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Abstract <p>High-octane gasoline, a critical component of modern transportation fuels, is commonly produced through the hydrofluoric acid -catalyzed alkylation process. However, the conventional design of this process, developed in the 20th century, falls short of meeting current environmental and safety standards. This study proposes a comprehensive strategy for redesigning the purification section of an alkylation plant located in Mexico, with the objective of transforming it into a more environmentally sustainable process. The proposed methodology comprises four case studies, encompassing the analysis and optimization of operating conditions, design parameters, and interconnection material and energy flows. A real industrial case study is used to evaluate and validate alternative eco-friendly scenarios. The optimized configuration demonstrates significant improvements over the baseline design, including reductions of up to 66% in heat duty, 66% in CO₂ emissions, over 90% in hydrofluoric acid content in the alkylate stream, 23% in operating pressure, and 20% in the total number of equilibrium stages. These results highlight the potential of process redesign to achieve enhanced environmental performance, improved safety, and increased sustainability in alkylation operations.</p> Graphical Abstract <p></p>

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Optimization and Retrofitting of the Purification Section of the Hydrofluoric Acid -Alkylation Plant toward a Sustainability and Efficient Process Conversion

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • R. Murrieta-Dueñas,
  • J. G. Segovia-Hernández,
  • A. Hernández-Aguirre,
  • R. Gutiérrez-Guerra,
  • S. Hernández,
  • J. L. Soto-Alcocer,
  • J. Cortez-González

摘要

Abstract

High-octane gasoline, a critical component of modern transportation fuels, is commonly produced through the hydrofluoric acid -catalyzed alkylation process. However, the conventional design of this process, developed in the 20th century, falls short of meeting current environmental and safety standards. This study proposes a comprehensive strategy for redesigning the purification section of an alkylation plant located in Mexico, with the objective of transforming it into a more environmentally sustainable process. The proposed methodology comprises four case studies, encompassing the analysis and optimization of operating conditions, design parameters, and interconnection material and energy flows. A real industrial case study is used to evaluate and validate alternative eco-friendly scenarios. The optimized configuration demonstrates significant improvements over the baseline design, including reductions of up to 66% in heat duty, 66% in CO₂ emissions, over 90% in hydrofluoric acid content in the alkylate stream, 23% in operating pressure, and 20% in the total number of equilibrium stages. These results highlight the potential of process redesign to achieve enhanced environmental performance, improved safety, and increased sustainability in alkylation operations.

Graphical Abstract