High performance separation system for alkylation unit - Manufacturing, Other

The key aspects of an alkylation unit pertain to the amount of acid that needs to be made-up on a continuing basis.

This cost becomes even more critical if the plant has no onsite acid regeneration, or the acid consumption exceeds the acid regeneration capacity.

  • Reduce Acid Make-up Costs – Approximately one-third of the acid consumption can be attributed to dilution caused by ingressing moisture
  • Debottleneck Caustic Treater – Reducing the acid entrainment to the caustic treater can increase the capacity of the caustic treatment
  • Debottleneck Water/Wash Treater – Reducing the caustic entrainment to the water/wash can increase the capacity of the water-wash section treatment
  • Reduce Hydrocarbon load on WWTP – SMuch of the hydrocarbons being sent to the WWTP is entrained in the effluent from the caustic and water wash sections.
  • Reduce Salt Carryover with Alkylate – The product alkylate stream carries water, and any entrained neutralization product. This can precipitate out following blending with other gasoline cuts.

Image

Pentair Porous Media’s POLAREX technology provides chemical manufacturers, refiners and gas processors dramatically improved separation of entrained and dissolved contaminants relative to that achievable through implementation of conventional water wash or solvent scrubbing towers. Conventional approaches to washing or scrubbing are often limited by contact efficiency and subsequent separation efficiency, resulting in limited performance and large capital investments. The POLAREX platform was developed utilizing our advanced micro and nano-fiber technology to create a single stage, highefficiency, structured contactor / separator.

The patented POLAREX technology may be applied to the extraction of soluble components from either liquid or gas process streams. The POLAREX technology has application to both contaminant removal (e.g. - caustic, dissolved acids, salts, acid gases or reaction by-products) as well as recovery of valuable products or solvents (e.g. – recover soluble amines from treated LPG) for as little as 20% of the capital associated with a conventional wash system.

Applied to batch chemical processes, the POLAREX technology increases process speed and operational flexibility. Traditional approaches to neutralization or product washing require a lengthy neutralization or wash step followed by decanting and transfer. Not only do these steps slow reactor turn over, they also frequently result in carry over of salts and impurities due to the limited separation effectiveness of decanting, particularly with emulsified product / water mixtures. The POLAREX technology allows neutralization or washing to proceed on-line during product transfer, allowing the wash / decant steps to be eliminated entirely.

Image

UltiSep sets a new standard in high-performance gas/liquid separation. UltiSep utilizes Pentair Porous Media’s proprietary microfiber media technology and patented APEX element design. These technologies are applied for high efficiency bulk liquid and aerosol removal from process streams. APEX technology affords the user an unprecedented ability to reduce liquid carryover and pressure drop while providing smaller footprints and lower capital costs. UltiSep housing configurations are designed via the use of Computational Fluid Dynamics (CFD) and other proprietary computer models that ensure accurate and complimentary design in conjunction with APEX. The implementation of these technologies offers the ideal business model for value added and optimized systems.

UltiSep offers the ability to maximize operational profitability by minimizing entrained liquids in process gas streams. Eliminating liquid and solid carry-over minimizes process upsets and the corresponding issues associated with them, such as; product loss, fluid make-up, off-spec products, contamination in feed streams entering processes, emulsions, foaming, fouling, corrosion and mechanical wear.

UltiSep allows the removal of liquids ranging from bulk fluids to entrained droplets as small as a viral particle, improving operational efficiency and profitability.

Image

LIQUISEP technology was developed to address the inherent deficiencies of conventional coalescers, making it possible to remove essentially all immiscible water dispersions from hydrocarbon process streams. The LIQUISEP technology overcomes the limitations of conventional separators, vane pack coalescers, wire mesh coalescers and even “high efficiency” mesh pads and filter separators, achieving superior separations under demanding conditions.

LIQUISEP technology makes use of proprietary LIQUIFORM™ media and our patented APEX element design to intercept entrained droplets of even sub-micron geometries and effectively remove them from the process. The high surface energy LIQUIFORM media effectively disrupts the stabilized water droplets, allowing for efficient capture. Additionally, the fiber geometries are specifically designed to promote accumulation and removal of free water from the process stream. The APEX element design works in concert with the media technology promoting uniform fluid flow, while minimizing the potential for turbulence and high fluid velocities which might interfere with water removal from the process stream.

LIQUISEP technology protects critical assets from water contamination and the salts, acids and bases which it may contain. Application of the LIQUISEP technology allows optimized performance of downstream treaters, salt beds, exchangers and reactors while assuring the elimination of haze from finished products.

Image

ProcessOR provides high performance solid-liquid separation. Solid contaminants range from sub-micron particulates as small as viruses to particles several hundred microns in size. The liquids range from aqueous to hydrocarbon systems with viscosities up to 60,000 cP. Pentair Porous Media’s sold-liquid technolgies have been applied in the oil and gas, refinery, chemical, petrochemical and power industries.

ProcessOR's standard elements are cored, however, you may upgrade to our COMPAX coreless element technology. The COMPAX coreless element flows from the outside-to-the-inside. This element is offered with an extended surface area media configuration utilizing our proprietary NexCel media. The media provides robust performance in glycol and aqueous service as well as hydrocarbon applications. The COMPAX coreless element designs currently being used by a large number of gas plants and hydrocarbon processes due to the superior operating economics and ergonomic advantages.