GUERNSEY process engineers are skilled at evaluating refinery operations to identify and develop alternatives to optimize system environmental performance. One such example is KOH management in HF Alkylation Units. KOH is used to neutralize HF in process unit vent gases, acid soluble oils and other hydrocarbon streams produced by the HF Alkylation Unit. The spent KOH/KF solution is typically reacted with CaO to convert the potassium value back to KOH for recycling to the Acid Relief Neutralizer. This greatly reduces the amount of fresh KOH that must be purchased. This batch process produces a large amount of high PH, wet filter cake for disposal. The recovery process is typically laborious and has several inherent safety issues that must be carefully managed. GUERNSEY engineers developed a process simulator and conducted optimization studies on multiple refineries that have HF Alkylation Units. The work in each case resulted in an improved understanding of the interactive process variables in the local facility and identified alternatives for reducing operating costs and improving safety performance. In one case, GUERNSEY conducted an economic study to determine the merits of external KOH toll processing via an outside vendor versus continuing with current in-plant operations.
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