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Sulfuric Acid Alkylation - Acid Foaming

Sulfuric Acid Alkylation - Acid Foaming

Sulfuric Acid Alkylation - Acid Foaming

(OP)
Has anyone experienced sulfuric acid foaming in a Kellogg / Exxon type Alkylation unit? We are experiencing acid foaming in our Acid Settler and cannot seem to settle it down. We have been seeing constant acid carryover into the downstream effluent treatment system.

There have been no changes in feedstock quality, acid COAs are all normal, outside isobutane feed COA is normal, no heat exchangers have been identified as leaking. Product quality of Alkylate has been great - high octane and normal endpoint. There is no indication of any acid runaway, no elevated temperatures or pressures, product is clear and seems normal. 1-3 Butadiene content in olefin feed is normal at less than 0.5%, low sulfur coming in with olefin feed as usual.

Apart from a physical/mechanical issue internal to the reactor/settler I cannot identify any other causes for foaming.

Thanks.

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