PROCESS DATA SHEET

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8474L-013
ML
Op. Center JOB No.
Op. Center Doc. No.
FEED Doc. No.

UNIT
Rev.

Serial N

Rev. index

001

Page

CCR UNIT (013)

OPERATING MANUAL

DUNG QUAT
VIETNAM
013
CCR

LOCATION

Rev.

Page

Page

Ch 1

Ch 2

Ch 3

Ch 4

Ch 5

Ch 6

Ch 7

Ch 8

Ch 9

Ch 10

Ch 11

Ch 12

Ch 13

Ch 14

Rev.

Equipment N

PETROVIETNAM

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VIETNAM OIL AND GAS CORPORATION

(PETROVIETNAM)
DUNG QUAT REFINERY

OPERATING MANUAL
VOLUME 3

CONTINUOUS CATALYTIC
REFORMER UNIT
UNIT 013
BOOK 1/2

Rev. 0

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

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OPERATING MANUAL
UNIT CCR (013)

March 2007
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CONTENTS

CHAPTER 1

BASIS
1.
2.
3.
4.
5.
6.
7.

OF DESIGN
DUTY OF THE PLANT
ENVIRONMENTAL CONDITIONS
FEEDSTOCKS AND PRODUCTS SPECIFICATIONS
OVERALL MATERIAL BALANCE OF THE UNIT
BATTERY LIMIT CONDITIONS
DESIGN FEATURES
GAS AND LIQUID EFFLUENTS

CHAPTER 2

PROCESS DESCRIPTION
1.
THEORY OF THE PROCESS
2.
PROCESS FLOW DESCRIPTION

CHAPTER 3

DESCRIPTION OF UNIT CONTROL

1.
DESCRIPTION OF FLOW WITH CONTROLS
2.
OPERATING CONDITIONS
3.
PROCESS VARIABLES
4.
INTER-UNIT CONTROL SCHEME
5.
UNINTERRUPTIBLE POWER SUPPLY (UPS)
6.
COMPLEX CONTROL DESCRITPION

CHAPTER 4

UILITY, CHEMICAL AND CATALYST REQUIREMENTS

1.
UTILITIES CONSUMPTION
2.
CHEMICALS CONSUMPTION

CHAPTER 5

PREPARATION FOR INITIAL START-UP

1.
PLANT CHECK-OUT
2.
LINE FLUSHING
3.
WATER CIRCULATION
4.
LEAK TESTING
5.
HEATER DRY-OUT
6.
CATALYST LOADING

CHAPTER 6

START-UP AND NORMAL OPERATION

1. SUMMARY OF START-UP
2. PRESTART-UP PRECAUTIONS
3. PREPARE UNIT FOR CHARGING
4. PURGE AND START THE NHT STRIPPER (T-1201), SPLITTER (T-1202), AND
PLATFORMING FRACTIONATION SECTION
5. EVACUATE AND PURGE THE PLATFORMING UNIT
6. HYDROGEN PRESSURE THE PLATFORMING REACTOR AND THE NET GAS
SECTION
7. START HYDROGEN CIRCULATION AND REACTOR WARMUP
8. START FEED TO THE PLATFORMING REACTORS
9. ESTABLISH SEPARATOR OPERATION

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

10.
11.
12.
13.
14.
15.

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START CHLORIDE ADJUSTMENT PROGRAM

ESTABLISH NORMAL FRACTIONATION SECTION OPERATION
LINE OUT
COMMISSION THE RECOVERY PLUS SYSTEM
SPECIFIC START UP PROCEDURES
NORMAL OPERATION

CHAPTER 7

NORMAL SHUTDOWN
1.
SUMMARY OF SHUTDOWN
2.
NORMAL SHUTDOWN PROCEDURES
3.
CATALYST UNLOADING
4.
RECOVERY PLUS NORMAL SHUTDOWN

CHAPTER 8

EMERGENCY SHUTDOWN PROCEDURES

1.
GENERAL EMERGENCY SHUTDOWN
2.
PROCESS FAILURES
3.
UTILITY FAILURES
4.
MAJOR UPSETS

CHAPTER 9

SAFETY EQUIPMENT AND PROCEDURES

1.
PRESSURE SAFETY DEVICES
2.
ALARM SETTINGS
3.
TRIP SETTINGS
4.
TRIP SYSTEM CHART
5.
CAUSE AND EFFECT DIAGRAM
6.
MATERIAL HAZARD DATA SHEETS
7.
SAFEGUARDING MEMORANDUM

CHAPTER 10

INSTRUMENT DATA
1.
CONTROL VALVES AND INSTRUMENTS
2.
ORIFICE PLATES

CHAPTER 11

SUMMARY OF MAJOR EQUIPMENT

1.
EQUIPMENT LIST
2.
LARGE ROTATING EQUIPMENTS
3.
HEATERS
4.
OTHER VENDOR INFORMATION

CHAPTER 12

ANALYSIS
1.
SAMPLING AND TESTING SCHEDULES
2.
ON-LINE ANALYZERS

CHAPTER 13

PROCESS CONTROL
1.
DISTRIBUTED SYSTEM CONTROL (DCS)

CHAPTER 14

DRAWINGS
1.
PLOT PLAN AND HAZARDOUS AREA CLASSIFICATION
2.
PROCESS FLOW DIAGRAMS AND MATERIAL SELECTION DIAGRAMS
3.
PIPING AND INSTRUMENT DIAGRAMS
4.
OTHER VENDOR DRAWINGS

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

CHAPTER 1

BASIS OF DESIGN

CONTENTS

1.

DUTY OF THE PLANT

1.1

LICENSOR

1.2

FUNCTION OF THE UNIT

2.

ENVIRONMENTAL CONDITIONS

2.1

AIR TEMPERATURE

2.2

RELATIVE HUMIDITY

2.3

RAINFALL

2.4

SNOWFALL

2.5

AIR BAROMATIC PRESSURE

2.6

WIND

2.7

ATMOSPHERE

2.8

MISCELLANEOUS DATA

3.

FEEDSTOCKS AND PRODUCTS SPECIFICATIONS

3.1

FEED CHARACTERISTICS

3.1.1
3.2

4.

Heavy naphtha properties

PRODUCTS SPECIFICATIONS

3.2.1

Reformate

3.2.2

Unstabilized LPG

3.2.3

Make Up H2 gas

3.2.4

Fuel Gas

OVERALL MATERIAL BALANCE OF THE UNIT

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
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UNIT CCR (013)

5.

BATTERY LIMIT CONDITIONS

5.1

FEEDSTOCKS BATTERY LIMIT CONDITIONS

5.2

PRODUCTS BATTERY LIMIT CONDITIONS

5.3

UTILITIES BATTERY LIMIT CONDITIONS

6.

DESIGN FEATURES

6.1

CCR CATALYST

6.2

RECOVERY PLUS PACKAGE

6.3

DEBUTANIZER WATER WASH SYSTEM PROVISION

6.4

DIFFERENCE BETWEEN NHT AND CCR CAPACITIES.

7.

GAS AND LIQUID EFFLUENTS

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

1.

DUTY OF THE PLANT

1.1

LICENSOR

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The CCR PLATFORMING PROCESS UNIT (Unit 013) is based on the UOP (Universal
Oil Products) process.
The Licensor has issued the following documents :
UOP Project Specification (Project 903369)
CCR PLATFORMING PROCESS UNIT
UOP CCR PLATFORMING: General Operating Manual
The CCR Regeneration Section (lUOP License) is also included in the CCR Unit (013).
A dedicated operating manual describes the basis of design, flow description and
normal / start-up and shutdown conditions of this section.
1.2

FUNCTION OF THE UNIT

The function of the Platforming unit is to process the hydrotreated straight run heavy
naphtha derived from Bach Ho crude oil to produce a high octane gasoline blending
component.
The plant capacity is 21100 BPSD (corresponding to 103496 kg/h) of heavy naphtha
from NHT unit (012) and sweet naphtha.
The catalytic reforming process is a catalytic refining process employing a bimetallic
catalyst to upgrade low octane number naphthas to higher octane motor fuel blendings.
The basic reaction of Platforming is to transform naphtenes into aromatics (most rapid
and efficient reaction). The paraffins conversion is very small, and the aromatics
hydrocarbons pass through the Platforming unit essentially unchanged.
The required RONC of the reformate is 102.
LPG is a valuable product so recovery of LPG in the naphtha complex is to be maximed
Hydrogen rich gas is another product of the catalytic reforming reactions, required for
the operation of units such as hydrotreatment units, isomerisation. Consequently, CCR
is a key unit in the refinery.
Hereafter are supplied the following documents:

Diagrams showing all processes and utilities connections with other units
FUEL GAS
TO FG UNIT (037)
MAKE UP GAS
HYDROTREATED
HEAVY NAPHTHA
FROM UNIT 012

TO UNIT 012

CCR UNIT
UNSTABILIZED LPG
TO LPG RECOVERY UNIT (016)

REFORMATE
TO TK-5107

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FUEL GAS FROM UNIT 037

HP STEAM
MP STEAM
LP STEAM
FLARE TO UNIT 057

PILOT GAS
COOLING WATER
SERVICE WATER
POTABLE WATER
CCR NITROGEN (2)

CCR
PLATFORMING
UNIT (1)

COOLING WATER

(UNIT 013)

VACUUM CONDENSATE

PLANT AIR
INSTRUMENT AIR
REFINERY NITROGEN
HP BFW

MP CONDENSATE

HP CONDENSATE

LP CONDENSATE

PLANT AIR
OILY WATER

(1) Utility connections are common for Units 012/013/023

(2) For CCR regeneration section.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

Overall block flow diagram of the refinery

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

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UNIT CCR (013)

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

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UNIT CCR (013)

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2. ENVIRONMENTAL CONDITIONS
2.1

AIR TEMPERATURE
a.
b.
c.
d.
e.
f.

2.2

Maximum recorded
Minimum recorded
Maximum monthly average
Minimum monthly average
Design maximum
Design minimum

41.4 C
12.4 C
34.4 C
18.9 C
36.0 C
16.0C

RELATIVE HUMIDITY
a. Maximum monthly average
b. Minimum monthly average
c. Average monthly humidity
d. Design maximum
e. Design minimum

2.3

RAINFALL
a. Maximum recorded annual
b. Minimum recorded annual
c. Average annual
d. Maximum recorded in 24 hours
e. Maximum rainfall intensity

2.4

89%
80%
85%
100%
40%

3052 mm
1374 mm
2268 mm
525 mm
40 mm for 10 min period
60 mm for 30 min period
108.1mm for 60 min period

SNOWFALL
Not applicable

2.5

AIR BAROMATIC PRESSURE

a. Maximum
b. Minimum
c. Average
d. Design

2.6

1023.6 mbar
988.8 mbar
1009 mbar
1013 mbar

WIND
a. Average velocity
b. Maximum hourly velocity
Direction
No wind
N/NE
W/NW
E/SE
S/SW

3.2 m/s
42 m/s
% of time for each Quadrant
43.8
9.7/6.2
4.1/14.3
12.8/6.7
1.1/1.0

The maximum velocity over a 2 minutes is 41.6 m/s for a return period of 50 years.
The maximum velocity over a 2 minutes is 32.7 m/s for a return period of 20 years
2.7

ATMOSPHERE
a. Extreme moisture
b. Marine exposure
c. Sand storms

- tropical climate
- salt spray
- not applicable

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d. Copper-attacking fumes
- sulphur
e. Exposure to conductive or corrosive dusts (carbon, iron oxide, ammonium nitrates or
phosphates, etc): NO
f. Exposure to corrosive agents (nitric or sulphuric acids, chlorine, caustic, etc): NO
g. Exposure to other pollutants originating from surrounding industrial plant: YES
2.8

MISCELLANEOUS DATA
a.
b.
c.
d.
e.

Frost Level
Not applicable
Typhoon frequency
2 to 3 per year
Thunderstorm frequency
102 storm days per year
Temperature inversion occurrence
Not applicable
Earthquakes to be taken into account and design shall be as per code UBC, zone
2
f. The site is subjected to possible flood condition

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3. FEEDSTOCKS AND PRODUCTS SPECIFICATIONS

3.1

FEED CHARACTERISTICS

3.1.1

Heavy naphtha properties

The Platformer is fed with hydrotreated Heavy Naphtha from Unit 012. The unit can also
be fed with sweet heavy naphtha from TK-5104 during start-up in addition of the straight
run hydrotreated heavy naphtha.
Cf. Operating Manual - Unit 012 for Heavy Naphtha characteristics.
Heavy Naphtha from NHT unit (Unit 012) will contain less than 0.5 wt ppm S (test
method: D-4045) and less than 0.5wt ppm N (test method: D-4629)
The Turndown of the CCR unit corresponds to 50% of the NHT unit (012) plus the sweet
naphtha. Consequently, the capacity of unit is around 60% of the CCR design capacity.

3.2

PRODUCTS SPECIFICATIONS

3.2.1

Reformate
Reformate is sent to the storage TK-5107 for blending.
The required reformate properties are the following:
Property

Value

Test Method

RONC

102 min

ASTM D-2699

MON

91 min

ASTM D-2700

C4- content, %vol

1% max

UOP 880

The molar composition of the reformate stream is the following:

Compound

3.2.2

Reformate
(mole %)

Ethane

ppm

Propane

0.02

i Butane

0.32

n Butane

0.92

i Pentane

1.87

n Pentane

1.25

C6+

95.6

Unstabilized LPG
The debutanizer net overhead liquid is treated in the LPG Chloride Treaters D-1308 A/B
and then sent to storage TK-5212 A/B/C/D/E.
C5+ content in LPG product shall not exceed 1.1%mol max (test method: UOP-539).
The molar composition of the unstabilized LPG stream is the following

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Compound

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Unstabilized LPG
(mole %)

3.2.3

H2O

0.006

H2

0.08

Ethane

0.21

Propane

36.61

i Butane

23.64

n Butane

33.87

i Pentane

0.88

n Pentane

0.05

C6+

0.06

Make Up H2 gas
Net hydrogen produced in the Platforming Unit is recontacted in the Recovery Plus
package (X-1301) and sent to chloride removal D-1302 A/B. After chloride removal,
some of the net hydrogen is sent to the make-up gas multi-stage compressors (C-1202
A/B/C) in theNHT Unit (012), where it is pressurized up to the consumers (NHT, LCO
HDT, Isomerization, NHT H2 storage drums) required pressure levels. Most of the net
gas product is sent to Fuel Gas system (Unit 037) .
The composition of hydrogen shall be the following in normal operation.
Compound

Make up Hydrogen
mole %

H2 (1)

93.3

Methane

2.5

Ethane

2.4

Propane

1.4

i Butane

0.1

n Butane

0.1

i Pentane

0.04

n Pentane

0.02

C6+

0.04

(1) Test Method : UOP 539

3.2.4

Fuel Gas
Fuel Gas from the Debutanizer reflux drum can be sent to Fuel Gas Network (Unit 037).
But normally, no flow is exported to FG network via the debutanizer reflux drum. Off gas
from the debutanizer receiver is sent to the recovery plus system X-1301.

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4.

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OVERALL MATERIAL BALANCE OF THE UNIT

The overall material balance presented here below is summarizing the UOP Heat and
Material balance and Process Flow Diagrams considering that CCR is fed with Heavy
Naphtha from NHT unit (012) and with Sweet Naphtha.
This CCR design case is also corresponding to Lean Feed Case since C6s from NHT
splitter are recovered in the PENEX unit (rich case is corresponding to PENEX alternate
case : C6 from NHT splitter are recovered in the CCR)

DESIGN CASE
(Kg/h)
PROCESS INLET
Hydrotreated Heavy Naphtha
from Unit 012
TOTAL INLET

PROCESS OUTLET
Reformate to TK-5107
Unstabilized LPG to Unit 016
Net Gas to Unit 012
Fuel Gas
TOTAL OUTLET

103 496
103 496

DESIGN CASE
(note 1)
(Kg/h)

DESIGN CASE
(note 2)
(Kg/h)

ALT. CASE
(note 1)
(Kg/h)

ALT. CASE
(note 2)
(Kg/h)

92 224
3 220
4 603
3 449
103 496

92 224
3 220
4 592
3 460
103 496

92 224
3 220
4 363
3 689
103 496

92 224
3 220
4 357
3 695
103 496

Note 1 : corresponding to PENEX unit at SOR conditions

Note 2 : corresponding to PENEX uhit at EOR conditions

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5. BATTERY LIMIT CONDITIONS

5.1

FEEDSTOCKS BATTERY LIMIT CONDITIONS

Feed to the platforming unit comes from the Naphtha hydrotreater Unit (Unit 012).
Heavy naphtha from TK-5104 can also be used for CCR start up or in addition of the
straight run hydrotreated heavy naphtha.
During Start Up, hydrogen is provided to the Platformer is provided via a connection
from the NHT hydrogen storage drums D-1251 A/B coming to the suction of the recycle
compressor C-1301.
This hydrogen is provided to D-1251 A/B via hydrogen bottles for the 1st start up of the
refinery and is filled-in via the 3rd stage of the make-up gas compressors (C-1202 A/B/C
during normal operation.

ORIGIN
Hydrotreated
Heavy Naphtha
NOTES:
5.2

Unit 012 (1)

OPERATING CONDITIONS AT B/L

PRESSURE (1) (2)
TEMPERATUR
Kg/cm2 (g)
E (C)
9.6
118

(1) At grade Unit 013 Battery Limit elevation is 6 m.

(2) At P-1213A/B discharge after cooling in E-1206.

PRODUCTS BATTERY LIMIT CONDITIONS

The reformate can be routed to storage TK-5107 for blending (normal operation),
to light slops header (for off spec reformate) or to NHT (for start up)
LPG is routed to LPG recovery unit 016, or to storage.
The excess off gas from debutanizer receiver is sent, on pressure control, to the
RECOVERY PLUS system X-1301. it is also possible to route off-gas to the Fuel
Gas system (NNF)
Part of the Net gas from chloride treaters is sent to hydrotreating unit (unit 012).
Excess net gas is routed to the Fuel Gas system (unit 037).

DESTINATION
Reformate
Unstabilized LPG
Make Up H2 Gas (2)
Fuel Gas (3)

NOTES:

TK-5107
Unit 016
Unit 012
Fuel Gas Network
(037)

OPERATING / DESIGN
CONDITIONS AT B/L
PRESSURE

Kg/cm2 (g)
3.5 / 13.1
14.0 / 23.5
4.7 / 14.5
4.0 / 14.5

(1)

TEMPERATURE

(C)
38 / 65
38 / 65
38 / 160
38 / 160

(1) At grade Units 012/013 Battery Limit elevation is 6 m.

(2) From D-1302 A/B
(3) From D-1303 (debutanizer receiver) & D-1302 (net gas chloride treaters)

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UTILITIES BATTERY LIMIT CONDITIONS

DESTINATION
ORIGIN
UTILITIES SUPPLY
HP steam
MP steam
LP steam
Cold Boiler Feedwater
Instrument Air
Refinery Nitrogen
CCR Nitrogen
HP BFW
Cooling Water
Fuel Gas
Plant Air
Service Water
Potable Water
Pilot Gas
20 Be Caustic
UTILITIES RETURN
HP Condensate
MP Condensate
LP condensate
Vacuum condensate
Cooling Water
Oily Water
Spent Caustic
Flare

OPERATING DESIGN
CONDITIONS AT B/L
PRESSURE

(1)

TEMPERATURE

Kg/cm2 (g)

(C)

OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL

42.3 / 48.3 (2)

14.1 / 16.8 (3)
3.6 / 6.3 (3)
4 / 16.3 (2)
7.5 / 10.5(2)
7 / 11.7 (3)
8.5 / 11.7 (3)
60 / 89.2 (3)
5.2 / 9.2 (3)
3.3 / 6.7 (1)
7.5 / 10.5 (2)
5 / 14.2 (2)
2.5 / 5.5 (2)
2 / 6.7 (1)
1.5 / 5.5 (2)

380 / 450
250 / 320
160 / 230
60 / 115
35 / 65
30 / 65
30 / 65
112 / 160
32 / 70
46 / 75
35 / 65
30 / 60
30 / 60
30 / 75
40 / 70

OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL
OSBL

7.5 / 48.3 (2)

7.5 / 16.8 (3)
2 / 6.3 (3)
2.5 / 4.7 (2)
2.2 / 9.2 (3)
3.5 / 4.7 (3)
4.5 / 10 (4)
0.2 / 3.5(1)

170 / 450
170 / 320
133 / 230
50 / 110
47 / 70
36 / 65
38 / 65
38 / 210

Notes: (1) At grade Units 012/013/023 Battery Limit elevation is 15 m.

(2) At grade Units 012/013/023 Battery Limit elevation is 12 m.
(3) At grade Units 012/013/023 Battery Limit elevation is 9 m.
(4) At grade Units 012/013/023 Battery Limit elevation is 6 m.
HP steam is produced in the CCR unit in the heaters convection section to be used in
the steam turbine CT-1301 and for the debutanizer reboiler E1308. Additional HP steam
from interconnecting header is required to ensure the unit consumption (around 11 t/h).

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6. DESIGN FEATURES
6.1

CCR CATALYST
Type of catalyst used in the CCR reactors is UOP catalyst R234. Catalysts from R230 series are used to produce high octane reformate and hydrogen. R-234 catalyst
is a low platinum version.
Physical properties of R-230 series catalysts are the following:
Circulating ABD (kg/m3) : 537
Static ABD (kg/m3) :
561
Nominal diameter (mm) : 1.6
Shape :
Sphere
R-234 platinum, wt%
0.290
R-230 series catalyst can be supplied in oxidized or reduced form.
The following quantities of catalyst are required:
Item
number
R-1301
R-1302
R-1303
R-1304

Service
Reactor n1
Reactor n2
Reactor n3
Reactor n4
CCR
Regeneration
section
TOTAL

Volume (m3)
11.6
13.5
14.9
15.9
25.1
81.0

Catalyst life is around 6 years. Addition of catalyst in continuous (0.55 m3) is required to
compensate fines losses.
For more information, MSDS are attached in 6 of Chapter 9.
6.2

RECOVERY PLUS PACKAGE

The RECOVERY PLUS System is designed by UOP to improve recovery of LPG and
reformate from the Platforming Process Unit net gas stream. Increased hydrocarbon
recovery improves liquid product yield of more valuable products and increased
hydrogen purity of the bet gas stream.
The RECOVERY PLUS system combines a net gas stream with a slipstream of liquid
from the Platforming Unit separator. The net gas and liquid streams are individually
cooled and enter the absorber, where vapor and liquid contact occurs through countercurrent flow. Cooling promotes the absorption of LPG and reformate hydrocarbons that
normally exits the Platforming process units debutanizer column stabilization prior to
being sent to storage. The gas stream exits the RECOVERY PLUS system to the
chloride treater at the Platforming process unit.

6.3

DEBUTANIZER WATER WASH SYSTEM PROVISION

Stabilizer column fouling sometimes occurs when the Platforming unit is processing
naphtha with high levels of nitrogen. This is especially true when the Platforming unit is
processing cracked naphtha or naphtha stock from inherently high niitrogen level
crudes; the nitrogen and chloride combine to form ammonium chloride salts which
deposit in the satabilizer feed/bottoms exchanger, on colum trays, and in the overhead
system/

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Sallt build-up on column trays decreases the fractionation efficiency and can lead to off
specification products. Typically, RVP control to reformate becomes difficult and the top
to bottom column delta P increases.
If the column is down for a turn around, the column and overhead system should be
cleaned and inspected for corrosion. Steaming out the system should sufficiently clean
the equipment of any ammonium chlorides salts which may be present.
However, when column performance deteriorates du to salt plugging it is not always
convenient to shut down and clean. The provision of water connections located at the
discharge of the debutanizer reflux pumps and on the top line of the debutanizer T-1301
allow the removal of chloride salts in dbutanizer tower while remaining on line.
6.4

DIFFERENCE BETWEEN NHT AND CCR CAPACITIES.

CCR design capacity is 21 100 BPSD, considering Heavy Naphtha from NHT Unit at its
design capacity (HN production: 82 947 kg/h) and addition of Sweet Naphtha (20 549
kg/h).
Turndown of the CCR Unit is 60% of its design capacity, corresponding to the turndown
of the NHT Unit (50%) plus Sweet Naphtha (20 549 kg/h).

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7. GAS AND LIQUID EFFLUENTS

The following document will be attached:
8474L-200-NM-6200-002

Liquid Effluents Inventory for units 12-13-23

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CHAPTER 2

DESCRIPTION OF PROCESS

CONTENTS

1.

THEORY OF PROCESS

1.1

PLATFORMING HYDROCARBON CHEMISTRY

1.1.1

Composition of Platforming feed and product

1.1.2

Platforming reaction

1.1.3

Relative reactions rates

1.1.4

Heats of reactions

1.1.5

Equilibrium considerations

1.1.6

Effects of pressure and temperature on reaction selectivity

1.1.7

Reactor profiles : commercial Platforming data

1.2

CATALYST CHEMISTRY

1.2.1

Dual function Platforming catalyst chemistry

1.2.2

Effects of pressure on catalyst design

1.2.3

UOP Platforming catalysts

1.3

FIGURES ATTACHED TO THE PLATFORMING CHEMISTRY

2.

PROCESS FLOW DESCRIPTION

2.1

REACTION CIRCUIT

2.1.1

Feed preheater section

2.1.2

Charge heater and inter heaters

2.1.3

Reactors

2.1.4

Reactor effluent

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2.1.5

Reactor effluent separator

2.1.6

Recycle compressor

2.1.7

Steam generation

2.1.8

RECOVERY PLUS system

2.1.9

Chemical injection

2.2

DEBUTANIZER SECTION

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1. THEORY OF PROCESS
The following is a discussion of both naphtha and catalyst chemistry involved in the
Platforming process. The subjects of naphtha chemistry and catalyst chemistry have
been segregated as much as possible to make the discussion easy to follow. However,
the two subjects are necessarily and inherently interrelated and some overlap of subject
matter in the ensuing sections is unavoidable. The subject material has been presented
with the assumption that the reader is familiar with basic organic chemistry and the
concept of thermodynamic equilibria.
1.1 PLATFORMING HYDROCARBON CHEMISTRY
1.1.1

Composition of Platforming feed and product

Feed naphtha to a Platforming unit typically contains C6 through C11 paraffins,
naphthenes, and aromatics. The purpose of the Platforming process is to produce
aromatics from the naphthenes and paraffins, either for use as a motor fuel (because of
their very high octane ratings) or as a source of specific aromatic compounds. In motor
fuel applications the feed naphtha generally contains the whole range of C6 through C11
hydrocarbons, essentially maximizing the amount of gasoline produced from the crude
run. In aromatics applications, the feed naphtha generally contains a more select range
of hydrocarbons (C6; C6-C7; C6-C8; C7-C8) which serve as the source of the desired
aromatic product. For either application the basic naphtha chemistry is identical.
However, aromatics processing, in most cases, emphasizes C6 and C7 hydrocarbon
reactions which are slower and more difficult to promote.
Naphthas from various crude sources vary greatly in their "ease of reforming". This
"ease of reforming" is primarily determined by the amount of the various hydrocarbon
types (paraffins, naphthenes, aromatics) contained in the naphtha. Aromatic
hydrocarbons pass through the Platforming Unit essentially unchanged. Most
naphthenes react rapidly and efficiently to aromatics. This is the basic reaction of
Platforming. Paraffins are the most difficult compounds to convert. In most low severity
applications, there is only a small amount of paraffin conversion to aromatics. In high
severity applications, paraffin conversion is higher, but still slow and inefficient
Figure 1 indicates the hydrocarbon conversion that must take place in a typical
Platforming operation on a "lean" naphtha (high paraffin, low naphthene content) and on
a "rich" naphtha (lower paraffin, higher naphthene content). For the richer feed, less
paraffin conversion will be necessary, making the operation much easier and more
efficient.
To provide a better understanding of Platforming hydrocarbon chemistry, the next
sections will detail the types of individual reactions, relative reaction rates, heats of
reaction, equilibrium constraints, and pressure and temperature effects involved in these
overall hydrocarbon conversions.

1.1.2

Platforming reaction
The following reactions take place in the Platforming process to an extent dependent on
the severity of the operation, the quality of the feed, and the catalyst type.
a. Dehydrogenation of Naphthenes
The final step in the formation of an aromatic from a naphthene (either a
cyclohexane or a cyclopentane) is the dehydrogenation of a cyclohexane; see

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Figure 2. The reaction of a cyclohexane to the corresponding aromatic is

extremely rapid and essentially quantitative. Naphthenes are obviously the most
desirable feed components because the dehydrogenation reaction is easy to
promote and produces by-product hydrogen as well as the aromatic hydrocarbons.
This reaction is very endothermic. It is promoted by a metal catalyst function and is
favored by high reaction temperature and low pressure.
The discussion of catalyst add and metal functions is contained in the 1.2
Catalyst Chemistry section. It is now important to only note which reactions are
catalyzed by the acid function and which ones are catalyzed by the metal function.
b. Isomerization of Naphthenes and Paraffins
(1) The isomerization of a cyclopentane to a cyclohexane, shown in Figure 3,
must occur as the first step in converting the cyclopentane to an aromatic.
This isomerization involves ring rearrangement and the probability for ring
opening to form a paraffin is quite high. Therefore, the reaction of
alkylcyclopentanes to cyclohexanes is not 100% selective. The reaction is
strongly dependent on the processing conditions.
(2) Paraffin isomerization, shown in Figure 4, occurs readily in commercial
Platforming operations but at typical operating temperatures the
thermodynamic equilibrium is not strongly in favor of the more desirable
(higher octane) branched isomers. In motor fuel applications this reaction
does make a contribution to octane improvement of the naphtha.
lsomerization reactions result from carbonium ion intermediate reactions. These
reactions are promoted by the acid function and are only slightly dependent on
operating pressure.
c. Dehydrocyclization of Paraffins
Dehydrocyclization of paraffins, shown in Figure 5, is the most difficult Platforming
reaction to promote. It consists of a very difficult molecular rearrangement from a
paraffin to a naphthene. In the case of light paraffins, equilibrium considerations
limit this reaction.
The paraffin cyclization step becomes easier as the molecular weight of the
paraffin increases, because of increased statistical probability for the formation of
the naphthene. Somewhat counteracting this effect is the increased probability of
the heavier paraffins to hydrocrack. Dehydrocyclization is favored by low pressure
and high temperature. Both metal and add catalyst functions are needed to
promote this reaction.
d. Hydrocracking
Because of the strained ring isomerization and ring formation reactions that the
feed alkylcyclopentanes and paraffins must undergo, and because the catalyst
needs to have an acid function, the possibility for acid-promoted hydrocracking,
depicted in Figure 6, is strong. Paraffin hydrocracking is relatively rapid and is
favored by high pressure and high temperature. The disappearance of paraffins
from the gasoline boiling range via hydrocracking does concentrate aromatics in
the product and hence contributes to octane improvement. The reaction does,
however, consume hydrogen and result in lower reformate yield.
e. Demethylation
Demethylation reactions, shown in Figure 7, generally occur only in very severe
Platforming operations (high temperature and high pressure). Under certain
conditions it may occur during the startup of a semi-regenerative Platforming Unit
following catalyst replacement or regeneration. The reaction is metal catalyzed
and is favored by high temperature and pressure. It can be inhibited by attenuation
of the catalyst metal function by addition of sulfur or a second metal (as in some
bimetallic catalysts).

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f. Dealkylation of Aromatics
The dealkylation of aromatics, shown in Figure 8, is similar to aromatic
demethylation differing only in the size of the fragment removed from the ring. If
the alkyl side chain is large enough, this reaction can be visualized as acid
catalyzed carbonium ion cracking of the side chain. The dealkylation reaction is
also favored by high temperature and high pressure.
Table 1 summarizes the conditions that promote the reactions that take place in
the Platforming process.
Table 1 Platforming reactions

Naphthene Dehydrogenation

Promoted by
Temperature
High

Naphthene Isomerization
Paraffin Isomerization
Paraffin Dehydrocyclization
Hydrocracking
Demethylation
Aromatic Dealkylation

A
A
M/A
A
M
M/A

Low*
Low*
High
High
High
High

Reaction

Catalyst

Pressure
Low
Low
High
High
High

* Low temperatures favor higher iso/normal ratios; rate of isomerization increases

with increasing temperature
Because of the wide range of paraffins and naphthenes included in the Platforming Unit
feed, and because the reaction rates vary considerably with the carbon number of the
reactant, these reactions occur in series and in parallel to each other forming the rather
complicated overall reaction scheme indicated in Figure 9.
1.1.3

Relative reactions rates

In experimental pure component work, individual hydrocarbons were reformed in a pilot
plant unit. Compounds studied were normal hexane, methylcyclopentane and
cyclohexane in the C6 hydrocarbon group, and normal heptane, methylcyclohexane and
dimethyl-cyclopentane in the C7 group. Operating pressure was varied between 5 and
21 kg/cm and reaction temperature was varied between 450 and 550C. Hydrogen to
hydrocarbon mole ratios were nominally 5 to 7, using recycle hydrogen. Most tests were
of short duration and were designed to establish relative rates of reaction and the effect
of operating conditions on selectivity to aromatics.
Data from runs with pure compounds made at low conversion were used to estimate the
relative reaction rates for the various C6 and C7 hydrocarbon types investigated.
Adsorption effects, catalyst deactivation, and other factors would alter the relative rates
in a blend of compounds or in a commercial naphtha feed, but this analysis provides
valuable insight into the basic Platforming kinetic mechanism. The results of the kinetic
analysis are summarized in Table 2. The reaction rates are reported relative to the rate
of dehydrocyclization of normal hexane.

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Table 2 : Relative reactions rates C6 and C7 hydrocarbons

Hydrocarbon Type
Carbon No.
Reaction Class
Isomerization
Paraffin
Naphthene
Dehydrocyclization
Hydrocracking
Decyclization
(ring opening)
Dehydrogenation

Paraffin
C7
C6

Alkylcyclopentanes
C6
C7
relative reaction rate*

Alkylcyclohexanes
C6
C7

10
1.0
3.0

13
4.0
4.0

10
-

13
-

5
-

3
-

100

100

* Data determined from initial rates for pure components and mixtures of pure
components. All rates relative to rate of dehydrocyclization of normal hexane.
The primary reactions for the C6 and C7 paraffins proceed at significantly different rates.
The rate of dehydrocyclization for hexane is one-third that of hydrocracking so the
fraction of the normal hexane converted to benzene is relatively low. Normal heptane
hydrocracks at about the same rate as normal hexane so the faster rate of
dehydrocyclization (about four times that of hexane) leads to significantly greater
fractional conversion to aromatics for normal heptane in comparison to hexane. Both
paraffins are isomerized rapidly to the various possible isomers.
Reactions of the naphthenes show marked differences between the alkylcyclopentanes
and alkylcyclohexanes. Cyclohexane types dehydrogenate very rapidly and completely
to aromatics. The cyclopentanes react at a much slower rate and undergo both
isomerization to form the corresponding cyclohexanes and ring opening to form
paraffins.
The ratio of the rate of isomerization to the total rate of reaction (isomezation plus ring
opening) is an indication of the expected selectivity to aromatics for the
alkylcyclopentanes. This ratio is 0.67 for the methylcyclopentane and 0.81 for
dimethylcyclopentane. The ease of isomerization increases with carbon number and the
C8+ alkylcyclopentanes have relatively high selectivities to aromatics.
The paraffins show the lowest reactivity and the poorest selectivity for aromatic
formation. The alkylcyclopentanes, while more reactive and selective than paraffins, still
provide less than quantitative yields of aromatics. The alkylcyclohexanes are converted
very rapidly and quantitatively to aromatics.
1.1.4

Heats of reactions
Generalized heats of reaction for the reactions of paraffin to naphthene, naphthene to
aromatic, and paraffin hydrocracking are shown in Table 3.
Table 3 Typical heats of reaction

H (Kcal/Mol H2)

Reaction
Paraffin

Naphthene

+ 10.5 Endothermic

Naphthene

Aromatic

+16.9

Endothermic

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-13.5

Exothermic

Dehydrocyclization of paraffins and dehydrogenation of naphthenes are both very

endothermic as manifested commercially by the large temperature decreases across the
first two Platforming reactors. Generally, the last reactor is promoting a combination of
paraffin dehydrocyclization and hydrocracking reactions and the total kinetics in this
reactor may be either endothermic or exothermic depending on processing conditions,
feed characteristics, and catalyst.
1.1.5

Equilibrium considerations
Most modern motor fuel Platforming Units operate at conditions such that the degree of
conversion of the major components in the feed is not limited by equilibrium. However,
BTX (*) naphtha feeds contain high concentrations of light hydrocarbons, and for these
feeds, the level of conversion is affected by equilibrium. The least reactive and most
strongly influenced by thermodynamic factors are the six-carbon-number hydrocarbons.
The effect of temperature and hydrogen partial pressure on equilibrium conversion will
be examined for this system. A similar analysis would apply for seven- and eight-carbonnumber hydrocarbon systems, but the degree of thermodynamic limitation would be
much lower.
(*) BTX = benzene, toluene, xylene.
The technique used to calculate equilibrium ratios for the various reactions is illustrated
by the following example. Consider the reaction of normal hexane (nC6) undergoing
dehydrocyclization to form methylcyclopentane (MPC).
k1
nC6
MCP + H2
k2
where k1 and k2 are the forward and reverse reaction constants, respectively.
At equilibrium, the following equation is valid
(PMCP ) (PH2 )
k1
=
(PnC6 )
k2
where Kp is the equilibrium constant and P is the partial pressure of the component. The
larger the value of Kp, the more favorable the reaction.
The equilibrium ratio for this reaction then becomes

Kp =

(PMCP )
=
(PnC6 )

Kp
(PH2 )

Values of Kp can be calculated from the thermodynamic properties of the reactants and
products and then the extent of equilibrium limitation established.
Figure 10 shows the effect of temperature and hydrogen partial pressure on the
equilibrium ratio for the conversion of normal hexane to methylcyclopentane. It can be
seen that, in general, the equilibrium ratio is low, but improves rapidly as temperature is
increased and hydrogen partial pressure is decreased. It must be noted that the level of
MCP in the reactor must be reduced below the equilibrium value before there will be any
net conversion of hexane to cyclic materials. Since the rate of hydrocracking is inhibited
by lower hydrogen pressures, the selectivity of the hexane to aromatics is greatly
enhanced by low pressure, high temperature operations.
The isomerization of methylcyclopentane to cyclohexane does not involve hydrogen as
a product or reactant, therefore the equilibrium ratio is a function of temperature only.
The effect of temperature on the equilibrium ratio of cyclohexane to methylcyclopentane
is illustrated in Figure 11. The equilibrium ratio is quite low over the normal Platforming
temperature region and decreases slightly as temperature is increased. This low

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equilibrium ratio inhibits conversion of methylcyclopentane to cyclohexane because the

cyclohexane concentration must be reduced to very low levels before the forward
methylcyclopentane reaction can proceed. The complexity of the ring isomerization
reaction and the unfavorable thermodynamics combine to reduce the selectivity of
methylcyclopentane to benzene substantially below 100%.
The dehydrogenation of cyclohexane to form benzene is the most rapid and simplest of
the Platforming reactions. The effects of temperature and hydrogen partial pressure on
the equilibrium ratio for this reaction are illustrated in Figure 12. The formation of
benzene is highly favored over the entire range of typical Platforming operating
conditions. Thus, this reaction is essentially irreversible and thermodynamic factors
have little effect on selectivity.
1.1.6

Effects of pressure and temperature on reaction selectivity

As an extension of the pure component equilibrium pilot plant studies, the effects of
pressure and temperature on the selectivity to aromatics for normal hexane,
methylcyclopentane, and normal heptane were investigated in detail. These
hydrocarbons have low selectivities and thus optimization of operating conditions to
maximize the selectivity is the key to improved yields of aromatics.
The effect of operating conditions on normal hexane selectivity to benzene is illustrated
in Figure 13. Here the selectivity to benzene is defined as the mole ratio of hexane
converted to benzene divided by the total moles of hexane converted (conversion was
based on disappearance of total hexane so that iso-hexanes in the product were treated
as unconverted normal hexane). This is, in essence, the extent to which the
dehydrocyclization of hexane is occurring. As shown in Figure 13, normal hexane
selectivity to benzene increases with temperature at each pressure. This is due to
equilibrium shifting in favor of dehydrocyclization with increasing temperature. Selectivity
improvement with decreasing pressure is due to the combined effects of improved
equilibrium ratio and a suppression of the rate of hydrocracking.
At a reactor temperature of 538C, decreasing the plant pressure from 14 kg/cm2g to 9
kg/cm g increases the selectivity of normal hexane to benzene by 33%, while a further
decrease to 5 kg/cm g yields a 70% improvement over the selectivity at 14 kg/cmg.
Benzene yields from hexane precursors will be greatly enhanced by operating at high
temperature and low pressures. At these conditions, however, the rate of coke formation
is very high, and catalyst stability becomes a primary concern.
The effect of process conditions on the methylcyclopentane selectivity to benzene is
illustrated in Figure 14. Methylcyclopentane shows the same trend of improved
selectivity with increased temperature and reduced pressure as noted for normal
hexane. At comparable conditions, however, the methylcyclopentane selectivity is two to
three times as large as the hexane selectivity. The best selectivity (about 70%) was
obtained at 7 kg/cm g pressure and 538C reactor temperature. Increasing the
pressure to 21 kg/cm lowered the selectivity to about 50%. Thus a 40% improvement in
methylcyclopentane selectivity to benzene is obtained by operating at the lower
pressure.
Figure 15 summarizes the results obtained when normal heptane was processed at
various conditions. Heptane selectivity to toluene follows a pattern similar to that found
for normal hexane to benzene. Again, the improvement in selectivity as temperature is
increased and pressure decreased is due to the combined effects of improved
equilibrium ratio and a suppression of the rate of hydrocracking. For example, at a
reactor temperature of 538C, reducing plant pressure from 21 kg/cm g to 14 kg/cm g
increased heptane selectivity to toluene by 30% while a further reduction to 7 kg/cm g
pressure provided a selectivity 60% greater than that at 21 kg/cm g pressure. Heptane
selectivity to toluene is two to three times higher than hexane selectivity to benzene at
identical operating conditions.

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The preceding pure component work indicates that the processing conditions utilized
can greatly affect the selectivity to aromatics for the C6-C7 paraffins. Specifically, more
aromatics are produced at low pressure, high temperature conditions. Note, however,
that the catalyst stability becomes a constraint as moves are made toward conditions
favoring increased aromatics production.
1.1.7

Reactor profiles : commercial Platforming data

Having considered the relative rates of the various Platforming reactions, equilibrium
constraints, and heats of reaction, the overall Platforming process can now be
examined. Consider a low pressure, motor fuel operation from the aspects of
hydrocarbon concentration, product quality, and temperature profiles as the reactants
pass through the reactor system.
The following data were obtained from a commercial, four reactor Platforming Unit.
Feed, product and inter-reactor samples were taken in such a manner as to follow
hydrocarbon conversion and product quality through the reactors. The profiles from this
unit vividly demonstrate the practical aspects of the hydrocarbon chemistry discussed
above.
Figure 16 shows hydrocarbon types yield, expressed as moles of the particular
hydrocarbon type per 100 moles of feed, across the reactor system. The lines at 0.1,
0.25, 0.50, and 1.0 fraction of total catalyst indicate individual reactor boundaries and
points of sampling. Note that in this particular operation, aromatic formation is 22, 10,
5.5, and 5.5 moles per 100 moles of feed respectively in reactors 1, 2, 3, and 4.
Because of their rapid reaction rate, 95 percent of the feed cyclohexanes disappear in
the first reactor. Slower to react, the cyclopentanes disappear at rates of 4.5, 4.0, 1.0,
and 0.5 moles per 100 moles of feed through reactors 1 through 4. Paraffin
disappearance on an absolute molar level is comparable to cyclopentane conversion
(4.0, 4.0, 7.0, and 6.5 moles per 100 moles of feed) but on the basis of percent
converted per mole of specific hydrocarbon feed, the paraffin conversion is much lower.
Table 4 quantifies the conversion of each hydrocarbon type based on the amount of that
hydrocarbon in the Platforming Unit feed.
Table 4 Paraffin and naphthene conversion per reactor
Reactor No.

Total
Conversion

Conversion of Feed
Hydrocarbon Type, Percent
Cyclohexanes

95

0*

1*

99

Cyclopentanes

39

35

87

Paraffins

13

12

39

* Concentration Too Low To Accurately Measure.

Figure 16 and Table 4 demonstrate the rapid quantitative conversion of cyclohexanes,
the slower conversion of cyclopentanes, and the very slow paraffin conversion. Note that
isomerization is not included in paraffin conversion.
Figure 17 demonstrates the effect of cyclopentane carbon number upon the rate of
conversion. In reactor one there is generally either no change at all, or actually an
increase, in the absolute amount of methylcyclopentane. Such an increase could result
from cyclohexane isomerization but is generally only observed in low severity units.
Figure 17 shows the more rapid conversion of the heavier cyclopentanes; C9 and
heavier cyclopentanes are essentially completely converted in the first two reactors. C8,
C7, and C6 cyclopentanes react progressively slower.

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Figure 18 shows the paraffin content of the reactant stream (moles of paraffin per 100
moles of feed) across the reactor system. It is interesting to note that in the first two
reactors there is an increase in the absolute amounts of C6 and C7 paraffins present.
This is due to cracking of the heavy paraffins (note the rapid disappearance of C9
through C11 paraffins) and possibly to decyclization of C6 and C7 cyclopentanes back to
corresponding paraffins. The more rapid conversion of the heavier paraffins results from
increased ease of ring formation, dehydrocyclization, and increased rate of
hydrocracking.
Figure 19 shows increasing isomerization in the C6 through C8 paraffin fraction across
the reactors. These iso/normal ratios approach but do not reach equilibrium values.
lsomerization plays a role in octane upgrading of the remaining paraffin fraction.
One of the more interesting aspects of these results is demonstrated in Figure 20. This
figure shows aromatic content by carbon number (again in moles of aromatic per 100
moles of feed) across the reactors. The absolute amount of an individual aromatic
formed, of course, depends on the amount of precursors in the feed. However, the rates
at which the aromatics form are indicative of the kinetics of the aromatic-forming
reactions. C10 and C11 aromatics are all formed in reactors one and two; there is no net
formation of these aromatics in the last two reactors. Figure 18 does indicate conversion
of C10 and C11 paraffins in reactors three and four and it is felt that some of the
converted paraffins are dehydrocyclizing, but that an offsetting amount of dealkylation to
lighter aromatics is occurring.
C7 through C9 aromatics continue to be produced throughout the reactor system.
Inspection of the previous figures show that very little C7-C9 aromatic production in
reactors three and four can be attributed to naphthene conversion, because most of
these naphthene precursors are converted in reactors one and two. This aromatic
production must then be attributed to paraffin dehydrocyclization and dealkylation of
heavier aromatics. Finally, very little net benzene production occurs in reactor three and
none occurs in reactor four. This is the result of rapid cyclohexane conversion in
reactors one and two, slower methylcyclopentane conversion in reactors two and three,
and minimal hexane conversion. Hexane conversion at these moderate severity
conditions was low, as expected. More severe processing conditions (lower pressure)
are employed in modern Platforming Unit designs to increase conversion of hexane to
benzene.
Figure 21 shows octane increase across the reactors. Predictably, the octane rating
increases more rapidly in the first reactors, a result of the extensive naphthene
conversion. Octane upgrading in the last reactors results from the slower isomerization,
hydrocracking, and dehydrocyclization.
Finally, Figure 22 shows the reactor temperature profiles. The inlet and outlet
temperatures can be measured commercially; the shape of the profile was determined
by a Platforming kinetic model.
1.2 CATALYST CHEMISTRY
1.2.1

Dual function Platforming catalyst chemistry

Examination of the reactions listed in Table 1 and Figure 9 shows that some of them are
acid-catalyzed while others are promoted by a metallic hydrogenation-dehydrogenation
catalyst function. As such it is necessary that a Platforming catalyst have a proper
balance between the metal and the acid function as shown in Figure 23. This is
important to minimize hydrocracking while maximizing the dehydrogenation and
dehydrocycilization reactions. This balance is maintained by proper H2O/Cl control
during a semi-regeneration catalyst cycle and proper regeneration technique.
The importance of water/chloride control can be illustrated by imagining the catalyst
surface as a ball and stick model with aluminum and oxygen atoms in a regular pattern
upon which hydrogen and hydroxyl groups are randomly arrayed. The vapor phase HCI

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and H2O are in equilibrium with the surface hydroxyl groups and chloride. Too much
water in the vapor phase will force chlorides from the surface leading to an
underchlorided catalyst. While too much chloride in the vapor phase has the reverse
effect. Therefore, proper control of water/chloride ratios is crucial in maintaining an
active acid site.
On the other hand, the metal sites (and of course the acid sites) are affected most
dramatically during catalyst regeneration. Using the ball and stick model, one can
imagine a platinum-chloride species somehow attached to the surface (i.e. through an
oxygen or aluminum atom). No one is quite sure of the anchoring mechanism but the
presence of chlorides in an oxidizing atmosphere is instrumental in redispersing the
platinum on the surface. Temperature also affects mobility of platinum and retention of
chloride.
The classical picture of a dual function catalyst involves two separate and distinct sites
with the reacting molecule migrating from one site to another. Current thinking leans
toward a modified picture in which a single site or single complex is responsible for the
entire reaction sequence. It should be pointed out that presently it is only a concept and
is not supported by unequivocal evidence. It is known that the method of catalyst
preparation affects the activity to at least the same extent as the absolute level of active
ingredients, indicating that a specific arrangement is critical. In addition, since the rates
of the reactions over a modern Platforming catalyst are high, one must question the
mass transfer limitations that would be involved in migration between separate sites.
The concept of a single complex site does not affect the innate dual-functional nature of
a Platforming catalyst. The surface must still possess both acidic and metallic
characters. The acidic character is mainly responsible for the formation of carbonium
ions by either extraction of hydride ions or addition of protons to double bonds.
Carbonium ions are, in turn, the intermediates in such reactions as isomerization and
hydrocracking. The metal function is responsible for the extraction of hydrogen from
hydrocarbons, the splitting of hydrogen molecules and subsequent addition of hydrogen
atoms to unsaturated species. Combination of these two functions into a single complex
site allows these reactions to occur in a concerted fashion.
1.2.2

Effects of pressure on catalyst design

For special purposes, the acidity of a Platforming catalyst can be increased. The best
example of this is the R-15 LPG Platforming system, where the target is the production
of propane and butane. This was accomplished by adding another acidic component to
a Platforming catalyst. Figure 25 illustrates the effect of such increased acidity on
product distribution in the case of a relatively mild processing of a mid-continent
naphtha.
If this same catalyst system is now operated at a lower pressure, there is a dramatic
shift in product yields because the acidity or cracking nature of the catalyst is
significantly reduced. Figure 26 illustrates the effect of lowering pressure on the
performance of an R-15 catalyst. At 7 kg/cmg, R-15 behaves very nearly like a standard
Platforming catalyst.
The pressure effect translates to standard Platforming catalysts where lowering reactor
pressure reduces cracking tendencies and increases selectivities of naphthenes and
paraffins to aromatics (as previously discussed).
Figure 27 illustrates the relationship between pressure and yield of light hydrocarbons
for a given Platforming system. As the pressure is decreased, there is an increase in
C5+ yield and hydrogen with a subsequent decrease in light gases.
The source of the light hydrocarbons is the cracking of paraffins. The yield of aromatics
from paraffins can increase by as much as 40% as the pressure is decreased from 35 to
11 kg/cm g. Figure 28 shows that this is the result of a substantial decrease in
hydrocracking and an associated improvement in the selectivity of them paraffins to
aromatics.

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With the increase in C5+ yield due to lowering reactor pressure, there is an increase in
the octane-barrel yield with the optimum occurring at higher octane severities*. Figure
29 illustrates that for a constant feedstock lowering reactor pressure from 21 kg/cm g to
7 kg/cm g the optimum octane for maximum octane barrel shifts from around 96 RONC
to about 99 RONC. Likewise in Figure 30, if pressure is held constant, as the feed N+2A
content increases, the optimum RONC for maximum octane barrel increases.
*
Octane barrel yield is defined as C5+ volume yield (barrels) times C5+ RONC.
1.2.3

UOP Platforming catalysts

The type of information presented above on the relationship between pressure and yield
encouraged UOP to focus attention on low pressure Platforming some time ago. The
yield advantages in that region are obvious, but the problem is catalyst stability.
Figure 31 illustrates the effect of increased octane and decreased pressure on catalyst
stability. Taking advantage of the optimum octane for maximum octane barrel from
Figure 29 would result in a six fold deactivation rate.

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1.3 FIGURES ATTACHED TO THE PLATFORMING CHEMISTRY

Figure 1 :
Figure 2 :
Figure 3 :
Figure 4 :
Figure 5 :
Figure 6 :
Figure 7 :
Figure 8 :
Figure 9 :
Figure 10 :
Figure 11 :
Figure 12 :
Figure 13 :
Figure 14 :
Figure 15 :
Figure 16 :
Figure 17 :
Figure 18 :
Figure 19 :
Figure 20 :
Figure 21 :
Figure 22 :
Figure 23 :
Figure 24 :
Figure 25 :
Figure 26 :
Figure 27 :
Figure 28 :
Figure 29 :
Figure 30 :
Figure 31 :

Hydrocarbon Types Volume Conversion in Platforming

Naphthene Dehydrogenation
Naphthene Isomerization
Paraffin Isomerization
Paraffin Dehydrocyclization
Hydrocracking
Demethylation
Aromatic Dealkylation
Generalized Platforming Reaction Scheme
Normal - Hexane/Methylcyclopentane Equilibrium
Cyclohexane/Methylcyclopentane Equilibrium
Cyclohexane/Benzene Equilibrium
Selectivity of Normal Hexane to Benzene
Selectivity of Methylcyclopentane to Benzene
Selectivity of Normal Heptane to Toluene
Hydrocarbon Types Conversion - Reactor Profile
Cyclopentane Conversion - Reactor Profile
Paraffin Conversion - Reactor Profile
Paraffin Isomerization - Reactor Profile
Aromatic Formation - Reactor Profile
C5+ Research Octane Rating - Reactor Profile
Temperature - Reactor Profile
Properly Balanced Catalyst
Acid Site
Standard Platforming Catalyst Versus R-15
Effect of Pressure on Yield Structure of R-15 Catalyst
Effect of Pressure on Yield Structure
Effect of Pressure on Paraffin conversion
Octane - Barrel Yield Response to Octane and Pressure
Octane - Barrel Yield Response to Octane and Feed Composition
Effect of Octane and Operating Pressure on Catalyst Deactivation

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2. PROCESS FLOW DESCRIPTION

2.1 REACTION CIRCUIT
2.1.1

Feed preheater section

The platformer feed, hydrotreated heavy naphtha, coming from the Naphtha Splitter
(Unit 12), enters the unit on flow control 013-FIC-003. This feed is filtered in filters to
remove any particles which may plug the welded plate-type exchanger E-1301.
In normal operation, the feed is directly supplied from the Naphtha Splitter (T-1202) via
the Stripper Feed Naphtha Splitter Bottoms cooler (E-1206). The setting of the flow
controller 013-FIC-003 is kept constant and the fluctuation in the upstream unit (NHDT
unit) will be detected by the level fluctuations in the splitter bottom (012-LI-019).
A recycle hydrogen rich gas is also supplied to the Combined Feed Exchanger E-1301
where it is mixed with the feed stream. The combined feed (liquid feed + recycle gas) is
heated up by heat exchange with the reactor effluent in E-1301 (true counter-current
exchanger designed for minimum pressure drop and maximum heat recovery).
The combined feed is then sent to the Charge Heater H-1301 to be heated up to the
desired temperature (controller 013-TIC-001) before entering the first reactor.

2.1.2

Charge heater and inter heaters

The heat and reheat section consists of the Charge Heater and three Interheaters
between the reactors. In the reactors, the chemical reactions that occur are mostly
endothermic, and so the outlet temperature of each reactor is less than the inlet
temperature. The function of the interheaters is to raise the temperature of each
reactors effluent back up to reaction temperature for the next reactor.
The Charge Heater and the Interheaters in UOP Continuous Platforming Units are
contained in a single, partitioned, multi-cell heater box. The heater box has a convection
section to recover heat from the flue gas to generate HP steam.
Fuel Gas used in the heaters firing systems is supplied from the FG Header from unit
037, in which Fuel Gas produced in all the units is mixed.

2.1.3

Reactors
The reactor stack is composed of four reactors constructed together to form one large
vessel. The bottom heads of the individual reactors are used to divide this vessel into
separate reactors. In order to have a low pressure drop, the reactors design is radial
flow where hydrocarbon enters at the top of the reactor and flows across the catalyst
bed from the outside to the inside of the reactor. Process vapors then flow through the
center pipe and out the reactor.
Internal expansion joints are built into the vapour outlet lines of all the reactors, except
the bottom one, to counteract thermal expansion of the vessel.
Catalyst enters at the top of the reactor, flows down through the reactor, and exits at the
bottom. The Platforming Unit is equipped with the CCR Section, and the reactor stack is
equipped with reactor internals that permit catalyst transfer series flow through the
stack; i.e. from one reactor to the next. Additional exterior equipment is provided to
transfer a spent catalyst form the reactor stack to the Regeneration Equipment and
return regenerated catalyst from the Regeneration Equipment to the reactor stack.
The temperature of the process vapor drops rapidly in going through the catalyst bed,
since the reactions are very endothermic. Therefore, they must be reheated before they

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enter Reactor No. 2 to support further reactions. After reheating, the vapors go to the
No. 2 reactor where the process is repeated.
Since small temperature changes can have large effects on the reactors performance,
the feed temperature is closely controlled by temperature controllers (013-TIC-001, 003,
005 and 007) located on process outlet of each heater, which regulate the fuel gas firing
of the respective heater/interheater (H-1301, 1302, 1303 and 1304).
2.1.4

Reactor effluent
Leaving the Reactor N4, the effluent is split into two streams :
one stream is used to heat up the recycle gas injected at the bottom of reactor
N4. The temperature of the recycle gas outlet controls the flow of the effluent
stream through the Reactor Purge Exchanger E-1302 (013-TIC-013),
the other stream is partially cooled by exchange with the combined feed stream in
the Combined Feed Exchanger E-1301.
These two streams are mixed downstream exchanger E-1301 and then further cooled in
the Products Condenser E-1303. After cooling, the reactor effluent is sent to the
Separator D-1301 to separate H2 rich vapor from the hydrocarbon liquid product.

2.1.5

Reactor effluent separator

In the separator D-1301, the cooled, condensed reactor effluent is separated into a
condensed liquid hydrocarbon and a hydrogen rich gas stream. A wire mesh is provided
inside the Separator D-1301 to catch any liquid entrainment.
After compression by the recycle compressor (C-1301), the gas stream is split into two
streams :
the majority of the gas stream is recycled back into the reaction section (to mixing
with the platformer feed upstream of the Combined Feed Exchanger (E-1301) and
to the bottom of reactor n4(via E-1302),
the remaining stream, so called Net Gas is cooled in the net gas cooler E-1304
and then sent to the RECOVERY PLUS system X-1301 to allow the recovery of
LPG / Reformate which remain in the net gas stream.
The pressure of the reaction loop is controlled at the level of the separator D-1301 off
gas line. This pressure control is performed by 013-PIC-004 acting on split range on two
control valves 013-PV-004A venting to flare and the second 013-PV-004B releasing net
gas to the fuel gas circuit.
In case of a pressure increase, the controller output first opens the 013-PV-004B
and then the vent to the flare, by the valve 013-PV-004A.
The Separator liquid is pumped on level control 013-LIC-002 by the separator pump
013-P-1301A/B to be recontacted with the liquid effluent from the RECOVERY PLUS
system X-1301.

2.1.6

Recycle compressor
The recycle compressor C-1301 is driven by a steam turbine CT-1301 using HP steam
from HP steam header.

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LP steam from the turbine exhaust is condensed in the surface condenser E-1311
(using cooling water). Condensate is pumped and routed to the vacuum condensate
system.
2.1.7

Steam generation
HP Steam is available from interconnecting header. But HP steam is also produced
using HP Boiler Feed Water from Header. BFW is preheated in the convection section
SG-1301 of the heater H-1301/02/03/04 before entering the disengaging drum D-1306.
Steam is then heated through the convection section of heaters.

2.1.8

RECOVERY PLUS system

The RECOVERY PLUS system contains five circuits that are described below. PFDs
and PIDs of this package are attached in 3 of Chapter 14.
a. Refrigeration Circuit
The refrigeration circuit in the RECOVERY PLUS system is a pressurized closed loop.
The propylene refrigerant flows to the Combined Chiller X-1301-E03 through LV-571.
The pressure drop across this valve vaporizes a portion of the liquid refrigerant, and the
resultant phase change chills it to the required operating temperature. The chilled liquid
refrigerant level is maintained 50 mm below the top of the tubes of the Combined Chiller.
The frothing of the refrigerant in the Chiller covers the rest of the tubes. Rich Net Gas
and Lean Oil pass through their respective tube bundles, cooled by refrigerant
evaporation. The vaporized refrigerant that leaves the Combined Chiller enters the
suction of the Refrigerant Compressor X-1301-C01. The Refrigerant Compressor
capacity increases (loads) or decreases (unloads) as required to maintain the setpoint
from TIC-579, controlling the temperature of the Lean Oil to the Absorber. Within the
Compressor, refrigerant vapor comes in contact with circulating synthetic lube oil, which
aids compression while lubricating and cooling the Compressor. Mechanical energy and
warm oil heat the refrigerant to a temperature well above the condensing point. The
compressed gas/oil mixture discharges from the Compressor to the Oil Separator X1301-V02.
In the Oil Separator, the refrigerant disengages from the oil and passes overhead
through coalescing elements where entrained oil is removed. Oil buildup from the
downstream side of these elements is sent back into the compressor suction via a liquid
oil drain line. The refrigerant leaves the top of the Oil Separator and enters the shell side
of the Refrigerant Condenser X-1301-E06, where it exchanges heat with the cooling
water and condenses. The lower section of the Condenser acts as a refrigerant surge
capacity. A level should be maintained in this lower section of the Condenser, to
maintain adequate liquid head pressure to operate the Lube Oil Cooler X-1301-E04.
Condensed refrigerant drains from the Condenser and is cooled further in the Subcooler
X-1301-E05, before entering the Combined Chiller. A portion of the condensed
refrigerant bypasses the Subcooler and is used in the thermosyphon Lube Oil Cooler,
which cools the lube oil for return to the Compressor. The refrigerant from the Lube Oil
Cooler is returned to the inlet of the Refrigerant Condenser.
b. Oil reclaimer System
Entrained lube oil in the refrigerant stream settles in the shell side of the Combined
Chiller, where refrigerant boiling occurs. This lube oil is drawn off the bottom of the
chiller shell to avoid accumulation; the lube oil gravity settles to the bottom of the Chiller.
Due to the rapid boiling of the refrigerant, this lube oil does not necessarily form a

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distinct interface with the refrigerant. Also, the refrigerant is somewhat soluble in the
lube oil. The lube oil is reclaimed via a small continuous draw off the lube oil/refrigerant
mixture, which is heated to vaporize the refrigerant fraction and returned to the
compressor suction. Heat is provided to the Oil Reclaimer system from the Lube Oil
circuit.
c.

Lube oil circuit

Lube oil is continuously supplied to the Compressor to lubricate and assist in

compression. Separation of the lube oil/refrigerant mixture is achieved in the Oil
Separator X-1301-V02. This is a two stage separator, using gravity settling in the first
stage and coalescing elements as the second stage. The bottom of the Separator
serves as an oil reservoir and is equipped with a level gauge for positive oil level
indication. A thermostatically controlled Oil Separator Heater X-1301-H01, maintains the
oil temperature for proper oil viscosity during Compressor shutdown. The Lube Oil
Pumps X-1301-P01A/B transfer lube oil from the Oil Separator to the Compressor. The
oil temperature to the Compressor is controlled by TCV-593, which allows hot oil to
bypass the Lube Oil Cooler X-1301-E04 and recombine with the cooled oil. Lube Oil
passes through a 10 micron element filter, Lube Oil Filters X-1301-F02A/B (10 micron),
before the oil is fed to the bearings, balance piston, shaft seal, compression chamber
and hydraulic capacity actuator.
d. Net Gas Circuit
The NET GAS IN passes through the Vapor Exchanger X-1301-E02, where it is cooled
by exchanging heat with the RICH NET GAS. The RICH NET GAS then enters the
vapor side of the Combined Chiller where it is further cooled. Some condensation of
heavier hydrocarbons occurs as the gas is cooled. Leaving the Chiller, the RICH NET
GAS enters the Absorber below tray 10. Passing upward through the Absorber, the gas
is contacted with the chilled Lean Oil which absorbs hydrocarbons from the gas. The H2
rich gas (LEAN NET GAS) leaves the top of the Absorber, is then heated in the shell
side of the Vapor Exchanger and sent to the Net Gas Chloride Treater (outside
RECOVERY PLUS battery limits).
e. Liquid Circuit
The Lean Oil in the RECOVERY PLUS system is a slipstream from the Lean Oil
Separator (outside RECOVERY PLUS battery limits). The rate of the LEAN OIL is
controlled by FIC-580. This stream flows to the Liquid Exchangers X-1301-E01A/B,
where it is cooled by exchanging heat with the absorber rich liquid. The LEAN OIL
enters the liquid tube side of the Combined Chiller where it is further cooled. TIC-579
adjusts the refrigeration circuit to control the temperature of the LEAN OIL leaving the
Combined Chiller. Leaving the Chiller, the LEAN OIL enters the Absorber above tray 1.
The liquid flows counter-current, absorbing hydrocarbon from the rising gas. Leaving
tray 10, the liquid accumulates in the bottom of the Absorber. The Absorber liquid level
is controlled by LIC-573. Rich Oil Pumps X-1301-P02A/B send Rich Oil to Liquid
Exchangers X-1301-E01A/B. The Rich Oil (net liquid) is heated in the shell side of the
Liquid Exchangers and further warmed in the shell side of the Subcooler. The RICH OIL
then flows to the Debutanizer Feed Bottoms Exchanger (outside RECOVERY PLUS
battery limits).

Recovered gas from X-1301 is sent to the Net Gas Chloride Treaters D-1302 A/B to
remove chloride components by activated Alumina (chloride is absorbed onto the
alumina).
The Net Gas Chloride Treaters outlet gas is separated into two streams :

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one stream is sent to the first stage of the NHT make up compressor suction drum
D-13
one stream is sent on pressure control, via 013-PV-004B to the fuel gas system,
The liquid from the RECOVERY PLUS system is sent to the Debutanizer section.
2.1.9

Chemical injection

2.1.9.1

Chloride injection package X-1307

Chloride and water are injected into the feed stream to obtain optimum activity and
selectivity of the catalyst.
Chloride from storage D-1399 is injected by means of the Injection Pump P-1305 (for
startup) or the Chemical and Condensate Injection Pumps P-1304 A/B which has a two
piston cylinder and common driver. Chloride is injected into the feed upstream of the
Combined Feed Exchanger E-1301.
The cold condensate which is received in the Condensate Break Tank D-1307 is
injected into the feed stream downstream of the Combined Feed Exchanger E-1301, by
means of the Chemical and Condensate Injection Pump P-1304 A/B.

2.1.9.2

Sulfide injection package X-1396

Sulfide from sulfide storage drum D-1396 is injected via the sulfide injection pumps P1306 A/B in the Feed from NHT stripper at the inlet of the combined exchanger E-1301.

2.1.9.3

Phosphate dosing drum X-1397

Phosphate is injected from phosphate feed drum D-1397 via the phosphate injection
pump P-1397 A/B to the Steam disengaging drum D-1306

2.2 DEBUTANIZER SECTION

The Debutanizer is used to control the vapor pressure of the gasoline by fractionating all
but a predetermined amount of C4s (butanes) overhead. The amount of butane left in
the gasoline will help determine the vapor pressure of the gasoline. The LPG product
shall contain less than 1.1% mole C5+ and the reformate shall contain less than 1% vol
C4 minus.
The liquid hydrocarbon from the following streams is pressurized or pumped through
level controllers and mixed at the inlet of the Debutanizer Feed-Bottoms Exchanger E1306 A/B/C/D :
Liquid from RECOVERY PLUS system (X-1301),
Liquid from the separator (D-1301) via pumps P-1301 A/B,
Liquid from Net gas chloride treaters (D-1302 A/B) via pump P-1308.
The mixed liquid is heated up by heat exchange with the Debutanizer bottoms liquid in
the Debutanizer Feed-Bottoms Exchangers E-1306 A/B/C/D, and enters the
Debutanizer T-1301 column above tray N21.
The overhead from the Debutanizer is partially condensed in the condenser E-1309 and
the trim cooler E-1310. The effluent of this condenser is separated into vapor and liquid
phases in the Debutanizer Receiver D-1303 :

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The hydrocarbon liquid is pumped from the Receiver by the Debutanizer Overhead
Pumps P-1302 A/B on flow control 013-FIC-011 reset by the Receiver level
controller 013-LIC-005, and split into two streams :
One stream is returned as reflux to the Debutanizer,
The other stream, LPG product, is sent to the LPG Chloride Treaters D-1308
A/B and then sent to the battery limit on flow control 013-FIC-010 reset by the
sensitive tray N8 temperature controller 013-TIC-027. In normal operation,
the cut point between LPG and reformate is performed by this temperature
control in tray N8 of the column.
The vapor phase (C4 and lighter) leaves the receiver and is routed to the
RECOVERY PLUS system on pressure control to regulate the Debutanizer
overhead pressure (013-PIC-012).
The sour water is removed from the Receiver boot on interface level control (013LIC-004) and sent to the battery limit (and further to the Sour Water Stripper Unit)
The stripping vapors in the lower portion of the column are provided by a steam reboiler
-E-1307. The heating medium (high pressure steam) is flow controlled (013-FIC-009) on
the HP condensate to achieve the required duty of the Debutanizer Reboiler E-1307
The stabilized material, so called reformate, is removed from the bottom of the
Debutanizer on level control 013-LIC-003 and partially cooled in the Feed-Bottoms
Exchanger E-1306 A/B/C/D. Further cooling is performed in the Debutanizer Bottoms
Cooler E-1308 and Trim Cooler E-1305 A/B before reformate is being sent to the battery
limit to storage.

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DESCRIPTION OF UNIT CONTROL

CONTENTS

1.

DESCRIPTION OF FLOWS WITH CONTROLS

1.1
Description of integrated control loops of the unit
1.1.1
Charge / Interheaters temperature outlet control
1.1.2
Reactor section pressure control system
1.1.3
Separator Level control
1.1.4
Net Gas Chloride Treaters Level Control
1.1.5
Steam generation controls

2.

OPERATING CONDITIONS

3.

PROCESS VARIABLES

3.1
Major Platforming independent variables
3.1.1
Catalyst type
3.1.2
Reactor temperature
3.1.3
Space velocity
3.1.4
Reactor pressure
3.1.5
Hydrogen / Hydrocarbon ratio
3.1.6
Charge stock properties
3.1.7
Feed additives
3.2
Platforming dependent variables
3.2.1
Catalyst activity
3.2.2
CCR Platforming Reactor quench
3.2.3
Catalyst selectivity
3.2.4
Catalyst selectivity to aromatics
3.2.5
Catalyst stability
3.2.6
Effect of Non-SRN on catalyst stability
3.2.7
Endothermic heat of reaction
3.3

Figures attached to the Platforming process variables

3.4

RECOVERY PLUS SYSTEM

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4.

INTER-UNIT CONTROL SCHEME

5.

UNINTERRUPTIBLE POWER SUPPLY (UPS)

6.

COMPLEX CONTROL DESCRIPTION

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1. DESCRIPTION OF FLOWS WITH CONTROLS

1.1 DESCRIPTION OF INTEGRATED CONTROL LOOPS OF THE UNIT
1.1.1

Charge / Interheaters temperature outlet control

PID reference:

8474L-013-PID-0021-010
8474L-013-PID-0021-011
8474L-013-PID-0021-012
8474L-013-PID-0021-013

The purpose of the Charge heater / Interheaters (H-1301/1302/1303/1304) temperature

outlet control system (013-TIC-001/002/003/004) is to control the temperature of the
product outlet from the heaters to the reactors.
The temperature control system (013-TIC-001/002/003/004) is operating as a master
controller in a cascade with the fuel gas firing controls based on fuel gas pressure (013PIC-618/621/6624/627)
1.1.2

Reactor section pressure control system

PID reference:

8474L-013-PID-0021-017
8474L-013-PID-0021-019
8474L-013-PID-0021-020

The purpose of the Separator D-1301 pressure control system (013-PIC-004) is to

control the reactor section pressure.
During normal operation, pressure controller 013-PIC-004 will operate in split range,
opening first valve 013-PV-004B at chloride treaters outlet to Fuel Gas system to
maintain the compressor suction pressure, and then the valve 013-PV-004A (located
upstream the RECOVERY PLUS system) to send excess gas to the Flare
1.1.3

Separator Level control

PID reference:

8474L-013-PID-0021-017
8474L-013-PID-0021-019

The purpose of the Separator D-1301 level control system (013-LIC-002) is to control
the level of the bottom of the separator, by means of a split range controller with three
outputs.
During normal operation, level controller 013-LIC-002 will first open valve 013-FV-580 to
ensure lean oil circulation in the RECOVERY PLUS system X-1301, and will open then
valves 013-LV-002A (and B) to maintain liquid level in the separator and to feed the
debutanizer T-1301.
The opening of the valve 013-FV-580 is also function of the lean gas flowrate (013-FT565) which adjusts the 013-FIC-580 setpoint in order to maintain constant the required
rich net gas / lean oil molar ratio.

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1.1.4

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Net Gas Chloride Treaters Level Control

PID reference:

8474L-013-PID-0021-020

The purpose of the Net Gas Chloride Treaters D-1302 A/B level control system (013LIC-010/011) is to control the level of liquid hydrocarbons in the treater in operation, by
increasing or decreasing the length of the stroke on the proportional pump P-1308.
1.1.5

Steam generation controls

PID reference:

8474L-013-PID-0021-032
8474L-013-PID-0021-033

Heater box has a convection section to recover heat from the flue gas. The heat that is
recovered is used to generate steam.
The objective of the generation controls is to control the level on Disengaging drum D1306 at a constant setpoint, based on the high pressure steam demand (013-FT-615),
as a major disturbance, like a feedforward variable, that impacts the level. Since the
demand increases, the level decreases, with a consequent action to increase the boiler
feed water flowrate (013-FT-616).

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2. OPERATING CONDITIONS
Refer to the Process Flow Diagrams 8474L-013-PFD-0010-001 thru 005 included in
section 2 of Chapter 14.

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3. PROCESS VARIABLES
The purpose of this section is to discuss the major Platforming operating variables, their
relation to unit performance and the estimation of shifts in performance due to
operational changes.
The operating variables which are the most pertinent are shown in the following table.
For practical purposes, these variables are sufficient to define a Platforming operation.
Major Platforming Variables
Independent Variables

Dependent Variables

Catalyst Type

Catalyst Activity

Reactor Temperature

Reactor Effluent Yields

Space Velocity

Product Quality

Reactor Pressure

Catalyst Stability

H2/HC Ratio

Charge Stock Properties

Feed Additives

Although there are inter-relationships between the variables (for instance the reactor
temperature, reactor pressure, and reactor effluent yield relationships discussed in
chapter 2 - 1 theory of the process), this section treats each independent variable
separately where possible.
3.1 MAJOR PLATFORMING INDEPENDENT VARIABLES
It is of interest at this point to discuss briefly and qualitatively the effects of the major
process variables on Platforming Unit operations.
3.1.1

Catalyst type
Catalyst selection has been tailored to the special processing requirements of
Continuous Platforming. The UOP Continuous Platforming catalyst has been optimized
with respect to yield, activity, and coking tendency. As such, basic catalyst formulation,
chloride level, platinum level, and activator level are not discussed in this section.

3.1.2

Reactor temperature
The temperature at which the Platforming reactor catalyst beds are held is the major
control parameter the refiner uses to meet product quality requirements. Platforming
catalysts are capable of operation over a wide range of temperature with little adverse
affect on product yield and catalyst stability. However, very high temperatures, above
560C, may cause thermal reactions which will decrease reformate and hydrogen yield
and increase the rate of coke laydown.
Reactor temperature can be defined in two fashions, either Weighted Average Inlet
Temperature (WAIT) or Weighted Average Bed Temperature (WABT).
These can be calculated as follows:

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total nbr of beds

WAIT =

(weight fraction catalyst in bed i x T

inlet Bed i

i =0

total nbr of beds

WABT =

i =0

3.1.3

(weight fraction catalyst in bed i x (

Tinlet Bed i + Toutlet Bed i

))
2

Space velocity
Space velocity is a measure of the amount of naphtha which is processed over a given
amount of catalyst over a set length of time. When the hourly volume charge rate of
naphtha and the volume of catalyst are used, the term is Liquid Hourly Space Velocity
LHSV When weights are used, the term is Weight Hourly Space Velocity (WHSV).
Either is applicable in monitoring a Platforming Unit operation when a set catalyst
density and volume is involved. LHSV, hr-1, is commonly used by UOP since most
refiners define their charge rate on a volume basis, and hourly rates give conveniently
sized numbers.
Volume of feed per hour
LHSV =
Volume of catalyst in Reactors
The LHSV is measured in h-1, and the volume of feed is based on the specific gravity of
the feed at 15C.
Space velocity has an effect on product quality (example: octane number). The higher
the space velocity (lower residence time), the lower the product RONC or the less the
amount of reaction that occurs at a fixed WAIT. Increased reactor temperatures will
offset this effect. Within normal Platforming design parameters, space velocity has little
effect on the unit yield performance. At very low LHSV, thermal reactions can occur to a
sufficient degree to decrease reformate and hydrogen yields. While there is no known
upper limit on space velocity, reactor temperatures have to be increased in order to
maintain the product quality (RONC) and above a certain point, can again cause
unfavorable thermal reactions which will lower yield performance.

3.1.4

Reactor pressure
Because of its inherent effect on reaction rates, hydrogen partial pressure is the basic
variable, but for ease of use, the information which follows has been adjusted so the
total reactor pressure can be used and the hydrogen purity is not needed.
UOP uses the last reactor inlet pressure as the average catalyst pressure since 50% of
the catalyst is usually in the last reactor. Separator pressure, as an operating parameter,
is of limited value since the system pressure drop varies from unit to unit and can be
considerably different even within the same unit as charge rate, recycle gas rate, recycle
gas gravity, etc. change.
The reactor pressure affects the Platforming Unit yield structure, reactor temperature
requirement, and catalyst coke rate. Reactor pressure has no theoretical limitations,
although practical design limitations have an effect.
Decreasing the reactor pressure will increase the hydrogen and reformate yield,
decrease the temperature requirement to make the product octane, and increase the
catalyst coking rate.

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Hydrogen / Hydrocarbon ratio

Hydrogen/hydrocarbon (H2/HC) ratio is defined as the moles of pure hydrogen in the
recycle gas per mole of naphtha charged to the unit.
Recycle hydrogen is necessary in the Platforming Unit operation for purposes of catalyst
coking rate. It has the effect of sweeping the reaction product and condensable
materials from the catalyst and supplying the catalyst with readily available hydrogen.
An increase in H2/HC ratio will move the naphtha through the reactor at a faster rate
and supply a greater heat sink for the endothermic heat of reaction. The end result is
decreased catalyst coking rate with little effect on the product quality or yields.
The effect of H2/HC ratio on the catalyst coking rate is not due to the recycle gas alone.
The hydrogen in the net gas has the same effect as the hydrogen in the recycle gas in
decreasing the catalyst coking rate. This effect, however, is less in the first reactor and
more in the last reactors because most of the net hydrogen is produced in the first
reactor. As will be described later, to compute the effect of H2/HC ratio on the catalyst
coking rate, Figure 20 is used. When using Figure 20, a total H2/HC ratio must be
defined that takes credit for the hydrogen produced in the reactors. The total H2/HC
ratio for the effect on catalyst coking rate only is defined as the H2/HC mol ratio in the
combined feed to the reactor plus 70 percent of the net hydrogen produced on a mol H2
in net gas to mol of feed basis.

3.1.6

Charge stock properties

The charge stock properties which are pertinent to this discussion of Platforming
variables are as follows :
Property

Laboratory Method

Source of Stock
Initial boiling point (IBP)
Mid boiling point (50%)

ASTM D-86 Distillation

End boiling point (EP)

Paraffin Content (P)
Naphthene Content (N)

UOP 880 (Hydrocarbon Types)

Aromatic Content (A)

Generally, the computation procedures described later on are based on correlations of

pilot plant and past commercial data. The preferred PONA analysis is UOP Method 880.
The UOP Method 273 will tend to give inaccurate naphthene results for full boiling range
feedstocks because of the presence of polycyclic naphthenes. The UOP Method 777 is
the method of choice if the olefin content is high (>2 LV%).
These correlations are to be used to characterize straight run naphthas only. Estimation
of other feeds such as FCC and coker naphthas fall outside the range of these
correlations.
Charge stocks with low IBP's [less than 77C will generally contain a significant amount
of C5- material. The pentanes in the feed cannot be converted to aromatics and,
therefore, these pentanes will pass through unconverted, isomerized and/or cracked to

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light ends. Because of their low octane, they will dilute the overall reformate octane and
result in higher (C6+) octane-severity in the Platforming Unit. On the next page is an
example of the effect of C 5's on reforming severity.
Charge stocks with low EP's have C6 and C7 hydrocarbons concentrated. These are
the most difficult species to reform. On the other hand, charge stocks with high EP's
cause higher catalyst coking rates. They also contribute significantly to high reformate
endpoint.
The following example helps to illustrate this dilution effect and provide a means to
estimate the new RONC severity (needed for the proceeding correlations for activity,
stability and yields).
a. Process Conditions
Feed Rate 1,590 m3/day (10,000 BPD)
Reformate C5+ Yield, LV-%
Reformate C5+ RONC
Total Pentanes in Feed (From Feed GC)

82.08
98.2
3.0 LV-%

n-Pentane

1.7 LV-%

i-Pentane

1.0 LV-%

Cyclopentane
0.3 LV-%
If individual pentanes are not known, assume 40% of total is iso-pentane and 60% is npentane.
b. Compute Total Product Octane-Cubic Meters (Octane-Barrels)
Feed

Yield

RONC

1,590 m3

8208

98.2

128,158 octane-m3

(10,000 BBL

8208

98.2

806,026 octane-barrels)

c. Compute Product C5 Octane-Cubic Meters (Octane-Barrels)

(Assume 90% of C5 in Feed Goes to Product)
Feed

(C5 Fraction to Product) x RONC

n-pentane

1,590
(10,000

x
x

(.017 x .9)
(.017 x .9)

x
x

63.0
63.0

=
=

1,532
9,639

octane-m3
octane-barrels)

iso-pentane

1,590
(10,000

x
x

(.010 x .9)
(.010 x .9)

x
x

92.3
92.3

=
=

1,321
8,307

octane-m3
octane-barrels)

cyclo-pentane

1,590
(10,000

x
x

(.003 x .9)
(.003 x .9)

x
x

101
101

=
=

434
2,727

octane-m3
octane-barrels)

total C5s

1,532
(9,639

+
+

1,321
8,307

+
+

434
2,727

=
=

3,287
20,673

octane-m3
octane-barrels)

d. Compute Total Octane-Cubic Meters (Octane-Barrels) Produced In Reactor

Total Product

Total C5s from Feed

Total Produced in Reactors

128,158

3,287

124,871

octane-m3

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(806,026

20,673

785,353

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octane-barrels)

e. Compute Total Cubic Meters (Barrels) Produced in Reactor

Total Product

Total C5s from Feed

Total Produced in Reactors

(1,590 x .8208)
((10,000 x .8208)

(1,590 x .03 x .9)

(10,000 x .03 x.9)

=
=

1,262
7,938

f. Compute Actual RONC =

124,871 octane - m 3
1,262 cubic meters
785,353 octane - barrels
(
7,938 barrels

cubic meters
barrels)

Total Octane Produced in Reactors

Total Product Produced in Reactors

= 98.9 RONC
= 98.9 RONC)

Therefore, the C5+ RONC that should be used for activity, yield or coking rate
calculations in this case is 98.9 rather than the reported 98.2.
The effects of C5 in feed will be greater as the product octane and/or pentanes in the
feed increase.
3.1.7

Feed additives
It is assumed that chloride addition to the regeneration section is sufficient to maintain
the recommended chloride content of 1.1-1.20 wt-% chloride on the regenerated
catalyst for R-30 series catalyst and 1.2-1.3 wt-% for R-130/230 series catalyst.
CCR catalyst is R-234.
Normally, chloride and water addition to the Platforming feed is not necessary while the
regeneration section is in white burn operation.

3.2 PLATFORMING DEPENDENT VARIABLES

In this portion of the Process Variables Section, the effects of the Platforming
independent variables on the major dependent variables is discussed. More importantly,
methods for estimating the effects of operating changes on one or more of the
dependent variables is illustrated.
3.2.1

Catalyst activity
Catalyst activity is a term used to describe the temperature at which a particular catalyst
must be operated to produce a given product quality. In this discussion, the catalyst
temperature will be defined exclusively as the WAIT or weighted average inlet
temperature. Product quality as it applies to motor fuel operations is defined as the C5+
RONC or research octane number clear.
The C5+ RONC is defined as the total RONC of the C5+ product reactor effluent. If the
reformate stabilizer operates as a debutanizer, then the C5+ RONC will be very close to
the RONC of the bottoms product of the stabilizer. However, if the stabilizer operates as
a depentanizer or a dehexanizer, then the C5+ RONC may be different from the RONC
of the bottoms product of the stabilizer. This is because the C5+ product that leaves as
overhead liquid from a depentanizer or dehexanizer will not be included in the bottoms
product, which is analyzed for RONC by the laboratory.

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The effect of C5's in the stabilizer overhead liquid on the stabilizer bottoms RONC varies
depending on the amount of C5's in the stabilizer overhead and the RONC of the
stabilizer bottoms. The following example helps to illustrate this effect and provide a
means to estimate the new RONC severity (needed for the correlations for activity,
yields and coking rate).
a. Process Conditions
1,590 m3/day (10,000 BPD)
5.0
LV-%
80.0
LV-%
99.0
RONC
100
LV-%

Feed Rate
Stabilizer Overhead Liquid Yield
Stabilizer Bottoms Yield
Stabilizer Bottoms Octane
Stabilizer Bottoms C5+ (from lab)
Stabilizer Overhead Liquid C5+ (from lab)
n-pentane

12

LV-%

i-pentane

LV-%

C6+

LV-%

b. Compute Total Produced C5+ Octane-Cubic Meters (Octane-Barrels)

Feed
1,590
(10,000

x
x
x

Yield
.80
.80

x
x
x

C5 Fraction
1.00
1.00

x
x
x

RONC
99.0
99.0

=
=

125,928
792,000

octane-m
octane-barrels)

n-pentane

1,590
(10,000

x
x

.05
.05

x
x

.12
.12

x
x

63.0
63.0

=
=

601
3,780

octane-m
octane-barrels)

iso-pentane

1,590
(10,000

x
x

.05
.05

x
x

.06
.06

x
x

92.3
92.3

=
=

440
2,769

octane-m
octane-barrels)

C6+

1,590
(10,000

x
x

.05
.05

x
x

.02
.02

x
x

76.5
76.5

=
=

122
765

octane-m
octane-barrels)

Total C5+

125,928
(792,000

+
+

601
3,780

+
+

440
2,769

+
+

122
765

=
=

127,091
799,314

octane-m
octane-barrels)

Stabilizer Bottoms

Stabilizer Overhead:
3

c. Compute Total Produced C5+ Cubic Meters (Barrels)

Feed
1,590
(10,000

x
x
x

Yield
.80
.80

x
x
x

C5 Fraction
1.00
=
1.00
=

1,272
8,000

cubic meters
barrels)

Stabilizer Overhead

1,590
(10,000

x
x

.05
.05

x
x

(.12 + .06 + .02)

(.12 + .06 + .02)

=
=

15.9 cubic meters

100 barrels)

Total C5+

1,272
(8,000

+
+

15.9
100

=
=

1287.9
8,100

Stabilizer Bottoms

d. Compute Actual C5+ RONC =

cubic meters
barrels)

Total C 5 + Octane Produced in Reactors

Total Product Produced in Reactors

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= 98.7 RONC

799,314 octane - barrels

= 98.7 RONC)
8,100 barrels

Therefore, the C5+ RONC that should be used for activity, yield or coking rate
computations in this case is 98.7 rather than the reported 99.0.
The effects of C5 in the stabilizer overhead will be greater as the product octane and/or
the pentanes in the overhead liquid increase.
The WAIT requirement to meet a given C5+ RONC is obviously affected by many things.
At the outset of a run with fresh catalyst, one would expect that the WAIT required would
only be affected by the feed character, RONC desired, feed rate, and catalyst type.
However, things are not this simple. An operational upset could occur which will effect
the water-chloride balance and the apparent catalyst activity will change.
There is a simple calculation procedure for estimating the start-of-run (SOR) WAIT
requirement. This SOR WAIT is the temperature at which a fresh catalyst loading would
operate in order to produce a certain RONC from a feed characterized by a certain N
and A content and charged at a given LHSV. There are at least two important ways at
which this estimate can be put to use:
i. CCR Platforming Unit WAIT target at startup.
ii. CCR Platforming Unit Delta WAIT (predicted SOR WAIT minus actual WAIT) for
tracking catalyst activity with respect to regeneration cycles.
The first use, (i), is fairly straightforward. The calculation enables the process engineer
or supervisor to estimate the WAIT required to meet product requirements.
Number (ii) requires some explanation, but the reader will note that the concept is
simple. The basic idea is to determine a number (Delta WAIT) which puts the catalyst
temperature requirement on a consistent or normalized basis for comparing day-to-day
operation. This would not be necessary, of course, if the Platforming Unit ran at the
same conditions (feed N and A, RONC, LHSV) all the time. Of course, this is seldom the
case.
What Delta WAIT does, then, is normalize reactor temperature data with respect to
Platforming feed N and A, RONC and LHSV. It is defined as the difference between the
WAIT the CCR Platforming Unit is operating at, given the three parameters above, and
the fresh catalyst WAIT requirement for the same parameters. It is the activity difference
between the real catalyst and fresh catalyst.
Tabulation or graphical plotting of Delta WAIT is a natural follow-up. In maintaining a
plot, the engineer can monitor the effects of operating changes made to remedy a
catalyst activity problem due to, for instance, a feed sulfur upset. In this case, Delta
WAIT can be plotted versus regeneration cycles. It probably would take a few catalyst
regeneration cycles for the catalyst activity to get back to normal, so on a day-to-day
basis, the engineer can track the improvement in activity. Disruptions in and recovery of
the water-chloride balance can also be tracked using the Delta WAIT calculation and
plot.
The SOR WAIT requirement calculation is now explained. The figures used are not
meant to cover all the variables which can affect the apparent fresh catalyst activity.
Predictions of the SOR WAIT requirements from the figures should, however, be within
plus or minus 3C of the actual requirement.
Below is an outline of how the computation proceeds, with reference to the appropriate
Figures for CCR Platforming applications:

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a.

Step
List -

RONC
N and A
N + 3.5A
LHSV
Catalyst Type

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- Actual Unit Operating Data-

b. Estimate SOR WAIT at 1.0 LHSV

Figure 1

c. Estimate Correction for actual LHSV

Figure 2

d. Add the results of b and c to give SOR WAIT

The following numerical example is presented in order to give the refiner a guide for
computing the SOR WAIT requirement.
CCR Platforming Unit
(Metric Units)
a. Process Conditions
Catalyst
R-34
RONC
95
1.9
LHSV, hr1
Feed N, LV-%
15
A, LV-%
8
N + 3.5A = 15 + 28 = 43 LV-%
b.

c.

d.

From Figure 1
SOR WAIT
= 494C
at 1.0 LHSV
From Figure 2
Correction
= + 16C
1.0 to 1.9 LHSV
SOR WAIT requirement
SOR WAIT
= 494 + 16
= 510C

Suppose that the CCR Platforming Unit on the day in question was running an actual
WAIT of 518C. The engineer would tabulate and plot for this day the following Delta
WAIT (Delta WAIT equals predicted SOR WAIT requirement minus actual WAIT):
Delta WAIT = 510-518 = - 8C
In other words, the catalyst activity is 8C below that of fresh catalyst. Day-to-day
calculations would allow the engineer to assess the catalyst activity on a normalized
basis and determine whether it is along the lines that would be expected.
The temperature-octane response for a Platforming Unit is shown in Figure 3. This chart
can be used to estimate the changes in the WAIT required to switch daily RONC target.
3.2.2

CCR Platforming Reactor quench

DEFINITION : Platforming reactor quench is a phenomenon which occurs in the catalyst
bed if the feed characteristics and process conditions are such that there exists more
catalyst than required in the front reactors to convert the naphthenes to aromatics. The
result is a large temperature drop in the front reactors. A portion of the catalyst in the
reactors is at temperatures which do not thermodynamically support the forward
Platforming reactions as depicted in the SOR WAIT Figure. In fact, the catalyst volume

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could be reduced somewhat in the front reactors and still maintain the same
temperature drop. A quenched reactor, therefore, appears to have less catalyst and the
catalyst appears to be less active than the SOR WAIT Figures would indicate.
Therefore, if quenching is occurring in the refiner's unit, the catalyst's activity may
appear below that of fresh catalyst.
MEASURING QUENCH : Computing the amount of quench in a unit is an important part
of accurately computing the Delta WAIT. There is an empirical correlation to adjust the
predicted SOR WAIT requirement for the measured quench effects. It uses the reactor
inlet and outlet temperatures, the catalyst distribution, and a constraint on the difference
between the actual WAIT and the actual WABT. The constraint is shown as Basis #5 of
Figure 1. If the term (WAIT-WABT) is greater than 20C, then a correction for quench
must be added for SOR WAIT requirement.
CORRECTING THE SOR WAIT FOR QUENCH
a. Compute the WAIT.
b. Compute the WABT.
c. Compute the Measured Quench (MQ).
Measured Quench (MQ) = WAIT - WABT
d. Compute the SOR WAIT Quench Correction (QC):
Quench Correction (QC) (C) = MQ (C) - 20C
NOTE: If QC is less than zero, set QC equal to zero.
e. Compute the corrected SOR WAIT (SORC WAIT):
SORC WAIT = SOR WAIT (from Figures and Table) + QC
NOTE: If QC equals zero, then SORC WAIT = SOR WAIT and there is no quench
correction.
f. Compute the corrected Delta WAIT:
Corrected Delta WAIT = SORC WAIT - WAIT
The following numerical examples are presented in order to give the refiner a guide for
computing the SOR WAIT requirement corrected for quench.
CCR
Platforming
(Metric Units)
a. Process Conditions
WAIT, C
WABT, C
SOR WAIT, C
b.

Measured Quench (MQ) =

527 - 503 = 24C

c.

Quench Correction (QC)

=
24 - 20 = 4C

d.

SORC WAIT =
525 + 4 = 529C

e.

Corrected Delta WAIT =

529 - 527 = 2C

Unit

527
503
525

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In other words, the catalyst activity corrected for quench is 2C above that of fresh
catalyst, rather than 2C below that of fresh catalyst.
3.2.3

Catalyst selectivity
Selectivity is defined as the tendency of a given catalyst and the operation of that
catalyst to produce the desired material. In most Platforming operations, the most
desired material is reformate or more specifically the yield of C5+ liquid. Also, for the
purpose of this section and those to follow, product quality will continue to be defined as
C5+ RONC, the research octane number clear.
The selectivity of a Platforming catalyst and operation is dependent upon several
variables. The effects of Platforming feedstock characteristics (N and A content, 50%
boiling point and end boiling point), product quality (RONC), and average reactor
pressure on selectivity to C5+ liquid is discussed.
There are two sets of four selectivity curves. One set is for full-boiling-range naphthas,
which are generally defined as having an initial boiling point of 82C and an end boiling
point in the range of 176-204C. The other set of curves is for light-boiling-range
naphthas which have an end boiling point less than 176C. Two sets of selectivity
curves are needed because in general the relative selectivity of reforming reactions
increases with increasing boiling point of the naphtha.

Process Variable

C5+ RONC
Feed Naphtha N+2A
Average
Reactor
Pressure
50% Boiling Point

CCR C5+ YIELD DELTA

Straight Run
Straight Run
Naphtha
Naphtha
Endpoint
Less
than
Full
Boiling 176C
Range
Figure 4
Figure 5
Figure 6

Figure 8
Figure 9
Figure 10

Figure 7

Figure 11

A preliminary glance at the selectivity curves allows the following general conclusions to
be made:
a. C5+ yield increases with a decrease in average reactor pressure. Furthermore,
comparing the pressure effect at two octane levels and constant N+2A shows the
higher the octane, the larger the increase in yield.
b. C5+ yield decreases as octane is raised at constant reactor pressure and feed
N+2A.
c. C5+ yield generally increases with an increase in feed naphtha N+2A at constant
pressure and RONC. The effect becomes less pronounced as feed changes occur
at high N+2A value.
It is important to realize that in the following procedure absolute yields are not
computed. The estimate gives the shift in yield in going from a base condition (the
current Platforming operation, for instance) to a new case.
Sample computations of the C5+ yield change estimate for a full-boiling-range naphtha
are given below

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1.

2.

95
34/10
54
110
5.0

Averages
RONC
N+2A

94
57

RONC Effect, Figure 4

A. C5+ yield decrease
= -.62 LV-% RONC
B. Yield Delta = (-.62) (2)
= -1.24 LV-%

4.

N+2A Effect, Figure 5

A. C5+ yield increase = .195 LV-%/(N + 2A)
B. Yield Delta = (.195) (-6)
= -1.17 LV-%
Pressure Effect, Figure 6
A. C5+ yield increase
= 1.4 LV-%/7 kg/cmg
B. Yield Delta = (1.4)(2)/(7)
= 0.40 LV%

5.

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CCR PLATFORMING UNIT (METRIC UNITS)

Process Conditions
Base
Case
RONC
93
N/A, LV-%
40/10
N+2A, LV-%
60
50% Point, C
130
Avg. Rx. Press., kg/cmg
7.0

3.

6.

50% Point Effect, Figure 7

C5+ Yield Delta = -1.4 LV-%

7.

Overall Yield Change

Net Yield
= (-1.24)+(-1.17)
Delta
+(0.40)+ (-1.40)
= -3.41 LV-% Total

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Case A

Sample computations of the C5+ yield change estimate for a light-boiling-range naphtha
are given below:

1.

2.

3.

CCR PLATFORMING UNIT (METRIC UNITS)

Process Conditions
Base
Case
RONC
98
N/A, LV-%
36/10
N+2A, LV-%
56
50% Point, C
105
Avg. Rx. Press., kg/cmg
5.5

96
30/10
50
115
4.5

Averages
RONC
N+2A

97
53

RONC Effect, Figure 4

A. C5+ yield decrease
= -0.92 LV-% RONC

Case A

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B.Yield Delta = (-0.92) (2)

= -1.84 LV-%
4.

N+2A Effect, Figure 5

A. C5+ yield increase
= 0.25 LV-%N+2A
B. Yield Delta = (0.25)(-6)
= -1.50 LV-%

3.2.4

5.

Pressure Effect, Figure 6

A. C5+ yield increase
= 3.8 LV-%/7 kg/cmg
B. Yield Delta = (3.8)(1)/(7)
= 0.54 LV%

6.

50% Point Effect, Figure 7

C5+ Yield Delta = -1.0 LV-%

7.

Overall Yield Change

Net Yield
= (-1.84)+(-1.50)
Delta
+(0.54)+(-1.0)
= -3.80 LV-% Total

Catalyst selectivity to aromatics

Selectivity to aromatics is defined as the tendency of a given Platforming catalyst and
the operation of that catalyst to produce aromatics. The selectivity to aromatics of a
Platforming catalyst and operation is dependent upon several variables. The effects of
operating severity (C5+ RONC) and feedstock composition (paraffins, naphthenes, and
aromatics in the feed) is discussed.
For a given catalyst system and plant configuration, the conversion of an aromatic
precursor in the feed to an aromatic depends primarily on operating severity (C5+
RONC). The higher the C5+ RONC, the higher the conversion of the aromatic precursor
will be. However, not all of the additional conversion that takes place at higher C5+
RONC produces aromatics; some of the additional conversion produces light gases.
Aromatic selectivity is defined for a given hydrocarbon type, as the percent of the
compound that is converted that goes to an aromatic hydrocarbon rather than light
gases.
The emperical correlations show the effect of changes in benzene, toluene, xylenes,
and A9+ aromatics yields over a range of C5+ RONC. Each curve uses a feedstock
parameter that is a combination of the paraffins, naphthenes, and aromatics in the feed
for the respective aromatic. These feedstock parameters are weighted toward the
naphthenes and/or aromatics because of the poor selectivity of the paraffins to convert
to the respective aromatic.
The following emperical correlations are for predicting a change in aromatics production
with R-30 or R-130 series Platforming catalyst:
AROMATIC
Benzene
Toluene
Xylenes
A9 + Aromatics

FIGURE
Figure 12
Figure 13
Figure 14
Figure 15

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It is important to realize that in the following procedure absolute aromatics yields are not
computed. The estimate gives the shift in aromatics yield in going from a base condition
(the current unit operation, for instance) to a new case.
A sample calculation of the aromatics yield change estimate is given below:

a. Process Conditions

Feed :
C6
C7
C8
C9+
Total

Base Case LV-%

P
N
8.6
1.7
14.0
3.4
15.3
4.4
33.0
10.4
70.9
19.9

A
0.5
1.5
2.8
4.4
9.2

Base Case LV-%

P
N
19.7
4.1
35.4
9.4
20.6
5.1
0.6
0.2
76.3
18.8

A
0.8
3.5
0.6
4.9

C5+ RONC: 99
Feed :
C6
C7
C8
C9+
Total
C5+ RONC: 99
b. Parameters

P6
+ N6 + 2A6
3
P7
+ N7 + A7
2
P8
+ N8 + A8
2

P9 CORR

Base Case

Case A

5.6

12.3

11.9

30.6

14.9

16.0

26.2

0.6

c. Benzene, Figure 12
A
Base Case Delta Benzene at 5.6 = 2.0 LV-%
B. Case A Delta Benzene at 12.3 = 5.8 LV-%
C. Benzene Yield Delta = 5.8 - 2.0 = +3.8 LV-% FF
d. Toluene, Figure 13
A. Base Case Delta Toluene at 11.9 = 5.0 LV-%
B. Case A Delta Toluene at 30.6 = 18.5 LV-%
C. Toluene Yield Delta = 18.5 - 5.0 = 13.5 LV-% FF
e. Xylene, Figure 14
A. Base Case Delta Xylene at 14.9 = 11.0 LV-%
B. Case A Delta Xylene at 16.0 = 12.0 LV-%
C. Xylene Yield Delta = 12.0 - 11.0 = 1.0 LV-%
f. A9+, Figure 15

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A. Base Case Delta A9+ at 26.2 = 23.5 LV-%

B. Case A Delta A9+ at 0.6 < 0 = - 2 LV-%*
C. A9+ Yield Delta = -2 -23.5 = -25.5 LV-%
[*NOTE: This value can be estimated from the curve by extrapolation because
Delta A9+ Aromatics Yield decreases by 1 LV-% for each 1 LV-% decrease in P9
CORR at 99 C5+ RONC.]
g. Total Aromatics Yield Change
Net Yield Delta = (3.8) + (13.5) + (1.0) + (-25.5) = - 7.2 LV-% FF
3.2.5

Catalyst stability
Catalyst stability is a measure of the coke-forming tendency of a given catalyst. For
CCR Platforming Units, apparent catalyst activity usually remains the same under
normal operating conditions. However, the coke-forming tendency of the CCR
Platforming Units catalyst will significantly affect the continuous regenerator's operation.
As more or less coke is formed, changes in the Platforming Unit and regenerator
operations will be required to ensure that coke burned is equal to or greater than coke
formed in the reactor section.
In the following discussion, calculation procedures for estimating the effects of process
variables on the coke-forming tendency of the catalyst will be illustrated. In CCR
Platforming Units, the measure of catalyst coke rate is the Relative Coking Factor. The
Relative Coking Factor is used to estimate the effect of changes in the operating
conditions of the Platforming reactor section on the rate of coke production.
The rate at which a given catalyst forms coke is set by the process variables listed
below.

Process Variables
C5+ RONC
Feed Naphtha N+A
Feed Naphtha End Point
Avg. Rx. Pressure
Hydrogen/Hydrocarbon Ratio

CCR
Relative
Coking Factor
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20

These curves are based on a combination of pilot plant and commercial data. The data
are normalized to eliminate inter-relationships between variables as much as possible.
The figures therefore, give the Relative Coking Factors in terms of single variables.
The rate at which a given catalyst forms coke also depends on the charge rate to the
CCR Platforming Unit. With all the other process variables listed above constant, the
change in coke laydown rate is proportional to the change in charge rate.
The following numerical examples illustrate how the stability measures for CCR
Platforming Units are estimated.
These examples demonstrate how to estimate the Relative Coking Factor and the
change in coke production between a base case (the current CCR Platforming Unit, for
instance) and a new case.
In using the procedure, one point cannot be overemphasized: to derive the greatest
possible accuracy in estimation of a new coke laydown rate, the process variables
(including feedstock) should be held constant for one complete turnover of the reactor
catalyst before actual coke laydown can be compared to the estimated value. Likewise,
when calculating the base coke laydown rate, the reactor inventory should be turned

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over one full time at constant processing conditions before the base coking level can be
established. Since many refiners do not always run with constant feedstock for one full
catalyst cycle at a time, this estimation method should be used only to show a direction
and a rough approximation of expected coke laydown rates.
The reader should also realize that any significant periods of Platforming operation
without catalyst circulation will increase the amount of carbon on the spent catalyst
above the level calculated by the estimating procedure.
When used with the proper caution regarding process variable changes, this estimated
coking procedure should allow the refiner to better anticipate regenerator coke loadings as
his processing needs vary.
CCR EXAMPLE (METRIC UNITS)
a. Process Conditions

Charge Rate, m3/day

N/A, LV-%
End Boiling Point, C
Total* H2/HC Ratio, mol/mol
Avg. Rx. Press., kg/cmg
C5+ RONC
CCR, kg/hr

Base
Case
2500
20/10
177
2.25
5
100
450

New
Case
3000
30/10
191
1.5
5.5
96
550

Spent Catalyst Coke, wt%

4.5

b. Coke Laydown Rate (Base Case)

Coke Laydown Rate =

Spent catalyst coke

x CCR
(100 - Spent catalyst coke)

Coke Laydown Rate (Base Case) =

kg coke
4.5
x 450 = 21.20
(100 - 4.5)
hr

c. Coke Laydown Rate (New Case)

RCFB = Relative Coking Factor (Base Case)
RCFN = Relative Coking Factor (New Case)
* Total H2/HC mol ratio equals the H2/HC ratio to the reactor plus 70% of the net
hydrogen produced on a net gas to feed mol ratio basis.
Coke Laydown Rate Coke Laydown Rate m 3 D N (RCFN ) (RCFN ) (RCFN ) (RCFN ) (RCFN )
=
x 3
(New Case)
(Base Case)
m D B (RCFB ) (RCFB ) (RCFB ) (RCFB ) (RCFB )
RONC N + A
EP
(Fig 16) (Fig 17) (Fig 18)
(3000) (.4) (1.05) (1.52)
= (21.20)
(2500) (.98) (1.42) (1.2)
= 15.35 kg/hr coke

Press. H 2 /HC
(Fig 19) (Fig 20)
(1.30) (3.35)
(1.38) (2.0)

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d. Spent Catalyst Coke (New Case)

Coke Laydown Rate
(New Case)
x 100%
Spent Catalyst Coke =
CCR + Coke Laydown Rate
(New Case)
15.35
=
x 100%
550 + 15.35

= 2.7 wt-% coke

CCR EXAMPLE
(ENGLISH UNITS)
a. Process Conditions
Base
Case
20,000
28/10
350
5.0
125
100
450
3.8

Charge Rate, BPD

N/A, LV-%
End Boiling Point, F
Total* H2/HC Ratio, mol/mol
Avg. Rx. Press., psig
C5+ RONC
CCR, lb/hr
Spent Catalyst Coke, wt-%

New
Case
18,500
26/10
350
4.5
125
98
450
?

b. Coke Laydown Rate (Base Case)

Coke Laydown Rate =

Spent catalyst coke

x CCR
(100 - Spent catalyst coke )

Coke Laydown Rate (Base Case) =

3.8

(100 - 3.8 )

x 450 = 17.78

lb coke
hr

c. Coke Laydown Rate (New Case)

RCFB = Relative Coking Factor (Base Case)
RCFN = Relative Coking Factor (New Case)
Coke Laydown Rate
(New Case)

Coke Laydown Rate

(Base Case)

(BPD N ) (RCFN ) (RCFN ) (RCFN ) (RCFN ) (RCFN )

(BPD ) (RCFB ) (RCFB ) (RCFB ) (RCFB ) (RCFB )
B

RONC N + A
(Fig 16) (Fig 17)

= (17.78)

(18,500)
(20,000)

(0.61)
(1.0)

(1.11)
(1.05)

EP
(Fig 18)

(0.76)
(0.76)

Press. H2 /HC
(Fig 19) (Fig 20)

(1.0)
(1.0)

(0.63)
(0.54)

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= 12.37 lbs/hr coke

d. Spent Catalyst Coke (New Case)

Spent Catalyst Coke

Coke Laydown Rate

(New Case)
x 100%
=
CCR + Coke Laydown Rate
(New Case)
12.37
=
x 100%
450 + 12.37

= 2.7 wt-% coke

3.2.6

Effect of Non-SRN on catalyst stability

As mentioned previously, these relative coking factors are for straight run naphthas
(SRNs). For situations where other stocks such as FCC and coker naphtha are included
as part of the feed, a rough approximation can be made of their impact on coking or
deactivation. But to do this, one must have a characterization of the feeds that went into
the Platforming Unit feedstock blend so as to evaluate each one separately and sum up
their effects to get the overall impact.
The deactivation rate or coke rate relative to a SRN will increase by about 1.6 times for
an FCC naphtha and by 2.0 to 3.0 times for a coker or thermally-derived naphtha
depending on end boiling point. To minimize the coking effect, the coker naphtha end
boiling point should be constrained to a maximum of 177C with a desired endpoint of
about 160C.
The yields on FCC naphtha will be comparable to a SRN of the same characteristics.
But because of the nature of a coker naphtha (produced in a hydrogen-deficient
environment) the C5+ yields will generally be worse than a SRN of comparable PONA.
The difference appears to be in the C5/C6 naphthene ring distribution with coker
naphthas having more of the less selective alkylcyclopentanes.
Hydrocracked naphthas have deactivation rates and yields similar to straight run
naphthas and as such can be treated like SRN.
Raffinate Processing
Raffinate processing is difficult because of the poor selectivity of C6 and C7 paraffins to
aromatics. As mentioned previously, lower pressure improves the selectivity of paraffins
to aromatics and as a result, a CCR Platforming Unit is more ideally suited for raffinate
processing than a semi-regenerative Platforming unit.
For illustrative purposes, the pitot plant yields are shown below for a raffinate of the
following composition: (see next page)
This figure illustrates the poor C5+ yield on raffinate at typical semi-regenerative and
CCR Platforming Unit pressures. Of course, even higher pressures will result in even
lower yields. Note that lowering the pressure from 17.6 kg/cmg to 5.3 kg/cmg improves
the yields by 10-15 LV-% at 85 RONC.

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Estimating stability and yields for a raffinate blend is beyond the scope of this section.
But it should be noted that the estimation technique is iterative and involves looking at
the raffinate stream as independent from the SRN. The raffinate stream is like C5's in the
feed in that it drags down the product RONC requiring the SRN to be processed at a
higher severity to compensate (i.e., if target blend was 98, then the SRN portion of feed
may require 101 RONC to offset the RONC achieved, say of 90, on the raffinate at a
fixed WAIT).
3.2.7

Endothermic heat of reaction

The final portion of this section will address an estimating procedure for the endothermic
heat of reaction for a given Platforming Unit operation.
The endothermic heat of reaction, when regularly calculated for a fairly constant charge
stock PONA and reformate octane number, may be used as an indication of catalyst
deactivation. The decreasing heat of reaction shows the decreasing aromatics forming
ability of the catalyst. These curves do not correct heat of reaction for charge stock
composition or product octane number because of the complexity of these relationships.
If these values vary, the heat of reaction will also vary.
The total delta T over the catalyst is directly related to the total heat of reaction. While
the heat of reaction is not a function of the H2/HC mole ratio, the total delta T is, due to
the diluent effect of the recycle gas. LHSV does not materially affect the heat of reaction.
Using Figures 21A and 21 B or Figures 22A and 22B, the heat of reaction may be
determined when the following are known:
Recycle gas purity (mole percent hydrogen)
H2/HC mole ratio
Total delta T
Charge stock molecular weight
The heat of reaction value as calculated from these graphs indicates the aromatizaton
ability more accurately than total delta T.
The following examples demonstrate the use of the figures in calculating the heat of
reaction.
HEAT OF REACTION (METRIC UNITS)
1.

Total delta T (all Platforming reactors)

Hydrogen/Hydrocarbon Ratio
Recycle Gas Hydrogen Purity
Charge Stock Molecular Weight (MW)

2.

From Figure 22A

Total heat of reaction (HR) = 460 (150/100)
(KJ/kg of naphtha)

3.

= 690

From Figure 22B

MW correction = +22 (150/100)

4.

150C
3
80%
115

The correct heat of reaction :

= +33

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= 690 + 33
= 723 KJ/kg of naphtha

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3.3 FIGURES ATTACHED TO THE PLATFORMING PROCESS VARIABLES

Figure 1 :

SOR WAIT Requirement At 1.0 LHSV

Figure 2 :

WAIT Requirement Correction for LHSV

Figure 3 :

Temperature - Octane Response

Figure 4 :

Effect of C5+ RONC on C5+ LV-% Yield

Figure 5 :

Effect of Cyclic Content on C5+ LV-% Yield

Figure 6 :

Effect of Reactor Pressure on C5+ LV-% Yield

Figure 7 :

Effect of Boiling Range On C5+ LV-% Yield

Figure 8 :

Effect of C5+ RONC on C5+ LV-% Yield

Figure 9 :

Effect of Feed N + 2A on C5+ LV-% Yield

Figure 10 :

Effect of Reactor Pressure on C5+ LV-% Yield

Figure 11 :

Effect of Boiling Range on C5+ LV-% Yield

Figure 12 :

Delta Benzene Yield

Figure 13 :

Delta Toluene Yield

Figure 14 :

Delta Xylene Yields

Figure 15 :

Delta A9 Plus Aromatics Yield

Figure 16 :

Effect of C5+ RONC on Relative Coking Factor

Figure 17 :

Effect of N+A on Relative Coking Factor

Figure 18 :

Effect of Charge Endpoint on Relative Coking Factor

Figure 19 :

Effect of Average Reactor Pressure on Relative Coking Factor

Figure 20 :

Effect of H2/HC Ratio on Relative Coking Factor

Figure 21A :

Total Heat of Reactor From Total Delta T

Figure 21 B :

Molecular Weight Correction to Heat of Reaction

Figure 22 A :

Total Heat of Reaction From Total Delta T

Figure 22 B :

Molecular Weight Correction to Heat of Reaction

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3.4 RECOVERY PLUS SYSTEM

The two major variables that effect RECOVERY PLUS efficiency are Lean Oil
temperature to absorber (TIC-579) and Lean Oil flow rate (FIC-580). The setpoints of
these parameters were considered to optimize recovery operations.
a. temperature
The temperature at which the RECOVERY PLUS system operates has a great effect
on hydrocarbon recovery. However, consideration must be given to economics,
metallurgical constraints, and icing.
1. Economics
The setpoint for TIC-579 has been set to provide the most economic recovery possible,
while safely operating outside the predicted hydrate formation point. Lowering this
setpoint results in more compressor duty and overall utility costs, but also could result in
hydrate formation. UOP is to be contacted before lowering this setpoint, as it may have
safety as well as operational consequences. Please see the following sections on
metallurgical constraints and icing-hydrate formation for more information.
2. Mettalurgical constraints
The metallurgy for the unit is based on a MDMT (Minimum Design Metal Temperature)
that is determined based on instrumentation safeguards. Without these safeguards in
place, the refrigeration system has the capability of refrigerating the system to very low
temperatures. To avoid this, TALL-581 is set to shut down the Compressor before the
piping reaches the rated MDMT for the piping. TALL-581 is located at the coldest point
of the system. Please refer to Appendix C for the setpoint of TALL-581.
3. Icing Hydrate formation
Ice formation and/or hydrate formation may occur if misoperation in the reforming unit
creates a high water content in the Rich Net Gas. This condition can also occur if the
setpoint for TIC-579 is decreased below the recommended setpoint. See Appendix C of
the Vendor Operating Manual for the recommended setpoint. Icing or hydrates may form
depending upon the water content of the Rich Net Gas, and temperature of the gas prior
to contacting the liquid in the Absorber. Figure 3.4.1 is a plot of Temperature (TIC-579)
vs. Rich Gas H2O mol ppm. At design conditions, the moisture MUST BE less than <40
mole ppm. Net Gas moisture should be checked prior to sending to RECOVERY
PLUS system, or monitor Reformer operations to be aware of any upset conditions
that might increase the water content of the Net Gas. If the moisture content differs from
design, the operating temperature must be adjusted according to Figure 3.4.1.
Note: These temperatures are based on the design pressure of the unit. If operations
differ from design, please contact UOP for operating temperatures.

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Figure 3.4.1 : Temperature Vs Inlet Gas H2O

b. Lean oil rate

The Lean Oil flowrate (FIC-580) should be kept constant to maintain the desired
hydrocarbon recovery (see Figure 3.4.2). A lower liquid/gas ratio results in a decrease in
reformate and LPG recovery, while a higher liquid/gas ratio may produce no marked
increase in reformate and LPG recovery, but will result in higher utility costs. Ratio
control FY-566 is used to automatically make this adjustment, as well as to reduce and
stop liquid flow in the case of reduction and loss of gas flow.
Note: Lean Oil flow should not be started until Rich Gas flow is established. Similarly,
during shutdown procedures, the Lean Oil flow should be stopped prior to bypassing the
Rich Net Gas. Safeguards are designed into the system to prevent Lean Oil flow in the
case of no Rich Gas flow. FY-566 should decrease Lean Oil flow as Rich Gas flow
decreases and FALL-571 stops the Rich Oil Pumps when the flow rate falls below the
pump minimum operating condition. See Appendix C of the Vendor Operating Manual
for the recommended setpoint.

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Figure 3.4.2 : Lean Oil Rate vs Net Gas In

c.

Refrigeration cycle

Figure 3.4.3 shows a pressure-enthalpy diagram upon which the design refrigeration
cycle is superimposed. The diagram assumes no hydraulic pressure losses. Beginning
at point #1, located on the saturated vapor equilibrium line, the Refrigerant Compressor
X-1301-C01 compresses the vapor, thus moving from point #1 to point #2. The work
adds heat to the vapor such that at point #2, the refrigerant contains some superheat.
The Refrigerant Condenser X-1301-E06 removes both superheat and latent heat in
moving from point #2 to point #3 on the diagram. Liquid subcooling of the refrigerant
occurs in the Subcooler X-1301-E05, moving from Point #3 to Point #4. An adiabatic
expansion of the liquid occurs between points #4 and #5. At point #5, a mixed phase
fluid exists, displayed on the diagram as between the saturated liquid and saturated
vapour lines. The Chiller X-1301-E03, evaporates the remaining refrigerant liquid into
vapor, thus moving from point #5 to point #1 to complete the cycle.

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Figure 3.4.3 : Propylene pressure - Temperature Design

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4. INTER-UNIT CONTROL SCHEME

The following signals are exchanged with other units:
a. Signals from Other Units to CCR
037-AI-001:
FG to burner flow indicators. This signal is transmitted from
FG Unit (037) to compensate - with the gas MW - the mass flowrate
indicators of FG to the heaters firing system (013-FI-618/619/620/621).

b. Signal from CCR to other units

013-FXALL-004: Low Low Flow Recycle Gas Flow. This signal is transmitted
to Make-up Gas Compressor C-1202A Shutdown (012-UX-006).

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5. UNINTERRUPTIBLE POWER SUPPLY (UPS)

The text will be prepared by JVD electricity and instrument managers of all OCs

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6. COMPLEX CONTROL DESCRIPTION

N/A

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CHAPTER 4

UTILITY, CHEMICAL AND CATALYST REQUIREMENTS

CONTENTS

1.

UTILITIES CONSUMPTION

1.1

UTILITIES CONSUMPTION SUMMARY

1.2

ELECTRICAL LOAD SUMMARY

2.

CHEMICAL CONSUMPTION

2.1

CATALYST AND CHEMICAL SUMMARY

2.2

CHEMICAL HANDLING

2.2.1

Chloride and condensate injection package X-1307

2.2.2

Sulphide injection package X-1396

2.2.3

Phosphate dosing package X-1397

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1. UTILITIES CONSUMPTION
1.1 UTILITIES CONSUMPTION SUMMARY
The characteristics of the utilities are given in the BASIC ENGINEERING DESIGN
DATA document (8474L-000-PP-204)

The ESTIMATED UTILITY CONSUMPTION summaries of CCR unit are given

hereafter for:

8474L-013-CN-0003-001

DESIGN CASE
100% Bach Ho or Mixed crude, Max Gasoline or Distillate

8474L-013-CN-0003-002

NORMAL CASE
100% Bach Ho, Max Gasoline or Distillate

8474L-013-CN-0003-003

NORMAL CASE
Mixed crude, Max Gasoline or Distillate

1.2 ELECTRICAL LOAD SUMMARY

The electrical load of each equipment of the CCR Unit is given in the hereafter
document:

Electrical Load Summary: 8474L-200-CN-1626-001

2. CHEMICAL CONSUMPTION
2.1 CATALYST AND CHEMICAL SUMMARY
CCR catalyst is R-234 (low platinum version)
Adsorbent used in the net gas treaters D-1302 A/B and the LPG chloride treaters D1308 A/B is UOP Molsiv Adsorbent type 9139A.
Sulfide injected in the feed at E-1301 inlet can be either DMDS or commercial diethyl
sulfide (DES).
DMDS properties are the following:
MW:
Purity:
Boiling Point:
Flash Point:
Density @ 15.6C:

94.2 g/mol
100 %wt
116C
24C
1.042 g/mL

DES properties are the following:

MW:
Purity:
Boiling Point:
Flash Point:
Density @ 15.6C:

90 g/mol
97.8 %wt
92.1C
-3C
0.843 g/mL

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Chloride used is Perchlorothylne. Properties of Perchlorothylne are the following:

Purity:
Color, APHA:
Appearance:
Acidity, ppm as HCl
Sp. Gravity @ 25C:
Non volatile residue, ppm
Water, ppm
Free Halogens, (ASTM D4755) Passes Test
Chlorides, ppm
Organically combined Oxygen, as O plus
Organically combined Nitrogen, as N, ppm:
Stabilizer, ppm

99.99 min
10 max
Clear + free suspended matter

5 max
1.617 1.621
10 max
25 max
1 max
15 max
10 max

The catalyst and chemical summary of the CCR Unit is given in the hereafter document:

Catalyst and Chemical Summary: 8474L-013-CN-0004-502

2.2 CHEMICAL HANDLING

2.2.1

Chloride and condensate injection package X-1307

Chloride storage drum D-1399 is fulfilled with containers using chloride transfer pumps
P-1309 A/B.
Quick coupling connections with double end shut off are used between containers and
pump suction (upstream chloride transfer pump suction filter F-1306).
Chloride being used at start-up, no specific filling is required during normal operation
Water tank drum D-1307 is fulfilled with vacuum condensate from Vacuum condensate
header.

2.2.2

Sulfide injection package X-1396

Sulfide storage drum D-1396 is fulfilled from NHT Unit via sulfide pump P-1208.

2.2.3

Phosphate dosing package X-1397

Phosphate is sent to the steam disengaging drum D-1306. Phosphate feed drum D1397 is filled with vacuum condensate from vacuum condensate header.

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CHAPTER 5

PREPARATION FOR INITIAL START-UP

CONTENTS

1.

PLANT CHECK OUT

2.

LINE FLUSHING

3.

WATER CIRCULATION

4.

LEAK TESTING

5.

HEATER DRY-OUT

6.

CATALYST LOADING

6.1

GENERAL LOADING GUIDELINES

6.2

CCR PLATFORMING CATALYST LOADING

6.3

ATTACHED DOCUMENTS FOR CATALYST LOADING

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1. PLANT CHECK OUT

This chapter deals with precommissioning operations that will be described in PP-903.

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2. LINE FLUSHING
This chapter deals with precommissioning operations that will be described in PP-903.

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3. WATER CIRCULATION
This chapter deals with precommissioning operations that will be described in PP-903.

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4. LEAK TESTING
This chapter deals with precommissioning operations that will be described in PP-903.

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5. HEATERS H-1301/02/03/04 DRY-OUT

The refractory of a new furnace or a furnace which has been idle for a long period
should be dried out slowly to permit accumulated water vapours to escape from the
lining.
In this way, entrapped water will vaporise slowly rather than boil violently, s^palling the
lining itself.
If a new furnace is idle during the cold season, measures should be taken to keep the
furnace above freezing temperature, either by lighting few burners, by steam circulation
through the coils, or by installing a portable heater in the furnace. Heating the system
that do not introduce flue gas directly into the furnace are preferred, as these do not
bring in extra water from combustion gases.
In new furnaces, drying-out can be started two days after the refractory lining has been
fininshed.
The entire dry-out procedure will take at least 4 days.
Considering the particular arrangement of the heaters H-1301/02/03/04 (common
convetion and stack), it is recommended to perform the dry-out of these heaters in the
same time.
During dry-out, check the burner operation and alternate burners so that all have been
used and found to perform satisfactorily and to evenly distribute heat through the
furnace. The dry-out procedure is as follows (temperatures are meant at bridgewall
temperatures, to be read by 013-TI-635, 013-TI-636, 013-TI-637, 013-TI-638 for H-1301,
H-1302, H-1303 and H-1304 respectively).
a The dry-out of refractory immediately follows the initial lighting of burners and
comprises of an initial holding period of at least 24 hours at 150C.
b Provide sufficient ventilation by opening the air registers of the burners not in
operation. The stack damper should be open as required (013-HV-620).
c Increase the flue gas temperature to 300C at a rate of 25C/hr and hold this
temperature for 24 hrs.
d Increase the flue gas temperature to 535C at a rate of 25C/hr.
e Start steam flow through the coils when flue gas temperature reaches 400C to
maintain the skin temperature of the tubes below the design value.
Start-up the water / steam system as per the procedure.
f Check coil outlet temperature hourly and regulate the steam flow so that coil outlet
temperature never exceeds the coill design temperature.
g Hold 535C for 24 hrs.
Check coil outlet temperature hourly (see point f above).
Check for hot spots or localised overheating on the external casing surface.
Check frequently that tubes do not glow red during dry out operation.
h When drying has been completed, reduce the bridgewall temperature by 50C/hr.
As the temperature reaches 200C the burner may be shutoff znd flow through the coils
stopped.
During drying procedure, check the progress of refractory drying by checking the
furnace shell temperature. When the burners are started in a new furnace, the moisture
at the outer surface of the lining evaporates readily into the combustions gases.
However, much of the moisture is held deeper into the lining next to the shell.
In the early of drying operation, the furnace shell remains cold. Then, as the heat density
in the combustion chamber increases, the lining heats through and the moisture from
the insulation begins to evaporate.
The furnace shell now heats up to evaporation of moisture.
When the moisture is driven from the insulation, the shell temperature will fall again.

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If the operator maintains a progressive account of the shell temperature, he may note
the rise ans the fall of the shell temperature during the dry-out process. When the shell
temperature has decreased to about 80C the furnace insulation is dried and the
furnace is ready for operation.
However, shell temperature should not be used to control dry-out schedule and the
procedure specified above should be followed. When the start-up operation is not
following immediately the dry-out procedure, it is recommended to keep the furnace in
hot conditions, otherwise lining will absorb humidity again.
If the furnace is shutdown after the dry-out procedure, when reheating it for the start-up
the furnace temperature increase should be limited to 50C/hr. Temperatures of 300c
and 535C should be hold for 3 hours.
The above mentioned dry-out procedures are meant to serve as a guide. It is quite
possible that a refractory manufacturer requires an extended/shortend period of dry-out
of refractory. If available the procedure prepared by refractory manufacturer should be
followed.
When dry-out of refractory is taking and a change of temperature is required, do not
increase the fuel pressure until all the burners are lit.
At this stage control the heat input exclusively with the number of burners in operation.
At no stage during the dry-out should a hard flame be used.
During refractory dry-out a regular check of skin temperature of the refractory casing is
necessary. If hot spots do occur, this is a sign of accumulation of moisture, and
additional holding time should be institued.
Care shall be taken for adequate ventilation and special care shall be paid to prevent
evaporated water condensing in cooler areas of the furnace. During dry-out operation
make intermittent checks of the stack damper (013-HV-620) to ensure that it operates
properly when hot.

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6. CATALYST LOADING
6.1 GENERAL LOADING GUIDELINES
Observance of the following guidelines during preparation for and completion of the
catalyst loading procedure are recommended.
a. An inspection of the reactors and their internals should be completed as soon as
possible prior to loading.
b. An inventory of catalyst, support material, and any reactor internals stored outside
the reactors should be made well in advance of the loading.
c. When the loading procedure is scheduled as a round-the-clock operation,
adequate lighting should be provided for safe nighttime activity in the working
area.
d. The placement of catalyst drums in the unit area and the stacking of empty drums
should be planed in advance to prevent confusion while reactor loading is
underway. The catalyst drums should not be unsealed until just prior to loading.
e. Do not discard empty catalyst drums. Store them with their lids and clamp rings in
a dry location. Normal practice is to use the empty catalyst drums for return of
catalyst fines or spent catalyst and for handling catalyst during unloading.
f. All catalyst loading equipment should be checked for availability and operability.
This would include loading hoppers, socks, hoists, safety equipment, lights,
ladders, etc.
g. Frequently, the personnel doing the work involved with catalyst loading do not
understand the operation of the unit or why loading details must be followed
exactly as designated. All personnel involved should be properly informed as to
the reasons and requirements for correct catalyst loading. In addition, procedure
for rigorous follow-up and attention to detail on the part of supervisory personnel
should be established prior to the loading.
h. Keep the tops of the scallop risers covered by caps to ensure no extraneous
materials fall or drop into the scallops.
i. No extraneous material should be left or dropped into the reactors. Aside from the
embarrassment of unloading a reactor to retrieve an object dropped or overlooked
during the loading period, serious problems during operation of the unit are likely
to occur as a result of an oversight in this matter.
j. Every effort must be made to minimize the time each reactor is open to the
atmosphere. A dry instrument air purge or blanket should be maintained on the
reactor system throughout the entire loading period to prevent moist air from
entering the reactor system. All reactor manways must be kept covered or closed
except during actual loading.
k. The catalyst loading should not take place during rainy or inclement weather as
exposure to any excessive moisture can alter the catalyst chemical properties and
reduce its activity.
l. Do not allow a natural draft of air to flow up through a reactor bed at any time.
Regardless of the state of the catalyst - fresh, spent, regenerated, hot or cold such a flow of air for a prolonged period may cause serious damage to the catalyst
and reactor internals.
m. For any Platforming unit loading in which the catalyst is sold in the prereduced and
presulfided state, the following precaution must be observed.

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CAUTION
Some of the UOP Platforming catalyst are presulfided. These presulfided
Platforming catalysts contain sulfur ; this results in a small partial pressure of H2S,
which may become significant if the catalyst is exposed to temperatures above
ambient temperature. Since both excess nitrogen and possible hydrogen sulfide
could be present in the reactors at some time during the loading, if it becomes
necessary to have personnel enter the reactor during the catalyst loading they
should be provided with proper protection for entering a contaminated
atmosphere. No one should be allowed to enter the reactor unless equipped with
the proper equipment and safety backup as specified for work in a contaminated
atmosphere.
A UOP representative will be able to confirm if the particular catalyst supplied is
sold in the prereduced and presulfided state.
n. Determine the correct catalyst loading for each reactor before beginning the
loading operation. Actual measurements should be used to calculate each bed
depth and volume. Refer to chapter 4 for catalyst requirements.

6.2 CCR PLATFORMING CATALYST LOADING

a. Overview
UOP currently recommends three different methods for loading catalyst into CCR
Platforming unit reactors. All three are acceptable regardless of unit design or
reactor size. Differences in the quantity of fines generated from one method of
loading to another are minimal. All fines that are generated from handling and
loading will be removed from the system during the first two or three catalyst
cycles. If the loading is done correctly, these fines will have no effect on the longterm operation of the unit.
A general description and a step-by-step description for each procedure is given
below. At this point it is assumed that all of the reactors and internals have been
assembled correctly, cleaned, and dried out (new units).
The selection of the catalyst loading method shall be done on site regarding the
time schedule and the availability of the equipment required for each method.
b. Reactor by Reactor Loading Procedure
(1) General Description
Of the three procedures, this has been the most common method used in the
past. Drums of catalyst are hoisted up to the reactor manway area where a
temporary loading hopper is situated. As catalyst is dumped into the hopper, it
flows out the bottom through piping or conduit and enters the reactor through
the reactor manway. At the end of the pipe or conduit is a loading sock which
extends a few feet below the reactor coverdeck. From the other end of the sock
the catalyst free fails to the bottom of the reactor. During the loading procedure,
the sock is shifted to different areas of the catalyst bed annulus so the catalyst
fills the reactor uniformly. If the catalyst falls in only one area, it will put an
uneven stress on the centerpipe, and cause variations in the loading density.
Obviously, this frequent movement of the loading sock requires that a man be
in the coverdeck area of the reactor throughout the loading. Dust protection is
required. The loading hopper can be bolted to the manway but it is usually
easier to locate it on a deck (permanent or temporary) above the manway. The
layout of the piping and sock must be arranged so the catalyst flows freely. An
angle greater than 35 degrees from horizontal should be acceptable. When

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everything is running smoothly the loading crew should be capable of moving

approximately 20 drums per hour or 2050 kg per hour.
A small variation to this approach can increase this loading rate significantly to
over 60 drums per hour or 6150 kg per hour. It calls for loading the catalyst into
large bins at grade and then lifting the bins up to the hopper. Typical bins used
by catalyst handling companies hold approximately 1400 kg of catalyst. A
separate crew at grade would be responsible for loading the catalyst into the
bins, always staying ahead of the bin transfers.
Regardless of whether drums or bins are used, loading should always start in
the lowest reactor and move up to the next highest when done. Loading in a
reactor is complete when the catalyst level is approximately one foot below the
open end of the catalyst transfer pipes. Short loading a reactor does not
present a problem. However, if a reactor is overfilled, it will make it impossible
to install the few coverdeck segments and catalyst transfer pipes not yet in
place.
For reactors with a conventional regeneration section, the reduction zone can
be loaded in a similar manner as the reactors by placing a catalyst loading
funnel above the catalyst inlet flange on top of the reduction zone. Lift catalyst
(drums or bins) and empty into the funnel. The reduction zone is full when the
nuclear level instrument is satisfied. This is also a good time to verify that this
nuclear level instrument works correctly. The side gas nozzle or the TI nozzle
on top of the reduction zone is an excellent location to take an outage.
Measure, and document the size, shape and location of the catalyst hill as the
nuclear level instrument comes on.
For reactors with a pressurized regeneration section, the reactor surge zone on
top of reactor no. 1 can be inventoried the same way the reactors were; using a
loading hopper, loading sock, and crane to lift the catalyst up to that elevation.
The output of the level instrument could be compared to a physical gauging of
the zone to verify the accuracy of the level instrument. This zone should be
filled to slightly more than the normal working volume to make up for slumpage
during the initial startup.
On units where the top of the reduction zone (or reactor surge zone for
pressurized regeneration sections) reactor no. 1 is too high for access or on
new units or when extensive work was performed on the regenerated catalyst
transport system, UOP recommends loading the top of reactor no. 1 and the
reduction zone (or reactor surge zone) using the regenerated catalyst transport
system. This procedure for loading using lift engager #2 is described in the
Chapter 5 of the CCR Regeneration Operating Manual.
(2) Step-by-Step Description
After a final reactor inspection following unit dryout or turnaround, the reactors
may be loaded by the following procedure:
a) Confirm that the manways on all reactors except the lowest reactor in the
stack are closed to prevent a natural draft.
b) Establish dry instrument air purges to the reactor stack by connecting air
hoses to the reactor outlet line pressure gauge connections or placing air
hoses in the manway of the open reactor.
c) Remove two or three coverplate segments at equal spacing around the
coverdeck in the lowest reactor in the stack.
d) Plumb bob each catalyst transfer pipe to insure it is unobstructed.

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e) Place covers over top of each scallop riser prior to reactor loading. (Should
be done as soon as the reactor manway is opened.)
f) Locate the catalyst loading hopper above the reactor manway. The deck
above, temporary scaffolding or a special structure can be used to support
the hopper. The loading hopper should be sized larger than the catalyst
drums or bins.
g) Attach piping or flexible hose from the loading hopper outlet to the reactor
manway.
h) Attach the loading sock to the piping or flexible hose; the sock should be
long enough to extend at least two feet below the coverdeck level at each of
the open coverplate locations.
i) If bins will be used to lift catalyst up to the reactor catalyst loading hopper,
set up scaffolding and a catalyst addition hopper at grade to facilitate
loading of the bins.
j) Start catalyst loading by lifting catalyst drums or bins up to the loading
hopper located above the reactor manway.
NOTE: If the reactor catalyst disposal nozzles were not filled during the final
reactor inspection with ceramic alumina balls as specified in the unit design
specification, this should be completed prior to catalyst loading.
k) As catalyst is loaded to the reactor, move the loading sock to the different
open coverplate locations; this will minimize the chance of loading at
different densities at different points in the reactor bed. Raising the catalyst
level evenly over the entire cross section of the reactor will also facilitate a
constant density loading and reduce centerpipe stress.
l) Continue sock loading until the catalyst level is within a foot of the bottom of
the catalyst transfer pipes.
m) For record purposes, measure the catalyst bed outage with respect to the
bottom of the coverplate and note the total number of drums loaded.
n) Restore all coverplate segments along with their respective catalyst transfer
piping. Carefully check transfer piping bolting for tightness and gaskets for
gaps with a feeler gauge. A 0.13 mm blade is recommended.
o) Remove any debris or catalyst spillage from the coverplate area and
remove the covers from the scallop risers.
p) Close reactor manway.
q) Proceed to load the other reactors in the same manner as described above,
moving from lowest to successively higher reactors in the stack.
r) Load the top of reactor no. 1 and the reduction zone (or reactor surge zone
for pressurized regeneration sections) via lift engager no. 2. See CCR
Operating Manual.
s) After the stacked reactors are loaded, load the regeneration tower and
disengaging hopper via the catalyst bins or drums. Load through the top
flange or manway on the disengaging hopper until the nuclear level device
indicates a level.
t) After catalyst loading is complete and the reactors are headed up, the
reactor system should be evacuated and placed under a positive nitrogen
pressure to await unit startup.

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u) At the conclusion of the catalyst loading activities, the quantity of catalyst

contained in each reactor should be determined. In addition, the loaded
density should be computed based on measured reactor volumes.

c. Entire Reactor Stack Loading Procedure

(1) General Description
This procedure calls for loading all the catalyst through the top of the reduction
zone (or reactor surge zone for pressurized regeneration sections) on top of
reactor no. 1. In many respects it is identical to the reactor by reactor loading
procedure except there is only one loading point. This is the preferred
procedure when the appropriate equipment is available to raise the catalyst to
this height. Rates in excess of 80 drums per hour or 18200 kg per hour are
possible when using large bins to lift the catalyst to the top of the structure.
Usually, a large hopper is centered over the catalyst inlet flange on the top of
the zone head and a sock or sleeve joins the hopper to the catalyst inlet
nozzle. Either butterfly or slide valve is located on the hopper outlet nozzle.
As the catalyst falls from the zone to reactor no. 1, to reactor no. 2 and so on, it
spreads out in each reactor, filling the reactor uniformly. There is no problem
with variations in loading density or uneven stresses on the centerpipe. It is felt
that this method will produce marginally more fines than the previous
procedure discussed but this should not pose a problem. As mentioned
previously, the fines will be removed during the first two or three catalyst
cycles.
(2) Step-by-Step Description
a) Use catalysts bins or drums to lift catalyst to the top of the reactor stack.
b) Load catalyst for all reactors through the catalyst inlet nozzle on top of the
reduction zone (or reactor surge zone for pressurized regeneration
sections).
c) Follow all the precautions and steps mentioned in the reactor by reactor
loading procedure as they apply in this case.
NOTE: All manways must be covered to minimize a natural draft through the
catalyst as it falls through each reactor.

d. Pneumatic Catalyst Loading Procedure

(1)

General Description
The pneumatic catalyst loading system consists of a stainless steel line
running up the reactor structure similar to the regenerated catalyst lift line;
only larger in diameter. At grade this line is connected to a rotary valve unit
which includes a rotary valve, catalyst hopper, and a dry air injection
system. This pneumatic loading system is permanent and is ready to use at
a moment's notice. With this system there is no need to plan ahead for a
crane, hoist, temporary scaffolding, or equipment to be installed on the
reactor structure.
Based on commercial experience to date the pneumatic system can load
approximately 20 to 30 drums per hour or 2050 kg to 3070 kg per hour.

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The system works as follows: Catalyst is loaded into the hopper above the
rotary valve or wheel. As the rotary wheel turns, it moves catalyst from the
hopper to the lift line pipe. Dry air injection into the bottom of the pipe
pushes the catalyst up the pipe to the reactors at approximately 10.5 m/sec.
The rotary valve makes it possible to continuously take catalyst from
atmospheric pressure up to approximately 1 kg/cm g in the lift line. The lift
line sections are connected by Dur-O-Lok* couplings. These easy-toassemble/disassemble couplings are located so the lift line can be diverted
into any one of the reactor manways and into the catalyst inlet line on top of
the reduction zone.
This system has been used with various levels of success. It is very
important that the rotary valve be as specified in the UOP Project
Specification. If the valve is not constructed correctly, there could be
excessive attrition, or there could be too much air leakage up through the
valve into the catalyst hopper or shaft packing. Excessive air leakage will
cause catalyst to be held up in the rotary valve inlet duct thus reducing the
lifting rate. In two cases this problem was fixed by making a simple field
modification. Both involved adding a small instrument air line into the rotary
valve. In one case, a small instrument air line was added to the housing in
the area after the rotary valve has picked up a load of catalyst and right after
the vane has past the inlet duct. Pressuring up this compartment in the
valve minimized the upward leakage rate and increased catalyst flow. Steps
must be taken to protect the rotary valve housing from overpressuring. In
the other case there was an air leakage problem. So, a small instrument air
line was tapped into the rotary valve inlet duct and a differential pressure
gauge was installed between the duct and the rotary valve catalyst outlet
line. The air rate to the duct was adjusted to maintain an acceptable delta
pressure and catalyst lift rate.
The lift line pressure is a function of how high the catalyst is to be lifted, air
rate, catalyst transfer rate and the diameter of the lift pipe. However, this
pressure should never exceed 1.4 kg/cmg since this is the relief valve
pressure at the base of the lift line. The relief valve is set to protect the
rotary valve and to minimize backwards air flow.

*UOP, CCR Platforming are trade and/or service marks of UOP. Dur-O-Lok
is a trademark of Dur-O-Lok.
If a refiner decides to use this loading option it is strongly recommended that
the equipment be carefully inspected and run-in long before it is time to load
catalyst. While running-in the equipment, check for maximum catalyst
transfer rate and catalyst breakage as the catalyst exits the top of the lift
pipe. If the rotary valve and lift line are properly fabricated, there should be
no noticeable difference between the percentage of fines in the loading
hopper and the lifted catalyst. For the run-in test, it is suggested that
catalyst or catalyst base be lifted to the highest point and vented into a drum
or hopper on the top deck. If using a hopper, a sock could be added to the
hopper outlet back down the structure to the rotary valve hopper; making a
closed loop.
The rotary valve specified by UOP is set at a fixed rpm. Some refiners have
made it adjustable (changeout gears) to increase the lifting rate without
increasing the apparent quantity of fines produced.
(2) Step-by-Step Procedure
See the UOP Project Specification and Drawings, if applicable.

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6.3 ATTACHED DOCUMENTS FOR CATALYST LOADING

The following documents show the catalyst quantity as well as the reactors R-1301 thru
1304 layout :
UOP Project Specification 903369-105-sheet 1 : quantity of catalyst,
UOP Project Specification for Ceramic/Alumina Balls (903369-312),
Data sheet of Reactors R-1301 thru 04 : 8474L-013-PDS-R-1301-001.

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CHAPTER 6

START-UP AND NORMAL OPERATIONS

CONTENTS

1.

SUMMARY OF START-UP

2.

PRESTART UP PRECAUTIONS

3.

PREPARE UNIT FOR CHARGING

4.
PURGE AND START THE NHT STRIPPER (T-1201), SPLITTER (T-1202), AND PLATFORMING
FRACTIONATION SECTION
5.

EVACUATE AND PURGE THE PLATFORMING UNIT

5.1

EVACUATE AND PURGE THE PLATFORMING REACTOR SECTION

5.2

EVACUATE AND PURGE THE NET GAS SECTION

6.

HYDROGEN PRESSURE THE PLATFORMING REACTOR, AND THE NET GAS SECTION

7.

START HYDROGEN CIRCULATION AND REACTOR WARMUP

8.

START FEED TO THE PLATFORMING REACTORS

9.

ESTABLISH SEPARATOR OPERATION

10.

START CHLORIDE ADJUSTMENT PROGRAM

11.

ESTABLISH NORMAL FRACTIONATION SECTION OPERATION

12.

LINE OUT

13.

COMMISSION THE RECOVERY PLUS SYSTEM

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14.

SPECIFIC STARTUP PROCEDURES

14.1

HEATERS H-1301/1302/1303/1304 IGNITION PROCEDURE (NATURAL DRAFT HEATERS)

Introduction
Starting Sequence
14.2
15.

RECYCLE COMPRESSOR START-UP PROCEDURE (C-1301)

NORMAL OPERATION

15.1

REACTION SECTION

15.1.1

Design operating conditions

15.1.2

Guidelines for operation of the reactor section

15.1.3

Feed quality and poison

15.1.4

Cause and effect table

15.1.5

Troubleshooting

15.2

DEBUTANIZER SECTION

15.3

OFF-SPEC IFICATION PRODUCTS HANDLING

15.3.1

LPG

15.3.2

Platformate

15.3.3

Off-specification handling table

15.4

TYPICAL EXAMPLE FOR COLLECTING DATA & QUALITY CONTROL

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SUMMARY OF START-UP
On the following pages, a logic diagram is presented to summarize the different steps of
an initial start-up of the Platforming Unit, as well as a table showing the expected start-up
schedule.

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Purge the NHDT Stripper (T-1201)

and the Platforming Debutanizer (T-1301)

Establish Naphtha Circulation Between NHDT and Platforming

Start Stripper T-1201 and Debutanizer T-1301

Purge the Reaction and the RECOVERY PLUS system

Hydrogen Pressure the Reactor and the RECOVERY PLUS system

Hydrogen Circulation and Reactor Warmup

Feed Introduction to the Reactors and then to the Debutanizer

Start Chloride Adjustment Program

Establish Normal Operating Conditions

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PRESTART UP PRECAUTIONS
This section describes the startup of the Platforming unit on a fresh load of catalyst. As a
CCR unit is attached, refer to it's manual for precommissioning and startup details.
However, in this situation the only section of the CCR that must be functional during the
Platforming Unit startup is the Lock Hopper No. 2 system. It is needed to reinventory the
reduction zone above reactor No. 1. During startup thermal and mechanical effects in the
stacked reactors will result in a loss of catalyst from the reduction zone and possibly
reactor No. 1. If it is not replaced via Lock Hopper No. 2 the catalyst seal in reactor No. 1
could be lost. Variations in the startup procedure described are possible on subsequent
startups, depending upon how complete a shutdown has previously been made.
NOTE: During the start-up of the unit, particular care should be taken not to exceed
equipment limitations.
Prior to startup, the Platforming reactor section should be dry to minimize leeching of
chlorides from the catalyst during the startup sequence. Any water which has collected in
the system during the shutdown should be drained. The wet areas of the unit should be
blown dry if possible. For the initial unit startup the unit should have been dried out before
the catalyst is loaded for those cases where the unit has been shutdown for catalyst
change-out and equipment has been filled with water for testing, circulation of hot gas
through the reactor section prior to catalyst loading is also advisable. A dryout procedure
will ensure a dry plant for catalyst loading.
Oil or flammable gas should never be charged into process lines or vessels
indiscriminately. If the lines or vessels have contained air, suitable purging should be done.
Similarly, air should not be allowed to enter lines or vessels which have contained
hydrocarbon until proper safety precautions have been taken. At no time should wet air
(ambient or plant air) or refinery fuel gas be purged through the catalyst bed. The moisture
in the air and fuel gas will leech the chloride off the catalyst as was mentioned earlier.
Also, the fuel gas could contain other catalyst poisons such as sulfur. The following
procedure for purging and preparing the unit for startup should be closely followed. If
varying the purge procedure appears necessary, the unit supervisors approval should
always be obtained.
Hydrotreated naphtha should be available for the unit startup. Hydrogen available in the
naphtha hydrotreater unit can be placed on-line before the Platforming Unit. Otherwise,
previously treated naphtha taken from storage can be used. Typically, such feed will have
the following contaminant levels:
Boiling Range
As per design
Total Sulfur
0.5 wt-ppm
Total Nitrogen
0.5 wt-ppm
Chlorides
*(0.5 wt-ppm)
Lead
*(20 wt-ppb)
Arsenic
*(1 wt-ppb)
Water + Dissolved Oxygen + Combined Oxygen = Low enough to produce less than
5 mole ppm water in the recycle gas with no water injection.
* as low as the analytical method used for analysis is capable of detecting; parenthetical
values are current UOP laboratory method limits.
For the first start-up of the CCR Unit, when hydrotreated feed is not available, startup may
be done on non-hydrotreated straight run naphtha providing it meets the following
limitations:
Total Sulfur
Total Nitrogen

100 wt. ppm maximum

1 wt. ppm maximum.

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Arsenic
5 wt. ppb maximum
Lead
25 wt. ppb maximum
Halides
1 wt. ppm maximum
End Point
204C maximum
Bromine N
1 maximum
The startup operating period on this feedstock must be limited to a maximum of twelve
hours and all reactor inlet temperatures must be maintained below 482C during this
period.
NOTE: Regardless of whether previously hydrotreated or untreated straight run naphtha is
used for the Platforming unit startup, the feed must be routed through a stripping column
for adequate stripping and drying prior to being charged to the Platforming unit.

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PREPARE UNIT FOR CHARGING

a. Check that all blinds have been removed and that all safety valves are installed.
b. Check that all utilities are available where required.
c. All instruments should be ready for service.
d. Leak check all sections of the unit including Lock Hopper No. 2 system. Slowly
pressure to 7 barg with either nitrogen or air (instrument air in the reactor section).
Check for leaks at all flanges, valves and fittings as required. Also monitor the
individual section pressures. If no leaks are found and system pressure holds for one
hour with no more than 0.15 bar loss, then the leak test has been successful. The
pumps and compressors should be isolated from the rest of the unit during the leak
test. They can be leak checked separately.

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4. PURGE AND START THE NHT STRIPPER (T-1201), SPLITTER (T-1202), AND PLATFORMING
FRACTIONATION SECTION
a. Purge the towers (NHT Stripper T-1201, Splitter T-1202, and Platforming Debutanizer
T-1301) with nitrogen until oxygen-free (less than 0.3% oxygen)
Introduce the nitrogen at low points. The towers should be purged from connections
at the base and vented at the highest point. All reflux and charge lines should also
be purged as well by using connections on the reflux and charge pump piping for
introduction of the gas. Continue purging until the vent gases escaping through the
vents on top of the tower and on the overhead receiver are oxygen free. Also be sure
all dead legs have been properly purged.
b. Prior to fractionation section startup, establish column pressures at design operating
pressure. or maximum sweet fuel gas header pressure (3.3 barg), whichever is less.
c. Line up startup naphtha to the NHT stripper tower T-1201 and then to the Splitter T1202.
d. Bypass the Platforming reactor section by closing the block valves on the charge
line from the stripper bottoms product line to the Platforming combined feed
exchanger E-1301 (the startup by pass line tie-in is located between the flow control
valve 013-FV-003 and the Combined Feed Exchanger Filters ). Do not flush
hydrocarbons into the Platforming reactor section
The startup naphtha is now lined up to the NHT stripper T-1201 and then onto the
Platforming Unit Debutanizer Feed-Bottoms Exchanger E-1306, bypassing the NHT
and Platforming reactor sections.
e. Start a flow of startup naphtha to the fractionation section of the NHT through the
normal charge lines using the reactor section bypass lines. Start a flow of startup
naphtha to the platformer Debutanizer (T-1301) through the Platforming reactor
section bypass line (taken downstream valve 013-FV-003).
f. When a good working level has been established in the Stripper T-1201 bottoms
(012-LIC-020), start heatup of that column (using reboiler H-1202). Continue in similar
fashion on other columns in the fractionation section.
NOTE: If there is any chance that water is in the towers, heatup very slowly. If water
vaporizes too quickly the pressure surge could damage the trays
g. Continue the startup naphtha flow until an adequate inventory has been established
in all towers T-1201, T-1202, T-1301 then discontinue flow.
h. Establish reflux on each column when adequate overhead receiver (respectively V-D1209, D-1210, D-1303) levels appear. Raise or lower column heat inputs, as
necessary, to maintain reasonable reflux to feed ratios. It might be necessary to
operate the towers at less than design pressure in order to establish reflux.
i. Establish circulation between columns of the NHDT Unit and the Platforming
Debutanizer and establish such circulation at approximately 50% of normal rate. In
this case, the reaction sections of the two units are bypassed and the Debutanizer
bottoms material is returned to the Feed Surge Drum D-1201 of the NHDT Unit,
using the startup by pass line located downstream of exchanger E-1305 A/B.
The startup loop is as follows :
D-1201
NHT Feed Surge Drum

T-1201
Stripper

T-1202
Naphtha Splitter

T1301
Debutanizer

j. Drain water from overhead receivers and system low points, as necessary.

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k. Rotate pumps and commission instruments to test as much equipment as possible

before cutting charge into the Platforming reactors.

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EVACUATE AND PURGE THE PLATFORMING UNIT

The evacuation and purge of the platforming reactor section and the RECOVERY PLUS
system can be done as one system.

5.1 EVACUATE AND PURGE THE PLATFORMING REACTOR SECTION

a. Close all drain and vent valves in the reactor system. Isolate Lock Hopper No. 1 from
the Platforming reactor section with blinds as necessary. Lift Engager No. 2 should
be lined up to the reduction zone. Isolate the Recycle Compressor C-1301.
b. Block in all instrument taps in the reactor section, including Lift Engager No. 2 block
valves on the compressors, and all valves and vents necessary to isolate the reactor
section from other sections of the unit and from other units.
c. Connect the vacuum ejector J-1301 to the Platforming Unit Product Separator D1301.
d. Evacuate the reactor section to a minimum of 600 mm Hg. If the CCR section is
installed, be careful with the valving on the recycle gas purge lines to the reduction
zone and the catalyst collector. Keep the lines blocked in while evacuating the
reactor section and crack open when purging with nitrogen. This will avoid sending
up too much gas up through the catalyst bed and maximizing air freeing of the
system. Repeat this step during each evacuation and nitrogen purge. If this requires
over an hour, there is excessive system leakage or the steam ejector J-1301 is not
functioning properly.
e. When maximum vacuum is attained, block in the ejector J-1301 and hold the
vacuum for an hour. If the unit is tight, there should be little or no loss of vacuum at
the end of the hour (less than 25-50 mmHg is considered acceptable).
f. Break the vacuum to a positive pressure of 0.35 barg with nitrogen from the
discharge of the Recycle Compressor C-1301.
NOTE: In all cases, while adding nitrogen or hydrogen to the Platforming reactor
system, normal flow through the catalyst beds should be used. This reduces the
danger of any catalyst displacement in the reactors.
CAUTION: To avoid the danger of pulling air into the compressors, no vacuum should
be put on the compressor cases. The compressors should be purged separately with
nitrogen from the suction through the discharge and out the vent line.
g. Repeat evacuation. Break the vacuum with nitrogen to 0.35 barg.
Evacuate the Platforming reactor system to 600 mm Hg. Break the vacuum to 0.1
barg using hydrogen consistent with the following specifications:
Hydrogen Analysis

Alternate Hydrogen
Analysis

99.5 min

75 min

Carbon monoxide, mol ppm

10 max

5 max

Carbon Dioxide, mol ppm

10 max

5 max

500 max

500 max

Water, mol ppm

50 max

50 max

Chlorine & Chlorides, mol ppm

1 max

50 max

nil

5 max

Hydrogen purity, mol %

Nitrogen, mol ppm

Total Sulfur, mol ppm

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5 max

NOTE: Hydrogen from refinery Hydrogen Manufacturing Plants is normally not

acceptable because of the inherently high moisture content.
5.2 EVACUATE AND PURGE THE NET GAS SECTION
This section includes:
The RECOVERY PLUS system (including X-1301-V-01)
The Net Gas chloride Treaters (013-D-1302 A/B)
The NHT Make Up gas Compressors (C-1202 A/B/C) including interstage coolers
and drums

a. Close all drain and vent valves in the net gas section.
b. Block in all instrument taps, isolate the reciprocating compressors C-1202 A/B/C
and block in all valves and vents necessary to isolate the net gas section from other
sections of the unit and from other units.
c. Connect the vacuum ejector J-1301 and evacuate this section to 600 mm Hg. If it
requires over a half hour, there is probably a leak or an open valve.
d. When the vacuum is attained, block in the ejector J-1301 and hold the vacuum for an
hour. If the unit is tight, there should be little or no loss of vacuum at the end of the
hour (less than 25-50 mmHg is considered acceptable).
e. Break the vacuum to a positive pressure of 0.35 barg with nitrogen. The nitrogen
should be connected so as to maximize purging of all the piping in this section. It
may be necessary to purge with nitrogen at more than one location. All dead legs
must be properly purged. For example, the hydrogen line to lift engager No. 2 must
be back purged.
f. Repeat evacuation with steam ejector J-1301. Break the vacuum with nitrogen to
0.35 barg.
g. Evacuate a third time and break the vacuum with hydrogen. It must be the same
quality as that used in the reactor circuit. Pressure to 0.1 barg.
h. Remove the last of the startup blinds.
i. Line up the reactor section to the Net Gas Chloride Treaters, bypassing the
Recovery Plus section.
j. Unblock all instruments in both the reactor and net gas sections.

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HYDROGEN PRESSURE THE PLATFORMING REACTOR, AND THE NET GAS SECTION
a. Line up the reactor section to the Net Gas Chloride Treaters, bypassing the
RECOVERY PLUS system. Using hydrogen from NHT storage D-1251, gradually
bring the reactor section to normal operating pressure, with additional hydrogen to
obtain 2.5 kg/cm g at the Separator D-1301 (013-PIC-004).
b. As pressure is increased, continue surveying the system for possible leakage.
NOTE: Do not exceed design operating pressure of the Separator D-1301, i.e. 2.5
barg.

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START HYDROGEN CIRCULATION AND REACTOR WARMUP

a. Be sure the recycle gas compressor C-1301 has been purged with nitrogen first and
then hydrogen. Any oxygen present from air will be displaced out the compressor
discharge vent line by admission of nitrogen into the compressor suction. The
admission of hydrogen by the same route will purge out the nitrogen.
b. As the CCR section is installed, open and close appropriate valves to establish
recycle gas purge flow to the reduction zone and to the catalyst collector. Open the
coalescer liquid drain line.
c. Check the compressor C-1301 suction and discharge lines for liquid. Check the
Separator D-1301 and any drains in the recycle gas circuit for liquid.
d. Start the Recycle Compressor C1301 using the manufacturer's procedure. (refer to
14.2)
e. With recycle gas flowing, purge the Platforming reactor Charge Heater and
Interheaters as per normal refinery practices, light fires, and begin raising the
reactors inlet temperatures to 370C at 30C per hour (013-TIC-001/003/005/007).
Due to the light heat load, only a limited number of burners will be required in the
heaters for the warmup period. Maintain maximum recycle gas circulation and line
up charge to the unit.
NOTES:
1. In order to preserve the select properties of fresh catalyst, the period of time
required to heat the catalyst to 370C should not exceed 12 hours.
2. Water circulation should be established in the steam generation section of the
waste heat recovery system on the heaters convection section prior to heater
firing. Similarly, process flow should be established at this point through any
process tubes, if any, installed in the heater convection section.

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START FEED TO THE PLATFORMING REACTORS

NOTE: The startup naphtha shall not contain more than 100 wt. ppm - preferably less than
0.5 wt. ppm - sulfur, and shall be as dry as possible. In order to assure a dry feed to the
Platforming Unit even including the case where startup feed is coming from hydrotreated
storage, the feed must be routed through a stripping column and be adequately stripped
prior to being charged to the Platforming Unit.
a. Line up the gas blanketed startup naphtha to the unit, if it was blocked in.
b. Check the startup naphtha to ascertain that it is clean, water free, and suitable for
reactor charging.
NOTE: The Debutanizer T-1301 should be warmed up at or near operating pressure
(i.e. 013-PIC-012 approximately at 9.8 barg) and on total reflux before charge is cut
into the reactor section.
c. When the reactor inlet temperatures reach 370C (013-TIC-001, 013-TIC-003, 013TIC-005, 013-TIC-007) start startup naphtha to the Platforming reactors at
approximately one-half design rate (i.e. approximately 50 t/h at 013-FIC-003). Close
the startup bypass line around the Platforming reactor section if it was being used for
fractionation section circulation.
NOTE: Manpower should be available to light additional burners in the Platforming
Charge Heater (H-1301) and Interheaters (H-1302/03/04) to pick up the increased
heat duty when charge is introduced.
d. Adjust firing on the Charge Heater and the Interheaters to hold 370-400C on the
reactor inlet temperatures until separator (D-1301) operation has been established.
e. Adjust charge rate as soon as possible to achieve 0.75 LHSV minimum.
f. Care should be taken to prevent the hydrogen-to-hydrocarbon mole ratio from
dropping below design during charge-in operation. This H2/HC ratio should be
maintained as the hydrogen production commences and the unit pressure stabilizes
(design operating value of H2/HC ratio = 2.9 mole/mole).

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ESTABLISH SEPARATOR OPERATION

a. When condensed reactor effluent has reached a satisfactory level in the separator D1301 (level 013-LIC-002), start the separator pump P-1301 A/B, unblock the
separator level control valves (013-LV-002 A/B) and the mini flow valve (013-FV-005),
and commission the level control instrument (013-LC-002) and the flow controller
(013-FIC-005).
b. After starting hydrocarbon flow from the Separator D-1301, a level will quickly build in
Debutanizer column.
c. Once operation of the Separator D-1301 is established, the reactor inlet
temperatures may be increased according to the following criterion:
1. If the unit was started on untreated straight run naphtha, the Platforming reactor
inlet temperatures can slowly be raised to produce the hydrogen needed for
startup of the NHT unit. The Platforming reactor inlet temperature should not be
increased any higher than necessary to produce the needed hydrogen quantity
and, in any case, should not exceed 482C until the recycle gas moisture
content has dropped below 200 mole ppm (analyzer reading 013-AI-003), the
sulfur content of the feed is 0.5 wt. ppm or less and the hydrogen sulfide content
of the recycle gas is below 2 mole ppm.
2. If the unit was started on hydrotreated charge, the reactor inlet temperatures can
be raised to 482C at 30C per hour (013-TIC-001, 013-TIC-003, 013-TIC-005, 013TIC-007). Do not exceed 482C until recycle gas moisture is below 200 mole
ppm, the sulfur content of the feed is 0.5 wt-ppm or less and the hydrogen sulfide
content of the recycle gas is below 2 ppm.
d. During the period that reactor inlets are being raised, the charge rate may also be
increased stepwise over a two hour period to the desired rate.

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10. START CHLORIDE ADJUSTMENT PROGRAM

a. As soon as feed is charged to the reactor, begin injecting an organic chloride
compound into the feed for catalyst chloride adjustment by starting up the Startup
Chemical Injection Pump (P-1305) or the Chemical and Condensate Injection Pump
(P-1304 A/B). The chloride injection rate of this pump must be adjusted according to
the recycle gas moisture content as illustrated below:
Recycle Gas Moisture
(Mole ppm)

Chloride Addition Rate

(Wt. ppm of Feed)

Over 500

50

300-500

30

200-300

20

b. Generally, the unit will never contain less than 500 ppm moisture in the recycle gas
on startup so the 50 ppm organic chloride injection rate should be the initial rate in
most cases.
c. Start up the Sulfide Injection Pump P-1306 A/B and begin sulfide injection as
required to maintain 0.25-0.5 wt-ppm sulfur in the feed.

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11. ESTABLISH NORMAL FRACTIONATION SECTION OPERATION

a. As soon as hydrocarbon flow reaches the Debutanizer section, line out of the
column should be initiated. The column should already be warm and on total reflux
so this should require only adjusting the column reflux rate and heat input
(Condensate from the Debutanizer Reboiler, 013-FIC-009) to obtain the desired
products.
b. Care should be exercised to ensure that material which has gone through the
Platforming reactor is not recycled to these reactors again.

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12. LINE OUT

a. If the charge stock used for startup was not the normal charge stock, the normal
design charge stock (hydrotreated heavy naphtha) should be placed in to the unit as
soon as it is acceptable for charging, i.e. meets the following requirements:
Boiling Range

As per design

Total Sulfur

0.5 wt. ppm

Total Nitrogen

0.5 wt. ppm

Chlorides

0.5 wt. ppm

Fluorides

*(0.5 wt. ppm)

Lead

*(20 wt. ppb)

Arsenic

*(1 wt. ppb)

Water + Dissolved Oxygen + Combined Oxygen = Low enough to produce less than
5 mole ppm water in the recycle gas with no water injection.
*as low as the analytical method used for analysis is capable of detecting;
parenthetical values are current UOP laboratory method limits.
NOTES:
1. Everything possible should be done to minimize the time non-hydrotreated feed is
brought into the unit.
2. Until the charge stock meets the above requirements, the recycle gas moisture
level is less than 200 ppm and the hydrogen sulfide in the recycle gas is less
than 2 mole ppm, 482C should not be exceeded on the reactor inlets.
b. When the moisture content of the recycle gas is below 200 mole ppm, the hydrogen
sulfide content of the recycle gas is below 2 ppm, and the sulfur content of the feed
to the Platforming is 0.5 wt. ppm or less (by the Nickel Reduction Method. UOP
Method 357 or Microcoulometric Method, UOP No. 727 or Tracor Atlas, ASTM D4045), the reactor inlet temperature can be increased to 493C.
c. As the unit continues to dry out, continue the chloride adjustment operation using
the following program:
Recycle Gas Moisture

Chloride Addition Rate

(Mole ppm)

(Wt. ppm of Feed)

100-200

10

30-100

Below 30

Normal rate

NOTE: If the recycle gas moisture analyzer (013-AE-003) is not operating properly or
cannot be properly calibrated, the following time schedule can be used as a guide to
adjusting reactor temperatures and chloride injection rates:
1. Assume 2 days are required for the recycle gas moisture content to be reduced
to 200 mole ppm.

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2. Assume an additional 2 days are required for the recycle gas moisture content to
be reduced to 30 mole ppm.
d. At 493C reactor inlet temperatures (013-TIC-001, 013-TIC-003, 013-TIC-005 and
013-TIC-007) the octane response should be checked. If the response for a 2 RONC
target increase is less than one clear octane number per 2-3C increase in reactor
inlet temperatures (WAIT), the catalyst chloride balance is low. In this event,
consideration should be given to increasing the organic chloride injection rate several
ppm for several days, and remaining at reduced severity until the octane response is
back to normal. Alternatively, the reactor inlet temperatures can be reduced below
482C, while still maintaining sufficient hydrogen production to keep the hydrogen
users in operation; into the inlet of each reactor inject 0.1 to 0.2 wt-% chloride based
on that reactor's pounds of catalyst over a minimum of 4 hours. This operation
should be closely supervised. Before increasing severity recheck the unit octane
response as discussed above.
e. When the recycle gas moisture content is less than 30 mole ppm, the reactor inlet
temperatures may be increased to achieve the desired product octane. At the same
time, the chloride injection rate should be reduced to normal. The normal chloride
injection rate will be dictated by the Platforming Unit recycle gas moisture content
and plant performance.
f. When the recycle gas moisture content decreases below 20 mole ppm, start the
pump P-1304 to begin the injection of water (as clean steam condensate) to the feed
to maintain the proper moisture content of the recycle gas. Typically 1 wt-ppm water
in the feed equals 3 mole ppm moisture in the recycle gas. Assuming there is 0.5 to
1.0 wt-ppm dissolved water in the Naphtha Splitter bottoms product, the normal
water injection rate would then be 4 to 4.5 wt-ppm based on the feed. Target
moisture levels in the recycle gas are 15 to 25 mole ppm.
g. As the unit is equipped with a CCR section, the reactor catalyst level will slump for
thermal and/or mechanical reasons after or during the Platforming unit startup;
excess catalyst slump will be indicated by a low catalyst level alarm at the
Reduction Zone (top of Reactor No. 1). Fresh catalyst must be transferred to the top
of Reactor No. 1, to prevent loss of seal in Reactor No. 1 . Catalyst transfer will have
to be accomplished by utilizing the regenerated catalyst transfer equipment (Lock
Hopper No. 2 system). Refer to the Catalyst Regeneration Unit Operating Manual for
this procedure.

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13. COMMISSION THE RECOVERY PLUS SYSTEM

Purging and inerting by means of N2 of the refrigerant compression can be performed in
parallel of the purging of the net gas section.
The complete procedure and acceptance criteria of the RECOVERY PLUS purging are
presented in the Vendor Operating Manual (8474L-013-A5016-4110-001-001 chapter IV D)
Introduce refrigerant in the system at the oil cooler X-1301-E-04 tubes side inlet and
pressure the refrigerant circuit.
When normal operation conditions is reached, the RECOVERY PLUS system is lined up
so as to treat gaseous effluent from the reactor. The main steps of the commissioning and
start-up sequence are the following
a.
b.
c.
d.

Circulate Net Gas and Lean Oil, Establish liquid level in the Absorber X-1301-V01.
Lube Oil Circulation
Refrigeration Section Start up
Compressor X-1301-C01 Start UP

A detailed procedure of the commissioning and start up sequence is presented in the

Vendor Operating Manual (8474L-013-A5016-4110-001-001 chapter IV D)

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14. SPECIFIC STARTUP PROCEDURES

14.1 HEATERS H-1301/1302/1303/1304 IGNITION PROCEDURE (NATURAL DRAFT HEATERS)
TO BE COMPLETED AND REVIEWED ACCORDING TO VENDOR OP. MANUAL WHEN
AVAILABLE
Introduction
Sequencing is required to ensure that operating events occur in proper order. The following
sequence description is applicable to heaters H-1301/1302/1303/1304. The sequencing will
permit a safe heater ignition by a series of interlocks that will be followed by appropriate
action taken by the field operators. The sequence will permit the pilot gas to be admitted
to the furnace after completion of a natural draft air purge, and will permit fuel to be
admitted to the burners only when there is sufficient ignition energy to ignite the fuel as it
enters the furnace. However, the sequence is based on starting the heaters from the field.
Certain functions in this sequence will be accomplished by interlocks, others by the local
operators. All corrective actions must be taken by the local operators.
The sequence described herebelow is applicable to first light-up of the heaters and all
subsequent starts from cold state.
Preparation for starting shall include a thorough inspection as to ensure the readiness of
the furnace for start-up. For this, follow the manufacturers instructions which are detailed
in his technical book.
All safety shutoff valves shall be closed, solenoids deenergized. All manual valves on
burners shall be closed.
Glossary of terms used:
to reset a solenoid on a valve: to put the valve in its normal operating position
(different from safety position).
Starting Sequence
The starting sequence shall be performed in the following order:
Natural draft heaters will be purged by natural draft with stack damper and air registers
fully open. Purge completion shall be verify by a portable explosive-meter.
a. Open damper (valve 013-HV-620) and burner registers to purge position.
b. Perform heater purge by pressing Start Purge button on local panel 013-HS-604.
The interlock will check (by means of limit switches) that:
1. all safety shut-off valves on fuel and pilot lines to heater are closed (bleed valve on
fuel gas open),
2. all manual shut-off valves on each individual pilot are closed.
If any of the mentioned valves is not closed the purge sequence will not start and the
light Purge Failure will go on.
If the confirmation is positive, an adjustable timer will start to count a preset value for
the purge time i.e. a period of not less than twenty minutes (to be confirmed by the
heater manufacturers technical documentation).
"Purge in progress" light on local panel will indicate that this step is being performed.
c. After purge step is completed as per timer, an indication on local panel "Ready to
start pilots" will be given.
d. Manually reset the solenoid valves on the pilot safety shutoff valves. The reset will
open pilot shut-off valves 013-XV-606 / 608. Once the pilot shut-off valves have

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changed their position to open, a 15 seconds timer shall be activated. After this
delay the low pressure trip switch shall be activated automatically (bypass will be
removed). The alarm lamp 013-PALL-616 shall go off because the pressure in the
line will close PSLL contact.
If for some reason the pressure in the line remains below the PSLL set point at the
end of 15 seconds period, the interlock will close the pilot line shut-off valves.
Investigate and correct the cause of failure. The sequence will go back to previous
step in point "c".
e. Check if the pilot gas pressure downstream of the pressure control valve (PCV) is as
required by vendor (approximately 0.9 bar g) and adjust PCV if necessary.
f. Adjust the air register or damper on the burner selected for the light-up to the
position recommended by manufacturer.
g. Open the individual pilot manual shutoff valve.
If flame on the pilot to be lit is not confirmed by its ionization rod within 10 seconds
delay, the interlock 013-UX-601 will deenergize the main pilot shutoff valve. The lamp
"Pilot Flame Failure 013-XA-619B" will go on. Determine and correct the cause of
failure to ignite.
For the first pilot ignition failure, repeat the ignition sequence for a maximum of four
(4) additional times. Otherwise, the complete purge sequence will have to be
repeated after remedy of the ignition failure cause.
If flame on the pilot is established as confirmed by its ionization rod lamp on the
panel, proceed with ignition of the next and all subsequent pilots.
The absence of flame even on only one pilot (TBC by Vendor) will cause heater
shutdown and the sequence will have to be restarted by pressing the heater Reset
button.
h. When all pilots are ignited the signal from ionization rods will switch on "Pilots flame
on" light on local panel. Manually bypass fuel gas line PSLL by putting its switch on
ON position. However, the bypass switch will only bypass the function but not the
alarm. This means that the PALL lamp will stay on when the pressure in the fuel gas
line is below the set point.
Bypassing of PSLL will allow the signal from ionization rods to energize solenoids on
the burner fuel gas shut-off valves thus enabling their reset.
At the same time, the sequence will force the controller on the fuel gas control valve
in manual mode and will set its output to 0%.
i. Manually reset the solenoids on the main fuel shutoff valve, control valve and the
burner header atmospheric vent valve. By resetting these solenoid valves the main
fuel shut-off valve will open and the vent valve will close. Main fuel control valve
remains closed and will open as required. The opening of the main fuel shut-off valve
will raise the pressure sufficiently to reset the low gas pressure trip switch and the
alarm lamp 013-PALL-617shall go off because the PSLL contact will close.
The fuel gas PSLL which has been bypassed during the previous steps will be
automatically activated (bypass will be removed) after 15 seconds have elapsed from
the moment the main fuel gas shut-off valve limit switch has changed position (after
manual reset).
If for some reason the pressure in the line remains below the PSLL set point at the
end of 15 seconds period, the sequence will close the fuel gas shut-off valve.
Investigate and correct the cause of failure. The sequence shall go back to previous
step in point "h".
j. Open the individual burner shutoff valve. Visually confirm that the burner has ignited
and that a stable flame exists. Proceed with the next and all subsequent burners
placed in operation.

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k. Adjust fuel gas control valve to produce stable flame patterns.

14.2 RECYCLE COMPRESSOR START-UP PROCEDURE (C-1301)

TO BE COMPLETED ACCORDING TO VENDOR OP. MANUAL WHEN AVAILABLE

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15. NORMAL OPERATION

The following paragraph gives guidelines to operate the unit in normal conditions. It also
includes recommendations for correction of deviations of the main parameters from normal
values.
Operating conditions presented in the heat and material balances and on the process flow
diagrams (PFDs) reflect the normal operating conditions.
15.1 REACTION SECTION
15.1.1

Design operating conditions

Hereafter tables giving the process design operating conditions for the reaction section, for
design case operation.
Design Case
Reactors inlets as WAIT

549

Reactor R-1301 delta T

108

Reactor R-1302 delta T

70

Reactor R-1303 delta T

48

Reactor R-1304 delta T

28

Separator D-1301 pressure

barg

2.5

Recycle Gas Flowrate

Nm 3/h

H2 / HC Ratio

mol / mol

Recycle Gas H2 Purity

mol %
3

-1

70600
2.9
85.2
3

LHSV, Overall

m .h / m

2.5

Chloride injection

ppm wt

0.4 to 4.0

Water injection

ppm wt

about 10

Water in recycle gas

ppm mol

15 to 25

Spent catalyst Coke

wt %

3 to 7

Regenerated Catalyst Chloride

wt %

1.1 to 1.3

Notes: (1) weight percent of liquid feed

A change in any one of these factors can affect the unit operation sufficiently to cover up a
change in the catalyst chloride level.

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Guidelines for operation of the reactor section

During normal operation, the unit must be operated so that two main objectives are
achieved. These are the production of the various product streams at proper specification
and the protection of the Platforming Catalyst. These objectives can only be achieved on a
long term basis if good control is exercised on the unit. Such control requires that the unit
weight balance (100 + 2 wt. %), accurate analyses be reported on feed and product
streams, the feed be properly treated to remove contaminants, and unit operation be
smooth at proper catalyst water/chloride balance with a minimum of upsets.

15.1.2.1

Reaction loop pressure

Hydrogen partial pressure is the basic variable because of its inherent effect on reactions
rates. But for the ease of understanding total reactor pressure can be used. Due to
catalyst distribution in the reactors, it is usually close to the last reactor (R-1304) inlet
pressure (013-PI-001).
All the hydrogen producing reactions i.e. dehydrogenation, dehydrocyclisation are
enhanced by low pressure.
Decreasing the reactor pressure will :
Increase the hydrogen and reformate yield
Increase the catalyst coking rate
Decrease the temperature requirement to make the product octane
The reactor pressure has no theoretical lower limitations, however there is little flexibility
since the unit and the recycle compressor are designed for a given pressure. Lowering the
operating pressure below the design pressure results in higher pressure drop and is limited
by the recycle compressor design power.

15.1.2.2

Reactors inlet temperatures

Catalyst activity is directly related to reactor temperature. Thus the most direct operating
variable available for the operator, to control product quality and yields, is the reactors inlet
temperature (013-TIC-001, 013-TIC-003, 013-TIC-005, 013-TIC-007).
As the Platforming is equipped with a Continuous Regeneration section, the coke amount
on the catalyst is maintained at a constant low level through the continuous regeneration.
Consequently a temperature adjustment is required only :
To change the reformate octane.
To process a different feed quantity.
To process a different feed quality.
To balance a temporary loss of activity due to a temporary poisoning.
To balance catalyst ageing which occurs slowly over several years.
An increase of temperature (i.e. WAIT*) has the following effects, assuming the space
velocity (i.e. the feed rate) and feed characteristics stay unchanged, it :
Increases octane.
Decreases the yield (of C5+ fraction).
Decreases the H2 purity.
Increases the coke laydown.

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At constant WAIT (*), the ageing of the catalyst (caused by the numerous regenerations,
the possible metal deposit, the unavoidable upsets) results in a slight but steady loss the
activity (i.e. of octane). A slight increase of temperature (WAIT) through the life of the
catalyst makes up for this activity loss.
(*) Refer to 3.1.2 of Chapter 3 for definition of WAIT.
15.1.2.3

Space velocity
The inverse of the liquid hourly space velocity i.e. (LHSV)-1 is linked with the residence
time of the feed in the reactor. The space velocity then affects directly the kinetics of the
reforming reactions.
When changing feed rate, an important recommendation derives from the above :
Always decrease reactor inlet temperature first and then decrease feed flow
rate afterwards.
Always increase feed flow rate first and then increase temperature
afterwards.
Lowering the space velocity (higher residence time) has then the same effects as
increasing the temperature i.e., it :
Increases octane.
Decreases the yield (of C5+ fraction).
Decreases the H2 purity.
Increases the coke deposit.
If temperature increase is limited (by heater design duty or anything else), lowering space
velocity (i.e. decreasing flow rate) can give an additional boost to octane.
Operators must keep in mind that each time liquid feed rate is changed a temperature
correction must be applied if octane has to be maintained. When feed is increased,
temperature must be raised and conversely, when feed is reduced temperature must be
lowered.

15.1.2.4

Hydrogen to hydrocarbon ratio

Hydrogen to hydrocarbon ratio (H2/HC) is defined as the moles of pure hydrogen in the
recycle gas per moles of naphtha charged to the unit.
Lowering the H2/HC ratio will :
Decrease the hydrogen partial pressure.
Increase coke formation.
Have little effect on product quality or yields.
Regarding the little effect on product quality or yields of H2/HC variations, and the inherent
limitations due to the Recycle Compressor characteristics (power, suction flow, ),
H2/HC ratio adjustments should not be considered as a major operating variable. However,
it is highly recommended to operate with a H2/HC ratio equal (or greater than) the design
value (2.9 for design case).

15.1.2.5

Chloride water balance

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Control of the catalyst chloride-water balance for optimum catalyst selectivity and
maximum product octane or maximum aromatics production is one of the most critical
areas of Platforming unit operation.
The water and chloride injection amounts may seem to be insignificant by virtue of their
size, but are actually very important items in the maintenance of the unit chloride-water
balance and hence proper unit operation and catalyst activity.
Uncontrolled injection rates of either water or chloride will severely handicap stable
operation. The water injection tank D-1301 and gauge glasses should be rigorously
calibrated, chloride blends carefully prepared, and injection rates frequently checked (using
stroke of pumps P-1304 A/B and/or P-1305). Under normal conditions, the injection rates
may vary from week, but, in most cases, will be continuous.
The water and organic chloride injection rates will be determined by monitoring the recycle
gas water and hydrogen chloride content, the chloride and water content of the naphtha
charge, the selectivity of the catalyst (aromatics in the product primarily) and the chloride
content on the spent catalyst (as CCR section is installed). The HCI content of the recycle
gas should be monitored once a shift with gas tubes, i.e., HCl Draeger tubes. With the
proper water injection rate the HCl in the recycle gas should be approximately 2 mole
ppm. The moisture content of the recycle gas can be obtained on a continuous basis
through use of the moisture analyzer installed on that stream (013-AI-003). A general rule
of thumb for correlation of water in the recycle gas is that one weight ppm of water in the
charge will give approximately three molal ppm water in the recycle gas. The continuous
moisture analyzer operation should be frequently cross checked with this rule of thumb to
insure its continued proper performance. Any discrepancies on laboratory analyses should
be checked. As this unit is equipped with a CCR section, the control of catalyst chloride
levels can be as precise as operational diligence and spent catalyst chloride analyses
permit.
The following approximate values should be used as operating guidelines :
Normal water injection rate : 4 to 4.5 wt-ppm of naphtha feed (using stroke of P-1304
A/B)
Target moisture level in the recycle gas : 15 ot 25 mol-ppm (analyser 013-AI-003)
HCl in recycle gas : 2 mol-ppm (by HCl Draeger tube)
In case water content in the recycle gas exceeds 50 mol-ppm, severity must be lowered to
protect catalyst against quick deactivation. Such water upset must be corrected : the
operation of the NHDT unit Stripper (T-1201) and Splitter (T-1202) or the source of water
contamination must be investigated.
15.1.3

Feed quality and poison

It is important to monitor the feed and products qualities regularly in order to protect the
unit from poor feed and to evaluate the performance of the unit.
A recommended laboratory test schedule has been provided in this manual in Chapter 12
(Analytical Requirements) to illustrate the typical control analyses, test methods and
frequency of sampling.
Above the recommended maximum levels of feed stocks contaminants, catalyst
performance will be measurably and negatively affected and steps should be immediately
taken to rectify the problem. In the case of sulfur and nitrogen, UOP strongly recommends
operation at as low severity as possible and not at the maximum allowable levels. Such
minimization of known poisons will help assure maximum selectivity and stability of a
Platforming operation.

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The suggested operational responses to the presence of poisons are those responses
that, in general, minimize catalyst and equipment damage. It often occurs that other
considerations such as product octane level, production quotas, shutdown schedules,
etc., are in conflict with the suggested operational response. If this does occur, the refiner
must weight the alternatives of additional catalyst and/or mechanical damage versus the
economics of the situation.
15.1.3.1

Sulfur
a. Maximum Allowable Concentration
Maximum allowable concentration in the naphtha feed is 0.5 wt-ppm. Operation at
0.1 to 0.2 wt-ppm in the feed is normally possible with most Naphtha Hydrotreaters
and will provide added assurance of realizing maximum catalyst stability and
selectivity.
b. Methods of Detection
(1) Feed naphtha sulfur analyses:
Nickel Reduction Method :

UOP 357

Good for reducible sulfur

May not give total sulfur
Microcoulometric Method :

UOP 727

Good down to 0.1 wt-ppm

Houston Atlas :

ASTM D-4045

Good down to 50 wt-ppb

Preferred method
NOTE: Neither a lamp sulfur method nor a doctor test are adequate for this purpose. Also,
experimentation has shown that the highly hindered (thiophenic) sulfur compounds are
unreactive under the conditions of the Nickel Reduction procedure. As a result this method
may not give total sulfur results (especially for high endpoint feeds).
(1) Sniffer tube H2S determinations to quantify H2S levels in the recycle and stabilizer
overhead gas. Note that a rule of thumb estimation is 1 wt-ppm sulfur in feed = 3
mol-ppm in recycle gas = 10 mol-ppm in stabilizer overhead gas.
c. Process Symptoms
Sulfur contamination in the Platforming Unit results in attenuation of platinum
activity. This in general means that the hydrocracking (acid catalyzed) reactions will
increase relative to the dehydrogenation and dehydrocyclization (metal catalyzed)
reactions. Resulting observable effects include:
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Decreased hydrogen production;

Decreased recycle gas hydrogen purity;
Increased hydrocracking (higher C3 and C4 yield);
Reduced reactor delta T's;
Lower C5 plus yield;
Lower catalyst activity in more severe cases; and
Increased catalyst coking rate (decreased stability).

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Data has shown that at levels of 10 mol-ppm H2S in the recycle gas corresponding
to 2-3 wt-ppm sulfur in the feed, a CCR Platforming Unit exhibits the following relative
to clean conditions:
An activity loss of 8-11C
A C5+ yield loss of 1-2 LV-%; and
A coking rate increase of approximately 50%.

d. Suggested Operational Response

Catalyst damage will be minimized by maintaining reactor temperatures as low as
possible. (There is no need to go below 482C.) If reactor temperatures are increased
to compensate for decreasing RONC while sulfur is present in the recycle gas, this
will rapidly accelerate coke laydown.
Every attempt should be made to eliminate sulfur from the feed. Once low sulfur
naphtha a feed has been restored, the sulfur will gradually desorb from the catalyst.
When the recycle gas H2S content has decreased below 1-2 ppm, normal operation
may be resumed.
Slightly increased chloride addition during the time in which sulfur is present in the
recycle gas will improve the rate of sulfur desorption from the catalyst. An increased
chloride addition rate to the chlorination zone will be needed in order to maintain 1.11.2 wt-% Cl on the regenerated catalyst. Furthermore, additional chloride addition
(perhaps 0.5-1.0 wt-ppm on a fresh feed basis) into the feed may improve sulfur
desorption in the reactors and help maintain normal chloride levels on the spent
catalyst. These increased addition rates may be required for 2-3 catalyst
regeneration cycles after the recycle gas H2S content has decreased to 1-2 mol-ppm
in order to completely remove the sulfur on the catalyst.
During the time in which sulfur is present in the recycle gas, the maximum allowable
catalyst circulation rate, within the constraints of the General Operating Curve, will
improve the rate of sulfur removal from the catalyst inventory. In addition, the lower
air rate should be increased to the design rate. Regeneration tower operations must
be watched carefully because the coking rate can be expected to increase by 50200% or more while sulfur is present in the system.
e. Possible Sources
(1)

(2)

(3)

(4)

Inadequate naphtha hydrotreating: This can result from low activity hydrotreating
catalyst or from simply running at too low of a hydrotreating reactor
temperature.
Recombination sulfur from NHT: Combinations of high hydrotreater temperature
and low hydrotreater pressure can promote recombination of hydrogen sulfide
with trace quantities of olefins Such problems can normally be solved by
lowering the hydrotreater temperature below 343C.
Hydrotreater stripper upsets: These may result in incomplete stripping of H2S.
Generally, water as well as H2S will come over from the stripper which also
aggravates the situation.
Inclusion of cracked naphthas in the Platforming Unit charge: Most cracked
naphthas have a high sulfur content. They must, therefore, be hydrotreated with
a more active hydrotreating catalyst or at a higher hydrotreating reactor
temperature.

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Processing of feeds with high end boiling points in the Platforming Unit charge:
In general, for any of the typical Platforming Unit feedstocks, as the end boiling
point increases, the sulfur content increases. In other words, compared to the
lighter boiling fractions of a given feedstock, the heaviest boiling fraction
contains the highest sulfur content as well as the sulfur compounds that are
most difficult to desulfurize. If the end point of any of the naphtha hydrotreater
feedstocks increases, the refiner must monitor the sulfur content of the
Platforming Unit feedstock to ensure that sulfur does not contaminate the
Platforming Unit.

f. Possible Mechanical Problems

Increased iron sulfide formation throughout the unit.
15.1.3.2

Nitrogen
a. Maximum Allowable Concentration
The maximum allowable concentration of nitrogen in the naphtha feed is 0.5 wt-ppm.
Every attempt should be made to absolutely minimize the nitrogen content of the
naphtha. A real level of 0.5 wt-ppm nitrogen in the feed to a 1590 m3/day (10,000
BPD) Platforming Unit will result in the deposition of 823 kilogram per year of
ammonium chloride deposits in the recycle gas circuit and stabilizer column
overhead. Also, every kilogram of nitrogen in the feed that reacts to form ammonium
chloride combines with 2.5 kilograms chloride, which must be made up or otherwise
the catalyst chloride level will fall.
b. Methods of Detection: Analyze Naphtha Feed
Kjeldahl Nitrogen method :

UOP 384

Good down to 0.1 wt-ppm

Chemiluminescence :
(Dohrman Apparatus)

ASTM D-4629

Good down to 0.1 wt-ppm

Preferred method

c.

Process Symptoms
Nitrogen is an acid function poison. Organic nitrogen that enters the Platforming Unit
will be converted to ammonia. This ammonia will react with chloride on the catalyst
to form volatile ammonium chloride. The overall effect is to reduce catalyst chloride
level producing the following symptoms:
(1)
(2)
(3)
(4)

Loss of catalyst activity;

Increased hydrogen production;
Increased hydrogen purity; and
Increased reactor delta T's.

d. Suggested Operational Response

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Catalyst coking will be minimized by not raising temperatures during the period of
nitrogen contamination.
Every attempt should be made to isolate the source of nitrogen and eliminate it from
the feed.
Slightly increased chloride addition to the chlorination zone during the time in which
nitrogen is present in the feed will be needed to maintain 1.1-1.2 wt-% Cl on the
regenerated catalyst. If accurate feed nitrogen analyses are available, the increase in
chloride addition can be estimated as the amount needed to offset the nitrogen
contamination in the feed.
e. Possible Sources
1. Inadequate naphtha hydrotreating: Most virgin straight run naphthas contain very
little nitrogen. Consequently, hydrotreaters processing such naphtha can be
designed at lower pressures than would be required if the naphtha contained higher
nitrogen levels. The difference in design pressure is normally 14 to 28 kg/cm2 and
cannot be compensated for after the unit is designed. Therefore, it is necessary to
avoid processing higher nitrogen content naphthas in hydrotreaters originally
designed for lower nitrogen naphtha. The hydrogen partial pressure is not sufficient to
accomplish complete nitrogen removal.
2. Inclusion of cracked naphthas in the Platforming Unit charge: Most cracked
naphthas have a high nitrogen content. They must, therefore, be hydrotreated at high
pressure in preparation for inclusion to Platforming Unit feed. A stream of cracked
naphtha, even though small relative to total Platforming Unit charge, should not be
included to Platforming Unit charge if only low pressure hydrotreating is available.
3. Processing of feeds with high end boiling points in the Platforming Unit charge: In
general, for any of the typical Platforming Unit feed stocks, as the end boiling point
increases, the nitrogen content increases. In other words, compared to the lighter
boiling fractions of a given feedstock, the heaviest boiling fraction contains the
highest nitrogen content as well as the nitrogen compounds that are most difficult to
hydrotreat. If the end point of any of the naphtha hydrotreater feedstocks increases,
the refiner must monitor the nitrogen content of the Platforming Unit feedstock to
ensure that nitrogen does not contaminate the Platforming Unit.
4. Improper use of inhibitors: Use of filming and neutralizing amines as corrosion
inhibitors throughout the refinery can sometimes lead to inadvertent naphtha nitrogen
contamination. Areas of caution are crude system overhead, hydrotreater stripper
overhead, and hydrotreater reactor effluent in addition to any other refinery units
processing a naphtha which will be sent to the Platforming Unit. Carefully monitored
ammonia and increased water injection is often a less expensive and less risky
solution than inhibitor injection. Where inhibitor usage is absolutely necessary,
strictly adhere to the recommended dosage.
5. Reprocessing of off-spec unleaded gasoline or contamination of Platforming Unit feed
tanks with unleaded gasoline: Nitrogen-containing chemicals are frequently used as
additives to unleaded gasoline.
6. Deactivation of hydrotreating catalyst: As the NHT catalyst loads up with metals, its
ability to remove organic nitrogen compounds fails off. Since nitrogen is more difficult
to decompose than sulfur or metals, it will be the first to show up in the stripper
product as the NHT catalyst fails.

f.

Possible Mechanical Problems

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Ammonium chloride deposits will accumulate in the Platforming Unit products

condenser, separator, recycle compressor suction lines, and stabilizer column. This
can result in decreased cooling capacity in the products condenser, possible
compressor damage (especially during regeneration when high water levels move the
deposits onto the compressor wheels or valves), and erratic stabilizer operation.
Moreover, extreme care must be taken when ammonium chloride contaminated
equipment is to be opened or inspected. Such equipment must first be thoroughly
washed to remove the ammonium chloride deposits. Otherwise, the hydroscopic
deposit will adsorb atmospheric moisture and cause serious corrosion problems.
15.1.3.3

Water
A Platforming Unit performs best when the feed to the unit is essentially dry and the
water/chloride balance is maintained via chloride injection into the chlorination zone of the
regeneration section. If an unknown source of water enters the system, the long term
effects can be an increase in catalyst coking rate and a decrease in yield and activity.
a. Maximum Allowable Concentration
A recycle gas water content of 30 mol-ppm indicates excessive water, dissolved
oxygen, or combined oxygen in the feed to the Platforming Unit. Moisture levels at or
above this level may lead to excessive hydrocracking reactions and coke laydown.
Additionally, the chloride will be stripped from the catalyst, upsetting the
water/chloride balance.
b. Methods of Detection
1. Suggested on-stream moisture analyzers:
Analyzer
Du Pont 560
Panametrics 3000
Mitsubishi Water Analyzer CA-03

Stream
Recycle Gas
Feed/Recycle Gas
Feed

2. HCl in recycle gas by sniffer tube (e.g., Draeger)

c. Process Symptoms
Water tends to act as a metal function poison (much like sulfur) and enhance the
acid function. Water also strips chloride from the catalyst to form HCI in the recycle
gas. In the short term, this high level of HCI accentuates the acid function, most
notably hydrocracking. Therefore, the short term observable effects may include:
1. Decreased hydrogen production
2. Decreased recycle gas hydrogen purity
3. Higher C3 and C4 yields
4. Reduced delta T's
5. Lower C5 plus yield
6. Increased catalyst coking rate
7. Increased recycle gas HCI levels

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If feedstock with a high water content is charged over a long period of time, the
catalyst may become chloride deficient. The extent of this deficiency will be
apparent in a decreased chloride contents of the spent and regenerated catalysts.
d. Suggested Operational Response
Catalyst damage will be minimized by maintaining reactor temperatures as low as
possible. [There is no need to go below 482C.] Failure to lower temperatures could
result in a substantially increased coke content of the spent catalyst. In turn, this
may affect the operation of the regeneration section, which should be kept at all
times within the constraints of the General Operating Curve.
Locate the source of the water contamination and either remove it outright or make
the appropriate process adjustments to the feed pretreating units. When the recycle
gas water has decreased to less than 30 ppm, re-establish normal operating
temperatures.
An increased chloride addition rate to the chlorination zone will be needed in order to
re-establish the recommended 1.1 -1.2 wt-% Cl on the regenerated catalyst.
e. Possible Sources
1. Inadequate hydrotreating of feed may allow unconverted oxygen compounds to
enter the Platforming Unit. Oxygenated hydrocarbon compounds frequently
contaminate naphthas in storage tanks.
2. Furthermore, any properly hydrotreated feed that is not completely stripped will
allow water and other catalyst poisons to enter the Platforming Unit.
3. Leaks in steam or water exchangers in upstream units.
4. Platforming Unit water injection system.
5. NHT stripper feed effluent exchanger leaks.
6. Inadequate drying in the drying zone of the regeneration tower.
7. Leaks in steam heaters or steam jackets in the regeneration section.
8. Leaks in cooling pads of blowers in the regeneration section (if applicable).
9. Leaks in cooling panel of the surge hopper in the regeneration section (if
applicable).
10. Improper operation of the reduction zone gas removal system (if applicable).

f. Possible Mechanical Problems

1. The excessively high HCI in the net gas from the Platforming Unit may be
corrosive to downstream equipment and units.
2. Excessively high HCI in the stabilizer offgas from the Platforming Unit may be
corrosive to the stabilizer overhead system and to downstream equipment and
units.
15.1.3.4

Metals
a. Maximum Allowable Concentrations

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Because of the quantitative and irreversible effects of Platforming catalyst metal

contamination, there should be no detectable levels of metals in the Platforming Unit
charge.
b. Method of Detection
For small concentrations in the naphtha feed there are some specific methods that
are improvements over AAS (Atomic Adsorption Spectroscopy) or more recently ICP
(Induction Coupled Plasma):

Arsenic in Petroleum Naphthas :

Trace Concentrations of Lead
Gasoline or Naphtha :
Copper in Gasoline and Naphtha :
Silicon in Aqueous Solution :

in

UOP 296
UOP 350

Detectability Limit
1 wt-ppb
10 wt-ppb

UOP 144
AAS

6-7 wt-ppb
0.1 wt-ppm

For analysis of a catalyst sample for possible metal contamination:

Impurities in Alumina Base
Catalysts by Spectrography:
UOP 303
c. Process Symptoms
Most metals are poisons to the platinum function of the catalyst. The observable
effects will be a loss of overall catalyst activity and selectivity as more and more
catalyst is contaminated.
d. Suggested Operational Response
Periodic checks for metal content should be made of the naphtha hydrotreater
charge. Any periods of significant metal content in the hydrotreater feed should be
documented in an attempt to quantify the total weight of metals going to the
hydrotreater. Normally, UOP hydrotreating catalyst can still function effectively with
up to a total metals loading of 2 to 3 weight percent. If the hydrotreating catalyst has
been exposed to sufficient metals to approach this 2 to 3 weight percent level, strong
consideration should be given to replacing the hydrotreating catalyst.
Likewise, if any detectable metals levels are found in the hydrotreated naphtha and
increased hydrotreater temperature does not eliminate the problem the hydrotreater
catalyst should be changed. Any metals that do enter the Platforming Unit will
irreversibly damage the catalyst, but quick detection and subsequent metal
contaminant removal on the refiner's part can often limit the damage to a small
percentage of the Platforming catalyst inventory.
e. Possible Sources
1. Some virgin naphthas contain measurable levels (ppb) of arsenic.
2. Lead can be introduced by either reprocessing of off-spec leaded gasoline or
contamination of Platforming Unit feed tanks with leaded gasoline.
3. Corrosion products:
Corrosion of plant hardware can result in migration of the corrosion products into
the reactors. Iron is the most common such corrosion contaminant;
molybdenum, chrome, and copper are other possibilities. Especially in the case

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of iron, these corrosion contaminants are better tolerated by Platforming

catalysts than are organic metals. These corrosion products often enter the first
Platforming reactor as sulfide scale from the charge heater, combined feed
exchanger and hydrotreater. The scale will accumulate in the first Platforming
reactor and may cause hydrocarbon flow distribution problems.
4. Water treating compounds containing zinc, copper, phosphorus, etc., have at
times been mistakenly added to Platforming Unit charge.
5. Some cracked (coker) naphthas can contain silicon, added as an antifoaming
agent elsewhere in the refinery.
6. Excessive injection of corrosion inhibitors on NHT strippers can result in the
inhibitor getting into the stripper bottoms. This is especially of concern when
there is no overhead liquid draw on the stripper.

f. Possible Mechanical Problems

Metallic scale migration into the Platforming reactors may cause pressure drop and
hydrocarbon flow distribution problems if the scale accumulation in the scallops is
great enough.
15.1.3.5

High Feed End Point

A Platforming Unit is designed to produce aromatic hydrocarbons. This aromatic
production apparently cannot occur without some very small amount of single ring
aromatic condensation into multi-ring polycyclic aromatics. These polycyclic aromatic
hydrocarbons are direct coke precursors. Once they are formed, they are strongly hold to
the catalyst surface and will further convert to what is typically referred to as coke on the
catalyst. The rate of natural formation of coke on the catalyst is fortunately very slow at
typical Platforming operating conditions. As discussed previously, coke formation does
increase significantly as Platforming Unit pressure and hydrogen circulation are
decreased, and/or temperature (octane) is increased. These are all changes that would
favor further aromatic condensation to coke. One other operating variable that was shown
to have a significant effect on catalyst deactivation (coke formation) was naphtha feed end
point. As the feed end point approaches 204C, increased levels of naturally occurring
polycyclic aromatics are carried with the naphtha. Since these compounds are still
present at ppm levels even at 204C naphtha end point, the absolute amount will probably
vary significantly with crude type and with fractionation efficiency. Since they are direct
coke precursors, these compounds can be considered as a catalyst poison. Once
deposited on the catalyst, they can only be removed by regeneration.
a. Possible Mechanical Problems
a.
204C is a critical temperature regime for the naphtha cut point. Above this end
boiling point (based on an ASTM D-86 distillation), the concentration of polycyclic
aromatics in the feed naphtha will increase rapidly. UOP does not recommend
operation above this end boiling point.
b. Methods of Detection
Measure the ASTM D-86 end point of EACH FEED STREAM to the unit or
hydrotreater. In some instances where blends of various feed types are used, a GC

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or True Boiling Point endpoint may better indicate a "tail" not picked up by the ASTM
endpoint.
c. Process Symptoms
The effect of more rapid coke deposition will be to increase the coke content of the
spent catalyst. In turn, this may affect the operation of the regeneration section,
which should be kept at all times within the constraints of the General Operating
Curve.
d. Suggested Operational Response
Analyze EACH FEED STREAM for ASTM D-86 end point once per shift and adjust
the fractionation to maintain each stream's end point below 204C. Maintain
sufficient reflux to minimize "sloppy" end points on all appropriate columns.
e. Possible Sources
As the Platforming Unit feed is coming from multiple refinery sources (straight run
naphtha, hydrocrakate, coker naphtha), EACH FEED STREAM should individually be
analysed for compliance with the 204C and point limitation. Blending of a high end
point stream with a low end point stream will mask" the high boiling fraction of the
heavy stream. The polycyclic aromatics will still be present, but may not be
indicated or detected by the ASTM D-86 end point.
f. Possible Mechanical Problems
There are no known mechanical consequences.
15.1.4

Cause and effect table

The following table summarises the theoretical effect on the unit performance of each
independent process variable separately.

Effect of process variables

Increased

RONC

Reformate yield

Coke deposit

Pressure

Temperature

Space velocity

H2/HC ratio

Sulfur content

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Nitrogen
content

EBP

IBP

NOTE : EBP : End boiling point ; IBP : Initial boiling point

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Troubleshooting

Process Symptom
1. Low Reactor T

Possible Cause

Operational Response

Charge stock less naphthenic

None

Sulfur contamination

Eliminate source

Do not increase reactor inlet

temperature (see 15.1.3.1.d
and note)

2. High Reactor T

3. Low H2 Purity, Production

Metals contamination

Eliminate source

High chloride on catalyst

Reduce chloride injection

High water in unit

Reduce water injection and

eliminate source of excess
water

Bad temperature indicator

Repair or replace

Charge stock more naphthenic

None

Nitrogen contamination

Eliminate source

Charge stock less naphthenic

None

Sulfur contamination

Eliminate source

Do not increase reactor inlet

temperature (see 15.1.3.1-d
and note)

Excessive chloride injection

Reduce chloride injection rate

Metals contamination

Eliminate source

Water contamination

Eliminate source

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4. Low Reformate Yield

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Operational Response

Charge stock less naphthenic

None

Sulfur contamination

Eliminate source

Do not increase reactor inlet

temperature (see 15.1.3.1 d
and note)

5. High Coking

6. High Reactor P

7. Low Reactor P

8. Loss of Chloride Injection

High chloride

Reduce chloride injection

High water

Reduce water injection and

eliminate source of excess
water

Low H2/HC ratio

Increase recycle rate

Charge stock highly paraffinic

None

Internal screens plugged

Shutdown and clean reactors

Excessive coke levels

Eliminate source of coke

Bad pressure indicator

Repair or replace

Loss of catalyst bed

Shutdown and repair reactors

Bad pressure indicator

Repair or replace

Pump stops or valve closed

Restart or line up

Suction or discharge check

stuck

Stop pump and repair ball

check

Note : Suspected causes of operating problems should be confirmed by analysis or otherwise

before action is taken, except in extreme or emergency cases.
Feed Crossovers
Occasionally, feed other than naphtha will be accidentally charged to the Platforming unit.
Some typical feed crossovers would be whole crude or leaded gasoline or Platformate
instead of naphtha. The process symptoms would be low reactor delta T, low H2 purity, low
H2 production, low Platformate yield and excessive coking. The operational response is to
eliminate the feed crossover and restore naphtha feed to the unit as soon as possible.

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15.2 DEBUTANIZER SECTION

The Debutanizer T-1301 is used to control the vapor pressure of the Platformate by
fractionating a predetermined amount of C4's (butanes) overhead.
Analytical results on the overhead and bottoms products are generally used as basis to
adjust the Debutanizer operation, i.e., changes to reboiler duty, and sensitive tray (N8)
temperature (cutpoint between LPG and platformate).
The feed temperature to the Debutanizer T-1301 is not directly controlled, as it results from
the heat exchange in the Feed-Bottoms Exchanger E-1306 A/B/C/D. In normal operation it
is important that the manual by-pass (on the hot side) of this exchanger be fully closed in
order to:
maximize heat recovery in the exchanger,
prevent from having a high vapor pressure product (platformate) to be sent to storage
at a high temperature.

a. Debutanizer Overhead

The Debutanizer overhead pressure is controlled by degassing vapor from the

overhead Receiver D-1303. The pressure has an effect on both LPG product and
stabilized reformate properties. An increase in pressure increases naphtha vapor
pressure while maximizing the recovery of LPG. The Debutanizer overhead
pressure should be controlled at approximately 9.8 barg in normal operation.

The temperature of the rectification section is controlled by net LPG production.

Temperature controller 013-TIC-027 adjusts the setpoint of the LPG product flow
controller 013-FIC-010 to maintain a constant temperature between trays N7
and 8. This temperature controls the end point of the LPG product. An increase
in the setpoint of controller 013-TIC-027 shall increase the LPG product flowrate
and consequently increase both the end point of the LPG and the initial boiling
point of the stabilized platformate product.

b. Debutanizer Bottom
The reboiler is manually adjusted (by the setpoint of the condensate flow controller
013-FIC-009) to perform the required cutpoints and separation between LPG and
stabilized platformate. Increasing this duty will increase the separation between the
two products (reducing both C4 minus content in platformate and C5 plus content in
LPG).
c. Water Wash Procedure
Nitrogen from Naphtha feed and chlorides combine to form ammonium chloride salts
which deposit in the debutanizer feed / bottoms exchanger, on column trays and in
the overhead system.
The following procedure is prescribed for the removal of chlorides salts in the
debutanizer tower while remaining on line.
1.

Prepare tower
a. Lower reboiler temperatures from 230C to 150C
b. Reduce tower pressure to allow for rapid water vaporization

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2.

Water injection and washing

a. Turn off the overhead reflux pump
b. Inject water at the top of the debutanizer at rate of 2 to 4 LV%
of the tower feed for 30 minutes.
c. When a 80-90% hydrocarbon level has accumulated in the
overhead receiver, begin injecting water downstream of the
reflux control valve at a rate of 2 to 4 LV% of tower feed for 30
minutes. Start reflux pump for this 30 minute period.
d. Repeat steps a, b and c until analysis show that most of the
salts have been removed. Be sure to alternate overhead reflux
pumps at each repeat.

3.

return to normal operation

Returning to normal operating conditions will cause large amounts of water

in the tower to pass overhead. This will complete the washing of overhead
lines and exchangers.
a. Increase reboiler temperature to normal operating level at
28C/h. Raise tower pressure to its normal operating level
overs a 30 minute period
b. Change reflux pumps every 15 minutes
c. Drain all low points every 15 minutes. Including all instruments
taps, especially at flow and pressure transmitters.
d. Line tower out at normal design conditions.
Each refiner should determine his acceptable water / chloride
contamination level in the reformate product tank. It may be better to run
the product to slop during the washing procedure.

During shutdown of the unit, steaming out is sufficient to clean the equipment of any
ammonium chlorides salts which may be present.

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15.3 OFF-SPEC IFICATION PRODUCTS HANDLING

15.3.1

LPG
They are coming from the Debutanizer Receiver D-1303 and they are sent to the Light LPG
Recovery Unit (Unit 016). In case of misoperation of the Debutanizer, they are sent to tank
TK-5102.

15.3.2

Platformate
The platformate is normally sent to storage for blending. In case of off-specification product
(misoperation of the Debutanizer resulting in too high a vapor pressure of the platformate,
for instance), the platformate can be routed to the light slop tank TK-5604 after cooling in
the Debutanizer Bottoms Trim Cooler E-1305 A/B (connection to slop line upstream of
battery limit).

15.3.3

Off-specification handling table

Off Spec product

Flowrate (t/h)
(1)

Origin

Normal
destination

Reformate

92.2

T-1301
Bottoms

TK-5107

Unstabilized LPG

3.22

D-1303

TK-5212
A/B/C/D

Notes :
1. Normal flowrate at 100% capacity (design)

Alternate
destination
TK-5604
(Light Slops Tank)
TK-5102

Actions

Manual valves

Manual valves

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15.4 TYPICAL EXAMPLE FOR COLLECTING DATA & QUALITY CONTROL

To assist the personnel which is operating the Platformer Unit, the following table
summarizes the main parameters (flows, temperatures, pressures, etc.) required for a
good monitoring of the unit.
This table, to be used as a logsheet, indicates for each parameter :
the measurement tag number,
its description,
The present log sheet (a level 1 log sheet) is intentionally limited in terms of parameters to
be collected. The purpose is to identify quickly the correct or incorrect operation of the
whole unit, by just selecting the key parameters in each section of the unit and comparing
with material balance given in Chapter 1 and key parameters values given in 15. By
collecting the following parameters, the operator will have an overall view of the unit, and
any change in unit performance that is not accounted for a corresponding change in unit
operating variables may be readily recognized and corrective action taken, if necessary.
In case DQR operation team needs more details on each section, it is suggested that
additional log sheets (level 2 log sheets) be developed on site, which, by evidence, will
include more records. This is not the purpose of the present Unit monitoring log sheets.

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CHAPTER 7

NORMAL SHUTDOWN

CONTENTS

1.

SUMMARY OF SHUTDOWN

2.

NORMAL SHUTDOWN PROCEDURES

3.

CATALYST UNLOADING

4.

RECOVERY PLUS NORMAL SHUTDOWN

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The following shutdown procedure covers a normal planned complete shutdown such as
would be required for a catalyst change and/or the periodic cleaning and inspection of
vessels.
The operations described in these sections must overlap to some extent. The extent to
which these operations may be conducted simultaneously will depend upon the
availability of operating personnel.

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1. SUMMARY OF SHUTDOWN

Shutdown Continuous Catalyst Regeneration Section

Reduce Heater Temperatures and charge rates

Cut out Platforming reactor charge

Shutdown Platforming separators

Shutdown all Platforming reactor heaters

Shutdown and block in debutanizer

Shutdown recycle compressor

Depressure and purge the reactor system

Isolate system and install necessary system blinds

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2. NORMAL SHUTDOWN PROCEDURES

When a normal, planned shutdown of the Platformer is to be executed, do the following :
1. Notify operating foreman and other units of shutdown
a. Notify foreman and other operating units concerned (such as Naphtha
Hydrotreater, the Crude Unit,) as to exact time when the shutdown
operations will start. Changes in fuel gas composition, steam requirements,
etc., may affect other units.
Alternative hydrogen supply has to be used to maintained Units 12 in operation.
b. Pumpers and others who might be concerned with handling charge and
product streams should also be informed of the coming change.

2. Shutdown the Continuous Catalyst Regeneration Section

a. Shutdown the Continuous Catalyst Regeneration section as outlined in the
manual for that section. This will stop catalyst flow through the Platforming
reactors.
b. Isolate the CCR section from the Platforming reactor section by closing the
appropriate valves at the Catalyst Collector and at the Reduction Zone.

3. Reduce heater temperatures and charge rates

a. Start reducing the Platforming reactor inlets to 455C at 15-30C per hour
(using temperature controllers 013-TIC-001, 013-TIC-003, 013-TIC-005 and
013-TIC-007).
b. At 482C reactor inlets, begin reducing the feed rate stepwise to half the design
rate (i.e. around 50 t/h at 013-FIC-003). LHSV must remain greater than 0.75.
Strive to reach 455C on the Platforming reactor inlets simultaneously with the
charge reduction rate.
c. As the reactors inlet temperatures are lowered, the octane of the Platformate
will gradually decline. Reroute the Debutanizer (T-1301) bottoms to slop in
order not to send low octane reformate in the blending section.

4. Cut out Platforming reactor charge

a. At 455C stop charge to the unit and block in valve 013-FV-003. Reroute the
NHDT Splitter (T-1202) bottoms product to the Sweet Heavy Naphtha tank TK5104, or shutdown the NHDT Unit (Unit 12) if necessary (alternative hydrogen
supply have to be used to maintain units 012 in operation).
b. Discontinue water and organic chloride injection (by stopping pumps 012-P1304 A/B and 012-P-1305 A/B).

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c. Adjust Platforming heater firing to hold 455C and maintain maximum recycle
gas rate for at least one hour to sweep all residual hydrocarbons from the
catalyst.
d. When sweeping of the catalyst is complete, cool the Platforming reactor inlets
to 400C (013-TIC-001, 003, 005 and 007).

5. Shutdown the Platforming separators

a. Gas production will cease as soon as hydrocarbon stops passing over the
Platforming catalyst. At that point the offgas lines from the separator to other
units and to fuel gas must be blocked in to maintain system pressure for
continued recycle compressor C-1301 operation. Block in the following valves :
Vent valve to flare : 013-PV-004A,
Net gas to FG valve 03-PV-004B and block valve between Unit 013 and
Make Up compressor section drum, after having shut down the
compressors Make Up compressors C-1202 A/B/C.
Make Up compressors (Unit 012) must be shutdown as per normal procedure
(refer to manufacturers instructions).
b. When liquid has ceased flowing into the Platforming separators, stop any
pumps P-1301 A/B on the separator liquid outlet stream and block in the level
control valves 013-LV-002 A/B. For example, when the liquid level reaches a
low level in the Separator D-1301, stop pumps P-1301 A/B and block them in at
suction and discharge. Line up the remainder of the liquid to the closed drain.
c. Drain all hydrocarbons from the separators, the Platforming Unit charge line
downstream of the flow control valve (013-FV-003), and all low points in the
system.

6. Shutdown all Platforming reactor heaters

a. After the reactors have been swept for at least one hour at 455C and then
cooled to 400C, shutdown all reactor heaters. Block in fuel lines to each
burner.
b. Continue recycle gas circulation to cool the reactor bed outlets to less than
95C at 30C per hour. If the catalyst is to be handled during the shutdown, the
catalyst beds should be cooled to less than 65C and preferably less than
55C.
In order to cool down faster, maximize combustion air rates (fully open burner
registers) and open stack damper (013-HV-620) as much as possible.
Likewise, the higher the system pressure is maintained (do not exceed design),
the faster the cool down will proceed.
NOTE :
If catalyst is to be regenerated or if the shutdown is only of a temporary nature,
do not cool below 400C. Following heater shutdown, circulate only long
enough to cool the heater tubes (15 to 20 minutes) and then stop the Recycle
Compressor C-1301. Then, block in the compressor C-1301 suction and
discharge valves as well as vent valve to flare (013-PV-004A) and separator D1301 off-gas line to Make Up compressors C-1202 A/B/C and to FG Network
(013-PV-004B) to hold the system pressure.

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Caution: Prolonged gas circulation (greater than eight hours) should be

avoided in order to preserve the catalyst properties.

7. Shutdown and block in the Debutanizer

Once all of the liquid from the Separator (D-1301) has been sent to the
Debutanizer, prepare to shutdown this column (if needed by the length and nature
of shutdown).
a. Discontinue sending overhead material (LPG) to storage and place the column
on total reflux. Gradually decrease reboiler flow (013-FIC-009) until the column
has cooled down. If necessary, fuel gas or nitrogen can be used during the cool
down to maintain the column under a positive pressure.
b. The overhead receiver D-1303 should be emptied by pumping the liquid back
into the column (using reflux pump P-1302 A/B).
c. The bottom level in the tower should be pressured out of the unit to the slop
tank TK-5107.
d. The tower overhead receiver and reboiler may be steamed out to gas free the
equipment after the tower has been emptied of oil and depressed to the offgas
and flare header. Normal refinery practice for purging and washing of this
equipment should be followed.

8. Shutdown Recycle Compressor C-1301

a. When reactor outlet temperatures have cooled down to the desired level,
shutdown the Recycle Compressor C-1301 (according to the Manufacturers
instructions) and take it off line.
b. To guard against the danger of getting oil or moisture into the compressor,
purge it out with nitrogen rather than evacuating. Any moist air that gets into the
compressor will combine with deposits to form corrosive compounds. Recycle
gas may be removed from the machine by blocking off at the suction and
discharge valves. After depressuring, purge with nitrogen through the machine
to the vent line.
c. Leave the machine blanketed with a slight positive pressure of nitrogen to
prevent any moist air from getting into the compressor.
d. Same for Make Up compressors C1202 A/B/C.

9. Depressure and purge the reactor system

Once the Recycle Compressor (C-1301) is shutdown, and if the Reactors and/or
any vessels will be entered during the shutdown, do the following :
a. Depressure the Platforming reactor system into the fuel gas system until the
fuel gas system pressure is reached. Do this using valve 013-PV-004 B
downstream the RECOVERY PLUS system.
b. Close the valve to the fuel gas and bleed the balance of the system pressure
off to flare (manual valve downstream valve 013-PV-004B). Also do this from
the Separator D-1301, using 013-PV-004A.
NOTE: During depressuring, evacuation and purging, normal flow through the
catalyst beds should be used. This reduces the danger of catalyst
displacement in the reactors.

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c. Isolate the reactor section from the RECOVERY PLUS system and
Debutanizer sections and connect the steam ejector J-1301 to the Separator D1301.
d. Start MP steam to the ejector J-1301 and evacuate Platforming Unit to at least
500 mm of mercury vacuum. Then, isolate the systems and stop the MP steam
to the ejector.
e. Break with nitrogen - injected into the discharge side of the Recycle
Compressor C-1301 - to 0.35 kg/cm2 (using the normal nitrogen 1 injection
line).
f. Repeat evacuation and purge twice.
NOTE: Make sure all dead legs are properly purged. As there is a CCR unit
attached be sure to keep the recycle gas purge line to the reduction zone and
to the catalyst collector closed during evacuation. During purging open the
block valves slightly so these areas are properly purged.
g. Check for explosive gas mixtures at various points in the unit. If any readings
are higher than the upper limits set by the refiner safety department (generally
O2 content < 0.5 vol%) repeat step f. Also check block valves which separate
this section of the unit from others that still contain hydrogen and/or
hydrocarbon.
h. The reactor section is now ready for insertion of the necessary blinds.

10. Isolate system and install necessary system blinds

a. Install blinds to isolate the Platforming reactor section from the remainder of the
unit. Exercise care while installing the blinds to ensure the catalyst is not
exposed to moisture.
b. If possible, establish a small nitrogen purge into the reactor section.
c. Install additional blinds at the battery limits and between equipment as
necessary for safety.

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3.

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CATALYST UNLOADING
NOTE: UNDER NO CIRCUMSTANCES SHOULD AIR BE PULLED THROUGH THE
PLATFORMING REACTORS SINCE SPONTANEOUS COMBUSTION IS POSSIBLE.
WOOD, CANVAS OR OTHER COMBUSTIBLE MATERIALS SHOULD NOT BE USED
IN THE CATALYST DUMPING OPERATION BECAUSE OF THE DANGER OF FIRE.
IN ADDITION, THE GENERAL AREA AROUND THE REACTORS SHOULD BE FREE
OF COMBUSTIBLE MATERIALS.
a. It is preferable to establish a nitrogen purge on the reactor stack section to prevent
air from entering into the reactors.
b. Do not open the reactors at the top and bottom simultaneously as this can set up a
natural chimney draft effect that will pull air through the reactors.
c. Be sure that several CO2 extinguishers are available and provide a small water
hose with a spray nozzle attachment.
d. Catalyst is removed from fixed-bed Platforming reactors through two 4-inch
withdrawal nozzles located on the bottom of the reactor stack. The blind flange is
removed from the nozzle and a dumping spout is connected. A slide valve in the
dumping spout allows the flow of catalyst to be stopped as necessary for catalyst
drum changing, etc. The catalyst support plate in the unloading nozzle is removed
through the opening in the dumping spout.
On units equipped with a Continuous Catalyst Regeneration section, the intereactor catalyst transfer pipes will permit dumping the catalyst from all reactors at
the bottom of the stack without any additional equipment. The catalyst can be
removed from the reactors via lift engager #1 bottom head if there is enough
clearance below the vessel for a valve and 55 gallon drum.
If unregenerated catalyst is to be unloaded, the reactors must be kept under a
nitrogen blanket so the spent catalyst does not contact air. Any personnel who
enter the reactors must be equipped with the proper safety equipment specified for
entry into a contaminated atmosphere (refer to chapter 10 - SAFETY).
e. If the catalyst becomes bridged in the unloading nozzle or is not free flowing,
break the plug with a blast of nitrogen.
f. Use only clean, dry metal drums for unloading and if possible dump directly into
drums. It is best to screen the catalyst after it has had time to cool to ambient
temperature. Each drum should be either purged with N2 during unloading or a
piece of dry ice should be placed at the bottom of each drum. Do not seal the
drum air tight since this could result in sudden rupture of the drum should
combustion occur. Burning of catalyst in the drums is not serious and can be
quickly extinguished with carbon dioxide or nitrogen.
g. It is expected that some "sparking" of the pyrites will take place. All workmen in the
area must be supplied with face and eye protection. In addition, they should wear
long sleeve shirts with the collars and cuffs tightly buttoned.
h. If ignition of pyrites takes place inside a reactor, increase the N2 purge to
maximum.
i. Return spent Platforming catalyst to UOP for metals recovery. This return will
normally be made in the original empty Platforming catalyst drums.
j. After the catalyst drums have cooled, the drums should be sealed with the proper
cover and rubber gasket to keep out moisture.
k. With the catalyst removed, the reactors are now ready for cleaning and internal
inspection.

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4. RECOVERY PLUS NORMAL SHUTDOWN

Refer to Vendor Operating Manual for normal shutdown procedures (Appendix 8474L013-A5016-4110-001-001 in chapter 6).

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CHAPTER 8

EMERGENCY SHUTDOWN PROCEDURES

CONTENTS

1.

GENERAL EMERGENCY SHUTDOWN

2.

EMERGENCY FUNCTIONS PHILOSOPHY

2.1

CONTROL & SAFETY SYSTEMS PHILOSOPHY

2.2

EMERGENCY SHUTDOWN SYSTEMS OF THE PLATFORMING UNIT

3.

PROCESS FAILURES

3.1

LOSS OF FEED

3.2

LOSS OF MAKE UP COMPRESSORS (UNIT 012)

3.3

LOSS OF RECYCLE COMPRESSOR

3.3.1

Total loss of recycle gas flow

3.3.2

Partial loss of recycle gas flow

3.3.3

Planned repairs which require stopping the recycle compressor

4.

UTILITY FAILURES

4.1

INSTRUMENT AIR FAILURE

4.2

COOLING WATER FAILURE

4.3

HP STEAM FAILURE

4.4

BOILER FEED WATER FAILURE

4.5

ELECTRICAL POWER FAILURE

4.6

LOSS OF REFRIGERANT

4.7

FUEL GAS FAILURE

5.

MAJOR UPSETS

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1. GENERAL EMERGENCY SHUTDOWN

Emergencies which occur in the Platforming unit must be recognized and acted upon
immediately. The operators and supervisory personnel should carefully study in
advance, and become thoroughly familiar with, the proper steps to be taken in such
situations. Some of the emergency conditions described here will not only result in a unit
shutdown, but if the situation is not handled properly, can lead to serious damage to the
catalyst and equipment.
Automatic shutdown systems have been developed to protect equipment against
process failure. In case abnormal conditions are detected (low flowrate, high
temperature, ) an automatic sequence is started to put the unit in a safe state (1).
It is strongly recommended that the emergency procedures and the automatic shutdown
systems be understood by all persons involved in the operation. In general, the objective
of the emergency procedures is to avoid damage to equipment and catalyst.
ln addition, specific rules cannot be made to cover all situations which might arise.
Therefore, the following procedures cover only those emergency situations which are
the most common and, for the most part, only the immediate steps to be taken are
listed.
Note (1) : Refer to the enclosed Cause & Effect charts of the Platforming unit

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PROCESS FAILURES

2.1 LOSS OF FEED

Loss of hydrotreated naphtha feed is detected by the low flow alarm 013-FAL-003. In
this case the operator shall reduce the heaters H-1301 to 1304 duty to compensate for
this loss of feed and avoid overheating the material in the heaters tubes and the tubes
themselves.
2.2 LOSS OF MAKE UP COMPRESSORS (UNIT 012)
In case of Make Up Compressors (C-1202 A/B/C) failure, the pressure control system of
Unit 013 will have the following effect :
Opening of the Net gas to fuel gas valve 013-PV-004B,
The Separator D-1301 off gas valve to flare (013-PV-004A) will be fully open.
2.3 LOSS OF RECYCLE COMPRESSOR
2.3.1

Total loss of recycle gas flow

In order to protect catalyst from coking, in case of loss of recycle gas flow, detected by
low low flow switches 013-FXALL-004 A/B and C (2 of 3 voting system), the following
will occur automatically :
Closure of the shutoff valves on fuel gas to the heaters H-1301 to 1304 (013-XV603 / 605), and opening of the bleed valve 013-XV-604 to flare (the pilots will stay
lit),
Closure of the naphtha feed to the combined feed naphtha exchanger valve (013XV-011) and 013-FV-003.
In parallel, the operator should perform the following actions 1 and 2 as quickly as
possible to protect equipment and catalyst :
In order to cool down the heaters faster, maximize the air combustion rate (fully open
burners registers) and fully open stack damper (013-HV-620).
1. Introduce steam into the heater boxes for its cooling effect.
2. Block in the separator off-gas valve 013-PV-004B. Shutdown the Make Up
Compressors and block in the manual valves to C-1202 A/B/C suction so that
system pressure will be maintained.
3. Follow the normal shutdown procedure in blocking in the separator D-1301 and
Debutanizer. Switch the NHDT Splitter (T-1202) bottoms to storage. Be sure to
stop organic chloride and water injection to the combined feed.
4. Restart the compressor if possible, or find out what is wrong. Remember that with
no flow through the furnace, the material in the heater tubes may become
excessively hot, and if it is put through the reactors, it could result in deactivation
of the catalyst, Thus, when a compressor is started after such a shutdown,
immediately check the reactor inlet temperatures. If they are 15C higher than the
normal operating temperature (reactors inlet temperatures before shutdown), stop
the recycle flow and continue cooling the heaters with purging steam until the
reactor inlet temperatures, with recycle flow, are below 495C

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5. When the compressor C-1301 is again in service, proceed with a normal startup.
Remember that normal operating pressure at the reactor products Separator D1301 is required for oil cut in (i.e., 013-PIC-004 reading = 2.5 barg).

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Partial loss of recycle gas flow

In case the recycle gas flow drops to a value higher than the shutdown threshold for
switches 013-FXALL-004 A/B and C, continued operation is possible provided that the
following actions are done immediately to protect the catalysts :
1. Lower the heater outlet temperature 10-15C for all reactors.
2. Reduce the reactor charge rate (013-FIC-003) to that permissible with the
remaining flow of recycle gas. In particular, hydrogen to hydrocarbon ratio must be
checked to be sure it is above the minimum required for operation (i.e. above 3.4)
Temperature adjustments can be made for continued operation after laboratory or
other tests indicate changes are required.

2.3.3

Planned repairs which require stopping the recycle compressor

1. Decrease reactor inlet temperatures to 480C. Lower the charge rate to one-half
rate (i.e. around 50 t/h at 013-FIC-003). LHSV must remain greater than 0.75.
Decrease reactor inlet temperatures to 455C. Cut out charge. Maintain gas
circulation for one hour at 455C inlet temperatures. Cut heater fires completely.
2. For this low pressure unit, it may be advisable to increase the unit pressure before
the shutdown. The purpose of the increase in pressure is to assure sufficient
hydrogen partial pressure for startup with consideration given for gas leakage
during the shutdown period.
3. Continue to circulate recycle gas while reducing reactor inlets to 370C.
4. Stop the Recycle Compressor C-1301.
5. Make the required repairs. Follow normal startup procedures (refer to Chapter 5).

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3.

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UTILITY FAILURES

3.1 INSTRUMENT AIR FAILURE

The following events should occur automatically as the pneumatic operated valves go to
their safety position (fail close or fail open) :
1. The fuel gas and pilot gas shutoff valves to all fired heaters will fail closed. The
common stack damper 013-HV-620 will stay in its current position (with a tendency
to open).
2. The CCR should go into a Hot Shutdown due to any one of a number of things. All
valves will go to a fail safe position, except for B-type valves. The B-type will fail in
their current position and can be manually closed.
3. Charge to the Platformer would stop as valve 013-FV-003 fails in the closed
position.
4. The Recycle Compressor C-1301 should continue to operate.
5. The level control valves for all vessels and Debutanizer bottom will fail closed and
these levels will begin to rise rapidly.
6. The net gas valves 013-PV-004A (to flare) and 013-PV-004B (to FG) from the
Platformer will fail closed to maintain the unit pressure in the Reactor section.
7. The Debutanizer overhead receiver net liquid control valve (013-FV-0110) will fail
closed and the reflux control valve (013-FV-011) will fail open placing the column
on total reflux. The overhead pressure (net overhead vapor) control valve (013PV-012) will fail closed to maintain column pressure.
8. Other pump minimum flow line control valves will fail open.
Action to be taken by Operators :
TRY TO RESTORE THE INSTRUMENT AIR SUPPLY AS QUICKLY AS POSSIBLE
1. Verify that the fired heaters H-1301 to 1304 have shutdown and the fuel gas and
pilot gas tight shutoff valves have closed. Block in the fuel gas at the
burners/pilots.
2. Block in the feed naphtha block valves of 013-FV-003. Stop the injection of organic
chloride and condensate if these were going before the instrument air failure
(pumps P-1304 A/B and P-1305).
3. Verify that the Recycle Compressor C-1301 has continued to operate. If C-1301
has also shutdown for some reason, see procedure for loss of Recycle
Compressor ( 2.3).
4. Stop the Separator bottoms pump (P-1301 A/B) and block in its discharge valve.
Drain liquid to the closed drain if necessary to lower the level in the Separator (D1301) to a safe level. The liquid levels in other drums can be lowered in the same
manner if necessary.
5. Watch other drum levels and use control valve bypasses as necessary to control
levels in safe ranges.
6. Conduct the remainder of the shutdown according to the normal shutdown
procedures as much as possible (refer to Chapter 7).
3.2 COOLING WATER FAILURE
In the event of a cooling water failure, a complete shutdown of the unit is required. Since
most of the heat is removed with aircoolers, the shutdown can be conducted in a

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controlled and smooth manner, except stop heaters H-1301 to 1304 and charge to the
unit immediately. However, the time for the shutdown is limited due to the loss of cooling
for the lube oil systems of the compressors, the loss of interstage and spillback cooling
of the Make Up compressors (unit 012), the loss of cooling in the condensing turbine
which drives the Recycle Gas Compressor.
The Recycle Compressor C-1301 has to be shutdown (or will automatically trip) when
the discharge temperature becomes too high (refer to 2.3 for consequences of a loss
of Recycle Compressor).
For a partial cooling water failure it may only be necessary to reduce the naphtha feed
rate to the unit to the extend required to maintain reasonable receivers and products
temperatures downstream of water cooled exchangers.

3.3 HP STEAM FAILURE

The following will happen simultaneously.
The steam driven compressor C-1301 will stop (refer to 2.3 for consequences of
a loss of recycle gas),
The reboiling of the Debutanizer T-1301 will stop.
Stop the Platforming unit according to the normal shutdown procedure (refer to Chapter
7).
3.4 BOILER FEED WATER FAILURE
Boiler feed water (BFW) feeds the steam generation in heaters H-1301 to 1304
convection zone. In case of failure of BFW supply from battery limit, the level in the
Steam Disengaging Drum will decrease and will imply the stop of the Circulating Water
Pumps P-1303 A/B.
The loss of the Circulating Water Pumps, detected by low low flow switches 013-FSLL613 A/B (2 of 2 voting system), will automatically partially stop the heaters H-1301 to
1304 (after a time delay) by :
Closure of the shutoff valves on fuel gas to the heaters H-1301 to 1304 (013-XV603 / 605).
Opening of the bleed valve 013-UV-604 to flare (the pilots will stay lit).
Stop the Platforming unit according to the normal shutdown procedure (refer to Chapter
7).
3.5 ELECTRICAL POWER FAILURE
In case of electrical power failure all pumps, air coolers and will trip. A sustained power
failure will require a complete shutdown of the unit, using the following guidelines :
a. Block in the feed to the Combined Feed Exchanger E-1301 (by closing 013-FV003). Reroute the NHDT Splitter (T-1202) bottoms to the storage area as
necessary.
b. Shutdown all fired heaters and block in the fuel gas supply to each burner.
c. Keep the Recycle Compressor C-1301 (turbine driven) in operation to cool down
the reaction section.
d. The separator D-1301 level (013-LIC-002) will increase if the Separator Pumps P1301 A/B are shutdown. Lower this level to the closed drain, if necessary. This

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level should not be allowed to increase high enough to cause liquid to accumulate
in the Recycle Compressor suction line.
e. The overhead pressure for the Debutanizer will increase by the effect of loss of the
reflux pumps P-1302 /AB (while the reboiler E-1307 is still in service).
In this case, the operator shall reduce and cut of the reboiler E-1307 (closure of
the HP steam supply to the reboiler).
The Debutanizer column will cool down automatically.
f. Proceed with an orderly shutdown of the unit by following the normal shutdown
procedures as much as possible (refer to Chapter 7).

3.6 LOSS OF REFRIGERANT

LOSS OF REFRIGERANT MAY BE A DANGEROUS SITUATION! The system should
be shut down immediately, and the reason for the loss located. A leak to the atmosphere
is hazardous and appropriate precautions should be made. The Lean Oil and Net Gas
should be stopped and bypassed, and the system should be depressurized if the leak
cannot be fixed immediately.

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3.7 FUEL GAS FAILURE

In case of fuel gas failure, heaters H-1301 to H-1304 will automatically shutdown due to
low low pressure detection at burners and pilots lines.
The reactors temperatures and the Debutanizer feed temperature will drop, thus leading
to off-spec production.
The naphtha feed to the unit has to be stopped and the recycle gas circulation should be
maintained. If the fuel gas cannot be restored rapidly, proceed with a normal shutdown.

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4.

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MAJOR UPSETS
The following procedures only apply to those situations which are deemed controllable
to the extent that the safety of the refinery personnel is in no way compromised. Not all
such emergencies can be handled in the same manner; however, in general TRY TO
ELIMINATE THE HYDROCARBON (FUEL) TO THE FIRE OR LEAK by isolating the
affected area (and depressuring to the flare) as much as possible.
In case of explosion, fire, line rupture or serious leak, do the following (if possible) :
1. Use the Emergency Shutdown switch 013-HS-001A to shutdown the fired heaters
H-1301 to 1304. The outside operator should verify that the fuel gas to the heaters
stops if he can reach the heater safely. He should also block in the fuel gas to
each burner, if possible.
2. Stop the naphtha charge to the Platformer by closing and blocking-in at 013-FV003. Wherever the fire, leak, or line rupture is located, try to isolate that section of
the unit from all other sections.
3. If possible allow the Recycle Compressor C-1301 to operate for a few minutes
after the fired heaters H-1301 1304 are shutdown.
4. Shutdown all other fired heaters in the affected area with their emergency
shutdown switches. Block in the fuel gas to each burner, if possible.
5. After a few more minutes of operation following the H-1301 to 1304 shutdown,
stop the Recycle Compressor C-1301.
6. Use the separator off-gas valve 013-PV-004A to depressure the unit to the flare.
7. If the leak or line rupture is in a fired heater, introduce snuffing steam to the heater
and try to eliminate the source of the fuel for the fire. Do not close the heater
damper (013-HV-620).
8. When the unit has depressured to the flare, purge the unit with nitrogen by
introducing it at the discharge of C-1301 if possible. Do not evacuate the unit.
9. Follow other normal shutdown procedures as much as possible (refer to Chapter
7).

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CHAPTER 9

SAFETY EQUIPMENT AND PROCEDURES

CONTENTS

1.

PRESSURE SAFETY DEVICES

2.

ALARM SETTINGS

3.

TRIP SETTINGS

4.

TRIP SYSTEM CHART

5.

CAUSE AND EFFECT DIAGRAMS

6.

MATERIAL HAZARD DATA SHEETS

7.

SAFEGUARDING MEMORANDUM

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1. PRESSURE SAFETY DEVICES

Refer to the following documents:
8474L-200-NM-0006-001

Flare Discharge Summary NHT / CCR / ISOM

In Tools specifications of safety valves and
rupture disk

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2. ALARM SETTINGS
Extract from I/O list of all instruments with alarm and alarm values will be attached in this
paragraph

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3. TRIP SETTINGS
Extract from I/O list of all instruments with trip function will be attached in this paragraph

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4. TRIP SYSTEM CHART

Refer to Cause and Effect Chart attached in Chapter 9.5 and Trip Setting list attached in
Chapter 9.3.

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5. CAUSE AND EFFECT DIAGRAMS

Refer to the following document:
8474L-013-DW-1514-201

Cause and Effect Chart NHT Unit 013

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6. MATERIAL HAZARD DATA SHEETS

MSDS of Chemicals and catalyst will be attached in this paragraph.

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7. SAFEGUARDING MEMORANDUM
HAZOP Action 2140: Water wash procedure is described 15.2 of Chapter 6.

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CHAPTER 10

INSTRUMENT DATA

CONTENTS

1.

CONTROL VALVES AND INSTRUMENTS

2.

ORIFICE PLATES

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1. CONTROL VALVES AND INSTRUMENTS

8474L-013-SP-1541-001
8474L-013-SP-1543-001
8474L-013-SP-1546-005
8474L-013-SP-1547-001
8474L-013-SP-1553-002

Control Valves
Pneumatic Ball Valves
Venturi Tubes
Vortex Flowmeters
Electronic DP Flowmeters
Control valves datasheets issued by In Tools
Flow instrument datasheets issued by In Tools

2. ORIFICE PLATES
8474L-013-SP-1546-001
8474L-013-SP-1546-002

Restriction Orifices
Orifice Plates
Orifice plate datasheets issued by In Tools
Restriction orifice datasheets issued by In Tools

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CHAPTER 11

SUMMARY OF MAJOR EQUIPMENT

CONTENTS

1.

EQUIPMENT LIST

2.

LARGE ROTATING EQUIPMENT

3.

HEATERS

4.

OTHER VENDOR INFORMATION

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1. EQUIPMENT LIST
8474L-200-EL-001

POC Project Equipment List

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2.

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LARGE ROTATING EQUIPMENT

8474L-013-A1001-1011-001-014
8474L-013-A1002-1011-001-018

Equipment Filled-In Data Sheets

Compressor C-1301
Performance Curves Compressor C1301

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3. HEATERS
8474L-013-A1001-0110-001-202

Heater Data Sheet H-1301/H-1302/H-1303/H-1304

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4. OTHER VENDOR INFORMATION

Vendor list of instruments with alarm and trip set points of compressors, heaters and important packages
(X-1301)

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CHAPTER 12

ANALYSIS

CONTENTS

1.

SAMPLING AND TESTING SCHEDULE

1.1

Sampling schedules / approved test methods

1.2

Analytical Methods

2.

ON LINE ANALYSERS

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1. SAMPLING AND TESTING SCHEDULE

This section outlines the sample schedule and analytical methods that UOP suggest for
monitoring the feed and product quality. The feed must be analyzed to be certain that it
conforms to the quality of the feed that was used for the design. This is important for
setting the operating severity level and for monitoring the catalyst deactivation rate. The
products must be analyzed to ensure that the unit is producing on grade materials.
1.1 SAMPLING SCHEDULES / APPROVED TEST METHODS
Refer to the enclosed table "Laboratory Analytical Schedule for Process and Utility Units
- Unit 013 - Platformer", hereafter called Table 1.
Certain feedstock and product analyses are required in order to monitor plant
performance. The streams that must be analyzed and typical analyses for those streams
are shown in the second column of Table 1. The list does include all tests that are
needed to assure the feed is suitable charge stock to the unit and all the tests that are
needed to complete a hydrogen weight balance around the plant.
The Table 1 indicates a sampling frequency for each test. This is very subjective and is
intended to give the refiner a rough idea of how much laboratory work will be needed.
With experience, the frequency of the tests may be optimized.
The tests marked "D" (Daily) are tests which should be run frequently primarily to keep
the products on specification. The tests marked "W" (Weekly) are tests which only need
to be run occasionally. These tests will be for monitoring plant performance beyond the
day to day operation and for checking that the feed quality is adequate for maintaining
catalyst stability. The tests marked "on request" are tests that are needed only during
test runs to obtain a hydrogen weight balance on the unit.
The analyses shown include all tests that are part of the guarantee agreements.
The PID for details of sample connections (8474L-013-PID-0021-060) is enclosed in 2
of Chapter 14

1.2 ANALYTICAL METHODS

The "Test Method" column in Table 1 presents the methods recommended for the test.
The methods represent, in UOP's opinion, the best methods for the analysis from an
accuracy, precision, convenience and speed point of view. Cost of special equipment
was also considered for the methods. Alternative methods may be substituted if the test
method is not specified in the guarantee agreements.
The tests labeled UOP are UOP Methods. The ASTM procedures given in the table can
be found in the Annual Book of ASTM Standards, Section 5, Volumes 5.01, 5.02, 5.03
and 5.04 and Section 6, Volume 6.03.

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TABLE 1 - LABORATORY ANALYTICAL SCHEDULE FOR PROCESS AND UTILITY UNITS

Item TAG / type

SCC-1301 / 8-133
(UOP)

PID
013-PID-0021-015

Stream / location
CCR Platforming Feed / 013-FV-003

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UNIT 013 - CCR PLATFORMER

Analysis

Frequency

Test Method

Normal

Start Up

3/D

3/D

API
Distillation
Color
Total Sulfur
Total Nitrogen
Chlorides
Composition (PONA)
Paraffins
Aromatics
PNA
Arsenic
Lead
Water
Bromine Index
Silicones
Fluorides
Copper
relative density
composition
H2S, HCl

ASTM D 4052
or ASTM D 1298
ASTM D 0287
ASTM D 0086
ASTM D 0156
ASTM D 4045
ASTMD 4629
UOP 395
UOP 880
UOP 690
UOP 744
UOP 870
UOP 296 or UOP 946
UOP 350 or UOP 952
UOP 481
UOP 304
UOP 787
UOP 619
UOP 144
UOP 114 or UOP 948
UOP 539
Detector Tube

3/D
3/D
3/D
1/D
1/W
1/W
1/W

3/D
3/D
3/D
1/D
1/D
1/D
1/D

1/M
1/M
On request
1/M
1/M
1/M
1/M
1/D
1/D
1/D

1/W
1/W
On request
1/W
1/W
1/W
1/W
3/D
1/D
3/D

Specific gravity

SCC-1302 / 8-134
(UOP)

013-PID-0021-018

Recycle Gas / C-1301 suction

SCC-1303 / 8-134
(UOP)

013-PID-0021-020

Net Gas / inlet D-1302 A/B

relative density
composition
H2S, HCl

UOP 114 or UOP 948

UOP 539
Detector Tube

1/D
1/D
1/D

3/D
1/D
1/D

SCC-1304 / 8133(UOP)

013-PID-0021-022

Debutanizer bottoms / outlet E-1305 A/B

Specific gravity

3/D

3/D

3/D
3/D
3/D

3/D
3/D
3/D

RON Clear
Color
Composition (PONA)
Paraffins
Aromatics
PNA
Bromine number

ASTM D 4052
or ASTM D 1298
ASTM 0287
ASTM D 0086
ASTM D 5191
or ASTM D 0323
ASTM D 2699
ASTM D 0156
UOP 880
UOP 690
UOP 744
UOP 870
UOP 304

1/D
1/W
3/W

1/D
1/D
1/D

API
Distillation
Reid Vapor pressure

1/W

1/D

SCC-1305 / 8-133
(UOP)

013-PID-0021-024

Debutanizer overhead Liq. / inlet D-1308 A/B

Specific gravity
composition
Residues in LPG
Chlorides

ASTM D 1657
UOP 539
ASTM D 2158
UOP 910

1/D
1/D
1/W
1/W

3/D
1/D
1/D
1/D

SCC-1306 / 8-133
(UOP)

013-PID-0021-026

Debutanizer Off gas / Outlet D-1303

relative density
composition
H2S
HCl

UOP 114 or UOP 948

UOP 539
Detector Tube
Detector Tube

1/D
1/D
3/D
1/D

1/D
1/D
3/D
1/D

SCC-1311 / 15

013-PID-0021-026

Process Waste Water to SWS / D-1303

pH

ASTM D 1293

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2. ON LINE ANALYSERS
Analysers located in the CCR unit are the following:

Item

PID ref.

Datasheet ref.

Analysis

013-AI-002

8474L-013-PID-0021-017

8474L-013-PDS-AE-001

Hydrogen Process Analyzer

013-AI-003

8474L-013-PID-0021-017

8474L-013-PDS-AE-003

Moisture Analyzer

013-AI-605
013-AI-606
013-AI-607
013-AI-608

8474L-013-PID-0021-028
8474L-013-PID-0021-029
8474L-013-PID-0021-030
8474L-013-PID-0021-031

Supplied by Heater
Vendor
8474L-013-PDS-AE-002

Oxygen Process Analyzer

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13

PROCESS CONTROL

13.1

DISTRIBUTED SYSTEM CONTROL (DCS)

The text will be prepared by JVD instrument manager for all OCs

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CHAPTER 14

DRAWINGS

CONTENTS

1.

PLOT PLAN AND HAZARDOUS AREA CLASSIFICATION

2.

PROCESS FLOW DIAGRAMS AND MATERIAL SELECTION DIAGRAMS

3.

PIPING AND INSTRUMENTATION DIAGRAMS

3.1

PROCESS AND UTILITIES PIDS

3.2

C-1301 VENDOR DRAWINGS

3.3

RECOVERY PLUS DRAWINGS

3.4

PACKAGES DRAWINGS

4.

OTHER DRAWINGS

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1. PLOT PLAN AND HAZARDOUS AREA CLASSIFICATION

8474L-012-DW-0051-001
8474L-012-DW-1920-001

Plot Plan NHT / CCR / ISOM

Hazardous Area Classification Plan NHT / CCR
/ ISOM

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2. PROCESS FLOW DIAGRAMS AND MATERIAL SELECTION DIAGRAMS

8474L-013-MSD-0011-001
8474L-013-MSD-0011-002
8474L-013-MSD-0011-003
8474L-013-MSD-0011-004
8474L-013-MSD-0011-005
8474L-013-PFD-0010-001
8474L-013-PFD-0010-002
8474L-013-PFD-0010-003
8474L-013-PFD-0010-004
8474L-013-PFD-0010-005

Reactors Section
Net Gas Section
Debutanizer Section
Steam Generation Section
Chloride, Condensate and Sulfide Injection
Section
Reactors Section
Net Gas Section
Debutanizer Section
Steam Generation Section
Chloride Condensate And Sulfide Injection
Section

X-1301 PROCESS FLOW DIAGRAMS

8474L-013-A0102-4110-001-001
PROCESS FLOW DIAGRAM OF RECOVERY PLUS SYSTEM
8474L-013-A0102-4110-001-002
PROCESS FLOW DIAGRAM OF RECOVERY PLUS SYSTEM

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3. PIPING AND INSTRUMENTATION DIAGRAMS

3.1 PROCESS AND UTILITIES PIDS
8474L-013-PID-0021-010
8474L-013-PID-0021-011
8474L-013-PID-0021-012
8474L-013-PID-0021-013
8474L-013-PID-0021-014
8474L-013-PID-0021-015
8474L-013-PID-0021-016
8474L-013-PID-0021-017
8474L-013-PID-0021-018
8474L-013-PID-0021-019
8474L-013-PID-0021-020
8474L-013-PID-0021-021
8474L-013-PID-0021-022
8474L-013-PID-0021-023
8474L-013-PID-0021-024
8474L-013-PID-0021-025
8474L-013-PID-0021-026
8474L-013-PID-0021-027
8474L-013-PID-0021-028
8474L-013-PID-0021-029
8474L-013-PID-0021-030
8474L-013-PID-0021-031
8474L-013-PID-0021-032
8474L-013-PID-0021-033
8474L-013-PID-0021-034
8474L-013-PID-0021-035
8474L-013-PID-0021-036
8474L-013-PID-0021-037
8474L-013-PID-0021-048
8474L-013-PID-0021-050
8474L-013-PID-0021-051
8474L-013-PID-0021-052
8474L-013-PID-0021-060
8474L-013-PID-0021-070
8474L-013-PID-0021-071
8474L-013-PID-0021-072
8474L-013-PID-0021-080
8474L-013-PID-0021-100
8474L-013-PID-0021-101
8474L-013-PID-0041-075
8474L-013-PID-0041-090
8474L-012-PID-0031-901
8474L-012-PID-0031-902
8474L-012-PID-0031-904
8474L-012-PID-0031-905
8474L-012-PID-0031-911

Charge Heater
N1 Interheater
N 2 Interheater
N3 Interheater
Reactors
Combined Feed Exchange
Chloride and Condensate Injection
Separator
Recycle Compressor
Recovery Plus System
Net Gas Chloride Treaters
Debutanizer Feed Bottoms
Debutanizer Bottoms Coolers
Debutanizer
LPG Chloride Treaters
Debutanizer Overhead System
Debutanizer Receiver
Fuel Gas Supply
Charge Heater Firing
N 1 Interheater Firing
N 2 Interheater Firing
N 3 Interheater Firing
Steam Disengaging Drum
Convection Section
Surface Condenser
Vaccum System
Phosphate Dosing Package
Sulfide Injection
CCR Interlock Details
E-1303 Air Cooler Details
E-1304 Air Cooler Details
E-1308/E-1309 Air Cooler Details
CCR Sample Connection Details
CCR Level Connection Details
CCR Level Connection Details
CCR Level Installation Typicals
CCR Regeneration Details
Regeneration / UOP interface
CCR Regeneration Section Tie-In Connection list
C-1301 INTERFACE - RECYCLE
COMPRESSOR
CCR Pump Auxiliaries Details
Flare and Fuel Gas
Flare And Fuel Gas
Flare And Fuel Gas
Flare And Fuel Gas
Closed Drain Collection

March 2007
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Chapter : 14
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

8474L-012-PID-0031-912
8474L-012-PID-0031-913
8474L-012-PID-0031-914
8474L-012-PID-0031-915
8474L-012-PID-0031-921
8474L-012-PID-0031-922
8474L-012-PID-0031-923
8474L-012-PID-0031-924
8474L-012-PID-0031-925
8474L-012-PID-0031-931
8474L-012-PID-0031-932
8474L-012-PID-0031-933
8474L-012-PID-0031-934
8474L-012-PID-0031-935
8474L-012-PID-0031-941
8474L-012-PID-0031-942
8474L-012-PID-0031-943
8474L-012-PID-0031-944
8474L-012-PID-0031-945
8474L-012-PID-0031-946
8474L-012-PID-0031-951
8474L-012-PID-0031-955
8474L-012-PID-0031-961
8474L-012-PID-0031-965
8474L-012-PID-0031-990

March 2007
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Chapter : 14
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Closed Drain Collection

Closed Drain Collection
Closed Drain Collection
Closed Drain Collection
HP MP & LP Steam
HP MP & LP Steam
HP MP & LP Steam
HP MP & LP Steam
HP MP & LP Steam
Cooling Water Service Water and Potable Water
Cooling Water Service Water and Potable Water
Cooling Water Service Water and Potable Water
Cooling Water Service Water and Potable Water
Cooling Water Service Water and Potable Water
Plant Air Instrument Air & Nitrogen
Plant Air Instrument Air & Nitrogen
Plant Air Instrument Air & Nitrogen
Plant Air Instrument Air & Nitrogen
Boiler Feed Water & Condensate Header
Boiler Feed Water & Condensate Header
Caustic
Closed Drain System
Utility Distribution - Oily Water System
Utility Distribution - Oily Mist System
Battery Limit

3.2 C-1301 VENDOR DRAWINGS

8474L-013-A01031011-001-002
8474L-013-A01031011-001-003
8474L-013-A01031011-001-004
8474L-013-A01031011-001-005
8474L-013-A01031011-001-006
8474L-013-A01031011-001-107
8474L-013-A01031011-001-108
8474L-013-A01031011-001-109
8474L-013-A01031011-001-110
8474L-013-A01031011-001-112

Piping & Instrument Diagrams - Lube Oil Unit C-1301 CT-1301

Piping & Instrument Diagrams - Shaft Line C-1301 CT-1301
Piping & Instrument Diagrams - Sealing C-1301 CT-1301
Piping & Instrument Diagrams - Vibration and Temperature Shaft
Line C-1301 CT1301
Piping & Instrument Diagrams - Steam Turbine - CT1301
Piping & Instrument Diagrams - Gland Condenser
Piping & Instrument Diagrams - Moving oil Conditioner
Piping & Instrument Diagrams - Steam Turbine Driven Oil Pump
PID Symbol - C-1301 CT-1301
Piping & Instrument Diagrams - Steam turbine driven condenser
pump

3.3 RECOVERY PLUS DRAWINGS

8474L-013-A0103-4110-001001
8474L-013-A0103-4110-001-

MECHANICAL FLOW DIAGRAM - PIPING SYMBOLS AND

NOMENCLATURE
MECHANICAL FLOW DIAGRAM - INSTRUMENT SYMBOLS AND

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

002
8474L-013-A0103-4110-001003
8474L-013-A0103-4110-001004
8474L-013-A0103-4110-001005
8474L-013-A0103-4110-001006
8474L-013-A0103-4110-001007
8474L-013-A0103-4110-001008
8474L-013-A0103-4110-001009
8474L-013-A0103-4110-001010
8474L-013-A0103-4110-001011
8474L-013-A0103-4110-001012
8474L-013-A0103-4110-001013

Chapter : 14
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NOMENCLATURE
MECHANICAL FLOW DIAGRAM - TYPICAL INSTRUMENTATION
DETAILS
MECHANICAL FLOW DIAGRAM - FEED AND HEAT
EXCHANGER SECTION
MECHANICAL FLOW DIAGRAM - CHILLER SECTION
MECHANICAL FLOW DIAGRAM - ABSORBER SECTION
MECHANICAL FLOW DIAGRAM - COMPRESSOR SECTION
MECHANICAL FLOW DIAGRAM - COMPRESSOR LUBE OIL
SECTION
MECHANICAL FLOW DIAGRAM - OIL SEPARATION SECTION
MECHANICAL FLOW DIAGRAM - LIQUID REFRIGERANT
SECTION
MECHANICAL FLOW DIAGRAM - UTILITY HEADER SECTION
MECHANICAL FLOW DIAGRAM - PUMP DETAILS
MECHANICAL FLOW DIAGRAM - COMPRESSOR / MOTOR
DETAILS

3.4 PACKAGES DRAWINGS

8474L-200-A0103-4046-001-151
8474L-200-A0103-4046-001-351
8474L-200-A0103-4046-001-391
8474L-200-A0103-4046-001-211
8474L-200-A0103-4046-001-261
8474L-200-A0103-4046-001-301

March 2007
Rev.
:0

Piping and Instrument Diagram X-1307

Piping and Instrument Diagram X-1359
Piping and Instrument Diagram X-1360
Piping and Instrument Diagram X-1396
Piping and Instrument Diagram X-1397
Piping and Instrument Diagram X-1398

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CCR (013)

4. OTHER DRAWINGS
Electric single line diagram
Underground sewer network
Fire fighting water distribution
diagram

March 2007
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Chapter : 14
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