Also known as:
In a refinery, alkylation is a common process unit that produces a high-quality gasoline blendstock by combining two LPG-range molecules to form one gasoline-range molecule. This involves reacting isobutane with some type of light olefin, typically either propylene or butylene.
The economic value from the alkylation unit comes from its ability to upgrade low-value light ends (C3s and C4s) to a high-value gasoline blendstock - one that has a premium quality with relatively high octane properties and containing no aromatic components. The capacity and/or throughput of the alky are typically limited by the availability of the olefin to feed it, most of which comes from the FCC.
The alky relies on, and compliments, the FCC. Most, if not all, of the light olefins generated in a refinery come from the FCC unit. Some may also come from the coker.
A mixture of isobutane and light olefins (either butylene, propylene or a mix) is injected into a series of reaction chambers filled with a liquid catalyst. The catalyst is typically either sulfuric acid (H2SO4) or hydrofluoric acid (HF), although a few units use a non-acid, ionic liquid catalyst. The catalyst causes the isobutane to combine with the olefin to produce either a C8 or C7 naphtha range product called alkylate.
The isobutane used to feed the alky is produced throughout the refinery as a product of other conversion processes. Typically this is supplemented with isobutane produced on-purpose in a C4 isomerization unit.
The olefin feed for the alky primarily comes from the FCC unit. Typically refiners will preferentially feed the alky with butylene because this yields the highest quality alkylate (octane and vapor pressure) and butylene has a lower-valued alternative use than propylene.
Propylene will also be used whenever there is insufficient volume of butylene available, and/or it is not possible to sell the propylene as a separate product.
C5 olefins (amylenes) are also used at times as a supplemental feed. However, this is less common.
The primary product from an alkylation unit is C5+ alkylate. The volume and quality of the alkylate will depend on the olefin feed used (butylene or propylene) and the operating conditions for the unit, but all alkylates benefit from having a zero level of aromatic components.
The alky unit will also yield any saturated propane and/or butane that was present in the feed. The alky also produces a small amount of alkylate bottoms.