
adjusted to produce pure hydrogen for
Fischer Tropsche
Reactor
Fischer
Tropsche
Liquids
Methanol
Unit
Methanol
be adjusted for use in the synthesis of
ammonia, methanol or oxo-alcohols.
Syngas
CO Shift/COS
Hydrolysis
Selexol
Unit
Sulfur
Guardbed
Technology
Partners
UOP/Ortloff
UOP
hydrogenation units.
93
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
RENEWABLES PROCESSES
RENEWABLES PROCESSES
UOP is committed to finding the right solutions that will protect
valuable land and water resources while still offering our customers
the ability to produce the highest quality transportation fuels.
RENEWABLES PROCESSES
With global energy demands expected to double by 2030, UOP continues to identify alternative energy
resources. Fuels and chemicals from renewable sources have the potential to support growing
energy needs while addressing concerns regarding climate change and greenhouse gas emissions.
UOP's innovative solutions enable you to play a vital role in this dynamic, emerging arena.
U
OP continues to develop its
portfolio of solutions to enable
Renewable JetTM process to that portfolio.
our customers to meet their renewables
UOP is also engaged in a joint venture,
obligations pursuant to governmental
Envergent Technologies, which offers a
regulations mandating the use of
technology to process cellulosic wastes
renewable technology in the transport
to an intermediate pyrolysis oil product
and power sectors. The first renewable
that can be further upgraded to
technology UOP introduced was our
transportation fuels.
solution for the production of green
98
diesel. UOP has since added its UOP
RENEWABLES PROCESSES
UOP/Eni EcofiningTM Process
Renewable diesel fuel
The Ecofining process is UOP’s solution for meeting the increasing
demand for a sustainable high-quality renewable diesel. UOP and
Eni S.p.A. of Italy developed the process jointly. It combines 95 years
of UOP process-licensing experience with joint UOP/Eni technology
and catalyst developments in the field of bio-feedstock processing.
T
he Ecofining process can be
The Ecofining process de-oxygenates
applied to a wide range of
and de-carboxylates tri-glyceride
bio-derived feedstocks. It is designed
and/or free fatty acid feedstocks, and
with the flexibility to handle a variety of
then saturates them to produce diesel-
natural oils such as rapeseed, canola,
range hydrocarbon chains. The resulting
soybean and palm, as well as animal
paraffins are then isomerized to create
fats. It can also process inedible oils
a high-quality hydrocarbon, such as
such as jatropha and camelina. Second-
green diesel fuel. If desired, the Ecofining
generation feedstocks, particularly
process has also been designed to
algae oils from various sources, have
produce between 10 and 15% of a
also been tested successfully in
paraffinic green jet fuel stream. The
Ecofining pilot trials. The generalized
principal by-products from the Ecofining
flowscheme for the Ecofining process
process are propane and light naphtha.
is illustrated below.
UOP/Eni Ecofining Process
Make-up
Hydrogen
Feed
Reactor
System
Acid Gas
Scrubber
Green Propane
and Light Ends
Green
Naphtha
Product
CO2
Green Jet
Product
Separator
Water
Green
Diesel
Product
Jet Option
Green
Diesel
Product
99
RENEWABLES PROCESSES
UOP/Eni Ecofining Process continued
Green diesel fuel
Green diesel fuel has a higher cetane
level than bio-diesel and traditional
petroleum diesel. The cloud point of the
product is controllable, ranging from 0°C
down to minus 35°C. It is indistinguishable from traditional diesel fuel and can
work as a drop-in replacement or as a
valuable blendstock that will enhance
the quality of the existing diesel pool.
The key properties of green diesel are
shown below alongside the properties
of ultra-low sulfur diesel (ULSD) and
bio-diesel fuels. It can be used undiluted
in existing automobiles without changes,
which will save significant infrastructure
investment expense as demand for
renewable transportation fuels grows.
ULSD
Bio-diesel
Green Diesel
synergistic blending benefits beyond
0
11
0
simply meeting bio-component target
Baseline
+10
-10 to 0
0.84
0.88
0.78
40-55
50-65
75-90
Sulfur, ppm
<10
<2
<2
Energy density, MJ/kg
43
38
44
Oxygen, %
NOx
Specific Gravity
Cetane
Cold flow properties
Baseline
Poor
Excellent
Oxidative stability
Baseline
Poor
Excellent
Additional benefits of green diesel
fuel include:
• Can be blended to any proportion
• Has excellent stability
• Offers superior cold-flow properties,
The Ecofining process leverages existing
Acid Methyl Ester (FAME) unit making
making it suitable for cold climate
refining and petrochemical infrastructure
bio-diesel, when processing the same
conditions
to drive down capital and operating
feed. Moreover, Life Cycle Analysis
costs, enabling licensees to position
(LCA) of green diesel shows greenhouse
themselves with a low-cost advantage
gas (GHG) savings of more than 50%,
while meeting bio-fuel targets.
relative to fossil diesel, depending on
the bio-feedstock processed and the
Evaluations have shown that the variable
calculation method used. When blended
operating costs of the Ecofining
into an existing petroleum diesel pool,
process result in a lower cost of
the high-cetane and low-density green
production than for a a typical Fatty
diesel can enhance the pool’s
performance characteristics. This brings
100
or mandate levels.
• Contains higher energy content per
volume compared to biodiesel
UOP offers licenses and basic
engineering design packages for the
Ecofining process to meet customer
requirements. In addition, UOP can also
provide complete project implementation
services through our alliances with
leading contractors worldwide.
RENEWABLES PROCESSES
UOP Renewable JetTM Process
Renewable oil hydrogenation
Commercial and military aviation is dedicated to reducing emissions
and identifying new sustainable fuel sources. UOP has worked with
aviation industry leaders to produce Green Jet FuelTM from sustainable
sources that can reduce emissions by as much as 80% with no
aircraft modifications required.
W
hile the Ecofining unit can
Feed flexibility
produce up to 15% by volume of
The Renewable Jet process can convert
synthetic paraffinic kerosenes (SPK jet
a variety of refined natural oils and fats
fuel), as a co-product with green diesel,
including edible and inedible natural
this new process is designed to maximize
oils, tallow and algae oils.
the yield of SPK to 50-70% by volume.
processing C18 oils such as soy, palm
This is achieved by optimizing the
A key difference between the jet process
catalytic processes of deoxygenation,
and the UOP Ecofining
isomerization and selective cracking of
need to reduce the natural oils carbon
and a variety of algal oils, to produce
the hydrocarbons present in natural oils
chain lengths to the required range for
SPK fuel that meets the SPK
and fats to yield a high-quality, ultra-low
jet fuel. To solve this, the renewable jet
specifications being considered by
sulfur jet fuel.
process uses a selective cracking step
ASTM International, a recognized
which reduces the natural oil feedstock's
standards body.
Co-products from this process are
diesel- and naphtha-range materials.
The process can be adjusted to produce
process is the
TM
C16-C18 carbon chain lengths to carbon
Testing and certification
required for jet fuel.
UOP actively participates in the fuel
qualification process for bio-derived SPK
Product properties
maximum diesel mode.
oil, inedible oils like jatropha and camelina
chain lengths in the C10 to C14 range
a specific freeze point of the SPK or,
alternately, can be operated in a
and canola oils, C12 oils such as coconut
jet fuel. To provide sufficient quantities of
UOP's development work has shown
SPK for these activities, UOP has worked
the technology is capable of
with its partners and a toll manufacturer
to produce thousands of barrels of SPK
for jet fuel qualification testing, including
several commercial and military flight
Renewable Jet Fuel Process
demonstrations
Selective
Hydrogenation
Deoxygenation
Product
Separation
Technology delivery
H2
UOP offers licenses and basic
engineering design packages for the
CO2
Light Fuels
renewable jet process to meet
customer requirements. UOP can also
Natural Oils,
Fats, Grease
Green Jet Fuel
provide complete project implementation
services and support via its alliances with
Water
Green Diesel
leading contractors worldwide.
101
RENEWABLES PROCESSES
The Envergent RTPTM Process
Bio-mass conversion
In September 2008, UOP and Ensyn announced the formation of a joint
venture company, Envergent Technologies, to offer Ensyn’s proven Rapid
Thermal Processing (RTP)TM technology to convert second-generation
bio-mass, such as forest and agricultural residuals, to pyrolysis oil for
use in power and heating applications.
T
his new company will also
that used in the UOP Fluid Catalytic
accelerate research and
Cracking process. RTP typically yields
development efforts to commercialize
65 to 75 Wt% pyrolysis oil from dried
next-generation UOP upgrading
woody bio-mass which can be utilized
technology to refine the pyrolysis oil into
as fuel for industrial heat and electricity
transportation fuels such as green
generation.
gasoline, green diesel and green jet fuel.
The RTP process is a fast thermal
process, where bio-mass is rapidly heated
in the absence of oxygen. The bio-mass
is vaporized and then rapidly cooled to
generate high yields of pyrolysis oil. The
process utilizes a circulating, transported
fluidized-bed reactor system similar to
Basic RTP Process Unit
Pyrolysis oil is clean-burning, with
The RTP process offers several unique
minimal sulfur and nitrogen content.
benefits including:
The pyrolysis oil produced using RTP
• Requires minimal utilities and
technology is almost carbon neutral,
infrastructure making it ideal for both
and is an ideal and cost-effective
remote and existing industrial facilities
solution for customers wishing to
reduce their carbon footprint. As a
• Meets the needs of diverse applica-
oil can service a wide range of
100 to 1,000 metric tons-per-day
sectors including:
• Allows ease of implementation due
• Refining
to a small footprint and compact,
modular construction
Pyrolysis
Oil Product
renewable fuel oil substitute, pyrolysis
tions with highly-scalable designs of
• Handles a wide range of feedstocks
• Utilities
• Pulp and paper
• Energy-intensive heavy industry
Bio-mass
Reheater
RTP
Process
102
RENEWABLES PROCESSES
RTP Pyrolysis Oil Yields as a Function of Bio-mass Feedstocks
Bio-mass
Material
Yield
(Wt%)
Gross Energy
Content
(Btu/lb)
Gross Energy
Content
(MJ/kg)
Hardwood
70-75
7,400-8,200
17.2-19.1
Softwood
70-80
7,300-8,000
17.0-16.6
Hardwood bark
60-65
7,180-8,680
16.7-20.2
Softwood bark
55-65
8,010-8,500
18.7-19.8
Corn fiber
65-75
7,559-8,680
17.6-20.2
Bagasse
70-75
8,100-8,200
18.9-19.1
Waste paper
60-80
7,300-7,400
17.0-17.2
The RTP process can be optimized to
The RTP process has proven experience
Since 1989, Ensyn Corporation has
produce a unique, high-quality pyrolysis
with a wide variety of second-generation
designed and operated seven RTP
oil for conversion to transportation fuels
biological feedstocks. Options include
units that use a variety of bio-mass
using UOP upgrading technology. Early
forestry and agricultural residuals like
feedstocks. These units have shown
results show that this UOP technology
expended fruit branches, lignin material
excellent on-stream reliability. Its unit
produces high-octane gasoline and
from the pulp and paper industry, and
in Renfrew, Ontario, Canada, can
other liquid transportation fuels.
other woody residuals. Refiners may
process up to 100 metric tons-per-day
also consider using purpose-grown,
of dry bio-mass.
sustainable energy crops like miscanthus
or switch grass.
RTP Integration
Electricity
Bio-mass
RTP
Process
Pyrolysis
Oil
Fuel Oil
Future
Upgrader
Liquid
Transportation
Fuels
(Gasoline, Diesel,
and Jet)
103
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
ADSORBENTS
ADSORBENTS
UOP offers a complete portfolio of adsorbent solutions
for removal of water, mercury and other contaminants.
ADSORBENTS
Produce low-sulfur fuels, output more propylene, switch to diesel - to accomplish any of these, you
need a practical and cost-effective adsorbent in your process to control and remove trace contaminants.
Molecular sieves, activated aluminas and other adsorbents are the most practical and cost-effective way
to accomplish this. Adsorbents are at the center of manufacturing and process industries.
R
efiners can rely on UOP adsorbent
products for effective dehydration
and contaminant removal. Purity
requirements of polymer-grade monomer
products can be met using UOP’s
specialty adsorbents. UOP's products
can handle trace contaminant removal
in many processes:
• Regenerative adsorbents for
sulfur and nitrogen compounds
• Oxygenates and mercury
• Adsorbents for solvents and
co-monomer streams
• Non-regenerative adsorbents for arsine
• Sulfur compounds
• Mercury
• Fluorides
• Chlorides
• Target organic contaminants
UOP adsorbents are designed to
last, and are tested extensively to
ensure they are suitable for use in
reactive streams.
108
ADSORBENTS
UOP Molecular Sieve Adsorbents
Refiners, petrochemical producers and gas processors use UOP
adsorbents because of their high surface area, selective structure and
other special properties, including robustness and cost-effectiveness.
They are used in UOP SorbexTM technologies.
Petroleum Refining
Petrochemicals
Refiners use UOP molecular sieves
The petrochemical industry uses UOP
for drying and purifying liquids and
molecular sieves to process feedstocks
gases in a wide range of applications
for ethylene and polymer plants. Typical
that include:
applications include:
• Drying of alkylation feeds to reduce
• Dehydration and purification of NGL,
acid consumption, regenerator use
and corrosion
• Drying of refinery hydrogen streams
to prevent corrosion in downstream
equipment
• Dehydration of refinery gases
to prevent line freeze-ups during
cryogenic processing
• Drying and desulfurization
ethane and propane feed streams
• Drying of cracked gases and
hydrogen streams
• Dehydration and purification of
ethylene, propylene, butadiene,
butylenes, amylenes and various
solvents and co-monomers
Natural Gas
Natural gas processors, one of the first
industries to use molecular sieves to
treat gases and liquids, now use
molecular sieves produced by UOP
for the following applications:
• Super-drying before cryogenic
recovery of hydrocarbon products
and helium
• Drying of isomerization feeds and
drying and purification make-up
and recycle hydrogen streams
• Desulfurizing ethane, propane
and butane
• Removing H20 and CO2 before
In addition, the drying and purifying of
liquids and gases with molecular sieves
is widely used in PSA units, sulfur
methane liquefaction
• Removing H20 and H2S to protect
transmission pipelines
removal units and pre-purification for
cryogenic separation units.
• Drying of hydrocarbon liquid
drying streams
109
ADSORBENTS
UOP Activated Aluminas
UOP manufactures and markets unique aluminas for use as adsorbents
and catalysts. UOP has the capability to produce catalyst supports from
a variety of materials, including high-purity VersalTM alumina powders,
amorphous silica-aluminas, alumina- and silica-bound molecular sieves,
clay-bound aluminas and amorphous silicas.
UOP Activated Aluminas are
Refining
high-surface-area beads that are
Refiners use activated alumina-based
activated to achieve specific surface
adsorbents to improve the quality of
chemistry and reactivity. Commonly
product feedstreams, protect valuable
used as adsorbents, desiccants and
catalysts and safeguard process
catalysts, the chemistry, size and
equipment. Contaminants removed
structure of these aluminas are tailored
include, but are not limited to:
to specific applications at UOP’s ISO
Natural gas
9001:2000-certified plant in Baton
• Arsine (AsH3)
Rouge, Louisiana, U.S.A. Promoters,
• Sulfur species
additives and metal oxides are also
• H2O
overall process economics by protecting
• Chlorides
process equipment and meeting
commonly used by UOP in the
manufacture of activated aluminas to
achieve even greater performance for
• Fluorides
total contaminant removal. UOP
• Mercury and mercury compounds
Activated Aluminas are commonly
• Oxygenates
alumina-based adsorbents to improve
product stream specifications.
Contaminants removed from natural
gas and natural gas liquids include:
• H2S
used in a wide variety of applications.
Petrochemicals
• COS
Petrochemical producers use activated
• Mercury and mercury compounds
alumina-based adsorbents to improve
product feed quality, protect catalysts,
safeguard process equipment and
prevent unwanted side reactions.
Contaminants removed include:
• AsH3
• Sulfur species
• Oxygenates
• H2O
• Tertiary Butyl Catechol
110
The natural gas industry uses activated
• H2O
• CO2
ADSORBENTS
Versal aluminas
Versal aluminas are a family of high-purity
alumina powders available in a variety
of rheological and physical forms. They
are used primarily as catalyst supports,
washcoat slurries and binders. Their
many forms and uses inspired the
name for this versatile group of
alumina products.
include pseudo-boehmite, bayerite and
gamma-powered aluminas, all with
varying densities, unique pore size
distributions and dispersibility ranges.
Versal aluminas allow catalyst
manufacturers to achieve finished
catalysts with enhanced pore volume,
density and metal-promoted properties.
In addition to being a key component
in many commercially-used catalysts,
The forerunner of the Versal alumina
line was a gel alumina, a name that
referred to the colloidal state of the
UOP’s Versal aluminas play key roles
in the polishing, abrasives and
surface-coatings industries.
powders. Through on-going alumina
development, the Baton Rouge
plant has developed a manufacturing
process, unique to UOP, for the
production of Versal products and
expanded this portfolio of products to
111
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
EQUIPMENT
EQUIPMENT
UOP-enhanced process equipment maximizes plant
performance for increased throughput and profitability.
EQUIPMENT
Just as important as the process technology, adsorbents and catalysts
that UOP perfects and produces is the process equipment that ensures
optimal performance and profitability. Some of the cutting-edge equipment
engineered and manufactured by UOP includes MD Trays, multiple
tubing options and the Raschig Super-Ring® packing element,
all which take separation technology to the highest level of efficiency
and effectiveness.
UOP Distillation Technology
UOP has been a leading supplier of high-performance trays for distillation, absorption, stripping and
extraction for more than 40 years. UOP MDTM trays allow customers to minimize their capital expenditures,
plant footprint and operating cost for grassroots plants. They also allow customers to maximize utilization of
existing plant assets by increasing unit throughput and optimizing energy usage.
F
ield experience unmatched in depth
and breadth confirm that UOP's trays
consistently deliver key benefits including:
• Reducing column diameters in
grassroots applications
• Increasing capacities for existing columns
• Maximizing the number of theoretical
trays for a given column height
• Providing easy scale-up to any diameter
• Allowing fast, simple installation and
short turnaround times
• Demonstrating low sensitivity to
out-of-levelness
• Minimizing or eliminating
foaming and fouling
low. These situations occur in medium- to
high-pressure distillation, in absorption
and stripping and in direct-contact heat
transfer applications.
MD trays can be used at close tray
spacings. They allow for a reduction in
the height and diameter of a new
UOP MD trays are used for large liquid
column, compared with a column fitted
loads, particularly when the volumetric
with conventional multi-pass trays.
ratio between vapor and liquid rates is
Additionally, using these trays can
significantly lower vessel shell costs.
When retro-fitting an existing column
with MD trays, a greater number can
be installed, providing increased product
purities and recoveries, as well as
allowing a lower reflux ratio, resulting in
reduced energy consumption and/or
increased column capacity.
116
EQUIPMENT
The use of MD trays has often reduced
MD trays can generally turn down to
the number of columns needed in
60 to 70% of their design flow rates,
difficult separations, such as super-
particularly when they are used with
fractionation of propylene-propane or
large tray spacings. The use of sieve
of xylene isomers.
decks helps keep tray efficiency constant
across variable loadings. And, in
Important MD tray features include:
• Long weir lengths and large
downcomer areas, providing high
liquid-handling capabilities
• 90° rotation of downcomers on
columns where a large number of trays
are required, only MD trays can be used
at the close tray spacings required.
UOP continues to improve the design
of its trays to meet specific customer
successive MD trays, which
needs. UOP ECMDTM trays were devel-
promotes lateral mixing and provides
oped to achieve even greater hydraulic
easy scale-up
capacities than could be achieved with
• Downcomers supported on a 360°
ring, so no bolting bars are required
• The ability to be fabricated with
MD trays, ~20% higher. The higher
performance of ECMD trays can be
used to revamp existing conventionaltrayed towers for additional capacity
underflow weir and vapor-seal
beyond MD tray capabilities, to revamp
downcomer options, resulting in
existing MD trayed towers for higher
large downturn ratios
column throughput, or to provide even
• Low tray pressure drops of
0.06-0.09 psi
smaller grassroots columns than that
achieved with MD trays. UOP PFMDTM
trays have been developed for optimum
performance for low- to medium-pressure
applications. These advanced trays are
based on the same operating principles,
design philosophies and experience as
the original MD tray. UOP has also
developed the UOP SimulFlowTM device
which utilizes co-current flow principles
and provides up to 70% higher
hydraulic capacity than ECMD trays.
Overall, UOP trays can improve
separation performance, reduce capital
and operating costs, and increase
The key to MD tray's high performance
column capacity in a wide range
is the very large total weir length, which
of applications.
gives low-liquid loads per unit weirlength even at very high total liquid
flow rates.
117
EQUIPMENT
UOP Heat Transfer Technology
UOP is a trusted provider of enhanced heat transfer technology with
more than 40 years of related commercial experience. UOP's enhanced
tubing allows customers to minimize their capital expenditures, plant
footprint and operating costs for grassroots plants. In revamps, UOP
tubes also allow customers to maximize utilization of existing plant
assets by increasing unit throughput and optimizing energy usage.
UOP High FluxTM Tubing
High Flux tubing operates exclusively
in the nucleate boiling mode, which is
characterized by the formation and
growth of bubbles on a hot surface.
In conventional bare-surface tubing,
bubbles originating at random pits and
correlations developed for in-tube
condensation and condensation on
vertical surfaces. Most heat exchanger
configurations using commercial High
Flux tubing are either horizontal kettles
and thermo-siphons, or vertical
thermo-siphon reboilers.
to allow the fully-optimized design in
scratches on the surface promote
vigorous liquid agitation. The High Flux
surface technology greatly improves
heat transfer during nucleate boiling,
achieving boiling co-efficients ten times
greater than that of bare tubes.
Design procedures for High Flux
UOP’s High Flux tubing's surface can
terms of initial capital investment and
be combined with UOP’s portfolio of
annual operating cost.
condensing surface profiles, including
OD tube fluting profiles for shell-side
In retro-fit situations, the higher thermal
condensing, as well as various spiral ID
performance of High Flux tubing can be
fin profiles for tube-side condensing in
captured to increase the heat exchanger
horizontal heat exchanger orientations.
capacity and reduce the required heat
exchanger LMTD, thereby allowing the
exchangers are similar to those that
use bare tubes. Computer programs
have been developed for the design
of horizontal and vertical High Flux
exchangers. These programs are
supplemented by heat transfer
The use of High Flux tubing results in
plant performance to be fully optimized.
substantial savings in capital equipment
When existing U-bundles are replaced,
and in operating costs. For grassroots
substantial savings also result from
applications, heat exchanger surface
re-using the existing heads, shells
areas and sizes are reduced. For large
and piping.
reboiler duties, a reduction in the total
number of exchanger shells required is
usually possible, resulting in additional
savings in piping, controls, foundation
and plot plan space. High Flux tubing
can be used to minimize the temperature
approach utilized in heat exchangers,
118
particularly for heat pump applications,
EQUIPMENT
UOP High CondTM Tubing
UOP expanded its enhanced heat
transfer product portfolio with the
development of High Cond tubing for
shell-side condensing in horizontal heat
exchanger orientations. High Cond
tubing is especially well-suited for use
in horizontal cooling water condenser
applications. The tube OD surface
has been optimized to minimize liquid
condensate film thickness and improve
condensate drainage. These technical
features maximize the tube’s
Specifying High Cond tubing in the
design of new plants can save
considerably on capital costs. The total
installed cost of the heat exchanger is
lower, especially in applications where
multiple bare tube shells are required.
In those cases, utilizing High Cond
tubing will typically reduce the number
of required heat exchanger shells by
half. This results in large cost savings,
less plot space, smaller/lighter
exchangers, less piping, smaller
structure and less civil foundation.
condensing and overall heat-transfer
coefficients. Improved heat transfer
performance allows for reductions in
capital investment, higher heat exchanger
Examples of applications for High
Cond tubing include:
• Propylene splitter
capacity, and process optimization.
• Overhead condensers
• Propylene refrigerant condensers
• Naphtha splitter condensers
• Other water-cooled shell and
tube condensers
119
EQUIPMENT
Raschig Packings
UOP is a provider of differentiated random and structured
packing through our partnership with Raschig GmbH.
Raschig Super-RingTM Packing
In addition, the elements' alternating
Raschig Super-Pak structured packing
wave structure prevents entanglement
is fundamentally different to the standard-
of the packing element within the
and high-capacity corrugated sheet
packing, thus guaranteeing problem-free
metal structured packings available for
assembly and dismantling. The open
decades. A common feature of these
structure makes it suitable for liquids
standard- and high-capacity
contaminated with solids.
structured packings is that both have
discrete crimped channels that force
The development of the Raschig
Super-Ring packing element sets new
standards in the field of separation
technology, helping to meet the industrial
demands on modern packing elements
more effectively. Raschig Super-Ring
elements allow customers to minimize
their initial investment for a given
capacity grass-roots applications, or
Raschig Super-Ring elements are
vapor-liquid traffic along preferred flow
available in numerous sizes in order
paths. In addition, the vapor-liquid
to provide the optimal solution for a
traffic is forced into sharp directional
specific project's requirements.
changes at the packing layer interface
Ultimately, the elements provide a lower
when packing elements are vertically
pressure drop, higher loading capacities
stacked. The net result is that the
and excellent mass-transfer efficiency.
enforced vapor-liquid flow patterns
within the 'closed' structure of a
Raschig Super-PakTM Packing
common packing element do not
necessarily utilize all of the available
increase the throughput of their existing
surface area for mass transfer, and
units versus other random packings.
impose restrictive forces that reduce
capacity and increase pressure drop.
As a result of their open structure, the
Raschig Super-Ring elements generate
Raschig GmbH adopted a different
a lower pressure drop than other
approach in developing the Raschig
high-performance metal packing
elements. The ring not only has a 33%
The new Raschig Super-Pak packing
Super-Pak packing. It is a more open
higher loading capacity than the 50 mm
is a novel development in mass transfer
structure such that vapor-liquid traffic
metal Pall ring, but it also displays a
technology because of its optimized
can flow freely within a packing element,
substantially higher loading capacity
surface design. It enables unprecedented
and no sharp directional changes exist
than previous modern packing
separation efficiency and high loading
at the layer interface. The rows of
element designs.
capacity, while keeping the pressure
sinusoidal waves within vertical packing
drop extremely small.
sheets are surface-enhanced to
The low specific packing weight of the
Raschig Super-Ring elements allow the
design of low-cost supporting elements
in the columns without sacrificing stability.
encourage greater turbulent radial
spread of thin liquid film flows on the
front and back of the waves on each
sheet within an element. This open
structure provides excellent hydraulic- and
mass transfer-efficiency characteristics.
120
EQUIPMENT
Hydroprocessing Reactor Internals
The UOP Unicracking and Unionfining technologies are distinguished by
both world-class catalyst system and advanced reactor internals design technologies.
I
n all hydroprocessing units, it is
extremely important that the radial
Pressure gradient over the vapor/liquid distribution tray
temperature spread of reactants on top
of the catalyst bed is minimized by the
use of an efficient quenching system,
liquid and vapor throughout an operating
cycle. This can be achieved by
installing reactor internals which are
specifically designed for each unit,
Increasing Pressure
and maintaining even distribution of
1. Base Case, std inlet diffuser, no RLDT
2. Modified inlet diffuser, no RLDT
ensuring uniform distribution of reactants
and minimizing radial temperature spread.
With poorly-designed reactor internals,
3. Std inlet diffuser and RLDT
4. Modified inlet diffuser and RLDT
even the best catalyst will not be used
to its full potential, resulting in poor
process performance. Those
The design of UOP's reactor internals
Throughout the refining industry, UOP
poorly-designed internals could allow
is based on extensive mathematical
has successfully replaced previous
channeling, and by-passing, a
modeling, computer modeling, cold
generations of our own reactor internals,
phenomenon in which a certain portion
flow testing, pilot plant testing, and a
as well as competitors’ designs in
of the feedstock passes through a unit
collective operating experience in
non-UOP licensed units. The UOP
without significant reaction. This
hydroprocessing with over 300 operating
system of hydroprocessing reactor
by-passing reduces the volume of
units and tens of millions of total
internals has performed so well that
catalyst available for reaction, and
operating hours. UOP’s reactor internal
UOP uses the same general design
therefore leads to a higher effective
designs have been commercially
in all hydroprocessing applications.
space velocity, requiring higher reactor
proven to provide excellent flow
bed temperatures for the same
distribution, helping refiners minimize
The following provides descriptions
conversion or product specification. The
radial temperature spread within the
of the component parts of UOP's
subsequent outcomes include loss of
catalyst beds. UOP has proven
hydroprocessing reactor internals.
catalyst life, poor product quality, and
experience in a wide range of
possibly unscheduled unit shutdowns.
hydroprocessing applications with
its reactor internals design.
121
EQUIPMENT
Inlet Diffuser
Vapor/Liquid Distribution Tray
UOP's inlet
In an ideal condition where distribution
diffuser dissipates
trays are perfectly level and the
momentum of
vapor-to-liquid ratio remains constant,
incoming reactants.
most distribution devices will, in all
It pre-distributes
likelihood, provide adequate performance.
fluid across the
In reality, tray level differences always
reactor cross-section where a liquid
exist due to fabrication and installation
level builds on the top rough liquid
tolerances, level gradients and waves
distribution tray (RLDT). For ease of
in the liquid level. Moreover, vapor-to-
maintenance, it can simply be lifted out
liquid ratios vary significantly during an
during shutdowns because it sits in the
reactor manway.
operating cycle, causing significant
variations in the pressures and liquid
heights on top of the distribution tray.
The vapor/liquid distribution tray (VLDT)
must be designed to perform optimally
under these realistic conditions.
UOP's vapor/liquid distributors are
designed to distribute liquid more evenly
than bubble-cap and riser-style
distributors, which are much more
sensitive to pressure differences caused
by vapor-to-liquid ratio variances. They
are designed for a very low pressure
Rough Liquid Distribution Tray
UOP's rough liquid distribution tray
(RLDT) is located above each vapor/
liquid distribution tray and serves
several purposes. Any residual fluid
momentum exiting the inlet diffuser
(or mixing chamber within an inter-bed
quench zone) is broken by the RLDT.
Each RLDT is custom-designed to
maintain an optimal liquid level, while
passing vapor feed around its outer
perimeter. The RLDT is also designed
to mate perfectly with its vapor/liquid
distribution tray, delivering a uniform
layer of liquid across the reactor
diameter. In the custom design to
ensure proper distribution, the operating
conditions at the various modes of
operation being considered are
analyzed to ensure that proper
functioning/distribution is occurring
across the trays.
122
drop across the tray, and therefore can
operate at vapor rates considerably
above their design value. The distributor
design also enhances distribution over a
wider range of liquid levels than bubble
cap and riser-style distributors, all while
providing increased resistance to fouling.
In addition to ensuring optimal design
of its vapor/liquid distributors, UOP
optimizes the design of the VLDT.
The spacing of distributors has been
increased for maximum cross-flow
between distributors, while maintaining
an optimal drip-point density. This
design accounts for distribution above
the tray and at the tray’s outlets,
spreading fluid evenly over the catalyst
bed. This distributor spacing also
allows for improved maintenance and
cleaning of the tray.
EQUIPMENT
Catalyst Support Grid
Quench Zone
UOP's catalyst support grid employs a
The quench zone contains UOP’s
design to maintain target throughputs
commercially-proven and patented
throughout the catalyst cycle, prevent
“centrifugal mixing” design. This consists
catalyst migration and maximize
of a liquid collection tray and mixing
catalyst volume, while virtually eliminat-
chamber. Quench gas is introduced to
ing catalyst bed fouling and plugging.
the process fluid on the liquid collection
As is the objective in the design of each
tray through the quench distributor
component in UOP's reactor internals,
(pictured below). The UOP quench
the catalyst support grid is designed to
distributor design has been optimized
minimize maldistribution which will
through extensive cold flow modeling
eliminate stagnant regions, therefore
and testing, as well as Computational
providing the most efficient use of the
Fluid Dynamics (CFD) studies.
entire catalyst bed.
Liquid and vapor on the liquid collection
tray pass into the centrifugal mixing
chamber designed to facilitate liquid
mixing. Mixed liquid then travels
to the RLDT below.
UOP's centrifugal mixing quench
zone equipment, combined with the
effectiveness of the vapor/liquid
distribution tray, achieves proper
thermal mixing and re-distribution
between catalyst beds.
Outlet Collector
UOP’s cylindrical outlet collector design
maximizes catalyst utilization and
minimizes catalyst bed fouling and
plugging, while virtually eliminating
effluent channeling.
123
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
UOP SERVICES
UOP SERVICES
UOP has assembled a wide range of advanced tools,
training and work process improvements and can advise
on organizational best practices that will help you to
achieve your operational goals.
UOP SERVICES
Keeping your refining, petrochemical and natural gas plants running efficiently and profitably is UOP's
top priority. We understand the challenges associated with today's operating environment and can work
with you and your staff to ensure all resources, both plant and human, are utilizing the industry's
best practices to maintain safe and reliable operations.
B
ased upon our extensive
Our areas of expertise include training,
inspection, process transformation,
experience, our service offerings
the best market opportunities while
performance optimization. startup
aid customers in achieving three
fulfilling all regulatory requirements
services, field operating services and
key priorities:
• On-stream
Ensuring that your plants are running
and delivering products exactly
when needed
128
• On-spec
Producing the right products to meet
technical knowledge and
• On-time
Enabling the agility to swiftly respond
to those market opportunities
regional services. Our in-depth
knowledge of the hydrocarbon
processing industries enables us to
understand challenges and provide
effective solutions.
UOP SERVICES
Services We Offer
Training
Successful operation of refineries,
petrochemical plants and gas processing
facilities depends on having well-trained
personnel to operate and maintain the
various process units. Recognizing this
need, our Training Services department
offers a wide variety of training programs
at your site, at a regional UOP office
or via the internet to help transfer our
technology to operators, engineers,
inspectors, managers and maintenance
personnel. These programs include
training for individual process
Aimed at providing technical knowledge
to all refinery personnel, including
operators, engineers and managers,
UOP’s web-based training (WBT)
provides a self-paced introduction to
UOP's process technologies and
engineering disciplines. The implementation of WBT allows employees to
engage in training whenever needed,
from wherever they are. A typical
course includes process overview,
chemistry, catalyst, process variables,
process flow and equipment. Most WBT
courses can be completed in one day.
technologies and specialized equipment.
For larger training requirements along
UOP's multi-company courses allow
engineers and operators to both attend
a course delivered by UOP’s technical
experts and interact with participants
from other companies throughout the
geographic region. Students leave not
only with our course materials, but also
with knowledge gained from other
attendees who work on similar units.
the entire refinery project life-cycle,
UOP offers customized long-term
training engagements. These programs
can vary from WBT site licenses to
long-term training engagements that
support new complexes from concept
through to start-up and beyond. The
long-term engagements are designed
alongside refinery personnel and
include multiple training platforms.
UOP's single-company training courses
are designed to deliver customer-specific
training that enables successful start ups
and ongoing operations with well-trained
operators and engineers.
UOP also offers its Customer Career
Development Programs, which are
modified to the customers' needs, and
Long-term engagements are facilitated
by a dedicated training project manager
customers with practical solutions to
and are a cost-effective way to ensure
mechanical problems based on a
that when a refiner licenses a process
worldwide history of solved process
unit from UOP, not only will they be
and maintenance challenges. Available
getting the best-designed unit, they will
services include fabrication shop
also be able to operate it on day one.
inspections, turnaround inspections,
inspection planning, on-stream
Inspection
inspections and inspection training.
based on UOP's industry-renowned
UOP has offered high-quality inspection
Career Development program. The
consulting services to refining and
UOP inspection specialists are trained
graduates gain invaluable hands-on
petrochemical customers worldwide for
in the specifics of UOP’s licensed units
experience in UOP's technologies, work
more than 60 years. Our vast experience
and their operations. They have access
processes and tools, as well as forming
in inspecting refinery and petrochemical
to the latest UOP specifications, as well
life-long relationships with UOP's experts.
process units enables UOP to provide
as the technical support of UOP’s
129
UOP SERVICES
engineering and technical services staff,
improving UOP's service-delivery
and they’re equipped to manage the
process. They’re constantly working to
entire scope of UOP's inspection work.
increase productivity and enhance the
Additionally, the UOP team can assess
quality of our services by providing
inspection strategies, practices and
on-line access to educational resources,
procedures, and train employees to
productivity-enhancing systems and
continue on their own with vital inspection
technical assistance to both UOP staff
procedures and processes.
and our customers. The process
transformation group offers a number
Process Transformation
of software solutions for improving our
UOP’s Process Transformation group
customers' operations, safety, reliability
is responsible for streamlining
and profitability, including Expert Systems
interactions with customers and
and the operations monitoring tool
UOP OpAwareTM.
Field Operating Services
The Field Operating Services (FOS)
group works to maintain close contact
between UOP's customers and our staff
in the field during the commissioning of
new UOP process units. Our on-site
startup team typically consists of a chief
process advisor, an instrument advisor
and three process advisors. From the
final phase of unit construction through
catalyst loading and the start of
round-the-clock operations, our advisors
will assist the customer's personnel
with unit operations, conduct plant
demonstration tests, and document the
unit’s initial performance. FOS' regional
presence allows the group to respond
quickly to customer needs and the
needs of UOP's on-site staff.
Regional Services
Our Regional Services (RS) group has
two main functions: to support the
delivery, startup and on-going operation
of all UOP technology at customer
sites; and to identify opportunities for
maximizing customer profits through
the use of all technology. RS
managers are each assigned a group
of customer sites and have the
responsibility to act as UOP's initial
point-of-contact for consultation and
troubleshooting, as well as to respond
to any technical service needs.
130
UOP SERVICES
Technology Services
UOP's Technology Services (TS) group
is composed of highly-skilled engineers
and scientists who are experts in their
particular process technology. These
When a customer purchases UOP
catalyst, adsorbent or equipment, they
get more than a world-class product.
They also get the dedicated attention of
a UOP TS specialist.
technology experts work closely with
their counterparts in UOP's research,
development, engineering, regional
services and field operating services
groups to deliver new technology, and
transfer knowledge to our customers.
UOP's TS specialists complete rigorous
training that includes assignments in
UOP’s field operating services,
engineering and development groups.
Specialists can draw upon a significant
network of R&D, engineering, analytical
TS specialists monitor the operation of
UOP processes, equipment, catalysts
and adsorbents by analyzing plant
and TS resources, as well as specialized
tools and operating data from many
other UOP units.
data. Guidance on operating conditions
and strategies is provided to support
customers as they optimize their units
for safe and profitable operation.
Technology Services also provides
startup, revamp and reload support
for customer turnaround planning
and execution.
At the time of a catalyst or absorbent
purchase, a UOP TS specialist will
review the customer's operations,
equipment and procedures to develop
the most appropriate and effective
startup for the new load. The specialist
can also provide advice on loading and
startup procedures for use by technical
and operations staff.
Once the unit is operational, the
UOP TS specialist will work with the
customer to review post-startup
operations and recommend operating
strategies to ensure optimal catalyst
performance. This initial review can be
supplemented by periodic on-site
performance reviews, which enable our
specialists to provide on-going technical
support to maximize system performance
through the end of the cycle.
131
UOP SERVICES
Optimization Services
UOP’s Optimization Services group
offers a suite of services to help you
achieve and maintain maximum
profitability. Our Technology-Integrated
Profitability Solutions (TIPS) consulting
services experts draw on their extensive
knowledge and experience, employing
a broad range of tools that look at
long-term investment planning and
configuration design, as well as
short-term opportunities for technology-
• Adapting the refinery to handle a
different crude slate
• Refinery expansions in either capacity
or up-grading capability
focused enhancements and improved
efficiencies in existing plants.
• Producing a cleaner slate of products,
or shifting to higher-value products
Strategic TIPS
• Increased diesel production capability
Over the life of the refining industry
there has been constant change in the
desired product mix and specifications,
crude availability and characteristics, as
well as consistent pressure to improve
efficiency and operate more cleanly.
Refiners must therefore routinely plan
forward 5-10 years to ensure that their
configuration is relevant and optimized.
This may involve designing a state-ofthe-art new refinery to achieve industry
leading margins. Or it may be working
with an existing site, to ensure that the
existing equipment can be adapted and
supplemented with the latest technology
to meet the feed, products and
regulatory challenges of the future.
Tactical TIPS
Our Tactical TIPS consulting solutions
focus on the profitability of customers'
current plant and help determine how
to unlock the most value from their
operations. From improving yields and
margins to addressing new regulations
and enhancing efficiency, UOP can help
customers meet their business
objectives. UOP's experts can evaluate
individual process units, the entire refinery,
petrochemical, or gas processing
complex, or even multiple sites to
identify key opportunities through a
combination of:
• Unit performance improvements
Our Strategic TIPS methodology, tools
and expertise for evaluation of a refinery
configuration is well-proven, with over
100 studies successfully completed
over the last decade. These studies
have covered a range of configuration
evaluations including:
• Naphtha complex studies to address
benzene regulations, or to evaluate
aromatics vs. gasoline production
• Petrochemicals production expansion
• State-of-the-art grassroots refinery
configuration development
132
• Refinery-wide profitability studies
• Energy and CO2 optimization
• Hydrogen and fuel gas management
• Scheduling and blending consultation
• Evaluation of processing options
• Debottlenecking
• Linear Program (LP) optimization
UOP SERVICES
Energy and CO2 Management
While there is constant pressure to
TIPS
Technology-Integrated Profitability Solutions
reduce energy usage and improve
environmental performance, refiners
Strategic Solutions
Tactical Solutions
may find that they can achieve those
goals while also maximizing product
yield, product quality and margins. To
achieve optimization of their energy and
process performance, UOP can apply its
tested methodology to assist refiners by:
• Collecting and analyzing current
Grassroots Configuration
Investment strategy
Configuration definition
Processing Solutions Configuration
Dieselization
Gasoline pool
Technology-Focused
Process unit or process block
Complex-wide or refinery-wide
Multi-site
Systems/Network-Focused
CO2/energy management
Hydrogen management
operating data
• Optimizing and controlling process
conditions
• Identifying and executing a range
of opportunities for improvement
• Reducing energy usage and CO2
emissions
• Improving throughput, yield and margin
One of the keys to reducing energy
costs is balancing changing energy
demands from the process with
adequate supply from the utilities plant.
UOP and Honeywell Process Solutions
(HPS) can jointly offer a suite of
software solutions to manage the
supply/demand equation, and optimize
turbine and boiler performance.
133
© 2011 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation
to practice a patented invention without a license.
We hope you have found this Processing Guide
useful and informative.
UOP thanks the many companies pictured
for their permission to use photography
in this brochure.
Find out more
If you are interested in learning more,
please contact your UOP representative
or visit us online at www.uop.com
UOP LLC, A Honeywell Company
25 East Algonquin Road
Des Plaines, IL 60017-5017, U.S.A.
Tel: +1-847-391-2000
www.uop.com
UOP5252
March 2011
Printed in U.S.A.
© 2011 Honeywell. All rights reserved.