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Podrebarac 2007
Podrebarac 2007
Hydrodesulfurization of cracked gasoline is now a vital step for the production of clean fuels. Along with
sulfur removal, however, olefin saturation occurs. Knowing the olefin content of the gasoline is key to achieving
a proper design, as olefin saturation largely sets the heat release and hydrogen consumption that will be
experienced. More specifically, the molar concentration of the olefins must be known, and determining this in
cracked gasoline is not as straightforward as it seems. There are a number of seemingly appropriate analytical
methods for olefin measurement. This study examines several of the more common methods used in the refining
industry and compares their performance on a sample of full-range FCC gasoline. A case is made that the
bromine number is the most appropriate measurement to use as the basis for a reactor design.
the FIA results, but there was some scatter when correlating find a method that gives essentially the same result as FIA but
the Br # technique against PIONA. Barman suspected that this with better precision. The data showed that all three olefin
scatter was due to interference from sulfur compounds methods provided similar average results but that the precisions
and higher dienes. However, some results from CDTECH’s of the Reformulizer and PONA methods were much better than
internal tests indicated that sulfur compounds in FCC gasoline FIA. The conclusion of the study was to recommend the
are not a very significant source of error. The diene content of Reformulizer method as the preferred approach.
FCC gasoline also tends to be fairly low relative to the olefin A summary of the relevant olefin analysis techniques is
content. presented in Table 1. This is not a complete listing but simply
A study by Lubeck and Cook7 compared the results of FIA a list of some techniques that are commonly used by refiners
with the Br # and found a reasonable agreement between the to analyze their gasoline samples. FIA is not included in Table
techniques. However, they reported difficulties with the FIA 1. Although FIA is very commonly referenced as a standard by
tests. They found an unusual nonlinearity in the FIA results as which other techniques are compared, it is a cumbersome
the gasoline sample was diluted with an inert hydrocarbon. They technique that many experts regard as being obsolete.
reported a significant error with FIA when samples were not When one considers the limitations and capabilities of the
depentanized and were critical of the difficulty in determining techniques in Table 1, it would appear that the Br # method is
the position of the boundary between different hydro- likely the most suitable measure of aliphatic unsaturation in FCC
carbon types. It was also reported that the FIA technique gasoline samples. There is, admittedly, some interference from
usually measured lower olefin concentrations than the Br # S compounds and dienes. However, the most significant S
technique. compounds, such as thiophenes1 and benzothiophene, show
Lubeck and Cook7 also discussed how the conversion from negligible responses to the Br # method. It is only compounds
Br # units to vol % olefins units can affect the results. A such as mercaptans and sulfides that have the potential to impact
conversion calculation is provided in the ASTM-1159 method, the measurement, and these components are present in very
but this calculation may not be adequate in every situation. small amounts. The amount of diene is also quite low as
Perhaps Barman’s6 problems correlating Br # to PIONA were compared to the olefin concentration, perhaps only 2 wt %. The
due to samples that did not conform to the requirements of the stated inaccuracies involved with the PONA and PIANO
ASTM conversion correlation. methods seem to be much more substantial. Even with the
A study was conducted by Beens et al.8 in which three of Reformulizer method, there is a valid concern that the olefin
the 10 gasoline characterization techniques that were studied content in certain fractions of FCC gasoline could exceed the
were capable of olefin measurement: Reformulizer (ASTM- stated 30% limit.
D6839), FIA, and PONA (ASTM-D6733). Their goal was to From our viewpoint, one of the advantages of the Br # is
that it is directly related to the number of moles of olefin in the
(6) Barman, B. N. Determination of hydrocarbon types in gasoline range sample. The determination of a molar concentration of olefin
samples by multidimensional gas chromatography, fluorescent indicator
adsorption, and bromine number methods. Fuel 1995, 74, 401-406. is one of the goals of this paper because this is easily related to
(7) Lubeck, A. J.; Cook, R. D. Bromine number should replace FIA in hydrogen consumption and heat release when conducting a
gasoline olefins testing. Oil Gas J. 1992, 90, 86-89. reactor design.
(8) Beens, J.; et al. A comparison of ten different methods for the analysis
of saturates, olefins, benzene, total aromatics, and oxygenates in finished This study examines how the results of three common olefin
gasolines. J. Chromatogr. Sci. 2003, 41, 564-569. measurement techniques compare when analyzing a sample of
2966 Energy & Fuels, Vol. 21, No. 5, 2007 Podrebarac and Judzis
Table 2. Properties of RFCC Gasoline Sample Table 3. PIANO Totals (Mass %) in RFCC Gasoline Sample
paraffins i-paraffins olefins naphthenes aromatics total
Method
C1 0.000 0.000 0.000 0.000 0.000 0.000
boiling range C2 0.000 0.000 0.000 0.000 0.000 0.000
ASTM-D3710 C3 0.000 0.000 0.000 0.000 0.000 0.000
ibp (°F) 42 C4 0.325 0.172 1.968 0.000 0.000 2.465
5% 94 C5 0.922 6.173 9.600 0.179 0.000 16.874
10% 101 C6 0.617 5.808 7.684 1.986 0.996 17.090
20% 144 C7 0.712 3.950 3.831 3.363 4.014 15.871
30% 170 C8 0.475 3.668 1.229 3.159 7.503 16.034
40% 199 C9 0.219 3.369 0.417 2.067 6.735 12.807
50% 231 C10 0.189 1.313 0.036 0.350 7.018 8.906
60% 261 C11 0.096 0.608 0.075 0.088 2.099 2.965
70% 290 C12 0.121 0.778 0.037 0.000 1.123 2.059
80% 339 C13 0.085 0.070 0.015 0.000 0.000 0.170
90% 396 total 3.762 25.908 24.891 11.193 29.487 95.242
95% 428 oxygenates 0.000 total C14+ 1.165
total unknowns 3.594 grand total 100.000
Ep 489
total S (ppmw) 740
density (g/mL) 0.7497 ASTM-D1159 method. Indeed, all three of these techniques
Br # (g/100 g) 63.2 seem to provide fairly consistent results when analyzing for wt
calcd olefins (wt %) by 28.85 % olefin.
A2.2 procedure
However, this is not the case when one converts the units of
PONA the PONA and PIANO measurements to match the units of the
av Mw (g/mol) 97.13
olefins (wt %) 28.77
Br #. The conversion is performed as follows:
calcd Br # (g/100 g) 47.3
olefin wt % × 159.8
PIANO calcd Br )
av Mw (g/mol) 92.46 Mw
olefins (wt %) 24.89
calcd Br # (g/100 g) 42.9 To use this equation, the engineer must have a good value
for the molecular weight (Mw). In many cases that we have
full-range cracked gasoline. There is not very much information encountered, the refiner provides an abbreviated output of the
in the literature with regard to neat samples of cracked gasoline. PONA or PIANO method, which only shows the wt % of olefin,
Only in the work of Lubeck and Cook7 were some neat FCC aromatics, etc. This leaves the engineer, who is not usually an
gasoline samples tested. This study also compares these analyti- expert in analytical chemistry, to make assumptions to fill in
cal techniques in different boiling ranges of the FCC gasoline. the Mw term. Frequently, as a first pass, this is assumed to be
the same as the average Mw of the gasoline sample. Results are
Experimental Procedures shown in Table 2 for calculations followed through on this basis.
It should be very clear that the calculated Br # values from the
A sample of cracked gasoline from a resid-FCC was obtained PONA and PIANO methods are substantially less than the
from a North American refinery for use in this study. This sample measured Br #.
was subdivided and submitted for Br #, PIANO, and PONA
As discussed, a common source of error in the conversion
analysis. An attempt was made to run the Reformulizer MD-GC
method, but no facility in the Houston, TX area was able to from wt % to Br # is the Mw term. The olefins in FCC gasoline
accommodate our request. are distributed preferentially to the light end. The average Mw
To measure the olefin concentration profile as a function of of the sample is higher than the average Mw of the olefin
boiling point, a 1 L sample of gasoline was batch distilled into 10 components. Thus, simply using the average molecular weight
× 100 cm3 fractions. The quantity of each gasoline cut was of the sample to convert the olefin content to a molar quantity
sufficient to run the various analytical tests, such as total S, Br #, is a very poor assumption. The design engineer should ensure
density, PONA, etc. that the full output from the PONA or PIANO method is
The fractionation was conducted in a 2 in. diameter × 36 in. provided. For example, a PIANO output of the components
high Oldershaw column. The column was vacuum jacketed for sorted by carbon number is shown in Table 3. On the basis of
insulation and contained 10 distillation trays. The condenser was the distribution of olefins provided in Table 3, the average Mw
cooled with a circulating cooling bath. The first eight cuts were for olefin components is 78.4 g/mol for the PIANO method,
obtained at atmospheric pressure, with a reflux ratio of 5:1. For
and a similar analysis works out to 81.46 g/mol for the PONA
the ninth cut, the reboiler temperatures became too high, so the
column was placed under vacuum to permit operation at lower method. Using these revised average Mw values for the olefin
temperatures. The ninth cut was collected overhead under vacuum, gives a calculated Br # of 50.5 g/100 g for the PIANO method
and the final tenth cut consisted of the material remaining in the and 56.4 g/100 g for the PONA method. Even with the corrected
reboiler. Mw, the Br # calculated from the PIANO analysis is still far
from the measured Br #. The measured Br # of 63.2 is 12%
Results and Discussion higher than the Br # based on PONA.
Curiously, the ASTM conversion of Br # to wt % olefins
The properties of the FCC gasoline sample are provided in gives almost perfect agreement, but the conversion of PONA
Table 2. Clearly, there are differences between the wt % olefin olefin to a Br # gives about 12% error. The difference seems to
by the PONA method and the wt % olefin by the PIANO reside within the correction factor published in section A2.2,
method. However, this magnitude of disagreement may not be Table A2.1 of ASTM-D11591. This correction factor compen-
too alarming. There is excellent agreement between the PONA sates for the boiling range of the sample and has been fitted to
method and the Br # method when the Br # is converted to wt allow the Br # to agree with PONA and/or FIA data. Conversely,
% olefins using the procedure outlined in section A2.2 of the when converting the units of the PONA and PIANO methods
Designs of FCC Gasoline Hydrodesulfurization Units Energy & Fuels, Vol. 21, No. 5, 2007 2967
Octane loss may also be understated if olefin conversion is understand the definition of olefin used by the PONA and
not based on the Br #. For example, if the previous feedstock PIANO methods and take the time to request and review the
is desulfurized (e.g., 95% sulfur conversion) in a fixed bed full output from the PONA or PIANO methods. Regardless of
hydrotreater, an octane loss prediction based on olefin measure- this effort, however, the designer still needs some measure of
ments by the PIANO method would be understated by 35% aliphatic unsaturation that will aid in calculating the hydrogen
relative to the octane loss prediction based on the Br # uptake and heat release in the reactor when dealing with heavy
conversion. This can have severe economic implications for the gasoline. It should be clear that the Br # characterizes all of the
refiner. reactive olefins in the cracked gasoline and helps prevent design
errors.
Conclusion At this point, the danger of designing an HDS reactor for
Three methods for measuring olefin concentration in FCC cracked gasoline based on PONA or PIANO data should be
gasoline have been compared. Two GC-based methods, PONA clear. Both of these techniques tend to understate the amount
and PIANO, were compared to the results of a Br # titration. of olefin in the feed. If this is carried through the design
The ASTM method descriptions of PONA and PIANO clearly calculations, the heat release, hydrogen consumption, and octane
state the limitations of using these methods to characterize losses will be underestimated. Once the reactor is built, the
olefins. The results of this study confirm that these limitations refiner will experience problems reaching the desired sulfur
are generally valid. However, despite the stated limitations, these conversion and problems with feed/effluent heat integration. The
methods find common applications in the refining industry in reactor unit could also be constrained by insufficient hydrogen
areas where their accuracy is questionable. availability. Ultimately, these complications could restrict overall
An analysis of a series of narrow cuts of the FCC gasoline unit throughput.
shows that these analytical techniques are in good agreement It is also demonstrated that the deviation in the olefin
for light gasoline fractions. However, for gasoline fractions measurements between the PONA and the PIANO techniques
containing C7 and heavier olefins that boil greater than 200 °F, and the Br # method become more pronounced with heavier
the PONA and PIANO methods diverge significantly from the fractions. This study was conducted on a full-range sample,
results of the Br #. In the heaviest fraction of the gasoline, the which includes C5 material. In practice, it is quite common to
PONA and PIANO methods were in error by essentially 100%. remove the C5 and C6 fractions of the gasoline and treat the
A key problem is that they both classify alkenyl aromatic C7+ gasoline fraction in the HDS reactor. This is precisely the
compounds, such as styrene, as aromatics. While one can make point where the PONA and PIANO techniques project a lower
a case that this is the proper classification of these compounds olefin content and heat release. Thus, designs to treat heavy
based on chemistry, this classification does not help the reactor
FCC gasoline based on PONA or PIANO data could be
designer.
substantially undersized and/or unable to cope with the heat
When designing HDS reactors, the saturation of olefinic side
release in this situation.
groups releases heat, consumes hydrogen, and therefore must
be quantified. Design engineers should take care to fully EF060593K