2020 REFINING PROCESSES HANDBOOK PROCESS CATEGORIES COMPANY INDEX ALKYLATION Recycle isobutane K-SAAT™ Application: KBR Solid Acid Alkylation Technology (K-SAAT) converts light olefins (ethylene, propylene, butylenes and amylenes) and isobutane to high-octane alkylate using a zeolite-based, solid-acid catalyst. The engineered catalyst does not contain precious metals and provides long alkylation cycle times. The process uses a simple fixed-bed reactor design with a low catalyst inventory. The technology can be used for grassroots alkylation units or to retrofit existing liquid acid alkylation units. Description: The reactants (olefin feed and isobutane) are sent to fixed-bed alkylation reactors. The reactors convert 100% of the olefins to high-octane alkylate using a solidacid catalyst. The K-SAAT process uses an engineered solid-acid catalyst to maximize the yields and quality of the alkylate produced, while eliminating the inherent safety concerns associated with liquid acid alkylation units. The process employs three fixed-bed reactors. While two reactors are operating in alkylation mode, the third is in catalyst regeneration mode. The engineered K-SAAT catalyst enables a 24-hr alkylation cycle at 50°C (122°F) and 20 barg before catalyst regeneration is required. Catalyst regeneration is carried out with a circulating loop of hydrogen-rich vapor heated to 275°C (527°F) at 20 barg. The reactor effluent is sent to a product fractionation section, where n-butane and alkylate are separated and isobutane is recycled to the reactors. The K-SAAT process does not produce any acid soluble oil (ASO) and requires no product post treatment. Reactor Olefin feed + makeup IC4 Deisobutanizer column N-butane Alkylate Products: Ultra-low-sulfur alkylate with high octane number and low Reid vapor pressure (RVP) as blending stock for gasoline. Alkylate RON of 99 can be achieved with MTBE or ETBE raffinate feed. Advantages: * Superior product quality. K-SAAT alkylate octane is higher than that produced by liquid acid technologies with a RON typically at least 1 point higher. * Higher alkylate yield. By producing no ASO byproduct, K-SAAT produces a higher yield of alkylate product per unit of olefin consumption. * Lower capital cost. The simple, fixed-bed reactor design has a low equipment count and no exotic metallurgy. * Lower maintenance cost. The K-SAAT catalyst is non-corrosive and safe to handle, delivering a lower maintenance cost and simplifying turnaround activities. Reactor Compressor Continued Copyright © 2020 Gulf Energy Information. All rights reserved.http://www.hydrocarbonprocessing.com/