Fuels For The 21st Century
Fuel Sulfur Solutions Hydrogen Solutions
Deciding which benzene-
management strategy to
use depends on the value
of hydrogen, total gaso-
line, and premium gaso-
line. It also depends on
the type of reformer, the
feedstock processed in the
reformer, and the refinery
configuration. Finally,
the benzene-management
strategy depends on the
target benzene level in the
final gasoline pool as
well as the other blend-
stocks used in making
gasoline.
Penex and Platforming
Synergy for Efficient
Naphtha Processing and
Benzene Control
More on the BenSat process
More on the Penex Plus
Process
MTBE Solutions Benzene Solutions
Benzene Solutions
Managing benzene in gasoline has become an important worldwide
issue because of health and environmental concerns. Because the
major source of benzene in gasoline is the napththa reformer, naph-
tha processing is the major focus for benzene reduction.
Two basic approaches may be used to reduce benzene from the
reformer and thereby reduce the benzene content of the gasoline
pool:
1. Prefractionation - By adjusting the cutpoint of the naphtha
splitter benzene and benzene precursors can be removed from
the reformer feed. Options for processing the light naphtha
are:
Blending - Light naphtha can be blended directly into the
gasoline pool if its benzene content is acceptable and if
there is no need for additional octane.
Isomerization - The octane of the light naphtha is
increased, and the benzene is saturated.
Saturation - Benzene is removed without upgrading the
light naphtha octane. Octane lost in saturating benzene
must be made up from other sources.
2. Postfractionation - Remove benzene from the reformate.
Processing options are:
Saturation - Benzene in the light reformate is saturated.
Octane must be made up from other sources.
Isomerization - Light reformate is processed together
with light naphtha in an isomerization unit. The octane
of the combined light naphtha and light reformate
streams is increased, and benzene is saturated..
Extraction - Benzene is removed from the reformate for
sale as a petrochemical feed.
 REFINING

Print This Tech Sheet

PENEX-PLUSTM PROCESS

GASOLINE APPLICATIONS
Many refiners must now reduce the concentration of Prefractionation of Benzene
benzene in their gasoline. The Penex-Plus light naphtha Precursors
isomerization process can not only reduce the benzene
LSR
content but also upgrade the octane of light naphtha or Penex-Plus
light reformate streams. Acceptable benzene levels for
Penex-Plus feedstocks range from a few percent up to Naphtha NS Gasoline
30 vol% benzene or more. The Penex-Plus product Pool
stream contains less than 0.1 vol-% benzene. The
choice of processing light straight run or light reformate C7+
feedstocks depends on the amount of benzene removal Reformer
required in the overall gasoline pool and the benzene
reduction strategy employed.

Conventional isomerization technology does not effi- Light Reformate Isomerization

ciently handle the saturation of high-benzene feedstocks.
The heat of reaction associated with hydrogenation of LSR
Penex-Plus
benzene is highly exothermic and results in a high reactor
temperature. This high temperature is detrimental to
isomerization, which is more favored at lower operating Naphtha NS Gasoline
Light Reformate Pool
temperatures. The Penex-Plus process is designed to
optimize conditions for both benzene saturation and
isomerization within one integrated unit. C7+
Reformer RS

BENZENE REDUCTION STRATEGY

Prefractionation of the feed to remove benzene and ben-
zene precursors from the reformer feedstock limits the
benzene produced in the reformer to that produced from
dealkylation-type reactions. Low-pressure reformers,
operating at less than 100 psig (690 KPA), produce a
low level of dealkylation reactions. In this case, prefrac-
tionation may produce a low-benzene reformate. A
PenexTM or Penex-Plus process unit may be needed to
saturate the benzene in the light naphtha while upgrad-
ing the octane of the stream.
Refiners with higher pressure reforming units may want
to use a reformate splitter to produce light reformate
feed for the Penex-Plus process unit as an alternative to
fractionating the benzene and benzene precursors out of
the reformer feedstock. Because of dealkylation of
heavy aromatics, high pressure reforming units can pro-
duce reformate with a significant amount of benzene
even though there are few benzene precursors in the
feed. Post-fractionation of reformate reduces the net
benzene to virtually zero, but costs somewhat more than
prefractionation due to the extra feed processed in the
reformer and the additional hydrogen consumption in
the Penex-Plus unit.
PROCESS DESCRIPTION
Within the Penex-Plus process unit, UOP has uncoupled
 benzene saturation from LSR Light
Penex-Plus
isomerization to optimize (High C7+) Reformate
Process
the overall performance of
Light Ends both. Because the benzene RONC C5+ 83 81
saturation section remains MONC C5+ 81 78
Hydrogen
Stabilizer
well integrated with the
Feed Column rest of the Penex-Plus ECONOMICS
process unit, overall capital Investment costs were evaluated for a Penex-Plus unit
Penex-Plus
costs are minimized. processing 15,000 BPSD of light straight-run naphtha
Shared vessels, such as the with a benzene level of 7 vol%.
stabilizer column and feed
Isomerate pump, contribute to the Inside battery limits, estimated erected cost (50%):
low cost of the design. US$ 11.9 MM.

Basis: U.S. Gulf Coast installation, 2nd quarter, 1998.

FEED QUALITIES
Penex feedstocks are typically light straight-run naphtha Utility estimates for this Penex-Plus process unit process-
streams. However, as refiners need to remove benzene ing 15,000 BPSD of light straight-run naphtha feed with 7
from gasoline, many must now consider processing light vol% benzene are summarized below:
reformate either separately or with the light straight run
naphtha. This combined feed can be processed efficiently Electric power 907kw 907kw
in the Penex-Plus process. Examples of two possible feed- Steam
stocks are shown below: MP steam 9.7 T/hr 21.4 M lb/hr
LP steam 0.2 T/hr 0.4 M lb/hr
Example Feedstocks, LV-% Boiler feed water 9.9 T/hr (21.8) M lb/hr
Cooling water 46 m3/hr 202 gpm
LSR Light
(High C7+) Reformate Parentheses denote quantity exported.

C5 (P+N) 32 0
C6 (P+N) 51 50 EXPERIENCE
Benzene 5 26 Four Penex-Plus process units have been commissioned
C7+ 12 24 and others are in various stages of design and construc-
tion. The first unit started up in 1994. The technology is
The Penex-Plus process can process a wide variety of based on UOPs years of experience with the Penex
feedstocks, including feedstocks with significant quantities process for paraffin isomerization and with the HB
of benzene and C7+ material. UnibonTM process for saturation of benzene to cyclo-
hexane.
YIELDS
Because of volumetric expansion, the overall C5+ volumet- FOR MORE INFORMATION
ric yield increases on converting benzene to cyclohexane. For more information, contact your UOP representative
Depending on the feed benzene levels, 98+ vol-% C5+ or UOP at:
yields can be expected for feedstocks that contain low
levels of C7+ material. Higher amounts of C7+ in the feed Phone: 847-391-2000
result in lower C5+ volume yields as a result of hydro- Fax: 847-391-2253
cracking.
uop TM

1999 UOP LLC. All rights reserved

This information is not to be taken as a warranty or representation for which UOP
UOP L L C
assumes legal responsibility nor as permission or recommendation to practice any 25 East Algonquin Road
patented invention without a license. It is offered solely for your consideration. Des Plaines, IL 60017-5017
UOP 2699D-35 899R1L