COURSE OVERVIEW:

The alkylation process is a critical refinery operation that combines low molecular weight olefins with isobutane in the presence of an acid catalyst to produce high-octane alkylate. This course explores the fundamental chemistry and thermodynamics of the alkylation reaction, emphasizing the production of a clean-burning gasoline blending component. It covers the specific mechanical and process requirements for both hydrofluoric and sulfuric acid technologies, providing a deep dive into the engineering principles that govern unit performance.

The scope of this training involves the detailed analysis of process variables such as temperature, acid strength, and isobutane-to-olefin ratios. Participants will learn how these parameters influence product quality, catalyst consumption, and equipment integrity. The coverage extends to specialized equipment found in alkylation units, including contactors, acid settlers, and deisobutanizers, highlighting the unique operational challenges associated with corrosive acid environments and the prevention of acid runaway scenarios.

A significant portion of the course is dedicated to diagnostic techniques for identifying and resolving operational upsets. Troubleshooting sessions focus on common issues such as poor acid-hydrocarbon separation, equipment fouling, and fluctuations in alkylate octane numbers. By integrating theoretical knowledge with practical case studies, the curriculum equips process engineers and operators with the skills needed to enhance unit reliability, optimize feed rates, and maintain the highest safety standards in acid handling.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Explain the chemical reactions and kinetic pathways involved in the alkylation process.

2.  Differentiate between sulfuric acid and hydrofluoric acid alkylation technologies and equipment.

3.  Optimize the isobutane-to-olefin ratio to maximize alkylate quality and minimize side reactions.

4.  Manage acid strength and catalyst makeup rates to ensure stable unit performance.

5.  Identify the critical process variables that control the research octane number of the product.

6.  Evaluate the performance of acid settlers and hydrocarbon wash systems for effective separation.

7.  Monitor and control reactor temperatures to prevent the formation of acid soluble oils.

8.  Perform detailed mass and energy balances around the deisobutanizer and stabilizer columns.

9.  Implement rigorous safety protocols for acid sampling, unloading, and emergency response.

10.  Diagnose causes of acid runaway and execute proper mitigation strategies to protect the unit.

11.  Troubleshoot fouling and corrosion issues in heat exchangers and fractionation internals.

12.  Analyze feed contaminants such as water and sulfur and their impact on acid consumption.

13.  Develop a comprehensive startup and shutdown plan for acid-containing equipment.

TARGET AUDIENCE:

Process Engineers, Unit Supervisors, Operations Managers, and Senior Plant Operators involved in refinery alkylation units.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.