“Hydrofluoric Acid Alkylation, or HF Alky unit safety with pH monitoring, is becoming a critical focus in petroleum refining. Refiners process chemicals such as isobutane and alkenes like butylene and propylene through these units to produce alkylate, a key component in gasoline production. pH measurements along various stages of the process line provide a direct, continuous signal of acid strength, alerting operators to contamination, dilution, or process upsets in real time.

The American Petroleum Institute (API) Recommended Practice 751 provides guidance on safe operation standards for HF Alky units. pH measurements directly impact aspects of API 751, specifically relating to mitigating process exposure, corrosion monitoring and temperature regulation through sample conditioning. As the product moves from feed condensate, settling, and scrubbing in various tanks along the process line, pH and temperature play a critical role, from ensuring product purity to monitoring for corrosion, fouling, and leakage.

Challenging the Volatility of HF Alky Units

Handling hydrofluoric acid is extremely dangerous. Like any hazardous process, addressing the need for operator safety is of the utmost importance. Diminishing manual process exposure in any capacity is beneficial not only for worker safety, but for the process itself when considering contamination risks. Real-time diagnostics and sensor health monitoring can significantly diminish the requirement of manual maintenance checks.

Additionally, glass is considerably prone to damage from hydrofluoric acid exposure. Sensors need robust reference systems and durable housing to withstand the chemical onslaught. Add extreme process temperatures to the mix, and you create a recipe for sensor drift and data loss unless you condition the sample correctly. Improperly conditioned or temperature-compensated process samples can lead to dangerous process exposure and inaccurate readings.

Solutions for Enhancing Safety and Accuracy

In cases where HF Alky unit operators previously checked for leaks manually, they can now use accurate digital pH sensors to detect spiking pH levels from a safe environment. Implementing sample coolers like M4 Knick’s SC Sample Cooler ensures that samples are conditioned at a stable, controlled temperature, which is vital for accurate testing. Temperature adjustments also affect moisture content, sample stability, and the overall accuracy of testing. For some processes operating at extreme temperatures like HF Alky units, a direct measurement taken without cooling could severely damage a pH sensor or other infrastructure. The SC Sample Cooler handles most liquid, gas, and steam processes, making it a suitable solution for the demands of HF Alky units.

Normally, a glass pH sensor would be unlikely to withstand the volatility of the process media found in HF Alky units. Through the introduction of Sample Conditioning, the SE555 is now suitable to maintain accuracy and digital diagnostics within the process. The integrated NTC 30 kΩ temperature element ensures accurate compensation of all pH measurements for the process media temperature. The pressurized reference system, along with the Silamid®reference electrode, helps extend the time between calibrations and reduce sensor replacement frequency, a common issue in HF Alky units.

Having intuitive knowledge of sensor health is important for volatile processes like hydrofluoric acid alkylation. Coupling diagnostic capabilities with hazardous area ratings, the Stratos Pro A2 transmitter fulfills these needs with ease. The transmitter provides unique operator guidance, complete with a sensor monitoring system that indicates the sensor’s maintenance needs.

Tangible ROI With M4 Knick’s Solutions

M4 Knick’s digital solutions, along with sample conditioning expertise, can significantly minimize manual process exposure and downtime. The implementation of smart digital sensors and efficient sample cooling and conditioning vastly reduces sensor replacement and enhances overall workplace safety. All of these benefits align with the cautions provided in API 751, making these solutions an essential choice for enhancing HF Alky unit safety with pH monitoring.