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1. Feed isobutylene content optimization:
The isobutylene content in the final feed to the
reactor has a direct influence on the polymer
production rate in the reactor. To keep it at a high
level, the plant is operated at nil or minimum
overhead recycle. However, this leads to higher
overhead loss of isobutylene as the overall
conversion drops.
KPL is undertaking test runs currently with high
concentration iC4 content in feed to determine an
optimum. Indczech will carry out this optimization
with all stream prices and derive best feed and
recycle rate to achieve the grade-wise target
capacity from the reactor and subsequent
equipment. The reactor and subsequent
equipment design need to take into account the
material flows thus generated.
2. Reactor modelling:
Reactor kinetic modelling has to be developed with
the kinetic data available. If kinetic model is not
possible, then a mathematical modelling has to be
developed using operational data available which
can be extra-palatable to the required target
capacity.
3.Reactor volumetric capacity and heat removal:
Reactor volumetric capacity is a current bottleneck
to increase feed flow. Residence time is
compromised in higher than design LHSV
operation. Reactor design has to be reviewed and
designed suitably.
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Statistical model performed from last 8 month plant data
(April – Nov) to achieve target production as per Scope of
work. Reactor feed rate & composition, reactor OVHD
recycle and Debutanizer feed finalized And proceeded
with Process Simulation with Aspen Plus. Agreed with
KPL to proceed with 36% isobutylene concentration
(maximising low IB content feed) in the reactor feed with
part of reactor overhead being recycled.
Trial runs were taken for both KVIS 10 & KVIS 200 grades.
Based on the trial run observation, existing reactor can
handle 36 % IB concentration feed on short term
(constraints in both upstream for low feed temperature
and downstream for hydraulics)
IndCzech proceeded with Statistical modelling – using
plant historical data.
Suggested to increase the volumetric capacity of the
reactor by withdrawing reactor product from the top
nozzle compared to present withdrawal from the
circulation pump discharge.
Separate low NPSH discharge pump provided for reactor
product withdrawal in line with original design.
Suggested to provide more cooling for the inlet feed by
 DEBOTTLENECKING STUDY AND BASIC ENGINEERING

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adding feed/effluent exchanger and chilled water (from
VAM unit) exchanger to remove sensible heat in the
reactor. No limitations found on overhead compressor
with respect to the flow rate to take care of latent heat
of vaporisation

4. Reactor conversion and selectivity Based on statistical model and simulation, optimum
optimization: value obtained for conversion, selectivity and yield.
Reactor conversion & selectivity has to be studied
and optimized to increase productivity.
5. Oligomer formation optimization: Oligomer formation was high due to high temperature
At present the Oligomer formation is high as operation in the reactor. Based on low temperature
compared to design. This leads to lower operation, Oligomer generation can be minimised. Exact
profitability. This has to be studied and optimized. quantity could not be determined in the absence of
kinetic data.
6. Reactor product draw-off: IndCzech’s design is with side draw to a low NPSH pump.
The reactor product draw-off is practiced from the For liquid retrained to compressor at high level,
reactor circulation line-up instead of the side draw- IndCzech has suggested to replace the existing KOD with
off nozzle, as high level required to cater for draw- a bigger Size KOD with agreed (both KPL and indczech)
off pump NPSH gives liquid entrainment to Liquid carry over assumption.
overhead compressor.
7.Process simulation of the entire train: Aspen plus V11 _ Polymer base Simulation package.
Carry out a complete process simulation of the 1. Pre-simulation – to match with existing plant
entire train and generate the streamwise and condition (27% iB conc).
component-wise mass balance. 2. 36% iB conc simulation for detailed model,
Simulation and Optimization performed.
- HMBT,
- Physical properties,
- Product quality (MW, Flash point, Viscosity)
3. Case study performed:
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 DEBOTTLENECKING STUDY AND BASIC ENGINEERING

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1. 13 stage Debutanizer column,
2. Worst case Atmospheric column,
3. Worst case Vacuum flash column and
4. Product quality (LP in PIB) and their spec.
5. Reactor OVHD, flash vessel – low
temperature flash.
8.Heat integration studies using pinch analysis: Heat integration exchanger possible check and suggested
Carry out heat integration studies using pinch on Reactor Feed/Efflent exchanger.
technique and identify optimum heat and cold
exchange design. As part of this study identify
which exchangers can be air-fin coolers instead of
current cooling water cooled, as the objective is to
reduce cooling water requirement as much as
possible.
9. Minimum Capital Expenditure: Maximum utilisation of as built equipment achieved.
Strive to use as many of as-built equipment as New equipment provided only when absolutely
possible with internal modifications as necessary to necessary.
keep capital expenditure at minimum.
10. Reactor feed & recycle chilling system: Chilled water from new VAM (100 TR) utilising waste
The current Freon based refrigeration unit is steam has been considered for feed cooling upstream of
unable to meet the temperature requirement of the Refrigeration unit.
the feed to the reactor. Utilize any steam or
condensate surplus to design a VAM system with
Lithium Bromide to provide the additional
refrigeration required to chill the feed and
overhead recycle to the reactor. This system
should be suitably integrated with the existing feed
chilling train.
11. Chilled water utility system: Since more cooling water is required to generate chilled
The extra refrigeration capacity from the VAM water this option was not considered.
system is to be utilized to design a Chilled Water
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Utility for use in additional exchangers to provide
further cooling where existing Cooling water-based
exchangers are ineffective.
12. Control system for feed IC4 blending: Feed flow and IB concentration control scheme finalised
Provide the basic design for control system of including a calculation block and measurement /control.
maintaining feed iC4 concentration using the
existing hardware of Blending station and Trim
controls.
13.Control system for feed moisture: IndCzech and KPL, mutually agreed to provide 3
Provide the basic design for a feed moisture location’s moisture analyser.
content management system, as the feed moisture - Drier outlet,
content has an optimum value per grade. This is - 13X unit (Adsorber) outlet,
maintained currently with a water injection pump - Blended feed to reactor.
system. Automation of 13x system being considered.
14.Control System for Reactor overhead and feed P&IDs updated To maintain reactor and feed
refrigeration compressor: temperatures.
Provide the basic design for control system for
maintaining the overhead and feed temperature of
reactor.
15.Reactor overhead polymer de-entrainment New KOD suggested for liquid entrainment.
system:
Existing KO Pot does not remove entrained
polymer efficiently. Review and provide the basic
design for reactor overhead polymer de-
entrainment.
16. Reactor overhead system capacity and By simulation and Equipment adequacy performance
condensation system: also performed. Process Calculation and
Provide the basic design for reactor overhead Process/Mechanical Datasheet enclosed in report.
system capacity and condensation system.
17. Catalyst preparation: Continuous Catalyst preparation, detailed Scheme (PFD)
Provide the basic design for a continuous catalyst and their process/ Mechanical and Instrumentation
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 DEBOTTLENECKING STUDY AND BASIC ENGINEERING

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preparation and injection system. datasheet and along with Vendor quote submitted.
18. Caustic preparation: Continuous Caustic injection scheme with Vertical mixing
Provide the basic design for a continuous caustic vessel (thorough mixing) scheme and Process /
concentration and flow management system. Mechanical and Instrumentation datasheet submitted.
19. Neutralisation and sludge removal system: Agitated vessel suggested for better caustic mixing and
Review and provide better neutralizing, spent existing downstream vessels checked for settling and
caustic, sludge and water/moisture removal from sludge removal.
the post-reactor stream. Caustic addition control is
to be controlled with residual acidity measurement
in feed to debutanizer.
20. Flash Section Revamp: Simulation case studies conducted in Atmospheric flash
Flash section is unable to meet product flash column and Vacuum flash column:
temperature target for some grades. Design a - Worst case (load)
complete revamp of the flash section, consisting of - By various operation condition (temperature and
an atmospheric and vacuum flash to achieve grade- pressure) and throttling valve operations.
wise product flash point specs, and consider Debutaniser column simulation checks done
replacing existing steam jet vacuum system by many times before proceeding for atmospheric
vacuum pumps in case this option is more energy column.
efficient.
21. Vent gas and flare gas recovery: IndCzech worked along with KPL, to support Off-gas
Review the vent gas system and all hydrocarbon recover system (Atmospheric column receiver and
evacuation loads during normal operation an Vacuum column receiver).
provide a basic design for recovery of these from
the flare system and generate LPG condensate to IndCzech modified Closed Drain System
storage. KPL does not have a sink for gaseous LPG - gravity drain and
in its offsites. - Pressurized Drain system
22. Cooling water consumption reduction: Indczech has provided control valves on cooling water
As the heat rejection of the process is mainly to return from exchanger based on process temperature to
cooling water, the consumption of make-up fresh minimise unnecessary cooling water circulation. Air
water is quite high, and is becoming a constraint. coolers are not an option due to high ambient
This has to be studied to reduce water temperatures and space constraint.
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 DEBOTTLENECKING STUDY AND BASIC ENGINEERING

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consumption.
23. Process control philosophy, SIL Analysis and Process control philosophy was discussed in details and
SIL 2 instrumentation: P&IDs updated accordingly. Reactor system isolation USD
Review the process control philosophy for the has been implemented. The isolation valves will meet
entire train and recommend changes. As part of minimum SIL 2 requirement. To be verified based on
this, also recommend changes required to conform vendor feedback during next stage of engineering.
the process safety instrumentation to SIL 2 at least.
This is apart from the review of control valve type
and sizing in the BDEP.
24. Process safety relief system: IndCzech performed calculation studies on PSV and PRV.
Review the process safety relieving philosophy of
the train apart from checking and re-sizing the
relief capacity of individual equipment arising out
of revised process conditions.

25. Flare System: During Detail Engineering based on the system volumes
Review and provide basic design for revamping of and the relief settings during detailed engineering. Some
the flare system for increased capacity arising out New equipment Sizes need vendor confirmation.
of debottlenecking.
26. PSM conformity: Design changes confirm to PSM guidelines.
KPL has recently performed a gap analysis and has
action in hand for conforming the plant and its
management systems to Process Safety
Management standards as defined in OSHA 29 CFR
1910.119. The BEC shall ensure that its design
recommendations continue to conform to PSM
guidelines.
27. Utility Requirement: Utility Summary submitted.
Provide revised battery limit requirements of all - Cooling water,
utilities including power. - Steam,
- Hot oil,
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- Power
28. Layout: IndCzech suggested, basic (new) equipment layout.
Review and ensure suitability of accommodating
modified equipment or new equipment suggested
in the basic design in the ISBL plot of existing two
trains.
29. HAZOP and HAZAN study: During Detail Engineering
Participate in HAZOP and HAZAN study, and
incorporate changes as required in the final design
submission.

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