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GENERAL GUIDELINE FOR OPERATING OLEFLEX UNIT (AREA 200)

BYPASSING REACTOR EFFLUENT CHILLER (EB-0232)


1.0 Purpose: The guideline is intended to assist Panel Operator to reduce CCR
catalyst circulation rate to gradually reach 900 lbs/hr from current 1200 lbs/hr
without having a coke breakthrough either into the Transition or the Drying
Zone.
2.0 Scope: This guideline is only applicable for White Burn mode and only for the
period before the TA2014 shutdown.
3.0 Basis: The CCR circulation rate reduction is motivated by the need to study the
behavior of the burn temperature fluctuation and the peak temperature location
which currently is located very close to the top blank-off area of the Regenerator
screen. The reduction in CCR rate is expected to increase the coke build up,
which at lower O2 concentration, is anticipated to shift the burn front far down
from the blank-off transition weld seam. The burn temperature fluctuation at
the top (TI-7020B/C) is not verified to be positively correlated to CCR rate
reduction, however the shift in the peak temperature to lower area of screen at
lower O2 level is expected to reduce the top temperature fluctuation.
Expected process impact:
i.
ii.

Potential coke build up to 3-4 wt% on spent catalyst.


Potential ROT#3 limitation due to higher spent coke in R-203.

iii.

Potential impact on production if RIT adjustment required.

iv.

Potential coke slippage to TZ or DZ if O2 control is not managed.

v.

Reduced catalyst fines generation.

vi.

Regenerator burn profile temperature changes and peak temperature


transition.

4.0 Guideline:
4.1 CCR Circulation Reduction
The CCR rate reduction will be done after CCR burn temperature
profiles are stable, at least for the past 24hr. RIT adjustment should be
avoided as much as possible to ensure no unexpected coke batches
entering the Regenerator. The rate reduction should be stopped if any
abnormal temperature rise is noted at either TZ or DZ upon rate
reduction or on the next rate reduction. Reduction of CCR circulation

rate is expected to shift the peak temperature to the top, but this is only
temporary as the coke build up would shift down the profile again.
This activity should be done at ONLY 5% REDUCTION EVERY 12H to
enable sufficient time for proper observation of temperature changes and
change in O2 demand.
4.1.1 Ensure all required readings are noted in the attached table before
first CCR circulation rate reduction is done.
4.1.2 Oleflex process should be stable and no RIT or H2/HC adjustment
should be done prior to or during the exercise.
4.1.3 Ensure the O2 demand valve, AV-7001 is stable and not trending
up or down significantly
4.1.4 Reduce CCR rate by 5% at the beginning of the Shift if all other
CCR parameters are stable.
4.1.5 Observe the process for the next 12 hours and fill in the parameters
table at the end of the 12 hours.
4.1.6 Adjust O2 within controllable range of 0.6-0.8 mol% if required,
else leave the setting as status-quo. The aim is to keep O2 at lower
range to allow the coke front to move lower into the tower. If AV7001 opening increases by 5-10% higher, introduce Upper Air into
the tower to maintain the normal valve output.
4.1.7 Monitor closely the changes in the TZ and DZ temperatures. If
temperature in the DZ increases by 5-10 degC, this may indicate
coke travel into DZ. Increase O2 setting by 0.05-0.1 mol%, and
temporarily decrease CCR rate further to slow down the coke
movement. This would temporarily assist coke to burn at BZ
instead of TZ or DZ. Adjust O2 higher if required based on TZ or
DZ temperature. In worst case, the operation should be switched to
Black Burn mode and later Dual Zone Burning mode. This would
be required if DZ temperature exceeds by 15 degC.
4.1.8 If operation is switched to Black Burn or Dual Zone Burning
mode, then do not reduce CCR rate any further until White Burn
mode is re-established.
4.1.9 Sample both Regenerated and Spent Catalyst coke every 8h and
record in the table provided.
4.1.10 As long as Spent Catalyst coke does not exceed 3.5 wt%, continue
reducing CCR circulation rate every 12hrs. The steps are repeated
as long the burning remains within BZ, and no significant increase
in temperature is observed at TZ or DZ. Monitor the Regeneration
Tower pressure closely, since air demand would rise when coke
builds up more, but AV-7001 may open higher and reduce the
tower pressure.
4.1.11 The final CCR circulation rate should be around 900 lbs/hr as long
Spent Catalyst coke does not exceed 3.5 wt%. Else return to
previous circulation rate if coke results indicate higher than 3.5 wt
%. However do not increase CCR rate abruptly without adjusting

the O2 content higher, since this would lead to coke travelling to


TZ or DZ.
4.1.12 If and when all temperatures and coke levels have stabilized,
reduce bottom air by 20-40 kg/hr. This is done only once and
should be done carefully to minimize rise in the DZ temperature
due to increase in catalyst thermal mass.
4.2 Process Parameters
Time
CCR Rate
BZ Peak
Temp &
Location
TZ Temp
Peak
DZ Temp
Peak
O2 %mol
AV-7001
Opening
Spent
Catalyst
Coke
Regenerated
Catalyst
Coke
Tower
Pressure (or
PI-7043)
Upper Air
FC-7041
Lower Air
FIC-7037
ROT#3 TI2025 & TI2026
DeltaT #3
RIT#3

28/03
07:00

28/03
19:00

29/03
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29/03
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30/03
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30/03
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