BUTANE

PLANT
MOHAMAD TURMIZI BIN JAAFAR
TECHNICAL SERVICES DEPARTMENT
CONTENTS
 01
INTRODUCTION
Butane plant is a plant where the initial
process begins. Butane and air as raw
material is used to produce Maleic
Anhydride. The raw butane which is mix
butane is supplied by PETRONAS and it
needs to be processed to have pure n-butane.
 02
BLOCK FLOW
DIAGRAM
 BLOCK FLOW DIAGRAM

PETRONAS
Metering Station
(PMS)

Mixed Butane
Driers (D-1902
 03
EQUIPMENT DIVISION
AND OPERATING DATA
 TYPES OF EQUIPMENT

HEAT REACTO
EXCHANGER R

RECEIVE DIB
R/VESSEL COLUMN
 HEAT EXCHANGER
A heat exchanger is a system used to transfer heat between two or more fluids. Heat
exchangers are used in both cooling and heating processes. The fluids may be separated by
a solid wall to prevent mixing or they may be in direct contact.

There are several types of heat exchanger in butane plant:

 Feed exchanger
 Cooler
 Heater
 Vaporizer
 Condenser
 Reboiler
 HEAT EXCHANGER
Combined feed exchanger (E-1909A/B/C)
Shell Tube

Location Before Charge Heater (E-1909).

Function Transfer heat between HC and H2

Type of fluid Hydrocarbon Hydrogen

Temperature

40 / 130C 177 / 100C

Operating
Parameter Pressure

30.6 bar 32.7 bar

Temperature

235C 260C
Design
Parameter Pressure

40 bar 38 bar
 COOLER
- To transfer heat from process stream to utility stream like water or air

n-Butane subcooler,E-1804

Shell Tube

Location After DIB n-Butane condenser (E-1802).

Function Cool down C4H10 using CW
Type of
n-Butane Cooling water
fluid
Temperature
30.7C -
Operating
Parameter Pressure

- -

Temperature

Design 73C 78C

Parameter Pressure

8 bar 5 bar
 COOLER
Feed water cooler, E-1904
Shell Tube

Location After DIB Column (C-1801) and before Iso guard Bed Dryer (D-1903).

Function Cool down HC (liquid) using CW

Type of fluid HC (mostly Iso Butane) Cooling water

Temperature

55 / 40C 31 / 50C
Operating
Parameter Pressure

8.2 bar 4 bar

Temperature

120C 120C
Design
Parameter Pressure

25 / 55 bar 20 bar
 COOLER
Startup Cooler, E-1913
Shell Tube

Location After Stabilizer (C-1901) and before Iso guard Bed Dryer (D-1903).
Function Cool down HC using CW

Type of fluid Hydrocarbon Cooling water

Temperature
88C -C
Operating
Parameter Pressure

22.5 bar 4 bar

Temperature

Design 140C 120C

Parameter Pressure

25 bar 19.5 bar

 CONDENSER
- To condense a gas into liquid by cooling process. Heat from gas is transferred to the secondary fluid and releases large
quantities of latent heat. So, the vapor quantity decrease, liquid increase at outlet.

Reflux condenser, E-1801

Shell Jacket
Location After Stabilizer (C-1901) and before Iso guard Bed Dryer (D-1903).
Function Cool down HC using CW
Type of
Hydrocarbon + lights (C1-C3) Cooling water
fluid
INLET : 56.6C
Temperature OUTLET : 48.6C

Operating
INLET : 7.81 bar
Parameter
Pressure OUTLET : 7.81 bar

Flow 108 kg/hr

Temperature

Design 120C 120C

Parameter Pressure
12 bar 9.5 bar
 CONDENSER
DIB n-Butane condenser, E-1802

Shell Tube

Location After DIB Column (C-1801) and before n-Butane Subcooler (E-1804).

Function Cool down HC using CW

Type of
Hydrocarbon (C4H10) Cooling water
fluid

Temperature

75.5 C -C
Operating
Parameter Pressure

- bar Bar

Temperature

120 C 120 C
Design
Parameter Pressure

12 bar 9.5 bar

 CONDENSER
Stabilizer condenser, E-1912

Shell Tube

Location After top stabilizer (C-1901) and before Stabilizer receiver (V-1907).

Function Cool down HC using CW

Type of
Hydrocarbon (C4H10) Cooling water
fluid

Temperature

- C -C
Operating
Parameter Pressure

- bar - Bar

Temperature

120 C 120 C
Design
Parameter Pressure

24.5 bar 19 bar

 CONDENSER
Regenerant condenser, E-1905 A/B

Shell Tube

Type of
Hydrocarbon Cooling water
fluid
Temperature

75 / 40 C 31 / 40 C
Operating
Parameter Pressure

4.15 bar 4 bar

Temperature

345 C 120 C
Design
Parameter Pressure

25 bar 28.5 bar

 RECEIVER
- Receiver is used for storage of chemicals, solvents and any type of liquids in small quantity for chemical or any
industry.

Butane Receiver (V-1802) Stabilizer Receiver (V-1907)

1. Des P / T = 12 bar / 120 C 1. Des P / T = 24.5 bar / 120 C
3. Op P = 2.3 bar 2. Op P = 21.1 bar
From n-Butane Subcooler,E-1804 From Stabilizer condenser, E=1912
to Bullet Butane,T-1801 A/B to Stabilizer, C-1901

Fuel Gas Receiver (V-1804)

1. Des P / T = 3.6 bar / 260 C
2. Op P / T = 2.04 bar / 81.8 C
From Raffinate vaporizer, E-1805 /
Reflux receiver, V-1801 / Net Gas
scrubber, C-1902 to Flare / Boiler

- Reflux drum, or accumulator, serves as a distribution point for reflux and distillate
Reflux drum (V-1801)
1. Des P / T = 12 bar / 120 C
3. Op P / T = 40 C / 7 bar
From Reflux condenser,E-1801 to
DIB Column,C-180`
DRUM
Feed Surge Drum (V-1904)
1. Des P / T = 9.5 bar / 120C,40C Regenerant Surge Drum (V-1903)
2. Op P = 6 bar 1. Des P / T = 25 bar / 12C,40C
From Iso Guard Bed Dryer D-1903 2. Op P / T = 0.5 bar / 40 C
to Combined Feed Exchanger, E-
1909 A/B/C

Make Up Knockout (KO) Drum (V- Chloride Injection Drum (V-1905)

1902)
1. Des P / T = 42 bar / 120C,40C
2. Op P / T = 30 bar / 40C
From Hydrogen Trailer to Make Up
Gas Dryer, D-1901 A/B
Bleeder Knockout (KO) Drum (V-
1909)
1. Des P / T = 3.5 bar / 120C
2. Op P / T = 2.3 bar / 40C
1. Des P / T = 3.5 bar / 120C,38C
2. Op P = 1.6 bar
3, Capacity = 1.34m3
From P-1803 to Charge Heater, E-
1908

Caustic Degassing Drum (V-1908)

1. Des P / T = 3.5 bar / 66C
2. Op T = 38C
From Regenerant surge Drum, V-
1903 & Net Gas Scrubber, C-1902
to Effluent Treatment Plant (ETP)

- Dryer is used to remove moisture and trace sulfur.
Mix Butane Dryer (D-1902 A/B)
1. Des P / T = 25 bar / 345 C
2. Feed flowrate = 6238.7 kg/hr
3. Temp (inlet) = 31.7C
From PMS to DIB Column,C-
1801
DRYER
Make Up Gas Dryer (D-1901
Isoguard Bed Dryer (D-1903)
A/B)
1. Des P / T = 9.5 bar / 120C
1. Des P / T = 42 bar / 345 C
2. Op P = 6 bar
2. Op P / T = 28 bar / 31 C
From Feed Water Cooler, E-
From Knockout Drum, V-1902 to
1904 to Feed Surge Drum, V-
Combined Feed Exchanger, E-
1904
1909 A/B
 HEATER
- To heat
Charge Heater, E-1908 Inter Heater, E-1910

Operating Shell = 35.5 bar Design Shell Operating Shell Design Shell
Tube = 28.5 bar 1. 38 bar 1. 177/197C 1. - bar
2. - C 2. - bar 2. 250C

Tube Tube Tube

1. 45 bar 1. 232C 1. - bar
2. 230C 2. - bar 2. 450C

Inner Inner
1. -C 1. - C
2. 28.5 bar 2. 45 bar

Outer Outer
1. -C 1. - C
2. 32.9 bar 2. 38 bar
 REBOILER
● Reboilers are heat exchangers typically used to provide heat to the bottom of industrial
distillation columns. They boil the liquid from the bottom of a distillation column to generate
vapors which are returned to the column to drive the distillation separation

Operating
Shell : 126.9 C / 1.5 Design
DIB Reboiler
bar Shell : 9.5 bar / 175 C
(E-1803)
Tube : 101.6 C / 8.5 Tube : 12 bar / 175 C
bar

Operating Design
Stabilizer Shell : 91 , 40 C / Shell : 24.5 bar / 120
Reboiler 22.2 bar C
(C-1911) Tube (HP Steam) : Tube (HP Steam) :
143 C / 3 bar 19 bar / 120 C
 VAPORIZER
Vessel (Butane) Tube
Operating : 43 C / 3.2 bar Operating : 143 C , 43 C / 3.2
Butane Vaporizer bar
(E-1806) Design : 73 C / 8 bar
Design : 200 C / 5 bar

Regenerant Shell Tube

Vaporizer (E- Design : 153 C / 24 bar Design : 120,175 C / 0.5 bar
1906)

Raffinate Shell (Pentane) Tube

Operating : 100 C / 3.5 bar Operating : 126 C / 8.4 bar
Vaporizer (E-
1805) Design : 12 C / 175 bar Design : 175 C / 9.5 bar
 Reactor
● There are two (2) Fixed Bed Catalyst Reactors in butane plant.
 04
PROCESS
DESCRIPTION
 PETRONAS Metering Station (PMS)

Supplier Drawn pressure

Supply mixed Butane to Mixed Butane drawn at
as raw material 22-32 bar.

Decrease pressure Boosted by pump

Before entering mixed If <15 barg, mix butane
butane driers (D-1902 will boosted by booster
A/B), the pressure is pump. It will be drawn
reduced at 15 barg. via pump bypass line
into driers.
 Mixed Butane Driers
2 driers in normal operation & The reading of moisture
1 for regeneration operation need to be below than 0.05
(operate when only required). ppm (using moisture
analyser)

01 02 03 04 05

To remove moisture Has molsieves and it has N-Butane will fed in this
and trace of sulfur 500cycles of life. Adsorbent drier from bullets (T-
adsorbs water and trace 1801A/B) for recycle.
sulfur, CO,CO2.
 De-Isobutane (DIB) Column
Separate
To separate isobutane, n-butane,
lights and heavies (mainly
pentanes).
Lights and Heavies
Lights : release at top condenser
and reflux into the column
Heavies : mostly pentanes, drawn
from the bottom and diverted into
the raffinate vapouriser. It will
goes to boiler as fuel gas.
Physical
120 trays –
Feed : 86th, 88th & 96th
Product : 116th (isobutane) & 22nd
(n-butane)
2.4m diameter(D)
61m heights(H)
Condition
7.5 barg & bottom temp 103-110⁰C
Flow
2 outlet streams for isobutane.
Stream 1: Top isobutane is refluxed
into DIB Column, passing through
condensor and vessel.
Stream 2: isobutane flow into
isbutane guard bed drier.
 Butamer
2 4
The isomerization reaction takes
place in H2 atmosphere to The flow goes to 2 reactors
MINIMIZE CATALYST (Fixed Bed Catalyst Reactor) V-
COKING and LIGHT ENDS 1906A/B, operated in series and
FORMATION. Mixture of H2 only one will be in line during
and HC goes to charge heater catalyst change.
(heat up to 190C)

1 3
Isobutane is subcooled in water Perchloroethylene (PCE) is
cooled exchanger and pass injected at suction line of charge
through a drier (guard bed). It heater (E-1908). It is to maintain
goes to a feed surge drum. then it the chloride content on the
will be pumped into the catalyst (Aluminium Chloride),
combined feed exchanger. reduce the activity of the catalyst.
 Butamer
6 8
The traces of sulfur available in feed gets
coated on the catalyst and reacts with H2
gas and forms as H2S. The catalyst
activity will drop if more sulfur is
deposited on it. Hence, the unit has to
under go stripping process (hot H2 is
passing through the catalyst bed for some
period, 24hrs)
High differential temperature will
pressurize the H2 to flare to cool
down the reactor. From reactor
passing through feed exchanger to
stabilizer, the fluid will contact with
30 trays (sieve tray) which separates
the lights (C1-C3), HCL, H2S and
H2 gas.

5 7
The reaction is endothermic, thus The outlet of lag (2nd) reactor will be
the outlet temperature of lead having the mixture of i-butane, n-
reactor will drop. The flow is heated butane, lights (C1, C2, C3), HCL,
through inter heater (E-1910) using H2S and free H2 which goes to
HP steam. Most of the reaction is stabilizer (C-1901). Reactor pressure
completed in 1st reactor meanwhile is 33 barg by using control back
the 2nd reactor is for touch up. pressure.
 Butamer
10
The gas scrubber (C-1902) is a packed
tower that 10% caustic is circulated at 1 st
bed of packing (carbon raschig rings) and
water is at 2nd bed to NEUTRALIZE HCL
AND H2S and wash out the caustic trace.
The caustic is drained to degassifier (to
ETP) and vent (to flare).

9 11
The stabilizer operating condition is
Top gases will go to fuel gas
22 barg and 112C (bottom). Top
tank/receiver to be used as fuel for
column = light gases non-
boiler. H2 content at top of scrubber
condensable (will proceed to net gas will be monitored by sampling and
scrubber (C-1902)) feed ratio is adjusted manually.
Bottom column (main stream) = i-
butane and n-butane. (will go into
DIB column (C-1801))
 H2 System

SOURCE OPERATING CONDITION FLOW

Drawn from Air Product
(company) trailer. There
are 3 trailers which is
interconnected.
Trailer = 200 barg H2 Header will go through
Header TCLM = 40 barg moisture trap and H2 driers
before enter the process. The
driers will under go
regeneration process if
required and similar to mix
butane driers.
 04
CONCLUSION
The pure product which is n-butane will be
stored in the bullets, T-1801A/B and flow
directly from butane vaporizer to the next
process, oxidation process in Oxidation
Plant.