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GS Lidong

Lid
Qingdao,
Qi d
China
Chi
ISOMAR UNIT
PROCESS TECHNOLOGY TRAINING
UOP ISOMARTM PROCESS
Section 1
Shutdown for Unloading

UOP Technology Services Aromatics


Heather Fleitz & Greg Ernst
June 2013

2012 UOP LLC. All rights reserved.

Shutdown Overview

7-2

Shutdown
Carbon Burn
Cooldown and Atmosphere
Preparation for Unload
Unload Existing Isomar with I-300

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Isomar

Shutdown

Goal: Stop feed and heat input, remove most


hydrocarbons
y
from the reactor section.
Notify all affected areas/units of shutdown
Reduce reactor inlet temperature to 370C or by
15C (whichever is lower)
Reduce charge rate to 70% of design stepwise
stepwise,
stabilizing between each step
Bypass and isolate liquid feed from reactor, adjust
compressor for max RG circulation rate
Place Parex/Isomar sections on long circulation

7-3

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Isomar

Shutdown - continued
Continue recycle gas to purge HCBN from the
p to 250-300C by
y
reactor,, reduce reactor outlet temp
~50 per hour
Strip hydrocarbons from catalyst with hydrogen
circulation for 12 hours.
hours
After hydrogen strip, cool reactor outlet
temperature to 80C by ~50C per hour
When the reactor has cooled to ~80C, the recycle
compressor can be shut down
Drain product separator to Deheptanizer
Shutdown charge heater

7-4

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Isomar

Shutdown - continued

Break long circulation loop


Place Deheptanizer on total reflux and gradually
reduce heat input to zero
Send Deheptanizer overhead and bottoms
inventory to downstream units
Depressure the reactor section to the fuel gas
header
Evacuate the reactor section, pressure and
depressure with nitrogen

7-5

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Isomar

Carbon Burn
Goal: removal of coke from catalyst to make it safer
g
for unloading
Conditions to target for maximum coke removal:
- Maximum reactor pressure
- Maximum recycle gas circulation rate
- Stable and close control of Rx Inlet temperature and other
-

7-6

operating conditions
Maintain close control of air injection rate
Target reactor delta T of 15C
15 C, do not exceed 20C
20 C

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Isomar

Carbon Burn - continued


Pressure reactor circuit to approx. 7 kg/cm2(g) with
g
nitrogen
Start recycle gas compressor, establish maximum
cooling upstream of product separator
Light burners in charge heater as necessary,
increase reactor inlet temperature to 360C by 50
per hour
Adjust separator pressure to highest possible
without exceeding compressor load or supply
pressure of air header, bring in additional nitrogen
as necessary.

7-7

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Isomar

Carbon Burn - continued


Add combustion air via globe valve around air
j
control valve until burn is under control,,
injection
then switch to control valve
Keep oxygen in recycle gas to the reactor below 0.4
mol%
Drain any liquid from low points generated by
combustion
Limit increase of reactor delta T to 10 per hour by
controlling air injection rate
Maintain carbon burn conditions for up to 48 hours,
hours
or until reactor outlet temperature has returned to
base levels and remained for 4 hours

7-8

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Isomar

Cooldown/Atmosphere Change
After carbon burn complete, cool reactor per
g guidelines.
g
Shutdown
S
charge
g heater.
cooling
Purge with once-through nitrogen or repeat
pressurization and evacuation
Continue to drain liquid from low points
Shutdown and isolate the recycle gas compressor
when the temperature approaches 40 C
C

7-9

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Isomar

Prepare for unload


Once sufficiently cool, evacuate reactor section and
purge
p
g with nitrogen
g
Pull vacuum at compressor suction, add nitrogen at
compressor discharge or reactor inlet
Prepare any necessary safety precautions for
unloading

7-10

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Isomar

Isomar Reactor Unloading


After Isomar reactor has been shutdown,
cooled, and a safe environment
established around the reactor it shall be
unloaded
Do not pull air thru the Isomar reactor as
spontaneous combustion of catalyst fines
is possible. Remove all combustible
materials from area around reactor
reactor.
Unload I-300 and inert ceramic balls via
the catalyst withdrawal nozzles (nozzles
D1/D2).
) Unload thru dumping
p g spouts
p
into metal drums. Drums should be
sealed with lid and rubber gasket to keep
out moisture.
Top manway may be opened
occasionally to check on progress. Keep
manway closed during actual unloading
to prevent natural draft.

7-11

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Isomar

Isomar Reactor Unloading Cont


Most of the catalyst should flow
freely thru the withdrawal nozzles
Last few drums of catalyst may need
to be swept out
Ensure the centerpipe remains in
proper position during unloading
Existing inlet flange (manway)
including the attached inlet diffuser
should be carefully removed
Prepare reactor as necessary for
f t
future
condition
diti

7-12

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Isomar

Questions and Answers

7-13

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Isomar