Gasoline Benzene Reduction Through Reformate Alkylation Catalytic Technology Dr. El-Mekki El-Malki ExxonMobil Research & Engineering Company (EMRE) Ronald Birkhoff AIChE Regional Process Technology Conference October 7th - 8th 2010 Galveston, TX Research and Engineering
Reducing Benzene in Gasoline Pool 1 vol % 0.62 vol % 1 vol % Europe 1-5 vol % range ASIA Americas 1.5-4 vol % range Middle East 1-2.5 vol % Africa range 1 vol % Australia & Pacific
Typical Gasoline Pool Benzene in US Average Typical Volume in Benzene Benzene Components Gasoline % Level % Contribution % Reformate ~ 30 3-11 ~ 75 FCC Gasoline ~ 36 0.5-2 ~ 16 Hydrocrackate ~ 3 1-5 ~ 3 Others ~ 31 0-3 ~ 6 Reference: EPA-HQ-OAR-2005-0036; 0036; FRL-8041-2 2, Table VII.F-2
Refiner s Options Reformer Feed Til Tailoringi Benzene Extraction Benzene Saturation Octane Gasoline Gasoline Hydrogen Light Volume Pool Balance Olefin Reduced Production No change High consumption BenzOUT No consumption Upgrade to Mogas
BenzOUT Process Configuration Benzene Concentrate Pretreatment Light Olefins Light end Full Reformate Splitter BenzOUT Reactor Splitter Products Fixed Bed Reactor Configuration Adiabatic or Isothermal Carbon steel equipment and no compressor needed Process Uses a Proprietary Catalyst High activity, high selectivity
BenzOUT Reducing Benzene while Boosting Product Value BenzOUT Process Alkylates Benzene-Containing Streams with Light Olefins to Produce Alkyl Aromatics for Gasoline Blending Incentives Include: Reduced Benzene to meet regulations Upgrading of Light Olefins to high octane gasoline Increased Gasoline volume and reducing RVP Avoidance of hydrogen consumption Retained Reformer flexibility e.g. hydrogen and octane production Commercially demonstrated
Benzene Conversion Can Be Achieved According to Need Benzene Conversion n (%) 100 0 Olefin/Aromatic Ratio Primary Reaction Chemistry is Alkylation of Benzene with Olefin Benzene conversion controlled by Olefin/Aromatic ratio
Example of BenzOUT Boosting Product Volume Benzene Concentrate Pretreatment Light Olefins Light end 40 KB/D Full Reformate Splitter BenzOUT Reactor Splitter Approx. 5% Volume Increase Based on Full Reformate 42.3 KB/D
Example of BenzOUT Product Properties Tempera ature ( o F) Typical Gasoline End Point Product Feed % Evaporated Final Product Properties are a Function of Feed Composition and Benzene Conversion Approx. (R+M)/2 increase of 2-5 Approx. RVP reduction of 0.5 PSI
Process Demonstrated in a North American Refinery Light Olefin Reformate BenzOUT Catalyst Mogas Blending BenzOUT Catalyst Drop-in Application Only minor modification to the Polygas Unit BenzOUT Demonstration Conducted in One of the 3 Tubular Reactors BenzOUT and Polygas Products Combined for Mogas Blending
Commercial Trial Results Confirmed Pilot Plant Results 100 Benzene Conversion (%) Olefin/Ar romatic rat tio 0 0 10 20 Days on 30Stream 40 50 60 High Benzene Conversion Demonstrated Commercial Results Confirm Pilot Plant Data
BenzOUT Technology Delivery ExxonMobil Research & Engineering Company (EMRE) and formed an alliance to license BenzOUT Technology BenzOUT offered exclusively by will be the contracting party responsible for the process license, proposals and basic design packages. EMRE will supply the BenzOUT Catalyst ExxonMobil and have a continuing 30 year history of licensing gpetrochemical processes
BenzOUT Advantages - Summary Benzene achieves low Benzene content in the gasoline pool AND: Upgrades light olefins to high octane gasoline blendstock Increases reformate volume and octane value Eliminates impact on hydrogen balance Simple and reliable process Flexible process design simple retrofit or grassroots tie-in Commercially demonstrated Available for license through -EMRE Alliance
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