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MSAT II and Benzene Management

The document discusses options for refineries to reduce benzene levels in gasoline to meet EPA regulations, including pre-fractionating naphtha, reformate splitting, alkylation of benzene with olefins, aromatic extraction, and saturation of benzene with hydrogen. It notes that reformate splitting is typically needed but not sufficient, and that the optimal solution depends on the individual refinery configuration and economics.

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Wong Yee Sun
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310 views2 pages

MSAT II and Benzene Management

The document discusses options for refineries to reduce benzene levels in gasoline to meet EPA regulations, including pre-fractionating naphtha, reformate splitting, alkylation of benzene with olefins, aromatic extraction, and saturation of benzene with hydrogen. It notes that reformate splitting is typically needed but not sufficient, and that the optimal solution depends on the individual refinery configuration and economics.

Uploaded by

Wong Yee Sun
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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MSAT II and Benzene Management Solutions | C&I Engineering

Page 1 of 2

Welcome to C&I: Engineering, Procurement and Total Project Management

MSAT II and Benzene Management Solutions


The U.S. EPA MSAT II (Mobile Sources Air Toxics Phase 2) regulation limits the annual average U.S.
gasoline pool benzene content to 0.62 vol% for most refiners. Steps to meet this limit are refinery-specific
and determined by the current refinery configuration, the amount of benzene contributed from other
blendstocks, and the use of credits. A brief review of the options refiners have to manage their benzene pool
follows.
NAPHTHA PRE-FRACTIONATION
This case represents the typical first step a refinery takes to reduce benzene, which is pre-fractionating the
incoming naphtha into light and heavy fractions. The light naphtha leaving the overhead of this column
contains the aromatic precursors, and bypasses the reformer. The heavy naphtha goes to the Reformer,
where due to the lack of the aromatic precursors in the feed benzene production is reduced. However some
benzene is still in the final product due to dealkylation of heavy aromatics.
The bypassed light naphtha stream is blended back into the reformate to produce a mixed stream going to the
gasoline pool. There is a drop in RON as a result of the lower benzene level as well as a loss in hydrogen
make. However, the reduction in benzene for this scheme is typically insufficient for the overall gasoline pool
to meet the MSAT II limit.
NAPHTHA PRE-FRACTIONATION FOLLOWED BY ISOMERIZATION
In this case, light naphtha leaving the Naphtha Splitter overhead is sent to an Isomerization unit prior to mixing
with the reformate. The Isomerization unit eliminates any benzene present in this stream and increases the
RON. There is an overall reduction in hydrogen make due to the reduced reformer feed benzene saturation,
though the loss in RON is not as high. The reduction in benzene is typically insufficient for the overall gasoline
pool to meet the MSAT II limit.
REFORMATE SPLlTTER OPERATION KEY TO BENZENE MANAGEMENT
With or without naphtha pre-fractionation, the bulk of the benzene in the gasoline pool comes from
reformate. As a result, any successful benzene management solution will involve some form of reformate
processing. To minimize the size of downstream benzene processing equipment, the Reformate Splitter can
be run to create a concentrated benzene stream, after which numerous process options can be considered.
REFORMATE FRACTIONATION FOLLOWED BY ALKYLATION
If the refinery has a source of light olefins such as ethylene and propylene, it can react them with the benzenerich stream leaving the Reformate Splitter to produce alkyl aromatics. This is a proven commercial process
(BENZOUT) that uses a platinum zeolite catalyst. No hydrogen is required. The resulting alky aromatic
blendstock increases the volume and the octane of the gasoline pool and incurs no hydrogen penalty. Very
low gasoline benzene levels can be reached with this process.
REFORMATE FRACTIONATION FOLLOWED BY EXTRACTION AND SEPARATION
A number of well-established commercial aromatic extraction processes exist that separate benzene, toluene,
and xylenes from reformate. These processes can reduce the benzene level in the gasoline pool to very low
levels, though this comes at the cost of octane and volume reduction. It is unlikely that MSAT II regulations
alone can justify the significant capital outlay for the addition of an aromatics extraction unit to a refinery, but
they have resulted in a renewed appreciation for the importance of these units. As a result, there is
considerable interest in debottlenecking and operational improvement projects for improving both the
throughput and product quality for existing extraction units.
REFORMATE FRACTIONATION FOLLOWED BY SATURATION

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MSAT II and Benzene Management Solutions | C&I Engineering

Page 2 of 2

Saturating benzene with hydrogen in a catalytic reactor is fast and typically close to stoichiometric, which
makes this a good, though expensive, option for benzene reduction. A number of benzene saturation
technology suppliers have been identified, including UOP (Bensat), GTC (BENzap), Axens (BENFREE), RHTHydrogenation, and CDTech (CDHydro). Process conditions are moderate, and only a slight excess of
hydrogen above the stoichiometric level is required. The high heat of reaction associated with benzene
saturation is carefully managed to control the temperature rise across the reactor. These units can guarantee
very low gasoline pool benzene levels, though at the cost of octane loss and hydrogen consumption.
WHICH SOLUTION TO GO WITH?
It is difficult or impossible to meet the gasoline benzene of 0.62 vol% with pre-fractionation of the naphtha
stream alone. Gasoline benzene reduction by saturation
requires hydrogen, reduces gasoline octane, and does not have an investment payback. Gasoline benzene
alkylation does not require hydrogen, increases gasoline octane, and does have an investment payback, but
requires a source of light olefins. Post-fractionation is energy intensive, but for most refineries will be
necessary step to reduce gasoline benzene to the required level. Aromatic extraction is expensive but
produces high purity benzene and other aromatic products that generate incremental revenue to pay back the
investment. The ultimate solution chosen will depend on many factors that are specific to the individual
refinery. C&I has the experience to help with this selection process.
2014 C&I Engineering, Inc. All rights reserved.

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