T E C N O L O G I A

ISAL: HIGH QUALITY GASOLINE

Nelson Martnez, Rodolfo Bruno Solari, Jos Armando Salazar and Arturo Mogolln
Rening Division, PDVSA-Intevep

SALTM, the technology developed by PDVSA-Intevep y UOP, offers reners an excellent opportunity to upgrade low-quality FCC naphtha for use in gasoline pool. The technology is based on typical hydrotreating ow schemes, and thus ease of operation and reliability are inherent to the process. Because the degree by which the available naphtha can be improved is dependent on the naphtha source, UOP and Intevep will provide the necessary information for specic processing requirements, since improvement of available naphtha depends on the source. Based on its wide experience in hydroprocessing technologies, UOP is well placed to offer ISALTM as a solution for improving the quality of FCC gasoline.

SALTM es una tecnologa desarrollada por PDVSA-Intevep y UOP que ofrece una excelente oportunidad a los renadores de mejorar la nafta de FCC de baja calidad a n de incorporarla a su pool de gasolinas. La tecnologa est basada en los esquemas tpicos de ujo de hidrotratamiento que proporcionan una fcil operacin y conabilidad al proceso. Tanto UOP como Intevep proveen toda la informacin necesaria relacionada con requerimientos especcos de procesamiento, en vista de que el grado en el que se puede mejorar la nafta disponible depende de su origen. Basado en su amplia experiencia en tecnologas de hidroprocesamiento, UOP est en capacidad de ofrecer ISALTM como una solucin para mejorar la calidad de la gasolina de FCC.

oday, the rening industry is facing the need for cleaner fuels. Because FCC gasoline is a major component of many gasoline pools, reners need to reduce the sulfur and olen content in the FCC gasoline. In many cases, hydrotreating is the only technology available to achieve adequate quality improvement. However, according to common wisdom, the major drawback to hydrotreating FCC gasoline is the resultant loss of octane that occurs when olens and some of the aromatics are saturated. This octane reduction can be in excess of 10 numbers, (R+M)/2. If a rener can live with this loss of octane, then FCC gasoline hydrotreating may be sufcient, and UOP is pleased to discuss the use of UOP Unionningsm technology for this application. However, when a loss of octane cannot be tolerated UOP and Intevep believe that our pilot plant and commercial database on FCC gasoline hytrotreating puts us in the unique position of being able to discuss the advantages of the process ISAL over conventional hydrotreating. This allows UOP and PDVSA-Intevep to recommend the option that is most suitable to a particular reners needs.

ISAL PROCESS DESCRIPTION The reactor circuit conguration in ISAL is quite similar to that used in simple hydrotreating processes. The feed naphtha is mixed with hydrogen and processed across a xed bed of catalyst at moderate temperatures and pressures. Reaction products are separated and hydrogen-rich to the reaction section. The naphtha stabilizer can be used for RVP adjustment to meet nal product specications.

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28,000 BPSD Feed: FCC-C9+ API: 40.3 Sulfur: 1420 wppm Nitrogen: 154 wppm Olens: 13.9 wt% MON: 79.2 RON: 88.6 RVP: 1.2
ISAL and Octane Recovery The purpose of the ISAL is to recover the octane lost by simple hydrotreating FCC gasoline. To keep the yield loss and hydrogen consumption to a minimum, ISAL utilizes selective isomerization reactions for full recovery of feed octane. While there is also some selective conversion of

26,412 BPSD

ISAL UNIT

Product: C5+ API: 43 Sulfur <100 wppm Nitrogen: <1 wppm Olens: 0.5 wt% MON: 80.8 RON: 87.1 RVP: 4.0

ISAL, which is the result of recently completed joint development work between PDVSA-Intevep and UOP, is a hydroprocessing technology designed to improve the quality of FCC gasoline with no loss in octane.

high molecular weight and low octane hydrocarbons into lighter components, these reactions are minimized in order to keep yield loss to a minimum. The result is a product with improved octane and minimum yield loss and hydrogen consumption. For full recovery of feed octane, the Cs+ yield is expected to be in excess of 95 vol%. ISAL can be adapted to different renery applications. Reners can choose to hold motor octane number (MON) of ISAL efuent at a value equivalent to MON of untreated FCC gasoline. Also, reners could select to control research octane (RON), so that no loss occurs across ISAL unit, or at a slight gain or loss, depending upon the pool octane requirements.

Characteristics of ISAL
ISAL reduces the naphtha sulfur and nitrogen content, and also the naphtha olen content. It diminishes the naphtha T-90, and it does not increase the aromatics content. It can maintain or increase naphtha octane. ISAL upgraded FCC naphtha is specically suited to meet reformulated gasoline specications in today's global market.

INVESTMENT
Investment required for installing ISAL in a renery today depends on the feedstock and processing severity. For sweet virgin naphtha feedstock, investment cost is similar to that of a simple naphtha hydrotreater. For more difcult feeds, such as cracked naphthas, investment is higher. As reference, the estimated erected cost of a 10,000 bpsd heavy FCC naphtha ISAL process unit is US$MM

Fig. 1. Sulfur reduction using conventional way.

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Fig. 2. Low severity ISALTM for light FCC naphthas.

Fig. 3. Low severity ISAL for light FCC naphthas.

14. This cost is based on US Gulf Coast installation during the 1st quarter of 1996.

ISAL applied to light FCC naphthas

Light FCC naphthas have been traditionally treated by chemical processes to reduce sulfur (10-15 wt%), as shown in Fig. 1, or sent to etherication to produce oxygenates from the C5-C6 iso-olens (23-25 vol% reduction of total

olens content); however, given the restrictions on the ozone formation, potential forming compounds, such as olens, need to be removed to a larger extent than the level achieved by any of the two processes described. An example of light FCC naphtha from a Venezuelan renery is presented in Table 1. Notice that using ISAL in a low severity range (Figs. 2 and 3), this stream can be desulfurized up to 40 wt% and

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Table 1. Light FCC naphtha properties.

Properties Light FCC naphtha (Distillate range 80-245F) 52 7.3 11.4 1.2 10.1 2.9 350 9

Total olens, vol% IC5= IC6= Diolens, vol% Naphthalenes, vol% Aromatics, vol% Total sulfur, wppm Sulfur (mercaptans, wppm)

Rodolfo Bruno Solari. B.S. in chemical engineering, Universidad de Chile, 1970; PhD in chemical engineering, University of California at Davis, 1974. In 1980 he joined Intevep where he has successively worked as process development section head, rening process dept. manager, and heavy oil upgrading program manager. Dr. Solari has been technology leader of heavy and extra-heavy oil activities, and he is part-time lecturer at Universidad Simn Bolvar (USB). He is specialist in heavy oil upgrading. In 1991, he became the recipient of UNESCO Science Award.

olens removal can reach up to 30 vol% with insignicant yield or octane penalties. Such option clearly would add more exibility, as shown in Fig. 4, to the rener for adjusting specications in his gasoline blending system, while complying with EPA regulations.

Jos Armando Salazar. B.S. in chemical engineering, Tulsa University; master & PhD in chemical engineering from the same university. For over twenty one years, he has been working in R&D of rening processes. He is currently leader of the hydroprocessing group in monitoring projects for catalytic reforming and hydrotreating units of all PDVSA reneries, as well as in technical assistance in the catalytic reforming area. Dr. Salazar participated in the ISAL conceptual engineering, and he is at present in charge of providing ISAL estimates according to reners requirements.

Fig. 4. Sulfur and olen reduction using ISAL.

Nelson Martnez. Chemist, University of Poitiers, France (1973); master in physicochemistry in the same university; PhD in chemistry in the University of Reading, 1978; master in management of technology, MIT, 1993. He has been leader of catalysis group in Intevep, and has coordinated several projects on catalytic cracking, new catalytic supports, and catalyst commercialization. He was manager of Process Development Department of Intevep. In 1994 Dr. Martnez was named member of the New York Science Academy. He was assigned in 1995 to the Strategic Planning Coordination of PDVSA to work in the technology management corporate group. He is presently working as specialist in catalysis.

Arturo Mogolln. B.S. in chemical engineering, Universidad Central de Venezuela (UCV). In 1980 he joined Inteveps Pilot Plant Department, where he worked as leader of pilot plants start-up teams, and was member of engineering task forces to carry out pilot plants basic design. He was involved in R&D activities in uid drying/incineration processes for HDH spent catalysts. Since 1994 he has been participating in the hydroprocessing group, where he leads R&D experimental programs to test catalyst for lube base oil upgrading, to assess UOPs Unicracking technology for VGO hydrocracking, and for the evaluation of new approaches to ISAL.. At present, Mr. Mogolln is assigned to Citgo Lemont Renery, where he is working as process technologist, assisting the renerys hydrotreating group.

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