Meet gasoline benzene limits with minimal octane loss.
Ben Prime™ saturates benzene in a concentrated C6 cut, up to 99.9%, so toluene and heavier aromatics keep their octane.
Ben Prime™ Benzene Saturation
Benzene compliance with the smallest possible octane penalty
Gasoline benzene limits, such as the US gasoline benzene standard, are not always solvable where the benzene is made. When geography or economics rule out processing the benzene-rich stream on site, Ben Prime™ hydrogenates it instead.
A reformate splitter revamped to DWC Prime™ concentrates benzene into a narrow C6 cut. Only that cut is saturated, in a compact liquid-phase reactor over a highly selective catalyst.
What Benzene Saturation Does to Octane
Saturating benzene to cyclohexane always costs some octane: benzene blends at roughly 100 RON, cyclohexane at about 83 RON. Ben Prime™ cannot avoid that chemistry, but it keeps the loss to the benzene actually converted.
| What is affected | Indicative octane impact |
|---|---|
| Each molecule converted | Benzene ≈ 100 RON → cyclohexane ≈ 83 RON, a loss of about 15–20 RON |
| Rule of thumb | About 0.15–0.2 RON lost per vol% of benzene saturated in the treated stream |
| Saturating whole reformate (3–6 vol% benzene) | About 0.5–1 RON on the reformate, plus any octane lost if other aromatics saturate |
| Ben Prime™ C6 cut only | Toluene, xylenes and heavier aromatics bypass the reactor; the selective catalyst targets benzene |
| Gasoline pool | Typically a few tenths of a RON, depending on reformate share of the pool |
Indicative ranges. The actual octane and hydrogen impact depends on feed composition and gasoline blend, and is quantified in a feasibility study.
Concentrate, Saturate, Stabilize
Concentrating benzene first keeps the reactor and its equipment small.
1 · Concentrate
The reformate splitter, revamped to DWC Prime™, draws a benzene-rich C6 cut.
2 · Saturate
Benzene is hydrogenated in the liquid phase over a highly active, highly selective catalyst.
3 · Stabilize
A stabilizer removes light ends before the low-benzene cut returns to the gasoline pool.
Typical Applications
Naphtha splitter overhead
An alternative to a C5–C6 isomerization unit for benzene control.
Downstream of the CCR
Where benzene is formed in the reformate.
Specialty products
Ahead of products with very low benzene limits, such as food, pharma and polymer grade hexane.
Compliance With Minimal Value Loss
Reliable chemistry
Hydrogenation is a proven, predictable route to as much as 99.9% saturation.
Minimal octane loss
Only benzene is converted; other aromatics keep their octane.
Long catalyst life
Simple equipment: a liquid-phase reactor and a stabilizer.
Flexible delivery
Handles a range of benzene-rich feeds, with modular construction options.
Licensed commercially
A grassroots Ben Prime™ unit was designed and licensed by DWC Innovations for CPCL’s Manali refinery.
Benzene Saturation: Questions Clients Ask
What is benzene saturation?
The catalytic hydrogenation of benzene to cyclohexane, used to meet gasoline benzene limits.
Does benzene saturation lower octane?
Yes. Benzene has a higher octane than cyclohexane, so converting it always costs some octane, roughly 0.15–0.2 RON per vol% of benzene saturated in the treated stream. Ben Prime™ minimizes the penalty by treating only a concentrated C6 cut and using a catalyst selective to benzene.
How much hydrogen does it use?
Three moles of hydrogen per mole of benzene saturated. Because the catalyst is selective to benzene, hydrogen is not wasted on toluene or heavier aromatics.
Can Ben Prime™ replace a C5–C6 isomerization unit?
For benzene control, yes: on the naphtha splitter overhead it is an alternative to building a C5–C6 isomerization unit.
What data do you need to evaluate it?
Reformate or naphtha composition, benzene target, gasoline blend and hydrogen availability.
Meet benzene limits without giving away octane
Send us your reformate or naphtha composition, benzene target and gasoline blend. We’ll quantify the octane and hydrogen impact of Ben Prime™ for your refinery.