BYCO PETROLEUM PAKISTAN

LIMITED

Plant-7 Platformer Unit ORC-II

Prepared By Advisory
 Introduction & Design Basis Plant-7
Fixed bed or semi regen. unit. It upgrade heavy naphtha octane (40-45) to gasoline
octane (90-95)----By converting naphthenes & paraffin into aromatics.
Design Conditions: Liquid Feed 24000 bpd but now it is 12000 bpd.
Feed Chacteristics: Composition C6-C11.
IBP/50%/EP-76/110/165 deg C. SG 0.7313
PONA- 65.3/-/18.3/16.3 wt%
Operating Conditions:
Liquid feed 12000 bpd, H2/HC ratio 6.0 (90 MMSCFD H2 Gas circulation), System
press 210Psig/14.8 barg, RXs press 260 psig/18.3 barg, RIT (WAIT) 488 deg C,
LHSV 1.26 1/hr. Feed additives include PERC 0.5 ppm & water condensate 5
ppm during normal operation.
Catalyst:
Type R-86 UOP, Composition Al2O3 (98 wt%), Pt (0.25 wt%), Rh (0.4 wt%) & Cl (1
wt%). Sock loading (density 665 kg/m3). Total mass loaded is 42000 kg &
volume 63 m3. Catalyst distribution is 20/40/40 wt% in RX-1, 2 & 3. Catalyst life
36 months.
Products: Reformate yield 85% wt (80.6% by volume), H2 yield 1.65 wt%. RON 92.

2
Liquid & Gas Feed for Startup
Liquid Feed:
Boiling Range As per design. However UOP recommend IBP should not go
below 77 C & EP should go above 204 C.
Total Sulfur 0.5 wt-ppm maximum Total Nitrogen 0.5 wt-ppm maximum
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 in feed.
If hydrotreated feed is not available, startup may be done on non-hydrotreated:
Total Sulfur 100 wt-ppm max, Total Nitrogen 1 wt-ppm max. 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 880°F
(471°C).
Gas Feed: H2 purity 75%, moisture 20 mol ppm max, N2 nil, O2 nil, Chloride
50 mol ppm, total Sulfur 5 mol ppm
Platforming Reactions

Dehydrogenation, isomerization & Dehydrocyclization reactions are desired reaction

while hydrocracking, demethylation & dealkylation reactions are undesirable.
 Catalyst Poisons
1-Sulfur:
Allowable Conc.: maximum limit in feed is 0.5 ppm. It damage metal function of Catalyst & react to
produce H2S. 1 wt ppm sulfur in feed=3 mol ppm H2S in R/C gas & 10 mol ppm in Stab. Off gas.
Process Symptoms: High sulfur in feed reduce metal activity of catalyst which results
decrease in delta T, H2 purity reduce, H2 production reduce, H2S in R/G & Stab. Off gas
Increase, cracking reaction increase, coking rate increase, C3/C4 yield increase, Platformate yield
reduce, RON reduces etc.
Suggested Operational Response: Drop reactors temp up to 900 F (482 C). Identify sulfur source &
eliminate it from feed. Slightly increase chloride injection around 1 ppm. When feed sulfur is 0.5 ppm &
H2S in R/G is 1-2 ppm normal operation may be resumed.
Possible Source: In adequate NHT operation, Poor stripping of H2S, Leakage in combine feed HXs.
2-Nitrogen:
Allowable Conc.: maximum limit in feed is 0.5 ppm. It damage acid function of Catalyst & react to
produce NH4Cl that deposits in cold section of unit & cause serious fouling issues. 0.1 wt ppm N2 in feed
consume 0.25 ppm chloride from catalyst. Therefore chloride should make up in the feed otherwise
catalyst will dry out.
Process Symptoms: High N2 in feed will result loss of acid function, will decrease catalyst activity, delta
Ts will increase, H2 production will increase. H2 purity in R/G will increase, C3/C4 yield will decrease etc.
Suggested Operational Response: Maintain extra chloride injection but should be limited to 5 ppm max.
Identify source of N2 & remove from feed. Do not raise reactor temperature during N2 contamination.
Possible Source: In adequate NHT operation, Improper use of filming & neutralizer amines. Leakage in
combine feed HXs.
 Catalyst Poisons
3-Water:
Allowable Conc.: Feed should essential dry & water-Cl balance should maintain by injection system. R/G
moisture should in range 15-20 ppm & upper limit is 30 ppm. High water in feed damage metal activity
same like the sulfur. For shorter period it enhance acid function of catalyst but for longer period it leach
out chloride from catalyst & damage acid function too.
Process Symptoms: Delta T will drop, H2 purity in R/G will reduce, H2 production will reduce, HCl in R/G
gas increase, coking rate increase, C3/C4 yield increase, Platformate yield reduce, RON reduces etc.
High moist in feed for longer time will create deficiency of chloride at catalyst & this impact may be
irreversible.
Suggested Operational Response: Drop reactors temp up to 880 F (471 C). Identify source &
eliminate it from feed. Adjust chloride injection as per following. moisture less than 30 ppm = 0.5 ppm
when 30-100 ppm= 1 ppm, 100-200=2, 200-300=4, 300-500=6, greater than 500 = 10 PPM.
Possible Source: In adequate NHT operation, Poor stripping of H2O, Leakage in steam re-boiler. Poor
control of water injection.
4-Organic Metals:
Lead, arsenic, Cu, Silicon etc have permanent damage to catalyst metal part. In straight run naphtha
have very less chance to have organic metals ingress to platformer catalyst. However coke or cracked
naphtha have organic metal contamination
5-High End Point of Feed:
Max limit for EP is 204 C. EP above 204 C will increase polycyclic aromatics in feed which are consider
poison to catalyst. These compound deposits on catalyst & generate high coke rate that will results
rapidly decrease in catalyst activity & product RON.
Suggested Operational Response: Do not increase distillation tower (1C-1) top temp above 270 deg F.
 Normal Startup

1. Perform leak test, make unit O2 free (<0.3%) & pressurize system with H2 gas (125 psig)
2. At H2 gas check flanges for leakages. Start compressor & establish gas circulation. Ensure all
safeties & securities are normal & response on DCS is okay.
3. Light up heaters, raise RIT @ 30 C or 55 F / hr. During temp ramp up conduct LEL survey of flanges.
4. In parallel prepare feed, depentanizer section & PERC solution.
5. At RIT 650 deg F (343 C) test for H2S at RX outlet. If test is +Ve then pre-sulfiding is not required. But
if test in –Ve then pre-sulfiding will be performed. R-86 catalyst is already pre-sulfide.
6. Do not prolong hot H2 circulation for more than 12 hours to prevent catalyst loss.
7. Raise further temp & cutin feed at RIT 700 F (371 C) @ 7500 bpd minimum or LHSV 0.75 1/hr min.
As soon as feed is cutin, start PERC injection @ 10 ppm.
8. Adjust feed flow as more as possible say 10000 bpd & RIT 700-750 deg F (371-399 C). Then
establish separator operation & depentanizer section.
9. H2 production will start & unit pressure will increase. Maintain system pressure at 210 psig.
10. Raise RIT upto 880 F(471 C) & send sample to lab for RON test. Octane 85 is okay for MS pool.
11. Adjust chloride injection with the change in moisture in recycle gas as per the following. Moist greater
than 500 = add 10 ppm perc, 300-500=6, 200-300=4, 100-200=2, 30-100 ppm= 1 ppm & moisture
less than 30 ppm = 0.5 ppm.
12. Conduct test for HCl & moist in R/G gas. If HCl is <15 ppm & moist <300 ppm. Put online moisture
analyzer in service.
13. Raise RIT 900 F (482 C) when moist in R/G is <200 ppm, H2S is < 2 ppm & sulfur in feed <0.5 ppm.
14. Monitor recycle gas for moist & when moist is <30 ppm. Increase RIT 910 F (488 C) to get desired
RON 92.0
15. Start water injection @ 4-5 ppm when moisture in R/G is in the range 15-20 ppm.
 Planned Shutdown

1. Notify to all concerns

2. Start reducing RIT @ 54 F (30 C) /hr. At 900 F, then reduce feed rate not less
than 0.75 LHSV.
3. At 850 deg F (454 C) stop feed to unit & continue gas circulation to sweep liquid.
4. Stop water & Perc injection.
5. When sweeping of the catalyst is complete, cool the Platforming reactor inlets to
750°F (399°C).
6. If shutdown is temporary then cool heater tubes for 20 minutes after fire cut off
and stop compressor & do not cool catalyst further below 750 F (400 C).
7. Shut down depentanizer section.
8. Maintain System pressure & vessel level.
 Unit Troubleshooting
Emergencies Operator Action
Partial Loss of H2 Gas (due 1. Reduce RIT 15-25 F for all reactors.
to low steam pressure, 2. Reduce feed to meet H2/HC ratio as 6.0. LHSV min 0.75 1/hr.
vacuum break) 3. Try to maintain H2 gas flow. When H2 flow is restore, then increase feed &
RIT to gain normal conditions.
4. If H2 flow can not maintain & it become too low to meet desired ratio, then
stop firing & stop liquid feed. Sweep catalyst & maintain system pressure.

Total loss of H2 Gas (steam 1. Stop firing in heaters. Open dampers & air register to cool heaters.
failure, compressor trip) 2. Stop liquid feed pump.
3. Depressurize system (half of system operating press) to remove heat &
sweep catalyst provided separate H2 is available for re-pressuring & re-
startup.
4. If H2 is not available then do not depressurize unit. Maintain system
pressure & block separator.
5. Find out fault, address it & re-start compressor to establish H2 flow.
6. Note if RIT is 25 F above the operating temp, then stop compressor &
further cool heaters until RIT are 925 F (496 C) with recycle gas flow.
7. If compressor can not start within 30 minutes, depressurize unit to sweep
liquid & when compressor is available follow start up procedure
8. Remember that normal operating pressure or 125 psia (8.8 kg/cm2
absolute) minimum H2 partial pressure, whichever is lower, at the reactor
products separator is required for feed cut in.
9. If H2 gas is not available then start up can be done on N2 gas.
Unit Troubleshooting

Emergencies Operator Action

Steam Failure (Boiler trip) 1. Compressor will stop & loss of H2 case will follow by operator

Cooling water failure 1. If cooling water failure is expected prepare for the shutdown of unit.
2. If failure is partial, reduce feed rate to allowable minimum level.
3. If it is total failure then unit will be shutdown.

Instrument Air failure 1. All Evs will move to fail safe position. Fire will turn off in heaters.
2. Stop liquid feed.
3. Keep continue H2 circulation to sweep liquid from heaters tube &
reactors
4. Start as per SOP when IA is restore

Explosion/Fire/Serious 1. Stop firing in heaters & isolate fuel at BL.

Leak/Rupture 2. Stop liquid feed & continue gas circulation if possible.
3. De-pressurize unit to flare.
4. Stop compressor when its minimum suction press limit is reached.
5. In case of heater tube rupture, donot close damper or open snuffing
steam.