C4 Oleflex CCR Section

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UOP 7200- 1. Oleflex CCR – Black Burn to White Burn Operation.

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Starting Coke Burn - Regeneration Tower Operating Modes During Startup.

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Start Regenerator in Blackburn. Stop catalyst circulation Set the “Burn Mode” to “Black Burn” (this controls %O2 by air injection for lower BZ) Set upper burn zone air FIC to zero Open air injection XV to regeneration from air drier Gradually open-air injection FCV valve to lower BZ Start lower burn zone air injection. Monitor %O2 on AIC Monitor oxygen level and peak temperatures. Gradually increase to ~0.6 mol% O2 Confirm stable %O2 level in upper and lower BZ.

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Start Regenerator in Blackburn. Once stable %O2 is established, start air injection to upper BZ Monitor bed temperatures When burn commences, temperatures will start rising Adjust the %O2 and commission the AIC on cascade with air injection FIC for upper and lower BZ Make sure both upper and lower BZ regen gas TIC is on auto Air is now flowing to the Regeneration zone Nitrogen is flowing to Chlorination zone.

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What is Black Burn?. Instrument air sent to Upper and Lower Burn Zones only Nitrogen sent to Chlorination/Drying Zone Regeneration Tower below Burn Zones is nitrogen atmosphere.

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Black Burn Flow. 6.

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Black Burn Controller – Set Up. 7. OLJAL ZONE AND LOLL AOAH EDAL *ANSYITTER 'ENT CAS SYSTEM DRIER 09 BLACK HICH BuRN FOR WHITE oro POINT FRE E DRAINING FREE CRAINtNC DRAINING VIBRATION 130t C ONTROL Loe 0 FT Etc 1301 FREE DRAINING BLOWERS PR—36 301 • TUBING 32 •.

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Oxygen Breakthrough. Initially all injected oxygen may be consumed for burn Monitor for oxygen breakthrough. Regeneration gas oxygen concentration increases gradually with air injection Peak temperatures achieved Reduced air injection rate required After breakthrough, once stable oxygen levels have been established, Restart catalyst circulation Increase catalyst circulation from 60% to 100% of design.

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Continue Black Burn. Start chloride injection at 0.8% of circulation rate Inject ~10-20% of total chlorine to Upper Burn Zone Remainder to Lower Burn Zone Circulate catalyst in black burn until the regeneration tower inventory turns over. After regenerator inventory has been circulated and while continuing circulating, sample catalyst once every two hours. Switch to white burn when two consecutive samples show less than 0.1 wt% coke on regenerated catalyst..

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Black Burn to White Burn. Stop catalyst circulation Stop air injection through the lower BZ air injection FIC, close FCV Open the Air injection XV valve to the air-heater, increase lower air through air FICs/FCVs to phase out N2 closing the N2 FIC Switch lower BZ AIC-A to AUTO to start directly controlling the vent valve opening to control %O2 in LBZ Air is now routed to the Chlorination Zone and Stripping/Drying Zone – Restart catalyst circulation Lower BZ AIC should now control the % O2 via vent valve Lower BZ air injection FIC would only open if the vent valve %MV>80% Upper BZ will continue on %O2 AIC- Air Flow FIC cascade.

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Black Burn to White Burn. Monitor temperatures in the: Transition Zone Upper Burn Zone Lower Burn Zone Monitor Upper and Lower Burn Zone oxygen content..

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What is White Burn?. Instrument air sent to Chlorination/Drying Zone Burn Zone O2 Concentrations: Upper Burn Zone: 0.6-1.0 mol% Lower Burn Zone: 2.0-5.0 mol% Regeneration Tower below Regeneration Zone is ~20 mol% oxygen atmosphere.

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What is White Burn?. Upper Burn Zone Cl2 (New).

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What is White Burn?.

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White Burn – Controller set up. 15. OLJAL ZONE AND LOLL AOAH EDAL *ANSYITTER 'ENT CAS SYSTEM DRIER 09 BLACK HICH BuRN FOR WHITE oro POINT FRE E DRAINING FREE CRAINtNC DRAINING VIBRATION 130t C ONTROL Loe 0 FT Etc 1301 FREE DRAINING BLOWERS PR—36 301 • TUBING 32 •.

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White Burn High Temperatures. If high temperatures are seen after switching to white burn: Open nitrogen & cut lower air flow Close tie line valve Restart air to lower burn zone to reach target O2 concentration High temperatures can cause catalyst or regenerator damage.

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White Burn Operations. Continue to monitor oxygen level both the Upper and Lower Burn Zone Continue to monitor peak temperatures Continue to monitor transition and chlorination zone temperatures Analyze regenerated catalyst for: Chlorine ~1.0 to 1.2 wt % Coke < 0.2 wt % Catalyst should be creamy white.

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White Burn Operations. Creamy White Pills.

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Start Regenerator in Black Burn, switch to Dual Zone Burn and then White Burn in sequence.

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Start Regenerator in Black Burn, switch to Dual Zone Burn and then White Burn in sequence.

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Start Regenerator in Black Burn. When burn commences, temperatures will start rising Monitor bed temperatures Overall temperature values and rate of increase Peak temperature – value and position Initially all oxygen may be consumed for burn . Monitor for oxygen breakthrough. Regeneration gas oxygen concentration increases gradually with air injection Bed temperatures Reduce air injection rate as required Confirm stable %O 2 level in Upper and Lower BZ Once stable %O 2 is established, start air injection to Upper BZ.

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Oxygen Breakthrough. Adjust the %O 2 and confirm the Lower BZ switch is set to “Black Burn & Dual Zone Burn” Commission the Lower BZ AIC on cascade Maintain Upper BZ FIC in automatic Restart catalyst circulation at ~60% design Confirm both Upper and Lower BZ heater TICs in auto Air is now constantly flowing to the burn zones Nitrogen is flowing to Chlorination Zone Once stable oxygen levels and controls have been established, increase catalyst flow gradually from 60% to 100% of design rate. Start chlorine injection at 0.6-0.8% of circulation rate into Chlorination Zone; inject 10-20% of total to Upper Burn Zone and balance to Lower Burn Zone.

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Black Burn Flow. 23.

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Continue Black Burn. Circulate catalyst in Black Burn until the complete Regeneration Tower inventory turns over After regenerator inventory has been circulated and while continuing circulating, sample catalyst once every two hours Switch to Dual Zone Burn when two consecutive samples show less than 0.2 wt% coke on regenerated catalyst.

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Switching from Black Burn to Dual Zone Burn. During Dual Zone Burn Air is injected into the Upper and Lower Burn Zones and Chlorination Zone %O 2 in Chlorination zone is between 0.1 - 20 mol% Verify lower air FVs are in manual and closed Open lower air XV Begin to open the smaller of the lower air FVs to target 0.1 mol% in the Chlorination Zone Monitor temperatures in the Chlorination and Transition Zones If temperature increases rapidly, reduce air injection rate Increase oxygen concentration in 20% increments (i.e. 0.1 to 0.12 mol%) every 60 min until 1 mol % is achieved.

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What is Dual Zone Burn?. Dry Instrument air sent to Chlorination/Drying Zone Burn Zone O2 Concentrations: Upper Burn Zone: 0.6-1.0 mol% Lower Burn Zone: 0.6-5.0 mol% Chlorination Zone is between 0.1-20 mol% oxygen.

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Dual Zone Burn Flow. 27.

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Dual Zone Burn. Once at 1 mol% oxygen, continue to increase mol% oxygen by 50% every hour increases every 60 min while monitoring the temperatures Example: Starting @1.0 mol%, subsequent increments will be 1.50,2.25, 3.38 etc. over approximately 8 hours reaching 21 mol%) As the concentration of oxygen increases in the Chlorination Zone the air injected into the Burn Zones will begin to decrease Lower Burn Zone air valve will close Vent valve should be placed in automatic (White Burn control) Air is now routed to the Chlorination Zone and Stripping/Drying Zone Lower BZ AIC should now control the % O 2 via vent valve Lower BZ air FIC should only be opened if the vent valve % output > 80%.

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Switching from Dual Zone Burn to White Burn. During White Burn Air is injected into the Upper Burn Zone and Chlorination Zone %O 2 in Lower Burn Zone controlled by vent valve opening Chlorination Zone contains ~20 mol% O 2 Upper BZ will continue on %O 2 AIC cascaded to FIC Maintain stable flow of gas to Chlorination Zone. Adjust ratio of air to nitrogen to gradually increase the O 2 concentration until no nitrogen is entering via the Air Heater Monitor temperatures in the: Chlorination and Transition Zones Upper and Lower Burn Zones Monitor Upper and Lower Burn Zone oxygen concentrations When all lower nitrogen has stopped, Regeneration Tower is in White Burn Close nitrogen XV.

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White Burn. High Temperatures Can Damage Equipment and Catalyst.

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White Burn Operations. 31.

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32. No reproduction or use of this material may be made without Honeywell’s prior written permission.