NOVEL fixed bed alkylation REACTOR

PCI is developing a novel reactor that offers a potential breakthrough in the design of a solid acid alkylation system, avoiding the polymerization that can too-quickly require catalyst regeneration. In a current DOE-supported program, PCI is developing this reactor for production of alkylate, a primary component of reformulated gasoline for cleaner automotive combustion and higher efficiency. The PCI technology offers a possible breakthrough in the manufacture of alkylate, offering improved oil refining efficiency, costs, and health safety with the potential over time for reducing the price of gasoline at the pump.

Alkylation is a major refinery process in which light hydrocarbons are converted to a clean-burning, high octane gasoline feedstock. Alkylate is an important, and expensive, component of reformulated gasoline. Alkylate improves combustion, reduces emissions, promotes longer engine life, and enables higher compression ratios for higher fuel efficiency. Replacing MTBE in reformulated gasoline has led to substantial increases in alkylate demand, boosting price premiums and driving higher gasoline prices, especially in summer.

Increasing alkylate capacity is challenging due to environmental, energy and safety issues and costs relating to current production processes (employing liquid sulfuric and hydrofluoric acids). There has long been strong refiner interest in replacing these with potentially lower cost fixed bed catalyst alternatives, but these approaches have been limited by the issues of catalyst poisoning and high regeneration costs.

The PCI reactor system is a new and novel approach to this challenge. Replacing current liquid acid processes with PCI's process offers the potential for improved yield, reduced energy consumption, elimination of liquid acid environmental and safety complications, simplification of plant design and reduced capital and operating costs. It also offers the potential for higher quality alkylate.

Contact PCI for more information.