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 PETROCHEMICAL PROCESSES 35

GASOLINE UPGRADING 6 AROMATICS 40

UOP CCR PlatformingTM Process 6 UOP ParexTM Process 40
UOP PenexTM and Par-IsomTM Processes 8 UOP Sinco Solid State Polycondensation Process 42
UOP PenexTM Process 8 UOP SulfolaneTM Process 44
UOP Par-IsomTM Process 9 UOP TatorayTM Process 45
UOP BenSatTM Process 10 UOP IsomarTM Process 46
GASOLINE FROM LPG 11 UOP MX SorbexTM Process 47
UOP HF Alkylation Process 11 UOP PX-PlusTM Process 48
UOP ReVapTM Modified HF Process 13
AROMATIC DERIVATIVES 49
UOP InAlkTM Process 14
Lummus/UOP EBOneTM Process 49
UOP ButamerTM Process 16
Lummus/UOP Classic SMTM Process 50
CONVERSION 18 Lummus/UOP Smart SMTM Process 51
UOP UnicrackingTM Process 18 UOP Q-MaxTM Process 52
UOP Fluid Catalytic Cracking Process 20 Sunoco/UOP Phenol Process 53
UOP LCO-XTM Process 22
OLEFINS 54
HYDROPROCESSING 23 UOP OleflexTM Process 54
UOP UnionfiningTM Process 23 UOP/HYDRO MTO Process 56
UOP MQD UnionfiningTM Process 23 Total Petrochemicals/UOP Olefin Cracking Process 57
UOP Distillate UnionfiningTM Process 24 UOP MaxEneTM Process 59
UOP VGO UnionfiningTM Process 24 Hüls UOP Selective Hydrogenation Process 60
UOP RCD UnionfiningTM Process 26 Hüls Butene-1 Recovery Process 61
UOP SelectFiningTM Process 27 UOP Propylene Recovery Unit 62

TREATING 28 DETERGENTS 64
UOP MeroxTM Process 28 UOP Linear Alkylbenzene (LAB) Complex 64
Liquid-Liquid Extraction Merox 28 UOP MolexTM Process 64
Sweetening Merox 29 UOP PacolTM Process 64
UOP DeFineTM Process 64
RESIDUE UPGRADING 30 UOP PEPTM Process 64
UOP UniflexTM Process 30 UOP/CEPSA Detal Process 64
UOP Catalytic Crude UpgradingTM Process 31
UOP/FWUSA Solvent Deasphalting Process 32
SYDEC Delayed CokingTM Process 33
 HYDROGEN 67 EQUIPMENT 113

UOP PolybedTM PSA System 71 UOP Distillation Technology 116

UOP PolysepTM Membrane System 72 UOP Heat Transfer Technology 118
Hydrogen Management Services 73 UOP High FluxTM Tubing 118
UOP High CondTM Tubing 119
Raschig Packings 120
Raschig Super-RingTM Packing 120
Raschig Super-PakTM 120
GAS PROCESSING 75 Reactor Internals 121
Inlet Diffuser 121
NATURAL GAS TREATING 79 Rough Liquid Distribution Tray 122
UOP Amine Guard FSTM Process 79 Vapor/Liquid Distribution Tray 122
UOP BenfieldTM Process 80 Catalyst Support Grid 122
De-hydration and Sulfur Removal 81 Quench Zone 123
Mercury Removal 82 Outlet Collector 123
Ortloff Technologies 84
UOP SelexolTM Process 87
Integrated LNG Feed Pre-treatment 89
UOP SeparexTM Membrane System 90
FLNG and FPSO Feed Pre-treatment 92 SERVICES 125
Syngas Treating 93
Services We Offer 129
Training 129
Inspection 129
Process Transformation 130
Field Operating Services 130
RENEWABLES 95
Regional Services 130
UOP/Eni EcofiningTM Process 99 Technology Services 131
UOP Renewable JetTM Process 101 Performance Optimization 131
The Envergent RTPTM Process 102 Optimization Services 132
Strategic TIPS 132
Energy and CO2 Management 132
Tactical TIPS 133

ADSORBENTS 105

Molecular Sieve Adsorbents 109

Aluminas 110
UOP PROCESSING GUIDE

Glossary of terms

UOP PROCESS COMMON INDUSTRY TERM

Envergent RTP Process Bio-mass conversion
Hüls Butene-1 Recovery Process Butene-1 production
Lummus/UOP Classic SM Process Styrene monomer
Lummus/UOP EBOne Process Toluene dis-proportionation
Lummus/UOP Smart SM Process Styrene monomer
Ortloff Technologies NGL recovery and elemental sulfur production
Sunoco/UOP Phenol Process Phenol (from cumene)
SYDEC Delayed Coking Process Delayed coking
Total Petrochemicals/UOP Olefin Cracking Process Olefin cracking
UOP Amine Guard FS Process Gas treating
UOP Benfield Process Gas treating
UOP BenSat Process Gasoline benzene reduction
UOP Butamer Process Butane isomerization
UOP Catalytic Crude Upgrading Process Stranded crude upgrading
UOP CCR Platforming Process Catalytic reforming
UOP/Eni Ecofining Process Renewable diesel fuel
UOP Fluid Catalytic Cracking Process Octane enhancement and propylene production
UOP/FWUSA Solvent Deasphalting Process Residue solvent deasphalting
UOP HF Alkylation Process Motor fuel alkylation
UOP/HYDRO Methenol to Olefins Process Methanol to olefins
UOP InAlk Process Motor fuel alkylation (indirect)
UOP Isomar Process Xylene isomerization
UOP LCO-X Process FCC light cycle oil conversion
UOP Linear Alkybenzene (LAB) Complex Bio-degradable detergent intermediate production
UOP MaxEne Process Naphtha separation
UOP Merox Process Hydrocarbon treating
UOP MX Sorbex Process Meta-xylene adsorptive separation
UOP Oleflex Process Propane dehydrogenation
UOP Par-Isom Process Light naphtha (LN) isomerization
UOP Parex Process Para-xylene adsorptive separation
UOP Penex Process Light naphtha (LN) isomerization
UOP Polybed PSA System Hydrogen purification
UOP Polysep Membrane System Hydrogen purification
UOP PX-Plus Process Toluene dis-proportionation
UOP Q-Max Process Cumene
UOP Renewable Jet Process Renewable oil hydrogenation
UOP ReVAP Process Motor fuel alkylation mitigation system
UOP SelectFining Process Olefinic naphtha selective hydroprocessing
UOP Selective Hydrogenation Process Selective hydrogenation
UOP Selexol Process Natural/synthesis gas treating
UOP Separex Membrane System Gas treating
UOP Sinco Solid State Polycondensation Process PET resin production
UOP Sulfolane Process Aromatics extraction
UOP Tatoray Process Aromatics dis-proportionation
UOP Unicracking Process Conversion
UOP Uniflex Process Slurry residuum hydrocracking
UOP Unionfining Process 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
O technical capabilities for
operational improvements, revamps
today because of the drive toward
low-sulfur gasoline and diesel fuels.
engineering services, adsorbent and
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
UOP has a long history of industry services. Recognizing the dynamic nature
leadership in gasoline production UOP is also dedicated to making the of our customers’ business environment,
technologies with the UOP Platforming , TM world a better place to live, work and UOP provides services such as
UOP Penex , UOP Butamer
TM TM and play by focusing a large portion of our configuration studies to assist you with
UOP HF Alkylation TM processes, as well efforts on developing clean and efficient maintaining your competitive edge in an
as the UOP Fluid Catalytic Cracking TM new technologies, including those for ever-changing world.
process. UOP has also developed renewable fuels and chemicals. The
newer technologies such as the outcome is not only cost-effective, but it After more than a century of developing
UOP SelectFining TM and UOP InAlk TM will make it easier for you to meet current innovative technology, UOP remains
processes to meet changing and future environmental regulations. committed to helping the world’s refiners
gasoline needs. address their evolving operating challenges.
UOP transfers its technology to your In the following pages, you’ll find descrip-
The UOP Fluid Catalytic Cracking, UOP refinery through a unique collection of tions of our refining processes, as well as
Unicracking TM and UOP Unionfining TM products and services, including process diagrams that illustrate how they fit together.
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
 Refining Process Flow

Gas H2 Plant Hydrogen Hydrogen

Concentration Amine Treating
Purification
Sulfur

Treating
LPG
Treating from FCC

Treating
Light
Naphtha
Hydrotreating Light Naphtha
Isomerization
To Black Oil
Hydrocracking Hydrotreating Reforming Gasoline
Heavy
Naphtha
Crude
Distillation
Kerosene
Treating Kerosene
& Jet Fuel
Middle Distillate
Hydrotreating
Diesel
Desalted
Crude Oil
Catalytic
Atmospheric Condensation
Gas Oil
C4
Isomerization
Alkylation
Treating SHP

FCC Treating

Cycle Oils Selective

Hydrotreating 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.

I CCR Platforming process upgrades
naphtha into aromatics-rich product for
And, 40 years ago, UOP again
revolutionized catalytic reforming with the
catalytic reforming, has more than 200
units on stream with the continual
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.
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
 GASOLINE UPGRADING REFINING PROCESSES

CCR Platforming Process

Stacked Reactors
Naphtha Feed
from Hydrotreating Net Gas Net H2-Rich Gas
CCR Compressor
Regenerator Recovery H2-Rich
Combined Section Light Ends
Feed
Exchanger
Separator
Stabilizer

Regenerated
Catalyst Aromatics-Rich
Fired Heaters 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.

OP has decades of global In commercial isomerization processes,

U experience with isomerization
technologies. The first commercial
reactions take place over a fixed-bed of
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-
promoted catalysts to isomerize C5/C6 Reactors Stabilizer
Off Gas
paraffins to higher-octane branched Make-up Hydrogen
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

Dryer
in more than 120 units worldwide. The
Isomerate
process has a wide range of recycle
configurations for optimum design flexibility. Feed

8
 GASOLINE UPGRADING REFINING PROCESSES

Par-Isom Process recycle compressor and back to the

reaction section. The liquid product is
The Par-Isom process is an innovative
sent to a stabilizer column where
application of a UOP-developed,
the light ends and any dissolved
non-chlorided alumina catalyst for light
hydrogen are removed. The stabilized
paraffin isomerization. In this process,
isomerate product can be sent directly
the fresh C5/C6 feed is combined with
to gasoline blending.
make-up and recycle hydrogen and
then directed to a heat exchanger,
More refineries are utilizing UOP
where the reactants are heated to
isomerization technologies because
reaction temperature. The heated
light naphtha isomerate is an excellent
combined feed is then sent to the
gasoline-blending component, due to
reactor. Conversion is accomplished
its high-octane, low-sulfur, low-olefin
across UOP’s PI-200 series catalysts,
and low-benzene properties. Light
an extremely robust, fully-regenerable,
paraffin isomerization can offset octane
noble-metal (platinum), light paraffin
loss from lead phase-out or from
isomerization catalyst.
de-sulfurization of FCC naphtha. In
addition, the process can provide a
The reactor effluent is cooled, and then
cost-effective solution to benzene
sent to a product separator where
management in motor fuels.
recycle hydrogen is directed to the

Par-Isom Process

Make-up Hydrogen Stabilizer

Off
Gas
Product
Reactor 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.

ost refiners achieve benzene

M reduction by managing benzene
production from the catalytic reformer.
The technology is based on years
of experience with the UOP HB UnibonTM
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.

ight olefins are important

L 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 high-
octane 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

KOH
Treater
HF
Stripper 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.

he ReVAP process was developed

T in the mid-1990’s, and was first
proven at the Torrance refinery in
The additive forms a complex with the
HF, which is recovered from the
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
Iso-butane Additive
Storage
Olefin
Feed

Main
Fractionator
Motor Fuel
Butane

KOH
Treater
HF
Stripper 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.

irect alkylation processes use

D HF or sulfuric liquid acids as the
catalytic medium. UOP has developed
extension of UOP's catalytic
condensation and olefin saturation
The InAlk process makes premium
alkylate using a combination of
commercially-proven technologies.
technologies.
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 Paraffinic and

Reactor Olefinic LPG

Stabilizer Make-up
Hydrogen
Hydrogenation
Reactor

Light Ends

Steam Cracker Separation

or FCC C4

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 commercially-
available 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 environmentally-

superior 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.

he Butamer process is a high-

T efficiency, cost-effective means of
meeting the demands for the production
reaction is equilibrium-limited, and the
production of iso-butane is favored by
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
100 economical carbon steel construction.
Isobutane/ΣButanes, mol%

80
i-C4/Total C4, mol%

60

40

20

0
200 300 400 500 600
(93) (149) (204) (260) (316)
Temperature, °F (°C)

16
 GASOLINE FROM LPG REFINING PROCESSES

Virtually-complete conversion of normal

Butamer Process
butane to iso-butane can be achieved
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
Stabilizer Scrubbing
column. Unconverted normal butane is and Fuel
recycled to the Butamer unit, along Dryer
with normal butane from the fresh feed.
n-Butane

The best feeds for a Butamer unit

contain the highest practical normal Dryer
butane content and only small
Make-up Isomerate
amounts of iso-butane, pentanes and
Hydrogen
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 near-
equilibrium 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
Olefin Alkylation
the butane feed. Feed Reactor
Section n-C4 Butamer
Unit
With more than 70 Butamer units on
stream with feed capacities ranging Saturated
from 800 to more than 35,000 BPSD Butanes Make-up
Hydrogen
(74 to 3,250 T/D), the Butamer process
provides refiners the design flexibility
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.

his critical technology can produce

T LPG, naphtha, kerosene and diesel,
as well as high-quality unconverted oil
contents can be optimized based on
their end users.

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
• The single-stage Unicracking
selectively produces products in the
process can be a once-through flow
desired boiling range. Selection of unit
scheme for partial conversion, or a flowscheme, the first stage provides
configuration, catalysts and process
recycle flowscheme for full conver- hydrotreating and partial conversion
conditions, such as space velocity and
sion. These flowschemes are simple of the feed. Products from this stage
pressure, are a function of the desired
and cost-effective designs widely are then separated by fractionation.
operating cycle life and required
used in refineries. The once-through The second stage of the two-stage
product qualities.
Unicracking process produces design provides the remaining high
hydrocracked products, as well as conversion of recycle oil. These
Feedstocks can range from naphtha
high-quality unconverted oil that can flowschemes offer several advantages
to light gas oils to non-distillable
be excellent feed for FCC or ethylene in processing heavier and highly-
components such as de-metallized oil.
cracking units. The UCO can also contaminated feeds. The two-stage
Depending on the refiner’s need,
be used as a high-quality lube flowscheme is also economical when
Unicracking products can include LPG,
base-stock. When high conversion the throughput of the unit is relatively
naphtha, kerosene, diesel, high-quality
is desired, the single-stage recycle high, regardless of feed properties.
unconverted oils (UCO), or virtually
flowscheme offers a simple and
any combination of these materials. In In a typical refining situation, a Unicracking
cost-effective design for moderate
general, the process chemistry favors unit can be used as a stand-alone
capacity hydrocracking designs.
highly-saturated products. However, conversion process to produce
the combination of the Unicracking • 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
 CONVERSION REFINING PROCESSES

UOP has developed several Unicracking

Single-Stage Unicracking Process
catalyst families that offer flexibility to
achieve product objectives within the
Make-up
reaction environment, depending on Hydrogen
Reactors
the level of severity created by the
Cold
flowscheme employed. Catalyst Separator
Feed Vent Gas
selection within these families is
dependent upon the required product HT HC Product
Separation
quality, product selectivity, and the
Butanes
process conditions required to Wash Cold
Water Flash
achieve them. Light
Drum
Naphtha

As market needs have evolved, UOP Heavy

Hot Naphtha
has continually adapted Unicracking Flash
Hot
technology to address these changes. Separator 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,

Make-up
a third dimension, hydrogenation, has Hydrogen Reactors
been added to describe catalyst Cold
formulations. The catalysts developed Separator
Feed Vent Gas
will be able to better meet the needs of
HT HC Product
refiners that encounter critical hydrogen Separation
management issues.
Butanes
Flash
Hot Drum
Since hydrocracking technology was Separator Naphtha
offered by UOP in the late 1950's, UOP
has continually improved both the Jet
Hot
process and catalyst systems. With more Flash
Drum Distillate
than 200 units awarded in over 40
HC
countries, UOP delivers the capabilities UCO
and experience necessary to help you
Recycle Oil
improve your bottom line.

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.

he UOP FCC process and its

T related processes can enable
refiners to convert straight-run atmos-
but have developed emission- and
yield-selective additives. Technology
licensors have continued to make
RxCAT Design

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.
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

FCC Process technology, UOP's FCC process
features elevated UOP OptimixTM feed
Main
Regenerator Reactor Column distributors, UOP VSSTM (Vortex
Fuel Gas to
Overhead Vapors Treating Separation System) riser termination
To and Unstablized
Flue Gas System C3-C4 to Treating,
device, and a combustor-style
Gasoline Gas
Concentration Alkylation regenerator or a two-stage regenerator
Unit or Polymerization
in cases where full combustion would
Debutanized
Gasoline result in excessive regenerator
Heavy Naphtha Product to Treating temperatures.
Light Cycle Oil Product
Heavy Cycle Oil Product Additional technological features include
catalyst coolers, UOP RxCatTM design,
UOP AFTM spent catalyst stripper
Main Column
Air Fresh Feed Bottoms Product technology, selective recycle, power

20
 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.

OP developed the LCO-X process, operation, reducing construction costs

U utilizing catalyst and process
systems to maximize the yield of
and risk associated with high-pressure
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 Make-up
Feed Hydrogen Stabilizer Fractionator

HT LPG Light
Naphtha

HC
Off Gas Aromatics Benzene
Maximization Mixed
HPS Xylenes
LPS

ULSD
Blendstock

22
 HYDROPROCESSING REFINING PROCESSES

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.

here are several Unionfining

T processes offered to meet a refiners
needs and project objectives. The basic
Single-Stage MQD Unionfining Process

Recycle Gas
flow schemes are fixed-bed catalytic Compressor
Fresh
hydrotreating technologies that operate Feed
at elevated pressure and temperature
Reactor Quench
and consume hydrogen, reducing the Gas
contaminant content of the feedstock.
Separation
Maximum Quality Distillate Light
(MQD) Unionfining Process Ends
Hydrogen Stripper
The UOP MQD Unionfining process is Makeup
a family of technologies that offers
Sour Steam
completely-integrated solutions to upgrade Water
difficult, refractory, distillate-range feeds Diesel
Product
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 Recycle Gas Amine Lean Amine
Reactor Compressor Scrubber
quality objectives. Process configuration Rich
Makeup Amine
Gas
and catalyst choice depend on the desired
product quality improvement and existing High Pressure
Cold Separator
refinery configuration. Quench
Gas Oil to
Hot
Stripper Low Pressure
Cold Separator
The MQD Unionfining process uses a Strip-
ping
single- or two-stage configuration. The Gas
Water
single-stage design is used with most
base-metal catalyst applications. The 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 Fresh
Feed
boiling-range feedstocks – kerosene, jet quality distillate-range material to
Make-up
fuel and diesel oils. This process uses better meet stringent fuel regulations. Hydrogen
state-of-the-art catalysts and The product can be blended directly
carefully-selected processing conditions into fuel, and can facilitate the blending Lights
Ends
to achieve the customer's product of other streams, depending on the
sulfur requirements, as well as desired refiner’s processing objectives.
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

The feeds processed in the UOP VGO Recycle Gas

Reactor Compressor
Unionfining TM process are vacuum gas Fresh
Feed Make-up
Hydrogen
oil boiling range feedstocks, including
straight-run vacuum gas oil, heavy
coker gas oil and visbreaker gas oil. Amine Lean Amine
Scrubber
The typical application of this technology
is in FCC feed pre-treatment. This
processing provides higher yields and Rich Amine
Cold
a better quality of FCC gasoline, and Separator
lower yields of FCC light and heavy
cycle oils. Product from the VGO Hot Fractionation Section
Separator
Unionfining process can also be used Wild
Naphtha
as low-sulfur fuel oil. Cold
Flash
Flash
Drum Gas

Hot
Flash Diesel
Drum Product

Sour Water

FCC
Feed

24
25
 REFINING PROCESSES HYDROPROCESSING

UOP Unionfining Process continued

RCD Unionfining Process Because of the typically high contaminant new-generation reactor internals,
levels, a guard bed reactor is used to innovative separation and process
The OP RCD UnionfiningTM process is a
control pressure drop associated with schemes, minimizing the capital
fixed-bed catalytic residue hydrotreating
large particles and solids that might be investment required to revamp existing
technology that uses base-metal
in the residue feed. Several reactors in assets. Combining the Unicracking and
catalysts to remove contaminants such
series are often required because of Unionfining processes, UOP offers
as sulfur, nitrogen, organo-metallics
the low reactivity and high contaminant refiners a number of integrated solutions
and asphaltenes in heavy feedstocks,
levels of the feedstocks. that take into account changing crude
such as atmospheric residue, vacuum
slates, feed segregation, diesel blending
residue and de-asphalted oil (DAO).
Hydroprocessing technology and hydrogen management to help
The relative processing severity of the minimize the cost of regulatory
The most common application of
Unionfining technologies is dependent compliance. Additionally, these solutions
the RCD Unionfining process is
on feedstock type and processing can provide flexibility for future increases
FCC/RFCC feed pre-treatment, in which
objectives. As a result of collaboration in production rates.
approximately 90% of the sulfur and
organo-metallics are removed. The within the Hydroprocessing Alliance,
UOP is able to offer refiners a unique Hydrotreating technology has been
process is also used for production
combination of processes and catalysts offered by UOP since the early 1950's.
of low-sulfur fuel oil and partial
to provide optimum performance. Many Our partnerships and technology
conversion of non-distillables to
Unionfining process features include developments have changed over
distillables.
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.

Residue Hot
Feed Separator

Make-up
Hydrogen
Fractionator
H2
Recovery Gas

Naphtha
Purge
To
Fuel Gas Distillate
H2S
Cold
Scrubber Separator
Hot
Cold Flash
Flash Drum
Drum Hydrotreated
Residue

26
 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.

he SelectFining process provides gasoline-blending components and

T refiners with a simple, flexible
solution to help meet sulfur specifications.
the types and amounts of olefinic and
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 Recycle sulfur removal.
Compressor

Lean
Fresh Amine
Feed Recycle Gas
Scrubber

SelectFining
Reactor

Stabilization Rich
Amine Light Ends
Reactor

De-butanizer
Product
Separator

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.

he Merox process is an efficient,

T low-cost, low-maintenance
mercaptan control technology. All
mercaptan sulfur with resultant reduction
of total sulfur. In this flowscheme,
the hydrocarbon is counter-currently
Merox Process for
Mercaptan Extraction

versions of the Merox process are contacted with Merox caustic in a Treated Product
Regeneration Section
characterized by the Merox catalysts' multi-stage, high-efficiency Merox Oxidizer
ability to promote the direct oxidation of extractor column. The caustic-extracted Spent Air
Extractor
mercaptans (RSH) to di-sulfides (RSSR) mercaptans are then efficiently oxidized
Air
Di-sulfide
in an alkaline environment. The process catalytically to di-sulfides in the Merox
H2S-Free
is broadly divided by application into regeneration section of the unit. Feed
Di-sulfide
“Extraction” and “Sweetening”. Separator

The mercaptan content of light FCC Caustic Lean Merox

Caustic
Liquid-Liquid Extraction naphtha can be reduced by more than
Merox Process 95% through application of the liquid-
Catalyst
Injection
Intermittent Use

Merox extraction is used with light liquid extraction Merox process with no
hydrocarbon streams, such as gas, yield or octane loss. 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
combined these operations into a single
Treated
Water Wash Water Gas Product vessel. Due to this improved design,
Section refiners can benefit from a reduction in
Regeneration Section
the unit capital cost of up to 30%. The
Extraction Spent cost-savings are achieved due to the
Section Air
Oxidizer
reduced number of vessels required, and
Caustic the corresponding plot space reduction.
Air
Prewash
Section Di-sulfide
Separator
Di-sulfide
Oil

To De-gassing
Drum
Gas
Feed

28
 TREATING REFINING PROCESSES

Sweetening Merox Process usage, greatly reducing spent caustic

Merox Process for
Merox sweetening is used with heavier disposal concerns. With the development
Fixed-Bed Sweetening
hydrocarbon streams for direct, in-situ of the caustic-free Merox process for

conversion of the mercaptans to gasoline treating, UOP has eliminated the Reactor
Air
di-sulfides, with no reduction in total use of caustic and its disposal concerns. H2S-Free
Feed
sulfur. The Merox sweetening process Sweetened
Product
is offered in various versions depending Benefits associated with the Minalk

on the hydrocarbon stream to be process include: Caustic

Settler
treated: conventional fixed-bed, UOP • Production of a “doctor negative” Caustic
MinalkTM fixed-bed and caustic-free Circulation
product, while minimizing removal
fixed-bed flowschemes. of phenols from the naphtha

• Long catalyst life

• Minimal operator attention

Minalk Process for
• A small continuous discharge of Fixed-Bed Sweetening
spent caustic
Air Reactor
• Low capital and operating costs H2S-Free
Naphtha

For more difficult-to-sweeten feedstocks

Continuous
such as heavy straight-run gasolines, Alkali Sweetened
Injection Naphtha
FCC gasolines, gasolines, light visbreaker and coker light naphthas, Product
straight-run gasolines and condensate and kerosenes, UOP offers its Drain
Interface Pot
gasolines typically contain easy-to- conventional fixed-bed Merox
sweeten mercaptans and can be treated sweetening process which utilizes a Spent Alkali
and Water
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.

Caustic-Free Merox Process

for Kerosene/Jet Fuel Sweetening
Salt Clay
Water Air Filter Filter
Reactor
Kerosene/
Jet Fuel Water
Feed Wash

Ammonia Sweetened
Water
Kerosene/
Merox Jet Fuel
CF Product
Additive

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.

he most common feedstock to In the Uniflex process, the feed, make-up Product and catalyst leave the top
T a Uniflex process unit is vacuum
residue, although atmospheric residue
hydrogen and a portion of the recycle
gas are heated to the desired
of the reactor, and are immediately
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

Uniflex Process selectively to produce distillates, naphtha
and VGO conversion unit feedstock,
the Uniflex process can provide very
Recycle H2
Make-up high refinery margins, especially in
Hydrogen
H CHPS
H Flash Gas comparison with traditional residue
P
S conversion processes, such as
C4-
Uniflex delayed coking.
Reactor CFD

Naphtha
H The Uniflex process also enables
F
D Diesel upgrading of several other refinery
systems. For example, co-processing
of FCC slurry oil will result in very high
LVGO
conversion of the slurry oil to distillate
Feed HVGO
and lighter streams.
Catalyst
Pitch

30
 RESIDUE UPGRADING REFINING PROCESSES

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
T to meet the needs of a variety of
stranded oil projects where natural gas
liquid product recovery than conventional
upgrading technologies. Because the
LPG product, or fired with fuel gas from
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
crudes that cannot be pipelined of both steam and electrical power.
because of pour point restrictions. 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
gravity drainage (SAGD) complex.

Catalytic Crude Upgrading Process The CCU process offers many benefits
critical to liberate stranded crudes,
Synthetic
Crude including self-sufficiency with regard to
Slurry Product
LCO Main Naphtha LPG utilities, minimized crude processing,
Oil
Column low capital cost, increased product
Raw Pre-Fractionator
Crude margin due to API gravity improvement,
higher volume recovery than other
Reactor/ upgrading technologies and no
Regenerator hydrocarbon waste by-products.

Steam 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).

he DAO can be further processed

T in conventional conversion units,
such as FCC or hydrocracking units.
precipitate out of the mixture. Separation
of the DAO phase from the pitch phase
occurs in the extractor. The extractor is
stripping of any entrained solvent.
The DAO and pitch product are then
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
DAO
Residue
Separator are relatively low compared to conversion
Charge
technologies such as delayed coking
and residue hydrotreating technologies.

Pitch
Stripper

DAO
Stripper

Pitch DAO

32
 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.

he chemical reactions of delayed

T coking are intricately complex
with three distinct reactions occurring:
The Selective Yield Delayed Coking
(SYDEC) technology, licensed by Foster
Wheeler USA Corporation (FWUSA), is
a low-pressure, low-recycle design for
• Partial vaporization and mild cracking
maximum liquid yields. In most parts of
(visbreaking) of the feed as it passes
the world, UOP has exclusive marketing
through the coker’s furnace
rights for the technology when the delayed
• Cracking of the reactants in the coker is part of a multi-unit project.
• Anode grade
vapor phase as it passes through
Coker types are defined by the types Anode grade coke is produced
the coke drum
of coke produced. from low-sulfur and low-metals type
• Successive cracking and feedstocks. It is used for anodes
• Fuel grade
polymerization of the liquid trapped in the aluminum industry.
The most common type of coker is
in the coke drum until it is converted
the fuel grade. Here the objective is to • Needle coke
to vapor and 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
SYDEC Delayed Coking Process is used for electrodes in the steel
industry and garners a high price.
Fuel Gas
Coke Drums Coke Drums Consequently, coke yield is more
Butane/Butene
Light Coker Naphtha important than liquid yield. When
Product
Recovery Heavy Coker Naphtha producing high-value needle coke,
Light Coker Gas Oil
the feedstock must be highly
Heavy Coker Gas Oil
aromatic, with low asphaltene, sulfur
and ash contents.
Switch Switch
Valve 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 industry-
leading 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.

major milestone came with the

A development of the UOP Sorbex
process in the 1960’s, and in particular
TM
investment to install, making better use
of available feedstocks and consuming
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 TM 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 TM 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 TM process in the early UOP/CEPSA DetalTM process, UOP
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,
SulfolaneTM process, generally used to 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.

38
Petrochemicals Process Flow

Feedstocks
Olefins
Coal
Petroleum Coke
Bio-mass Methanol Methanol
Synthesis
Ethylene
Methane Methanol
to Olefins
Propylene
C3/C4
Dehydrogention
MTBE
C4
Processes Mixed Butenes
Steam Butene-1
Ethane Cracking
1,3 Butadiene
Propane Olefin
Cracking
Butanes
n-Paraffin
Naphtha Recovery Propylene
Recovery
High
Gas Oil Severity FCC Heptenes
Catalytic Octenes
Condensation Nonenes
Dodecenes
Gasoline & Aromatics
Aromatics
Pressure Swing High Purity
Adsorption Hydrogen
Ethylene
Ethylbenzene
EB
Alkylation Dehydrogenation Styrene

Propylene
Cumene Phenol
Alkylation Oxidation
& Cleavage
Acetone
Benzene

Hydrogenation Cyclo-hexane
Benzene
Naphtha Aromatics Toluene
Reforming Recovery o-Xylene
m-Xylene
Melt PET
PTA Poly SSP
Isomerization PX Resin
& Transalkylation

Detergents
Normal
Paraffins
Normal Olefin
Paraffins Linear
Recovery Mono-Olefins
n-Paraffin Paraffin
Kerosene Recovery Dehydrogenation
Linear
Alkylation Alkyl-benzene
(LAB)

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.

he Parex process relies on combined benefits of the latest adsorbent

T innovative technology that operates
in liquid-phase and uses counter-
operate continuously, remaining
on stream for many years between
infrequent planned maintenance events.
technology and engineering features
enable new designs at much higher
current adsorptive separation, employing capabilities. The world’s first one million
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
Parex Process
results in the lowest-cost method for
para-xylene production. Experience with Concentrated
Extract
the rotary valve is vast, with more than (Para-xylene)
110 rotary valves having been placed in
De
so

Rotary Extract Extract

rb

operation in commercial Parex units as Column

en

Valve
t

of 2010. The high reliability of the rotary Ext

rac
t
valve is well documented, with greater Desorbent
than 99.9% process availability being
d
commonplace. The nature of the Fee Concentrated
Raffinate
process, and a design that has been
te
na
ffi

refined through vast commercial

Ra

Raffinate
experience, ensure Parex units can Raffinate Column
Adsorbent
Chamber
Feed

40
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.

OP Sinco SSP units in operation

U around the globe are producing
over 7.5 million metric tons of resin
With UOP Sinco’s precise control of
critical process parameters, the final
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 providing basic design, detailed design,
The process accommodates feed chips
agglomerates. These and other quality equipment and material supply, unit
from every major melt polymerization
parameters are backed up by UOP’s construction and startup services.
process and can change product
performance guarantee. Projects range from pilot plant scale to
grade (IV) rapidly.
the largest commercial production

The UOP Sinco SSP offers a choice of units, including new and retro-fit units.

flowschemes using either gravity or a lift

Pre-crystallizer
system (to minimize height), both of
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 PETROCHEMICAL PROCESSES

Crystallizer Nitrogen Purification Unit (NPU) impurities from the SSP reactor to
carbon dioxide and water — the only
The crystallizer completes the The entire process is performed under
waste materials from the entire SSP
crystallization under process conditions an inert nitrogen atmosphere to ensure
unit. Both the catalyst and molecular
optimized to the behavior of the feed production of the best quality chips.
sieves are UOP formulations designed
polymer. Crystallization is performed in UOP Sinco’s patented NPU purifies
to minimize consumption of utilities and
a moist nitrogen environment, one the recirculating nitrogen gas and a
promote optimum process conditions.
feature of UOP Sinco’s patented flow catalytic reactor converts the organic
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

A process is its solvent system,
which has the highest aromatic
grades for cyclohexane and other
petrochemical uses. It can also be
and extractive distillation. Strictly
extractive distillation applications offer the
advantage of being the most cost-effective.
used to meet ASTM specifications for
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
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

Stripper Recovery
Column

Raffinate Solvent
Wash Regenerator
Feed Column

44
 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

T key advantages that make it the
most economical way to increase xylene
need for regeneration. Higher conversion
results in smaller recycle streams, and
along with less recycle hydrogen, this
conditions are similar to those for a
variety of refining and petrochemical
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

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.

arex unit raffinate, typically depleted

P to less than 1% para-xylene, is
mainly composed of a mixture of
Two different types of Isomar catalysts
are used, depending on the target
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 Benzene to to their very high activity and close
Gas Benzene approach to equilibrium per pass, these
Reactor Recovery
catalysts allow for smaller equipment
throughout the aromatics complex,
lowering capital and energy costs. With
Separator
the commercialization of its UOP I-350TM
Parex Deheptanizer
Raffinate catalyst, providing the same EB-
dealkylation performance and stability of
the previous generation UOP I-300TM
catalyst, the Isomar process can now
Makeup offer the added benefit of a high-purity
Hydrogen benzene by-product that does not
To Xylene
Splitter 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
 AROMATICS PETROCHEMICAL PROCESSES

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.

ince the mid-1990's, all

S meta-xylene capacity added
worldwide uses MX Sorbex technology.
MX Sorbex Process

The MX Sorbex process has become Adsorbent Chambers

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
mixed xylenes derived from reformate, Raffinate

hydrotreated pyrolysis gasoline or a

UOP TatorayTM unit. The MX Sorbex Extract
Raffinate Column
process can be integrated into an Column
existing UOP aromatics complex that
includes a Parex unit.
m-Xylene
Raffinate to Storage Product
or Isomerization 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.

ue to the high para-xylene The PX-Plus process converts toluene

D concentration in the product, the
PX-Plus process offers para-xylene
to benzene and xylenes by selective
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
PX-Plus Process processes, allowing existing equipment
to be easily revamped and put into
PX-Plus service. The PX-Plus process
Separator
Purge can also be integrated into new
Gas
large-scale grassroots para-xylene
Reactor Overhead Liquid
complexes when relatively high
to Platforming Unit
Debutanizer benzene production is desired.

Stripper

Toluene

To Benzene/Toluene
Fractionation
Recycle Gas
Make-up
Hydrogen

48
 AROMATIC DERIVATIVES PETROCHEMICAL PROCESSES

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.

OP’s EBZ series of catalysts • Low benzene-to-ethylene (B/E)

U provide for exceptional run
lengths (three to five years), eliminating
operations for reduced utility
requirements
product from ethylbenzene feedstock,
and the Lummus/UOP Smart SM
styrene monomer technology for
the need for frequent regenerations cost-effective revamps and expansions.
• Carbon steel construction with no
and change outs. An EBOne unit combined with a Classic
fired heaters resulting in lower
SM or Smart SM unit provides a highly
investment costs
The process provides a number of heat-integrated complex that results in
features and benefits, including: • 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
UOP also offers the Lummus/UOP Lummus/UOP EBOne process in the
• High EB product purity for increased Classic SM process for the early 1990's, Lummus and UOP have
purity styrene monomer production manufacture of styrene monomer been awarded over 39 projects
worldwide.

EBOne Process

Alkylation Transalkylation Benzene Ethylbenzene Poly-ethylbenzene

Reactor Reactor Column Column Column
Ethylbenzene
(to SM Unit)

Heavy
Ethylene Ends
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.

OP’s on-going program of catalyst

U and process development
provides clients with technologies that
• Low equipment pressure drop which
permits the reactor to operate at
high vacuum, resulting in higher
have significant capital and operating product quality and lower EB feed
cost advantages. consumption

• Minimum pressure-drop radial • Low steam-to-hydrocarbon ratios,

The Classic SM process provides a
bed reactors for lower operating resulting in lower steam imports
number of features and benefits, including:
pressure, resulting in lower EB and production costs
• High styrene monomer purity feed consumption and reduced
(at least 99.95%) by-product formation Since its introduction the 1970's,
Classic SM technology has been
• High per-pass EB conversion for • Energy savings from a highly-efficient
selected for more than 60 major
lower operating costs heat recovery scheme that does not
projects throughout the world.
require compression equipment
• High product yields resulting in lower
EB feed consumption

Classic SM Process Ethylbenzene Benzene/

Recycle Toluene
Column Splitter
Benzene
Ethylbenzene Recycle Ethylbenzene
(from EB Plant)

Off Gas
Toluene
Inhibitor
Steam Off Gas Ethylbenzene
Recovery Styrene
Dehydrogenated Splitter
Mixture
Dehydrogenation Styrene
Superheated Steam Reactors

Separator
Styrene
Finishing
Column
Condensate

Tar

50
 AROMATIC DERIVATIVES PETROCHEMICAL PROCESSES

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.

n the oxidative reheat section of the

I reactors, hydrogen is oxidized to
supply the heat for the dehydrogenation
The process provides a number of
features and benefits, including:

• High styrene monomer purity

reactions. The oxidation is accomplished
using UOP’s OC series of catalysts • High per-pass EB conversion for
which are highly selective. This increased throughput Since the introduction of the
eliminates the costly interstage Lummus/UOP Smart SM process
• Reduced superheated steam
reheater and reduces superheated in the mid-1990's, SM producers
requirements, resulting in lower
steam requirements. For existing SM worldwide have a cost-effective route
production costs
producers, revamping to the Smart 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/

Recycle Toluene
Column Splitter
Benzene
Ethylbenzene Recycle Ethylbenzene
(from EB Plant)

Off Gas
Toluene
Inhibitor
Steam Off Gas Ethylbenzene
Recovery Styrene
Dehydrogenated Splitter
Oxidation/ Mixture
Superheated Steam Dehydrogenation Styrene
Reactors
Separator
Styrene
Finishing
02/Air 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.

he Q-Max process represents

T a substantial improvement over
older cumene technologies, and is
• High catalyst stability, resulting in
fewer unit turnarounds

• Carbon steel construction keeping

characterized by its exceptionally-high
investment costs low
yield, superior product quality and low
investment costs. UOP’s QZ series of
The Q-Max process can be designed
catalysts exhibit outstanding stability,
to handle refinery-, chemical- or
even when operating at low benzene-
polymer-grade propylene. The quality
to-propylene (B:P) ratios.
of the cumene product produced in a
Q-Max unit is strongly influenced by
The process provides a number of
the specific contaminants present in
features and benefits, including:
the feedstocks.
• High cumene purity (at least
99.95 Wt%) 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
• High cumene yields (at least 99.7
Combining the Q-Max process with the 4 million MTA cumene capacity
Wt%), resulting in lower feedstock
Sunoco/UOP Phenol process results in licensed, it has provided a significant
consumption
higher phenol yields, improved product portion of capacity additions worldwide.
• Low B:P operations, as low as quality and lower utility consumption.
2.0 molar, resulting in lower
utility requirements

Q-Max Process

Alkylation Transalkyation Benzene Cumene Poly-iso-proplbenzene

Reactor De-propanizer Reactor Column Column Column

Recycle Benzene
Benzene Cumene

Propylene Recycle DIPB

Propane

Heavies

52
 AROMATIC DERIVATIVES PETROCHEMICAL PROCESSES

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.

he Phenol process features

T low-pressure oxidation for
improved product yield and safety,
Phenol Process

Neutralizing
advanced CHP cleavage for high Spent Air Acid Agent
product selectivity, an innovative direct Phenol and
Acetone Acetone
product neutralization process that Cumene Purification Phenol
Oxidation Decomposition
minimizes process waste, and an Air
Concentration Neutralization Residue
improved, low-cost product recovery
H2 AMS
scheme. The result is a very low- Hydrogenation
Recycle Cumene or
cumene feed consumption ratio that is 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
O to C4 olefin production by
processing an iso-butane feed or
that is formed on the catalyst, which
suppresses the catalyst activity and
recovery/fractionation section in which
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
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
Turbo FluxTM tubing, all of which help optimize
Expander
C the techno-economic performance
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 have been commissioned worldwide.
H2 Recycle Recovery
A significant portion of on-purpose
propylene demand growth continues
Fresh and Net Separator
Recycle Feed Off Gas to be met by the Oleflex process.

54
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.

atural gas or gasified coal is first

N converted to methanol, and then
the methanol is sent to the MTO unit.
The process combines proven process
technologies used in Fluid Catalytic
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 CO2 R the product recovery section in which
polymer-grade propylene and ethylene
C1
are produced via treatment and
WR
fractionation. This fractionation is
H2O D DE AS DM basically the same as in a steam
Flue cracker. In addition to the polymer-grade
Gas
98+% Purity
ethylene and propylene, a small C4+
Reactor Ethylene olefinic stream is produced. The olefins
Regenerator 98+% Purity Propylene in this stream can be easily converted
into propylene and ethylene by integration
with the Total Petrochemicals/UOP
DP
OCP. This boosts the overall olefin
Crude Air
MeOH yield, while eliminating a by-product.
Product Recovery Section Legend C4+ Product
WR = Water Removal DE = De-ethanizer
CO2 R = CO2 Removal AS = Acetylene saturator
DM = De-methanizer C = Compressor
DP = De-propanizer D = Dryer

56
 OLEFINS PETROCHEMICAL PROCESSES

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.

CP uses fixed-bed reactors that

O operate at moderate temperatures
and low pressure. The process utilizes a
system. The Olefin Cracking process
can be integrated with several different
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.

Olefin Cracking Process Steam Cracker Integration

C2= /C3=

Olefinic Naphtha
C4-C8 C2=
OCP Product
Reactor Section De-propanizer Furnace Recovery & C3=
Section Purification
Section Fuel Gas
PyGas
C4
C4-C6
By-product Olefin-rich
Paraffin-rich
C4-C6 By-product
De-butanizer
OCP
C5+ Unit
By-products

57
 PETROCHEMICAL PROCESSES OLEFINS

UOP Olefin Cracking (OCP) Process continued

FCC refinery integration MTO integration

FCC Refinery 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. FCC Gasoline
Gas Oils
Unit Cycle Oils
from the FCC and coker units to The OCP unit can be used to convert C2=
high-value light olefins which are C4+ olefin to propylene and ethylene. C3=
C4-C8 C5+
recovered as products. The by-product By integrating OCP into an MTO Olefin-Rich Olefin
By-product Recovery
of the OCP is a gasoline stream low in complex, the overall propylene and LPG
olefins, with virtually the same octane ethylene yield in the complex can be OCP
number as the feed to the OCP due Unit Light
greatly increased, approaching 90% Olefins
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 MTO Integration
light olefins.

MTO C2=
MeOH
Unit C3=
C4-C5 Light
Olefin-Rich Olefins
By-product
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
 OLEFINS PETROCHEMICAL PROCESSES

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.

he latest application of the UOP shape-selective adsorbent to simulate is recovered from this stream by
T Sorbex TM technology, the MaxEne
process is a continuous process that
moving-bed, counter-current adsorptive
separation. The separation process
fractionation and sent to the naphtha
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
• The raffinate stream, which contains
naphtha. The naphtha is first using a specific desorbent. The rotary
non-normal paraffins and the liquid
hydrotreated and is then sent to the valve, which is used periodically to
desorbent. Naphtha depleted in
MaxEne unit. The extraction of switch the position of the liquid feed,
normal paraffins is recovered from
normal paraffins takes place in an desorbent and withdrawal points in
this stream by fractionation and
adsorption chamber that is divided into the adsorbent chamber, creates four
sent to a refinery or an aromatics
discrete beds. Each bed contains major streams:
complex, while the recovered
shape-selective adsorbent, as well as a
• The feed stream, which is the desorbent is recycled.
specialized grid to support the
naphtha feed containing a mixture
adsorbent. The grids are designed to • The desorbent stream, which is the
of hydrocarbons
provide highly-efficient flow distribution in liquid desorbent that is recycled
the chamber. Each bed in the chamber • The extract stream, which contains from the fractionation section to
is connected to a UOP Rotary Valve. normal paraffins and the liquid desorbent. the chamber
The rotary valve is used along with the Naphtha that is rich in normal paraffins
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 years without the need for maintenance.
Chamber Extract
1 Column
Desorbent On-stream availability for a Sorbex
Rotary
Valve process unit is very high, with minimal
2 Normal maintenance required, the result of the
Paraffins
3 Desorbent mild operating conditions.
4 Extract
5
6 Feed

7 te
8 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.

or all these processes, the reaction

F takes place at low temperatures
and pressures. The hydrogenation
• The Hüls Complete Saturation
Process (CSP) converts essentially
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
to the lower limit of detection.
• The Hüls Selective Hydrogenation
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
used to convert C4 dienes and Recovery
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 Alkylation
Make-up Unit
less than 10 ppm. Hydrogen

Olefin Feed

60
 OLEFINS PETROCHEMICAL PROCESSES

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.

echnology selection for the • If BD is not a desired product, B-1 is then sent to two super-fractionators
T production of high-purity butene-1
depends on the producer's needs for
production would require an SHP-CB
unit, an MTBE unit and the B-1
for the recovery of 99.5% B-1. This
separation requires ~200 trays in each
butadiene (BD). Typically multiple Recovery unit. fractionator. The close spacing of UOP
technologies, including B-1 recovery, are MDTM distillation trays makes it possible
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
Butene-2 Butene-1
Methanol C4/C4= Column Column
Light Ends
Make-up & Iso-butane
Hydrogen

Ethermax
C4 Stream
from Cracker 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

T on the feed expected to be
processed in the unit. Assuming the
The propane-propylene fractionation
is a difficult separation, historically
requiring two towers to accommodate
• A heat pump compressor system
functions as the reboiler and
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,
of the de-propanizer bottoms is refinery- High Flux tubing and the heat pump
• UOP’s MDTM multiple-downcomer
specific. The C3 splitter then fractionates system, together with UOP adsorbents
distillation trays reduce tower height
propane and propylene. Propane is – results in the most economic
and diameter without sacrificing
sent from the bottom of the column to separation of propylene from
product purity.
storage, while the propylene is taken propane available.
overhead and sent downstream for • UOP’s High Flux TM tubing reduces
further treating. 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

Propane/Propylene
C3/C4 Splitter Splitter Solvent
System
De-ethanizer

Mixed Sand Dryers Treater

C3/C4 Feed Filter

Propyl
Propane Produ
Product
C4
By-product

62
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.

OP's LAB processes are the most the UOP PEPTM process and the
U economical technologies available
today, providing LAB producers with
UOP/CEPSA Detal TM process.
range of molecular weight, is produced.
The Distillate Unionfining process
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
combination for new complexes, or Recovery of normal paraffins UOP Sorbex technology. It operates in
retro-fitted into existing complexes.
from kerosene liquid phase and simulates a moving
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
Molex TM process, the UOP Pacol TM containing the desired normal paraffins normal paraffin separation process
process, the UOP DeFineTM process, for the production of LAB with a certain available commercially.

Integrated LAB Complex

Kerosene Benzene

Prefractionation Hydrogen Light Ends Aromatics

& Hydrotreating Heavy
Alkylate

UOP Molex n-Paraffins UOP Pacol/ UOP PEP UOP/CEPSA

Process Detal Process LAB
DeFine Processes Process

Recycle n-Paraffins
Return Kerosene

64
 DETERGENTS PETROCHEMICAL PROCESSES

Production of LAB from The PEP process allows for the commercialization in 1995, over 75% of
normal paraffins and benzene 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
are highly active and selective. The continuing stream of innovations driven
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 PolysepTM Membrane systems. These

U and approach to analyze a
refinery’s hydrogen system. The
waste streams is often an important
strategy to improve hydrogen network
efficiency. Producing, recovering and
technologies are provided in the form
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.
bottom line. Recovering hydrogen from include UOP Polybed TM PSA and UOP

70
 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%.

o meet refiners' and petrochemical • Controls the variation of the tail gas
T producers' increasing need for
reliable, high-purity hydrogen for their
stream’s Wobbe index

• Offers reduced plot requirements,

downstream processing, UOP offers
fast delivery times and low installation
the PSA system. Polybed PSA systems
costs based on the modular design
are used in many applications to recover
and purify hydrogen. The hydrogen
Since the Polybed PSA system’s
from a steam reformer is typically purified
commercialization in the 1960’s, UOP has
by a PSA system. The PSA system
installed more than 900 PSA systems in
produces high-purity hydrogen to meet
more than 70 countries. The system has of hydrogen from gasification syngas,
downstream process requirements.
demonstrated exceptional economic purification of helium for industrial gas
In addition, Polybed PSA systems are
value in many applications, including use, adjustment of synthesis gas for
the technology-of-choice for recovering
recovery of hydrogen from refinery ammonia production, purification, of
and purifying hydrogen that otherwise
off-gases, purification of hydrogen from methane for petrochemicals production,
would be wasted to fuel.
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.
The Polybed PSA system:
• Provides a reliable, low-maintenance
Polybed PSA Process Steps
and very cost-effective alternative to
replace complex wet scrubbing Gas Product
Gas to Re-pressurize
purification systems Gas to Purge & Equalize

• Simplifies plant configuration

and operation
Counter Current De-pressurization

• Requires minimal manpower due

Co-Current De-pressurization

to automatic operation, as well as

Re-pressurization
Adsorption

minimal feed pre-treatment and utility

Purge

requirements

• Produces hydrogen with higher purity

levels than traditional wet scrubbing
systems

• Provides valuable heat input to the Feed Gas Step 1 Step 2 Step 3 Step 4 Step 5
Tail
H2 Gas
reformer furnace 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.

olysep membrane systems are • Minimal manpower requirements • Future expandability by adding
P modular units containing hollow
fiber spiral-wound membrane elements.
Automatic operation features require
no special operator consideration.
modules or skids

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 from hydroprocessing, methanol and
• High reliability
a skid in series or parallel configurations, ammonia plants. UOP has supplied
Historical operating data indicates
depending upon feed-gas volume and more than 70 units, including installations
minimal unscheduled shutdowns,
product requirements. High membrane- providing more than 55,000 Nm3/h of
with an on-stream factor
packing density minimizes system size enriched hydrogen.
exceeding 99.8%
and cost.

Polysep membrane systems offer:

• Ease of installation and maintenance

Modular design and shop fabrication
allow for compact design, but
membrane elements are carefully-
oriented for ease of maintenance

72
 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.

ydrogen – specifically hydrogen improvements can be made. It can • Consider impact on process units
H partial pressure – has a strong
impact on profitability because of its
lower refinery operating costs or new
hydrogen plant capacity by reducing
UOP combines analyses of hydrogen
network and purification systems,
effect on throughput, product quality, overall hydrogen needs. with a thorough understanding of the
conversion, yield and catalyst life. role of hydrogen partial pressure, to
By combining hydrogen network UOP uses a four-stage approach: identify hidden profit potential in
analysis with an in-depth understanding the process units. Because process
• Analyze refinery hydrogen balance
of the role that hydrogen plays in changes require re-design of the
A systematic methodology is used
hydrogen-consuming processes, UOP hydrogen network, the analysis
to set the minimum hydrogen
can help open opportunities for becomes iterative.
requirements and identify where
increased refinery profitability far
network improvements can be made. • Sustain the benefits
beyond the benefit realized by simply
The full benefits of hydrogen
reducing hydrogen costs. • Improve/add hydrogen purification
management can only be realized
Improvements to existing hydrogen
if network optimization becomes an
UOP’s approach provides a means of purification units are evaluated, as
integral part of refinery operations.
setting minimum consumption targets well as various alternatives for new
A UOP hydrogen network model
and direction on where network purification.
running on the engineer’s desktop
allows optimization and what-if
Benefits of UOP H2 Management Studies
analyses on a routine basis.

12 H2 savings only
UOP Hydrogen Management Studies
$MM/yr Profit Improvement

H2 savings plus process improvements

10 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 F G H I
Project

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.

OP’s broad and overlapping

U technical solutions ensure that we
can provide the right technology for
The diagram below shows where these
technologies fit based on the acid gas
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
from acid gas streams.
• UOP Amine GuardTM FS process

• UOP BenfieldTM process

1000 1000
Partial Pressure of Acid Gas in Feed, psia

• UOP Selexol TM process Selexol

Process Separex
Benfield Process Membrane
• UOP SeparexTM Membrane systems Systems
100 Polybed 100
• UOP MOLSIVTM adsorbents PSA
Systems
• UOP GBTM adsorbents
Amine Guard FS
10 Process 10

MOLSIV Adsorbents
1.0 1.0
UOP GB
Adsorbents

0.1 0.1
0.001 0.01 0.1 1.0 10 100
Partial Pressure of Acid Gas in Product, psia

78
 NATURAL GAS TREATING GAS PROCESSING

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.

cid gas (AG) partial pressure is

A an important parameter for
selection of the best Amine Guard FS Amine Guard FS Process with
process flowscheme. Feed conditions 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.
Amine
The process is capable of achieving Absorber
Acid
very low product gas specifications, to Gas

1 ppmv of H2S and 50 ppmv of CO2. Acid Gas

Flash Gas Knock-Out
to Fuel Drum
Header
Amine
Feed Stripper
UOP employs either the thermal- or Gas Rich Flash
Drum
flash-regenerated Amine Guard FS
process to selectively remove H2S and
other sulfur components from the feed Make-up
Rich Flash Water
gas stream or to achieve bulk removal Column
of CO2. Hydrocarbon, H2 and CO losses
Amine
are minimal in the Amine Guard FS Lean/Rich
Reboiler

Exchanger
process due to their low solubility in
the UCARSOL solvent. Amine Guard FS Process with
Selective H2S Removal Option
Amine Guard FS process technology
was introduced over 20 years ago. Treated Gas Acid Gas

UOP has licensed over 400 Amine

Amine
Guard units for commercial service Amine
Stripper
Absorber
throughout the world. 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.

here are a variety of Benfield • Lowers the CO2 in product gas

T flowschemes available that permit
process optimization and energy
by 25-85%

• Lowers the carbonate solvent solution

reduction with this near-isothermal
circulation by 5-15%
unit operation. Existing plants can be
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 typically used in the following applications
• Increases feed gas throughput by
performance packings. and markets:
5-15%
• Synthesis gas treating for CO2
UOP’s Benfield ACT-1TM activator is a • Reduces the consumption of
removal in ammonia plants
promoter for the absorption of carbon anti-foam and other chemicals
dioxide (CO2) by hot potassium • Synthesis gas treating for CO2 removal
• Reduces or eliminates the reduction
carbonate solution. ACT-1 activator can in direct iron ore reduction plants
of vanadium valence state from V+5 to
do one or more of the following in
inactive V+4 in ammonia or hydrogen • Natural gas treating to achieve either
comparison with DEA activation:
purification service LNG product or pipeline specifications

• Recycle gas purification in an

Benfield Process ethylene oxide facility

Product Gas 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 range from a few hundred ppmv to few
Gas Hydraulic
Turbine
(optional) 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.

olecular sieves are adsorbents

M composed of aluminosilicate
crystalline polymers (zeolites). They
UOP manufactures molecular sieve
products in various UOP MOLSIV
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
The natural gas processing industry
allows us to select the optimum
uses molecular sieves for:
products on a case-by-case basis.
• Natural gas dehydration

• Natural gas mercury removal

• Natural gas/LPG desulfurization

• Natural gas CO2 removal for

Open Cycle Molecular Sieve Dehydration System “peak shaving”

• Ammonia synthesis gas purification

Spent
Regeneration
Gas Number of operating units,
Feed Gas Molecular Sieve worldwide:
Separator Adsorbers
Regeneration Natural gas dehydration 1,000+
Gas Separator
Dehydration with regenerative
Wet Feed mercury removal 50+
Gas Condensed
Liquid Natural gas treating (sulfur, CO2) 200+
CO2 removal for
Regeneration
Gas Heater “peak shaving” LNG facilities 100+

Condensed LPG combined

Liquid dehydration/desulfurization 100+
Regeneration Gas
Synthesis gas purification 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.

OP HgSIVTM adsorbents are

U silver-laden molecular sieves
specially formulated to remove mercury.
Mercury Removal Unit Upstream of the Amine and Dryer Units

Regen Off Gas

The adsorbent can be loaded into an
UOP GB MRU
existing molecular sieve de-hydration
unit to simultaneously remove mercury,
water and other impurities. HgSIV Spent
Regeneration
adsorbents are regenerated with a Gas
clean gas stream. The mercury is
rejected with the regeneration gas and,
if desired, can be captured on a bed of
Natural Gas
non-regenerable GB series adsorbent. UOP MOLSIV
Adsorbents
The GB series are spherical, metal
oxide adsorbents designed for the Feed Gas Separator
non-regenerative removal of mercury. CO2 Removal Dehydration
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 Spent
Regen Off Gas Regeneration
vessel. Mercury removal units may
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 Natural Gas UOP MOLSIV
Adsorbents
single supplier, generally resulting in and
cost savings. UOP HgSIV
Adsorbents
Feed Gas Separator
Product Gas
CO2 Removal Dehydration

82
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 the stream. With appropriate design The SCORE process is applied to:
Recycle Process features, a plant using the SCORE
• Achieving high propane recovery
The Ortloff Single Column Overhead process can also be switched to operate
from natural gas or refinery off-gas
REcycle (SCORE) process is a state-of- in an ethane recovery mode utilizing the
streams with minimum compression
the-art gas processing technology suited Ortloff Gas Subcooled Process (GSP).
requirements, while rejecting lighter
to the recovery of propane and heavier components to meet liquid product
hydrocarbons from a natural gas stream. GSP typically achieves ethane recovery
specifications
The SCORE process is one of many of greater than 85%, with propane
Ortloff technologies capable of extremely recovery greater than 98%. Although • Allow gas processing plants to realize
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
• Providing flexibility to gas processing
97%, with 99% or higher easily not required in most cases.
plants where varying economic
achievable, while rejecting all ethane in
conditions may favor operating in
either ethane recovery or ethane
rejection modes for extended periods

Ortloff SCORE Process The SCORE process can accommodate

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 the addition of a refrigeration system.
Expander/ In normal operation, the SCORE process
Inlet Gas Compressor
produces a mixed LPG product stream,
Heat
Exchanger De-ethanizer typically meeting a maximum ethane-
in-propane liquid product specification.
When converted to GSP mode, a mixed
NGL product stream is produced,
typically meeting a maximum methane-
in-ethane liquid product specification.
NGL or LPG Product

84
 NATURAL GAS TREATING GAS PROCESSING

Recycle Split Vapor Process • Provide gas processing plants

operational flexibility where varying
The Ortloff Recycle Split Vapor (RSV)
economic conditions may favor
process is an enhancement of Ortloff’s
operating in either ethane recovery
original Gas Subcooled Process (GSP)
or ethane rejection mode
technology. The RSV process can
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
increased while still providing high Exchanger
recovery. This provides a greater
Residue
margin of safety from CO2 freezing. Gas
De-methanizer/
The RSV process can be applied to: De-ethanizer
Residue Gas
• Achieve high- to ultra-high ethane Compressor
recovery from natural gas streams, Expander/
Inlet Gas Compressor
with essentially no loss of propane Heat
and heavier components Exchanger

• Achieve high propane recovery from

natural gas streams while rejecting
lighter components to meet liquid
NGL or LPG Product
product specifications

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 their quality and reliability:
for improved sulfur recovery plant
• Robust waste heat boiler design
operation. Ortloff's Sulfur Vapor Line
Valve Assemblies are provided to meet • Indirect re-heat for higher conversion
the demanding cyclic process and
• Cold catalyst bed startup
mechanical requirements for sulfur
vapor service. • Reliable sulfur valve assemblies

• Superior sulfur-conversion catalyst

For applications where a high level of
performance
overall sulfur recovery is required (more
than 99.5%), Ortloff provides Shell's • Reliable sulfur drain seal assembly
SCOT tail gas clean-up process. This
• Extended turn-down range
process is the best-proven technology
available in the industry and can • Enhanced sulfur condenser design
achieve overall sulfur recovery
performance in excess of 99.9%.

86
 NATURAL GAS TREATING GAS PROCESSING

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.

he Selexol process is a well-proven

T commercial process that uses a
physical solvent to remove acid gases
The Selexol process can be tailored and
optimized for either bulk or trace acid
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
• The selective removal of H2S and
removal of H2S and COS and/or CO2
COS in an integrated gasification
to very low levels in the treated gas,
combined cycle (IGCC), with high
providing on-spec products, protection
CO2 slippage to the treated product
of catalysts as well as equipment, and
gas and high sulfur levels in the acid
environmental compliance. Sulfur levels
gas to downstream sulfur recovery
below 1 ppmv can be achieved with
systems
variable and optimized CO2 capture
levels. The process uses The Dow • 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 H2S Acid Gas
to remove mercaptan sulfur. The sol- Stripper
Treated Gas XXXX
Reflux
vent will remove the minor amounts of Accumulator
ammonia, HCN, metal carbonyls and
other contaminants that are typically Make-up
Sulfur Water
found in synthetic gas streams. Absorber
H2S
Compressor 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

remove sulfur, with a CO2 capture section CO2
Absorber
added as a second-phase project.

Acid gas partial pressure is the key

driving force for the Selexol process. CO2 H2S Acid Gas
Stripper
Typical feed pressure is greater than XXXX
Reflux
350 psia with an acid gas composition Accumulator

of CO2 plus H2S of 5% or greater by

volume. The product specifications Make-up
Water
Sulfur
achievable depend on the application Absorber
and feed characteristics and can be as H2S
Concentrator
low as 1 ppmv total sulfur with greater Feed
Gas
than 95% CO2 capture.
Packinox
Exchanger
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
 NATURAL GAS TREATING GAS PROCESSING

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.

hen confronted with a

W highly-contaminated natural
gas stream containing both H2S and
strength while maximizing integration to
minimize capital and operating costs.
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 and recycled back to the Amine unit
technology units required, and how 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
Acid Gas than a conventional flowscheme. The
(H2S, CO2, COS) integrated flowscheme has been
Dehydration RSH implemented in several operating LNG
Acid Gas Recovery NGL Treated Gas
NG and Hg Removal
(UOP Amine Recovery (To pipeline, complexes in the Middle East.
Feed Guard FS Process) (UOP MOLSIV
(Ortloff) LNG, GTL)
Adsorbents)

Acid Gas C2
(RSH, H2S, COS) Product
C3 C4
Treated RSH Removal
Regeneration (UOP Selexol COS, RSH Removal C3 Product
Gas Process) (UOP MOLSIV
Adsorbents) 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 site-specific, but may include:
are used for the removal of acid gas
• 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, gas pre-treatment to extend membrane

• Lower operating costs and manpower life. Improved pre-treatment, combined
depending on process requirements.
requirements with the continuing development of
Separex membrane systems are
typically used in the following • Increased flexibility to meet product advanced membranes, has further

applications and markets: 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,
• Remote and offshore locations
• Shorter, easier startup and shutdown engineering services are readily available
• Enhanced oil recovery (EOR) through our worldwide Gas Processing
operations • Higher permeate gas pressure, technical service organization.
which reduces re-injection
• Bio-gas methane recovery
compression requirements The combination of extensive
• Debottlenecking of existing acid gas engineering design experience,
removal units 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.

ompact and lightweight natural Footprint and weight are of vital

C gas treating systems are critical to
cost-effective gas production and rapid
concern in FPSO, FLNG and platform
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 UOP Separex UOP Amine Guard UOP MOLSIV
Mercury Removal Unit Membrane System FS Process Unit De-hydration Unit

Feed Treated Gas to

Gas Liquefaction
Technology

Sour Gas Water

(CO2 + H2S)

92
 SYNGAS TREATING GAS PROCESSING

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 gas removal processes. The capability

U and expertise in gas processing
have been combined to provide gas
These processes include:

• CO shift or COS hydrolysis, or both

to produce a high concentration of H2S
in the acid gas for the Claus plant and
purification complexes that can • Acid gas removal the ability of the Selexol unit to
produce clean syngas for power re-process the Claus tail gas contribute
• Claus sulfur recovery
generation or hydrogen, and to such effective results.
ratio-adjusted syngas for chemicals • Claus tail gas treating
production. The flexibility of the Selexol process to
• Hydrogen extraction and purification
accommodate recycle of hydrogenated
As a leading technology supplier, UOP • H2/CO and H2/N2 ratio adjustment Claus tail gas not only improves
has developed unique expertise in process economics, but also:
project definition as well as optimization, For a sulfur complex of an IGCC flow
• Eliminates additional processing units
engineering and technical support. scheme (defined as COS hydrolysis,
(tail gas treater and off-gas incinerator)
During project definition, UOP selects acid gas removal, Claus sulfur plant,
with their added complexity
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.
• Enables the plant to easily tolerate
periodic breakthroughs of SO2

UOP Optimized Syngas Purification Complex

UOP can develop a gas purification
complex to produce syngas that meets
SRU
Tail gas the specifications required for specific
TGCU
downstream chemicals manufacturing.
Sulfur
SRU Product Using a combination of UOP Polybed
CO2 PSA and UOP PolysepTM membrane
PSA Tail gas Acid Gas Product
systems, the syngas composition can
H2 be adjusted for use in the synthesis of
PolyBed PSA Product
ammonia, methanol or oxo-alcohols.
CO Shift/COS Selexol IGCC Power The syngas composition can also be
Syngas Hydrolysis Unit
Sulfur SNG adjusted to produce pure hydrogen for
Guardbed Methanation Product
hydrogenation units.
Fischer Tropsche Fischer
Technology Tropsche
Reactor Liquids
Partners
UOP/Ortloff Methanol Methanol
Unit
UOP

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.

OP continues to develop its

U portfolio of solutions to enable
our customers to meet their renewables
diesel. UOP has since added its UOP
Renewable JetTM process to that portfolio.
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
 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.

he Ecofining process can be The Ecofining process de-oxygenates

T applied to a wide range of
bio-derived feedstocks. It is designed
and de-carboxylates tri-glyceride
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

Feed Make-up Green Propane

Hydrogen and Light Ends

Reactor Acid Gas Green

CO2 Naphtha
System Scrubber
Product
Green Jet
Product

Separator Jet Option

Green
Diesel
Product Green
Water 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 indistinguish-
able 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

Oxygen, % 0 11 0 simply meeting bio-component target
or mandate levels.
NOx Baseline +10 -10 to 0
Specific Gravity 0.84 0.88 0.78
Additional benefits of green diesel
Cetane 40-55 50-65 75-90
fuel include:
Sulfur, ppm <10 <2 <2
Energy density, MJ/kg 43 38 44 • Can be blended to any proportion

Cold flow properties Baseline Poor Excellent • Has excellent stability

Oxidative stability Baseline Poor Excellent
• 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
• Contains higher energy content per
costs, enabling licensees to position (LCA) of green diesel shows greenhouse
volume compared to biodiesel
themselves with a low-cost advantage gas (GHG) savings of more than 50%,
while meeting bio-fuel targets. relative to fossil diesel, depending on
UOP offers licenses and basic
the bio-feedstock processed and the
engineering design packages for the
Evaluations have shown that the variable calculation method used. When blended
Ecofining process to meet customer
operating costs of the Ecofining into an existing petroleum diesel pool,
requirements. In addition, UOP can also
process result in a lower cost of the high-cetane and low-density green
provide complete project implementation
production than for a a typical Fatty diesel can enhance the pool’s
services through our alliances with
performance characteristics. This brings
leading contractors worldwide.

100
 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.

hile the Ecofining unit can Feed flexibility

W produce up to 15% by volume of
synthetic paraffinic kerosenes (SPK jet
The Renewable Jet process can convert
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 and canola oils, C12 oils such as coconut
catalytic processes of deoxygenation, and the UOP Ecofining TM process is the oil, inedible oils like jatropha and camelina
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 C16-C18 carbon chain lengths to carbon
diesel- and naphtha-range materials. chain lengths in the C10 to C14 range Testing and certification
The process can be adjusted to produce required for jet fuel. UOP actively participates in the fuel
a specific freeze point of the SPK or,
qualification process for bio-derived SPK
alternately, can be operated in a Product properties
jet fuel. To provide sufficient quantities of
maximum diesel mode.
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 Product
Deoxygenation Hydrogenation 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
Green Diesel leading contractors worldwide.
Water

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.

his new company will also

T accelerate research and
development efforts to commercialize
that used in the UOP Fluid Catalytic
Cracking process. RTP typically yields
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. Pyrolysis oil is clean-burning, with
The RTP process offers several unique minimal sulfur and nitrogen content.
The RTP process is a fast thermal benefits including: The pyrolysis oil produced using RTP
process, where bio-mass is rapidly heated technology is almost carbon neutral,
• Requires minimal utilities and
in the absence of oxygen. The bio-mass and is an ideal and cost-effective
infrastructure making it ideal for both
is vaporized and then rapidly cooled to solution for customers wishing to
remote and existing industrial facilities
generate high yields of pyrolysis oil. The reduce their carbon footprint. As a
process utilizes a circulating, transported • Meets the needs of diverse applica- renewable fuel oil substitute, pyrolysis
fluidized-bed reactor system similar to tions with highly-scalable designs of oil can service a wide range of
100 to 1,000 metric tons-per-day sectors including:
• Allows ease of implementation due • Refining
Basic RTP Process Unit
to a small footprint and compact,
modular construction • Utilities
Pyrolysis
Oil Product • Handles a wide range of feedstocks • 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

Gross Energy Gross Energy

Bio-mass Yield
Content Content
Material (Wt%)
(Btu/lb) (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

Pyrolysis
Bio-mass Oil
RTP Fuel Oil
Process
Liquid
Future Transportation
Upgrader 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.

efiners can rely on UOP adsorbent

R 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 ethane and propane feed streams
and corrosion Natural Gas
• Drying of cracked gases and
• Drying of refinery hydrogen streams hydrogen streams Natural gas processors, one of the first
to prevent corrosion in downstream industries to use molecular sieves to
• Dehydration and purification of
equipment treat gases and liquids, now use
ethylene, propylene, butadiene,
molecular sieves produced by UOP
• Dehydration of refinery gases butylenes, amylenes and various
for the following applications:
to prevent line freeze-ups during solvents and co-monomers
cryogenic processing • Super-drying before cryogenic
recovery of hydrocarbon products
• Drying and desulfurization
and helium
• Drying of isomerization feeds and
• Desulfurizing ethane, propane
drying and purification make-up
and butane
and recycle hydrogen streams
• Removing H20 and CO2 before
In addition, the drying and purifying of methane liquefaction
liquids and gases with molecular sieves • Removing H20 and H2S to protect
is widely used in PSA units, sulfur 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)
The natural gas industry uses activated
Rouge, Louisiana, U.S.A. Promoters, • Sulfur species
alumina-based adsorbents to improve
additives and metal oxides are also • H2O overall process economics by protecting
commonly used by UOP in the
• Chlorides process equipment and meeting
manufacture of activated aluminas to
product stream specifications.
achieve even greater performance for • Fluorides
Contaminants removed from natural
total contaminant removal. UOP • Mercury and mercury compounds
gas and natural gas liquids include:
Activated Aluminas are commonly • Oxygenates
used in a wide variety of applications. • H2S
Petrochemicals • COS
Petrochemical producers use activated • Mercury and mercury compounds
alumina-based adsorbents to improve
• H2O
product feed quality, protect catalysts,
• CO2
safeguard process equipment and
prevent unwanted side reactions.
Contaminants removed include:

• AsH3
• Sulfur species
• Oxygenates
• H2O
• Tertiary Butyl Catechol

110
 ADSORBENTS

Versal aluminas include pseudo-boehmite, bayerite and

gamma-powered aluminas, all with
Versal aluminas are a family of high-purity
varying densities, unique pore size
alumina powders available in a variety
distributions and dispersibility ranges.
of rheological and physical forms. They
Versal aluminas allow catalyst
are used primarily as catalyst supports,
manufacturers to achieve finished
washcoat slurries and binders. Their
catalysts with enhanced pore volume,
many forms and uses inspired the
density and metal-promoted properties.
name for this versatile group of
In addition to being a key component
alumina products.
in many commercially-used catalysts,
UOP’s Versal aluminas play key roles
The forerunner of the Versal alumina
in the polishing, abrasives and
line was a gel alumina, a name that
surface-coatings industries.
referred to the colloidal state of the
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.

ield experience unmatched in depth • Allowing fast, simple installation and low. These situations occur in medium- to
F and breadth confirm that UOP's trays
consistently deliver key benefits including:
short turnaround times high-pressure distillation, in absorption
and stripping and in direct-contact heat
• Demonstrating low sensitivity to
transfer applications.
• Reducing column diameters in out-of-levelness
grassroots applications
• Minimizing or eliminating MD trays can be used at close tray
• Increasing capacities for existing columns foaming and fouling spacings. They allow for a reduction in
the height and diameter of a new
• Maximizing the number of theoretical
UOP MD trays are used for large liquid column, compared with a column fitted
trays for a given column height
loads, particularly when the volumetric with conventional multi-pass trays.
• Providing easy scale-up to any diameter 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: columns where a large number of trays
are required, only MD trays can be used
• Long weir lengths and large
at the close tray spacings required.
downcomer areas, providing high
liquid-handling capabilities
UOP continues to improve the design
• 90° rotation of downcomers on 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
MD trays, ~20% higher. The higher
• Downcomers supported on a 360°
performance of ECMD trays can be
ring, so no bolting bars are required
used to revamp existing conventional-
• The ability to be fabricated with trayed 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
smaller grassroots columns than that
• Low tray pressure drops of
achieved with MD trays. UOP PFMDTM
0.06-0.09 psi
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 weir-

length even at very high total liquid
flow rates.

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 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 correlations developed for in-tube

condensation and condensation on
High Flux tubing operates exclusively
vertical surfaces. Most heat exchanger
in the nucleate boiling mode, which is
configurations using commercial High
characterized by the formation and
Flux tubing are either horizontal kettles
growth of bubbles on a hot surface.
and thermo-siphons, or vertical
In conventional bare-surface tubing,
thermo-siphon reboilers. particularly for heat pump applications,
bubbles originating at random pits and
to allow the fully-optimized design in
scratches on the surface promote
UOP’s High Flux tubing's surface can terms of initial capital investment and
vigorous liquid agitation. The High Flux
be combined with UOP’s portfolio of annual operating cost.
surface technology greatly improves
condensing surface profiles, including
heat transfer during nucleate boiling,
OD tube fluting profiles for shell-side In retro-fit situations, the higher thermal
achieving boiling co-efficients ten times
condensing, as well as various spiral ID performance of High Flux tubing can be
greater than that of bare tubes.
fin profiles for tube-side condensing in captured to increase the heat exchanger
horizontal heat exchanger orientations. capacity and reduce the required heat
Design procedures for High Flux
exchanger LMTD, thereby allowing the
exchangers are similar to those that
The use of High Flux tubing results in plant performance to be fully optimized.
use bare tubes. Computer programs
substantial savings in capital equipment When existing U-bundles are replaced,
have been developed for the design
and in operating costs. For grassroots substantial savings also result from
of horizontal and vertical High Flux
applications, heat exchanger surface re-using the existing heads, shells
exchangers. These programs are
areas and sizes are reduced. For large and piping.
supplemented by heat transfer
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,

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 EQUIPMENT

UOP High CondTM Tubing Specifying High Cond tubing in the

design of new plants can save
UOP expanded its enhanced heat
considerably on capital costs. The total
transfer product portfolio with the
installed cost of the heat exchanger is
development of High Cond tubing for
lower, especially in applications where
shell-side condensing in horizontal heat
multiple bare tube shells are required.
exchanger orientations. High Cond
In those cases, utilizing High Cond
tubing is especially well-suited for use
tubing will typically reduce the number
in horizontal cooling water condenser
of required heat exchanger shells by
applications. The tube OD surface
half. This results in large cost savings,
has been optimized to minimize liquid
less plot space, smaller/lighter
condensate film thickness and improve
exchangers, less piping, smaller
condensate drainage. These technical
structure and less civil foundation.
features maximize the tube’s
condensing and overall heat-transfer
Examples of applications for High
coefficients. Improved heat transfer
Cond tubing include:
performance allows for reductions in
capital investment, higher heat exchanger • Propylene splitter
capacity, and process optimization.
• Overhead condensers

• Propylene refrigerant condensers

• Naphtha splitter condensers

• Other water-cooled shell and

tube condensers

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 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
Raschig Super-Ring elements are vapor-liquid traffic along preferred flow
The development of the Raschig
available in numerous sizes in order paths. In addition, the vapor-liquid
Super-Ring packing element sets new
to provide the optimal solution for a traffic is forced into sharp directional
standards in the field of separation
specific project's requirements. changes at the packing layer interface
technology, helping to meet the industrial
Ultimately, the elements provide a lower when packing elements are vertically
demands on modern packing elements
pressure drop, higher loading capacities stacked. The net result is that the
more effectively. Raschig Super-Ring
and excellent mass-transfer efficiency. enforced vapor-liquid flow patterns
elements allow customers to minimize
within the 'closed' structure of a
their initial investment for a given
Raschig Super-PakTM Packing common packing element do not
capacity grass-roots applications, or
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
The new Raschig Super-Pak packing Super-Pak packing. It is a more open
elements. The ring not only has a 33%
is a novel development in mass transfer structure such that vapor-liquid traffic
higher loading capacity than the 50 mm
technology because of its optimized can flow freely within a packing element,
metal Pall ring, but it also displays a
surface design. It enables unprecedented and no sharp directional changes exist
substantially higher loading capacity
separation efficiency and high loading at the layer interface. The rows of
than previous modern packing
capacity, while keeping the pressure sinusoidal waves within vertical packing
element designs.
drop extremely small. sheets are surface-enhanced to
encourage greater turbulent radial
The low specific packing weight of the
spread of thin liquid film flows on the
Raschig Super-Ring elements allow the
front and back of the waves on each
design of low-cost supporting elements
sheet within an element. This open
in the columns without sacrificing stability.
structure provides excellent hydraulic- and
mass transfer-efficiency characteristics.

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 EQUIPMENT

Hydroprocessing Reactor Internals

The UOP Unicracking and Unionfining technologies are distinguished by

both world-class catalyst system and advanced reactor internals design technologies.

n all hydroprocessing units, it is

I extremely important that the radial
temperature spread of reactants on top
Pressure gradient over the vapor/liquid distribution tray

of the catalyst bed is minimized by the

use of an efficient quenching system,
and maintaining even distribution of
Increasing Pressure

liquid and vapor throughout an operating

cycle. This can be achieved by 1. Base Case, std inlet diffuser, no RLDT 2. Modified inlet diffuser, no RLDT

installing reactor internals which are

specifically designed for each unit,
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 operating cycle, causing significant

variations in the pressures and liquid
UOP's inlet In an ideal condition where distribution
heights on top of the distribution tray.
diffuser dissipates trays are perfectly level and the
The vapor/liquid distribution tray (VLDT)
momentum of vapor-to-liquid ratio remains constant,
must be designed to perform optimally
incoming reactants. most distribution devices will, in all
under these realistic conditions.
It pre-distributes likelihood, provide adequate performance.
fluid across the In reality, tray level differences always
UOP's vapor/liquid distributors are
reactor cross-section where a liquid exist due to fabrication and installation
designed to distribute liquid more evenly
level builds on the top rough liquid tolerances, level gradients and waves
than bubble-cap and riser-style
distribution tray (RLDT). For ease of in the liquid level. Moreover, vapor-to-
distributors, which are much more
maintenance, it can simply be lifted out liquid ratios vary significantly during an
sensitive to pressure differences caused
during shutdowns because it sits in the
by vapor-to-liquid ratio variances. They
reactor manway.
are designed for a very low pressure
Rough Liquid Distribution Tray drop across the tray, and therefore can
operate at vapor rates considerably
UOP's rough liquid distribution tray
above their design value. The distributor
(RLDT) is located above each vapor/
design also enhances distribution over a
liquid distribution tray and serves
wider range of liquid levels than bubble
several purposes. Any residual fluid
cap and riser-style distributors, all while
momentum exiting the inlet diffuser
providing increased resistance to fouling.
(or mixing chamber within an inter-bed
quench zone) is broken by the RLDT.
In addition to ensuring optimal design
Each RLDT is custom-designed to
of its vapor/liquid distributors, UOP
maintain an optimal liquid level, while
optimizes the design of the VLDT.
passing vapor feed around its outer
The spacing of distributors has been
perimeter. The RLDT is also designed
increased for maximum cross-flow
to mate perfectly with its vapor/liquid
between distributors, while maintaining
distribution tray, delivering a uniform
an optimal drip-point density. This
layer of liquid across the reactor
design accounts for distribution above
diameter. In the custom design to
the tray and at the tray’s outlets,
ensure proper distribution, the operating
spreading fluid evenly over the catalyst
conditions at the various modes of
bed. This distributor spacing also
operation being considered are
allows for improved maintenance and
analyzed to ensure that proper
cleaning of the tray.
functioning/distribution is occurring
across the trays.

122
 EQUIPMENT

Catalyst Support Grid Quench Zone Liquid and vapor on the liquid collection
tray pass into the centrifugal mixing
UOP's catalyst support grid employs a The quench zone contains UOP’s
chamber designed to facilitate liquid
design to maintain target throughputs commercially-proven and patented
mixing. Mixed liquid then travels
throughout the catalyst cycle, prevent “centrifugal mixing” design. This consists
to the RLDT below.
catalyst migration and maximize of a liquid collection tray and mixing
catalyst volume, while virtually eliminat- chamber. Quench gas is introduced to
UOP's centrifugal mixing quench
ing catalyst bed fouling and plugging. the process fluid on the liquid collection
zone equipment, combined with the
As is the objective in the design of each tray through the quench distributor
effectiveness of the vapor/liquid
component in UOP's reactor internals, (pictured below). The UOP quench
distribution tray, achieves proper
the catalyst support grid is designed to distributor design has been optimized
thermal mixing and re-distribution
minimize maldistribution which will through extensive cold flow modeling
between catalyst beds.
eliminate stagnant regions, therefore and testing, as well as Computational
providing the most efficient use of the Fluid Dynamics (CFD) studies.
Outlet Collector
entire catalyst bed.
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.

ased upon our extensive • On-spec Our areas of expertise include training,
B technical knowledge and
experience, our service offerings
Producing the right products to meet
the best market opportunities while
inspection, process transformation,
performance optimization. startup
aid customers in achieving three fulfilling all regulatory requirements services, field operating services and
key priorities: regional services. Our in-depth
• On-time
knowledge of the hydrocarbon
• On-stream Enabling the agility to swiftly respond
processing industries enables us to
Ensuring that your plants are running to those market opportunities
understand challenges and provide
and delivering products exactly
effective solutions.
when needed

128
 UOP SERVICES

Services We Offer

Training Aimed at providing technical knowledge

to all refinery personnel, including
Successful operation of refineries,
operators, engineers and managers,
petrochemical plants and gas processing
UOP’s web-based training (WBT)
facilities depends on having well-trained
provides a self-paced introduction to
personnel to operate and maintain the
UOP's process technologies and
various process units. Recognizing this
engineering disciplines. The implemen-
need, our Training Services department
tation of WBT allows employees to
offers a wide variety of training programs
engage in training whenever needed,
at your site, at a regional UOP office
from wherever they are. A typical
or via the internet to help transfer our
course includes process overview,
technology to operators, engineers,
chemistry, catalyst, process variables,
inspectors, managers and maintenance
process flow and equipment. Most WBT
personnel. These programs include
courses can be completed in one day.
training for individual process
technologies and specialized equipment.
For larger training requirements along
the entire refinery project life-cycle,
UOP's multi-company courses allow
UOP offers customized long-term
engineers and operators to both attend
training engagements. These programs
a course delivered by UOP’s technical
can vary from WBT site licenses to
experts and interact with participants
long-term training engagements that
from other companies throughout the
support new complexes from concept
geographic region. Students leave not
through to start-up and beyond. The
only with our course materials, but also
long-term engagements are designed
with knowledge gained from other
alongside refinery personnel and
attendees who work on similar units.
include multiple training platforms.
Long-term engagements are facilitated
UOP's single-company training courses
by a dedicated training project manager customers with practical solutions to
are designed to deliver customer-specific
and are a cost-effective way to ensure mechanical problems based on a
training that enables successful start ups
that when a refiner licenses a process worldwide history of solved process
and ongoing operations with well-trained
unit from UOP, not only will they be and maintenance challenges. Available
operators and engineers.
getting the best-designed unit, they will services include fabrication shop
also be able to operate it on day one. inspections, turnaround inspections,
UOP also offers its Customer Career
inspection planning, on-stream
Development Programs, which are
Inspection inspections and inspection training.
modified to the customers' needs, and
based on UOP's industry-renowned UOP has offered high-quality inspection
consulting services to refining and UOP inspection specialists are trained
Career Development program. The
petrochemical customers worldwide for in the specifics of UOP’s licensed units
graduates gain invaluable hands-on
more than 60 years. Our vast experience and their operations. They have access
experience in UOP's technologies, work
in inspecting refinery and petrochemical to the latest UOP specifications, as well
processes and tools, as well as forming
process units enables UOP to provide as the technical support of UOP’s
life-long relationships with UOP's experts.

129
 UOP SERVICES

engineering and technical services staff, improving UOP's service-delivery Field Operating Services
and they’re equipped to manage the process. They’re constantly working to
The Field Operating Services (FOS)
entire scope of UOP's inspection work. increase productivity and enhance the
group works to maintain close contact
Additionally, the UOP team can assess quality of our services by providing
between UOP's customers and our staff
inspection strategies, practices and on-line access to educational resources,
in the field during the commissioning of
procedures, and train employees to productivity-enhancing systems and
new UOP process units. Our on-site
continue on their own with vital inspection technical assistance to both UOP staff
startup team typically consists of a chief
procedures and processes. and our customers. The process
process advisor, an instrument advisor
transformation group offers a number
and three process advisors. From the
Process Transformation of software solutions for improving our
final phase of unit construction through
UOP’s Process Transformation group customers' operations, safety, reliability
catalyst loading and the start of
is responsible for streamlining and profitability, including Expert Systems
round-the-clock operations, our advisors
interactions with customers and and the operations monitoring tool
will assist the customer's personnel
UOP OpAwareTM.
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 When a customer purchases UOP

catalyst, adsorbent or equipment, they
UOP's Technology Services (TS) group
get more than a world-class product.
is composed of highly-skilled engineers
They also get the dedicated attention of
and scientists who are experts in their
a UOP TS specialist.
particular process technology. These
technology experts work closely with
UOP's TS specialists complete rigorous
their counterparts in UOP's research,
training that includes assignments in
development, engineering, regional
UOP’s field operating services,
services and field operating services
engineering and development groups.
groups to deliver new technology, and
Specialists can draw upon a significant
transfer knowledge to our customers.
network of R&D, engineering, analytical
and TS resources, as well as specialized
TS specialists monitor the operation of
tools and operating data from many
UOP processes, equipment, catalysts
other UOP units.
and adsorbents by analyzing plant
data. Guidance on operating conditions
At the time of a catalyst or absorbent
and strategies is provided to support
purchase, a UOP TS specialist will
customers as they optimize their units
review the customer's operations,
for safe and profitable operation.
equipment and procedures to develop
Technology Services also provides
the most appropriate and effective
startup, revamp and reload support
startup for the new load. The specialist
for customer turnaround planning
can also provide advice on loading and
and execution.
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 a broad range of tools that look at • Adapting the refinery to handle a
long-term investment planning and different crude slate
UOP’s Optimization Services group
configuration design, as well as
offers a suite of services to help you • Refinery expansions in either capacity
short-term opportunities for technology-
achieve and maintain maximum or up-grading capability
focused enhancements and improved
profitability. Our Technology-Integrated
efficiencies in existing plants. • Producing a cleaner slate of products,
Profitability Solutions (TIPS) consulting
or shifting to higher-value products
services experts draw on their extensive
Strategic TIPS
knowledge and experience, employing • Increased diesel production capability
Over the life of the refining industry
there has been constant change in the Tactical TIPS
desired product mix and specifications,
Our Tactical TIPS consulting solutions
crude availability and characteristics, as
focus on the profitability of customers'
well as consistent pressure to improve
current plant and help determine how
efficiency and operate more cleanly.
to unlock the most value from their
Refiners must therefore routinely plan
operations. From improving yields and
forward 5-10 years to ensure that their
margins to addressing new regulations
configuration is relevant and optimized.
and enhancing efficiency, UOP can help
This may involve designing a state-of-
customers meet their business
the-art new refinery to achieve industry
objectives. UOP's experts can evaluate
leading margins. Or it may be working
individual process units, the entire refinery,
with an existing site, to ensure that the
petrochemical, or gas processing
existing equipment can be adapted and
complex, or even multiple sites to
supplemented with the latest technology
identify key opportunities through a
to meet the feed, products and
combination of:
regulatory challenges of the future.
• Unit performance improvements
Our Strategic TIPS methodology, tools
• Refinery-wide profitability studies
and expertise for evaluation of a refinery
configuration is well-proven, with over • Energy and CO2 optimization
100 studies successfully completed
• Hydrogen and fuel gas management
over the last decade. These studies
have covered a range of configuration • Scheduling and blending consultation
evaluations including:
• Evaluation of processing options
• Naphtha complex studies to address
• Debottlenecking
benzene regulations, or to evaluate
aromatics vs. gasoline production • Linear Program (LP) optimization

• Petrochemicals production expansion

• State-of-the-art grassroots refinery

configuration development

132
 UOP SERVICES

Energy and CO2 Management

TIPS
While there is constant pressure to Technology-Integrated Profitability Solutions
reduce energy usage and improve
environmental performance, refiners Strategic Solutions Tactical Solutions
may find that they can achieve those
Technology-Focused
goals while also maximizing product Grassroots Configuration
Process unit or process block
yield, product quality and margins. To Investment strategy
Complex-wide or refinery-wide
Configuration definition
achieve optimization of their energy and Multi-site
process performance, UOP can apply its Processing Solutions Configuration
Systems/Network-Focused
tested methodology to assist refiners by: Dieselization
CO2/energy management
Gasoline pool
Hydrogen management
• Collecting and analyzing current
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. UOP5252
Tel: +1-847-391-2000 March 2011
Printed in U.S.A.
www.uop.com © 2011 Honeywell. All rights reserved.