Alkylation Complex Start up Plan

Objectives:

1) To have a flawless & smooth start up

2) To achieve the dead line set for RFSU ( 31st March 2008)
3) To commission the unit with feed available from DTA

Start up recommended By Licensor:

The sequence of start up is summarized below:

 The start up of the unit requires Alkylate. Alkylate is required for

dewatering, flushing & proving of pumps, Mixers and for calibration &
proving of critical instruments in the reactors/settlers.
 Alkylate is required for start up of two reactors.
 Fresh acid inventory in the reactor/settler
 Start up of Fractionation section by inventorying Sat LPG & Alkylate
 Build up of IC4 inventory for filling the refrigeration & reactor sections
 Start up of Refrigeration compressor. Stabilizing the refrigeration
system.
 Cool the reactor to feed cut in temperature
 Olefin feed cut in to the reactor & stabilization
 With the available unsat LPG & IC$ available without Butamer, min
feed to one reactor can be cut in.
 To cut in feed in subsequent reactors IC4 from Butamer will be
required. Meaning Butamer should be commissioned to provide
additional IC4 for the feed cut in subsequent reactors. Alkylate available
after feed cut in will be utilized for flushing and start up of subsequent
reactor settler trains.
  Quantity of Alkylate required for start up of two reactors = MT
(Annexure)
 Quantity of Fresh acid required for start up of two reactors = MT
(Annexure)
The start up as suggested by Licensor needs Alkylate to be imported. This
warrants creation of additional one time facility at Marine, MTF & RTF. Also the
quantity to be imported will include the dead inventory at and between Marine,
MTF & RTF.

Proposed normal start up:

 Use HTLN (Hydro-treated Light Naphtha) instead of Imported

Alkylate. HTLN is available from DTA as confirmed by EPS.
 The use of HTLN is approved by Licensor with a condition that the
HTLN from the reactor and settler to be drained completely before
inventorying fresh acid in the system (Refer Annexure). The reason
for emptying out the system before inventorying acid is that the
Aromatics in the HTLN react with Acid which results in foaming.
The Licensors have also confirmed that many units have started with
Naphtha having higher Aromatics content. We will have a written
down procedure to ensure that all the HTLN from the reactor system
is drained before inventorying fresh acid.
 The other steps for start up remain the same as above.
 The normal start up takes 69 days to commission all the reactors
from Mechanical completion of the unit.
 It is expected that SAR will be started with Fresh acid & Acid gas
from DTA to build up Strong acid Inventory.
 (Annexure shows detailed sequence of Normal Start up)
Proposed crash start up:

 Inventory HTLN in the fractionation section. Stabilize the

fractionation section with available Sat LPG from DTA
 This is done to provide NC4 required for early start up of Butamer.
 The reactor section start up will remain the same as normal start up.
 With early commissioning of fractionation section & Butamer the
total duration for product out reduces to 42 days from the date of
mechanical completion.
(Annexure shows detailed sequence of Crash Start up)

Modifications required:

 Modification at OSBL to bring in HTLN via Alkylate rundown line.

 Modification to route Debutaniser bottom to DIB column, for
standalone start up of fractionation section.
 Modification to route stabilizer bottoms in Butamer to DIB overhead
receiver. This is required to pump out the contaminated material.

Construction priorities:

 Utilities( Power, steam etc)

 Fractionation section, Flare system, Steam system & DIOS
 Acid unloading facilities & Acid storage tanks
 Butamer
 Rx trains R 101 to R401
 SAR
  Rx trains R501 to R801
Early mechanical completion of:

1. Fractionation section (DP, DIB, DB)

2. Storage tank and unloading facility
3. Butamer unit
4. OSBL facility including Control Room

Advantages of Crash schedule:

 Advancement of product out date

 Higher production of 115.5 KT Alkylate.

Materials Required For Startup:

i. Fresh Sulfuric Acid 9000MT

ii. HTLN for flushing 8500M3
iii. Anhydrous HCL 3000KG

• Expected production of fresh acid is 200TPD from Acid Gas.

• IC4 buildup expected from Sat LPG(DTA) is 288 TPD

Issues to be resolved:

1. Refrigeration Compressor trial to be discussed with Vendor and CES.

2. Requirement of Chemical Cleaning in Butamer.
Modifications Required:

Line between:
1. Butamer stabilizer bottom to DIB O/H Receiver.
2. DB Column bottom to DIB column.

Assumptions:

This proposal is based on following assumptions:

1) All utilities are available at battery limit
2) Flare System and Control room available
3) Mechanical completion of piping and equipments.
4) DTA Sat and Unsat LPG available