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HF Alkylation Solutions
HF alkylation units require precision. Pall solutions help reduce corrosion, cut acid costs, and maintain consistent product quality.
Ensure your HF alkylation unit operates reliably with minimal corrosion, reduced acid consumption, and consistent on-spec product output. Pall Corporation offers advanced filtration and separation technologies to help refineries meet operational, safety, and environmental goals.
Hydrofluoric Acid (HF) Alkylation Units
In HF alkylation, olefins (C3–C4) from the FCC unit are combined with isobutane (i-C4) and first treated with a molecular sieve bed to remove water. Concentrated hydrofluoric acid (HF) is then introduced and fed to the reactor. The alkylation reaction combines olefins and isobutane to form high-octane alkylate, a premium gasoline blending component.
The HF and alkylate are separated in a settler, allowing the HF to be recovered and reused in the reactor. The reactor effluent, which comprises alkylate, unreacted isobutane, n-butane, and propane, is sent to a main fractionator. There, isobutane is recycled, alkylate is drawn from the bottom, and n-butane is separated and treated with caustic (KOH). Overhead vapors primarily consist of HF acid fumes and propane gas.
Watch our video to see how Pall coalescers improve liquid separation and particle removal in refinery applications.
HF Alkylation Unit Requirements
To maintain safe and efficient operations, HF alkylation units must:
- Ensure equipment reliability to meet 4–6 year turnaround cycles
- Minimize acid makeup costs by preventing water ingress
- Deliver on-spec products, including high-octane alkylate and caustic-free propane/n- butane
- Prevent fugitive HF emissions through effective separation and corrosion control
Common HF Alkylation Challenges and Pall Solutions
| Challenge | Solution | Pall Product |
|---|---|---|
| Bed fouling, off-spec products | Remove water and caustic from feed and product streams |
|
| Corrosion and plugging in towers | Eliminate emulsified water, acid droplets and solids |
|
| Acid dilution from wet feeds | Protect molecular sieve dryers |
|
This table highlights how Pall’s filtration and coalescer technologies address the most common pain points in HF alkylation operations, improving uptime and product quality.
Application Points and Recommended Pall Products
Pall offers a range of filtration and coalescence solutions tailored to each stage of the HF alkylation process:
Key Application & Filter Recommendations for HF Alkylation Units
| Steps(s) | Application Description | Pall Products(s) | Customer Benefit |
|---|---|---|---|
| 1, 3, 5, 7, 9 | Pre-filtration before liquid/liquid coalescer | Ultipleat® High Flow or Profile® Coreless PPS filter | Extend coalescer life and reduce operating costs |
| 2 | Feed water or caustic removal | AquaSep® XS liquid/liquid coalescer | Prevent HF acid dilution and corrosion; extend molecular sieve life |
| 4 | Water removal from propane | PhaseSep® EL liquid/liquid coalescer | Ensure propane purity; prevent KOH dilution |
| 6 | Water removal from n-butane | PhaseSep® EL liquid/liquid coalescer | Ensure n-butane purity; prevent KOH dilution |
| 8 | HF acid removal after reactor settler | PhaseSep® EL liquid/liquid coalescer | Reduce corrosion and fouling in isobutane stripper |
| 10 | Water removal from olefin regenerant (mol sieve) | PhaseSep® EL liquid/liquid coalescer | Enable olefin reuse and protect downstream equipment |
Fast-Track Upgrades – No CAPEX Required
- Pall-Fit™ Retrofits: Upgrade to Pall quality using your existing filter housings
- Rental Housings: Deploy advanced filtration quickly for urgent process improvements
Why Choose Pall for HF Alkylation?
Pall’s high-efficiency liquid/liquid coalescers and filtration systems are engineered to withstand the harsh conditions of HF alkylation. Our solutions help refineries:
- Improve alkylate quality and yield
- Reduce acid consumption and maintenance costs
- Enhance safety and environmental compliance
Ready to optimize your HF alkylation unit?
Contact our experts to learn how Pall can help improve your process performance.
