Gasoline Merox

INDEX
S. NO.
1.0
2.0
DESCRIPTION
PAGE NO.
General
Introduction
1.1
Glosssary
1.2
Plant Description
Design Basis
2.1
2.2Process Description
2.3Equipment Description
2.4
Process Principles
2.5
Simplified Flow Diagram
2.6
Material Balance
2.7
Unit Layout Plan
2.8
Feed and Product Specification
2.9
Utility Description
2.10
Utility condition and requirement
3.0
4.0
5.0
Interconnectivity
Precommissioning Activities
Normal Start-Up
Process Variable
6.0
7.0
Normal Shutdown.
Emergency Shutdown Procedure
/var/www/apps/conversion/tmp/scratch_5/312514705.rtf
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8.0
Unit Protection System
9.0
Laboratory Requirements and Schedule
10.0
11.0
12.0
Equipments and Instruments Summary

Special Procedure
Reactor Hot Bed Washing.
Catalyst Reimpregnation
12.1
List of Special Equipments.
12.2
Trouble Shooting
13.0
14.0
Chemical Consumption During Initial and Normal

Operation.
Fire & Safety
15.0
16.0
2 / 66
CHAPTER1
GENERAL
1.1 INTRODUCTION
Petroleum distillates normally contain small amount of mercaptans
(organic sulfur compounds) which impart obnoxious odour to the
product.
The LPG feed from FCC and Delayed Coker may contain some
mercaptans, but most of them are formed during cracking reactions.
Mercaptans are also formed when sulfur compounds decompose or H 2S
and olefins react. Mercaptans may be alkyl or aryl in nature.
UOP Merox process is an efficient and economical catalytic process for
the treatment of light hydrocarbon products . This process is used for
the conversion of mercaptan sulfur to another less objectionable form
of sulfur compound or remove the mercaptan sulfur from the
distillates. The UOP Minalk Unit (Minimum Alkali) is employing a
sweetening process to oxidize mercaptans to disulfides using air as the
source of oxygen. This reaction proceeds at nominal temperature in
presence of a catalyst in alkaline environment.
Merox treatment has the following objectives
1. To improve lead susceptibility of light gasolines
1. To improve the susceptibility of gasoline to oxidation inhibitors
1. To improve the odour of the products
2. To meet product specification
3 / 66
1.2
GLOSSARY
azeotrope
a mixture of substances that behaves as a single

substance in that the vapor produced by partial
evaporation has the same composition as the
antioxidant
barrel
BPD
caustic
C/H
disulfide
liquid.
chemical additive to inhibit oxidation reaction.
42 U.S. gallons measured at 60F
barrels per day (also BPSD)
sodium hydroxide solution
caustic/hydrocarbon volume ratio
class of sulfur compounds characterized by a
sulfur-to-sulfur bond and relatively low volatility
EP
extraction
GC or GLC
gph
gpm
gum
hydroperoxide
represented by the general formula RSSR.

endpoint (ASTM distillation).
removal of mercaptan sulfur from hydrocarbon.
gas chromatography
U.S. gallons per hour
U.S. gallons per minute
polymerized hydrocarbon
compound responsible for propagation of gum
IBP
inhibitor
forming chain reaction (-OOH)

initial boiling point (ASTM distillation)
compounds
responsible
for
delaying
LHSV
mercaptan
terminating a chemical reaction

liquid hourly space velocity
common name given to class of compounds
or
having thiol functional groups represented by the

naphthenic acid
Nm3
std. m3
organo-metallic
general formula RSH

organic (carboxylic) acid
normal cubic meter ( 1 atm. 0C)
standard cubic meter ( I atm. 15C)
complex compound characterized
PW
carbon to metal bonds

prewash
re-entry sulfur
entrained disulfide sulfur in regenerated caustic

that
enters
and
dissolves
into
by
the
weak
exiting
4 / 66
RX
SCFH
sweetening
hydrocarbon product from an extractor

reactor
standard cubic feet per hour ( 1 atm. 60F)
conversion of mercaptan to disulfide without
stability
desulfurization
quality of a fuel to remain unchanged for long
thiol
thiophenol
periods of time in storage

sulfur-to-hydrogen bond
common name given to aryl mercaptans: also the
compound C6H5SH
5 / 66
CHAPTER2
2.1
PLANT DESCRIPTION
DESIGN BASIS
This unit is designed to process 30,000 BPSD of Gasoline which will be

coming from Main column section and unsaturate gas concentration
section of FCC unit ( 413 , 414 ). Gasoline containing 90 ppm RSH
( Max. ) and 1 ppm H2S ( Max. ) can be processed in this unit. This unit
can process Light Mogas and Heavy Mogas. .
URG COMPONENTS (Light Mogas) ::
1.
Naphtha Splitter Overhead stream (C5-105 deg C)
2.
Depentaniser bottom stream (C6-105 deg C)
3.
Deisohexaniser overhead stream (iC6)
RFG COMPONENTS: (Heavy Mogas) :
1.
Naphtha Splitter sidecut stream (105 180 deg C)
2.
Heavy cracked Naphtha stream (180-215 deg C)
6 / 66
2.9 UTILITIES DESCRIPTION

LP STEAM SYSTEM
Refer P & ID :G 42 RF 416 101

A 6 header provided with battery limit isolation valve, blind, local PG
100, TG 050, DCS flow indication ( FI060 ), totaliser indication ( FQI
060). Main header divided into several branch headers, which supply
LPsteam to the following equipment.
A 6 header supplies LP steam to Desuper heater
The unit is also provided with 10 Nos. of LP steam utilities stations.
COOLING WATER SYSTEM
Refer P & ID :G 42 RF 416 121

A 12 cooling water supply header provided with battery limit isolation
valve, blind, local PG 103, TG 051, DCS flow indication ( FI 061 ),
totaliser indication ( FQI 061). A 12 cooling water return header with
battery limit isolation valve, blind, local TG 052 and corrosion coupon
CC001.
Cooling water distribution :
7 / 66
A 8 Cooling water supply header is provided to Gasoline Cooler

No.1 (S51), S52, S53. Same size of return header is provided.
A 6 Cooling water supply header is provided to spent wash water

cooler(S54). Same size of return header is provided.
POTABLE WATER DISTRIBUTION SYSTEM
Refer P & ID :G 42 RF 416 122

A 3 potable water header provided with battery limit isolation valve,
local PG 105, TG 053.
The main header serves potable water to the following points.
fountain through 3/4 line.
Safety Drinking water Shower & Eye wash ( PYWRF001) through 1

line.
COLD CONDENSATE SYSTEM
Refer P & ID :G 42 RF 416 122
8 / 66
A 6 cold condensate header provided with battery limit isolation

valve, local PG 107, TG 055, DCS flow indication ( FI 063 ), Flow
recorder ( FR 063 ).
The main header serves cold condensate to the following points.
A 4 line to water heater ( Y 52 )
A 4 line to Caustic storage tank ( MT RF416- 01 )
UTILITY WATER SUPPLY SYSTEM
Refer P & ID :G 42 RF 416 122

A 2 potable water header provided with battery limit isolation valve,
local PG 106.
The main header serves Utility water to the following points.
To pump seal P 01 A. ( line).
To pump seal P 01 B. ( line).
9 / 66
The unit is also provided with 10 Nos. of utility water stations.
FUEL GAS SYSTEM
Refer P & ID :G 42 RF 416 131

A 3 header provided with battery limit isolation valve, local PG 114,
TG 071, DCS flow indication ( FI 062 ), flow recorder ( FR 062). Main
header divided into several branch headers, which supply fuel gas to
the following equipment.
A 3 header supplies fuel gas to URG header for startup purposes.
A 2 header supplies fuel gas to LP flare header.
A 2 header supplies fuel gas to LP flare sub header.
PLANT AIR SYSTEM
Refer P & ID :G 42 RF 416 141

A 3 plant air header header with battery limit isolation valve, local PG
109.
10 / 66
A 1 header is supplying air to Caustic storage tank(MT-RF416 -01)

The unit is provided with 10 Nos. of plant air utility stations.
NITROGEN SYSTEM
Refer P & ID :G 42 RF 416 141

A 2 plant air header provided with battery limit isolation valve, local
PG 108.
Main header divided into several branch headers, which supply
Nitrogen to the following equipment.
A 1 header supplies Nitrogen to Reactirs (R01,R21) and for R31 &

R41 (future).
A 2 header supplies Nitrogen to LP flare header.
A 2 header supplies Nitrogen to LP flare sub header.
BREATHING AIR SUPPLY SYSTEM
Refer P & ID :G 42 RF 416 142

A 2 breathing air header provided with battery limit isolation valve,
local PG 111 and DCS pressure indication ( PI 135 ) with low pressure
and high pressure alarm.
11 / 66
The unit is provided with 1 Nos. of breathing air utility stations.
INSTRUMENT AIR SUPPLY SYSTEM
Refer P & ID :G 42 RF 416 142

A 2 instrument air header provided with battery limit isolation valve,
local PG 110.
Various instrument air tapping are taken from this header.
LP FLARE AND RELIEF SYSTEM
Refer P & ID :G 42 RF 416 111

A 18 flare header provided in the unit enters LP flare knockout drum
( 415 V 17 ). The header is provided with battery limit blind, isolation
valve(Valve up side down), local PG 101.
12 / 66
The PSVs & vent etc. ..discharge to LP flare header.
PSVs on Reactor (R 01) 101 A/B.
PSVs on Reactor (R 21) 121 A/B.
PSVs on Reactor (R 31) 131 A/B. (future)
PSVs on Reactor (R 41) 141 A/B.(fututre)

PSVs on Gasoline feed cooler No.1 (S51)
PSVs on Gasoline feed cooler No.2 (S52)
PSVs on Gasoline feed cooler No.3(S53)
The header is provided with battery limit blind, isolation valve(Valve

up side down), local PG 044 and sampling point.
Fuel gas purge to main header through PCV 090.
Nitrogen PCV 091 for purge connection.
CLOSED DRAIN (CRACKED SLOP) SYSTEM
Refer P & ID :G 42 RF 416 152

Underground main header of 6 size provided in the unit with several
branch header connected to it for collecting drain from various points.
All lines are connected to headers or branch header are provided with
13 / 66
an isolation valve and spectacle blind. Following drains are connected

to main header.
Drains from S51
Drains from S52
Drains from S53
Drain from HV015, HV017, PSV 153, PSV 154
Drain from R01,
Drain from sample points PA002, PA004, PA007, PA009.
Drain from R21.
Drain from PA005, PV001, PA010 and PV002.
This header is discharging into V 09 ( CRACKED SLOPS DRAIN TANK).

This tank is provided with 2 nitrogen supply line through PCV 072,
local press indicator PG 053 and Flow Orifice FO 050. V09 is provided
with pump P 06A & local PG 053 which is discharging to Cracked slops.
P 06A motor is on auto start from DCS MHS 020, run hours ML 020,
based on LI 030 low low level stop and high high level start facility is
also provided. V 09 is vented to LP flare through 8 line, which is
provided isolation valve (Valve up side down) and blind.
CLOSED DRAIN (CAUSTIC) SYSTEM
Refer P & ID : G 42 RF 416 151

Underground main header of 6 size provided in the unit with several
branch header connected to it for collecting drain from various points.
14 / 66
All lines are connected to headers or branch header are provided with
an isolation valve and spectacle blind. Following drains are connected
to main header.
From V 04 (2 line).
From MP RF 416 P51A (3/4 line).
On spent caustic line to ETP (2 line)
From LG022 and LT001 drain( both these combined and come in
2line)
From LG023, LT002
From LV002 drain (1 line)
From LV 001 (1 line).
Drain (2 line) from Caustic Storage tank , LG020 drain(3/4 line) and
LG020 drain(3/4 line) joins in a sub header (6 line) and this
subheader joins the main header.
This header is discharging into V 08 ( CAUSTIC DRAIN TANK). This tank
is provided with 2 nitrogen supply line through PCV 073, local press
indicator PG 061 and Flow Orifice FO 051. V08 is provided with pump P
05A & local PG 060 which is discharging to caustic system. P 05A
motor is on auto start from DCS MHS 021, run hours ML 021, based on
LI 031 low low level stop and high high level start facility is also
provided. V 08 is vented to LP flare through 8 line, which is provided
isolation valve (Valve up side down) and blind.
15 / 66
2.4 PROCESS PRINCIPLES

The word `Merox' has been derived from the prefixes of
2 words MER - Captan and OXidation. The Merox process is a
chemical treatment of Hydrocarbons to remove mercaptans
or to convert mercaptans into disulfides. The principle is
based on the ability of catalyst to promote the oxidation of
mercaptans to disulfides at ambient temperature using air as
the source of oxygen.
Mercaptans are represented by general formula
RSH, where ` R ' stands for hydrocarbon alkyl group and `SH'
for mercaptan group consisting of sulphur and hydrogen
atoms. Mercaptan concentration is represented in terms of
the sulphur in the mercaptan molecule.
Mercaptans are undesirable in finished petroleum
products, due to odour, stability and total sulfur content. In
Gasoline Merox treatment a fixed bed sweetening is used.
The Merox 8 catalyst (It is an activated carbon which
have been impregnated with Merox F B reagent ) which is
water insoluble is deposited on a support bed of a selected
granular activated charcoal. Merox 8 is loaded directly into
the fixed bed reactor and requires no additional impregnation
or activation prior to use. The activated charcoal bed
adsorbs
Phenols ,
Naphthenic Acids and
Basic Nitrogen compounds, which affect the conversion
reaction.
The Hydrocarbon (Gasolinee), air, and caustic
are
simultaneously contacted
over a solid support
(charcoal bed) in the reactors, impregnated with Merox
catalyst. The sweetening reaction proceeds at normal refinery product rundown temperature, in the presence of alkali
and Merox Catalyst according to the following formulae.
4RSH + O2 ------------->
2SSR + 2H2O
RSH + NaOH ---------> NaSR + H2O
--- (1)
---- (2)
16 / 66
Merox
2NaSR + 1/2 O2 + H2O -----> -------- + 2NaOH + RSSR
----(3)
catalyst
Mercaptans, react with sodium hydroxide to form sodium
mercaptide and water, which is reversible. The sodium
mercaptide is then oxidized over Merox catalyst, to form
disulfide, thus regenerating sodium hydroxide. The total
reaction is as follows;
4 RSH + O2 ------------>
2 RSSR + 2 H2O
------- (4)
The disulphide is insoluble in caustic and remains in

the Gasoline.
CHAPTER 6
PROCESS VARIABLES
6.1
FEED
STOCK PROPERTIES:-
Hydrogen sulfide :The presence of sulfide suppresses

the oxidation of mercaptan, as sulfides get oxidised at
a slower rate than mercaptan.
Hydrogen Sulfide if
present in the feed stock results in formation of Sodium
Sulfide which gets oxidised to Sodium Thiosulphate.
This is a neutral salt which causes no hindrance except
that it consumes more caustic.
Boiling range : As the end point of feed stock is
increased the presence of catalyst poison in the feed
increases and it becomes more and more difficult to
convert the mercaptan present in the feed.
17 / 66
Mercaptan
: As the concentration of mercaptan
(RSH 90 WtPPM max) increases the ease of treating
decreases. Also the molecular structure of mercaptan
determines its ease of sweetening. Generally branched
secondary or tertiary alkyl mercaptans, do not get
sweetened as easily, as primary mercaptan.
Sweetening is defined as conversion of Mercaptan to
dilsulfide or some other form of innocuous sulfur
compound, without actually removing it.
6.2
REACTION TEMPERATURE
The higher the temperature the easier the oxidation of

mercaptan processes.
But in normal operation the
reaction temperature of Gasoline will be kept at 38 50C.
6.3
REACTOR PRESSURE :Sufficient pressure ( 5.7 kg/cm2) should be held on reactor to keep air in dissolved form. The pressure should
be sufficient to consume all the air used while
sweetening.
Channeling will take place through the
reactor if a separate air phase is present. Pressure drop
across reactor should be less than 0.7 Kg/cm2
6.4
AIR
INJECTION RATE
:-
Air injection is controlled to provide 120 to 200 % of the

stoichiometric oxygen requirement. The stoichiometric
oxygen requirement is 0.89 NM3/Kg/RSH-S present in the
feed. Air is injected by means of air compressor ( C 01
A / B ) through FIC 003. The air injection rate is
governed by the Gasoline feed rate, and mercaptan
sulfur loading. Air must be completely dissolved in
the Gasolineo
by sufficient
system
pressure.
Undissolved air will cause channeling in packed beds
of charcoal and it must be vented off the system and
18 / 66
appropriate actions must be taken to avoid the

situation. Hence air to be injected slowly to required
level.
6.5
ALKALI INJECTION RATE :

Injection of dilute caustic (3Be) is done on ppm
basis. First enough caustic is injected to supply the alkalinity required to maintain the mercaptan sweetening
reaction.
Additional caustic will be consumed by H2S.
The amount of spent caustic will vary according to
moisture in feed, temperature of feed stock, H2S
content and air injection rate.
6.6
CATALYST
UOP Merox 8 ( 44 m3 /reactor) is the catalyst used. It
is in solid form ready to use. The Merox catalyst is not
dispersible in caustic and this property prevents the
caustic from removing the catalyst from the charcoal
surface.
6.7
UOP MEROX PLUS (CATALYST PROMOTER)

7.4 Ltrs/hr (Max)( Typical inj.rate is 1.5lL/hr) of UOP
Merox Plus is continuously added to the reactor charge.
This is because, over a period of time gradual catalyst
deactivation occurs as evident by a gradual increase
in the RSH content of the product. Merox plus is a
reagent, a liquid activity promoter, that boosts the
catalytic activity of the system and extends the treatment period.
This is an alternative to avoid
unscheduled hot water washing to remove foreign
materials absorbed by charcoal and
effecting
reactivity of the catalyst. In short Merox Plus allows
long term stable operations for all fixed bed Merox
applications and can extend run length, increase unit
flexibility and reduced air and caustic consumption.
19 / 66
2.2
PROCESS DESCRIPTION
Gasoline (Light Mogas and Heavy Mogas) from Main
column section and Unsaturate Gas concentration
20 / 66
sections of the FCC ( 413 & 414 ). Light Mogas is

received at Gasoline Merox B/L by a 10" line, provided
with block valve and bleeder valve at 9.0 Kg/cm2g
pressure and 112C temperature and Heavy Mogas at
6.5 Kg/cm2g pressure and 91oC.
Gasoline(Light Mogas at 91 deg C and 6.5 Kg/cm2g and
Heavy Mogas at 112 deg C and 9 kg/cm2g are coole din the
Gasoline Feed coolers (S52 and S53) .The Gasoline is flow
is measured by the flow transmitters FT 015A/B. To this
Gasoline stream 3 o Be caustic from 3
Be caustic storage
tank ((MT RF 416 01) pumped by caustic injection pumps

P01 A and P21 and Merox Plus (activity promotor) pumped
by Merox Plus injection pumps P02 A and P22 are joined.
The caustic injected Gasoline is mixed with the air in a
special mixer and this air plus Gasoline mixture is sent to
Reactor R01 and R21 where the catalytic oxidation takes
place. The air is supplied from air compressors in Kerosene
Merox unit. The normal flow is 53kg/hr at 12.9 kg.cm2g
and 55 deg C. The air flow is controlled by FV 016 for
Reactor No. 1 and FV 018 for Reactor No.2. Air line is
provided with ESD valves XV 001 and XV002 . When the
Gasoline flow is low as sensed by FT 015A/ FT 015B the
ESD valve XV 001 on the air line to Reactor No. 1 will
automatically get closed. Similarly for the Reactor No.2
FALL 017 will trip XV 002. To the treated Gasoline UOP No.
5 inhibitor is added to increase the oxidation stability. The
pressure in the reactor is controlled by the backpressure
controllerPIC 001 for reactor No.1 and by PIC 002 for
reactor No.2
MEROX REACTOR ( R 01 )
21 / 66
Merox reactors, is a vertical vessel packed with UOP

Merox 8 (It is an activated carbon which have been
impregnated with Merox F B reagent ) catalyst. The
function of the activated carbon is to provide a vast
surface where Mercaptan, catalyst, caustic and oxygen
may come into contact for completion of the sweetening
reaction. To provide the alkaline medium the charcoal
is kept saturated with caustic solution with intermittant
flow of caustic ( 3o Be ) by circulation pump P 01 A / B.
Reactor consists of an upper inlet distributor, lower side
outlet collector and bottom drain screen.
The
function of the inlet distributor is to provide a uniform
lateral flow distribution over the reactor cross section.
The distributor holes are oriented upward. The outlet
collector
and
vessel drain pipes are specially
constructed stainless steel and provided with UOP
Johnson screen Reactor bottom header is filled with
concrete and epoxy resin coated. Merox promoter
(UOP Merox Plus) is continuously added to the reactor
charge at the reactor upstream at a rate of 1.5 Ltrs/hr.
Air under FIC 016 is sent to a mixer where it is mixed
with hydrocarbon charge and then sent to the reactor.
This stream then proceeds downward over the Merox
catalyst bed. The Mercaptans present in Gasoline are
converted to disulfides which goes along with the
sweetened Gasoline.
2.8 FEED AND PRODUCT SPECIFICATIONS
RSH - S wppm
H2S wppm
Operating Conditions
Inlet pressure Kg/cm2 g
Inlet temperature C
:
:
90 ( Max.)
1 ( Max.)
:
:
7.7
38
22 / 66
Product Quality
Mercaptan
5 ppm
2.3 EQUIPMENT DESCRIPTION :

MEROX REACTOR (R 01 )
Merox reactors, is a vertical vessel packed with UOP

Merox 8 catalyst (It is an activated carbon which have
been impregnated with Merox FB reagent, which is not
soluble in water ). Merox reactor consists of an upper
inlet distributor, lower side outlet collector and bottom
drain screen.
The function of inlet distributor is
designed to provide a uniform lateral flow distribution
over the reactor cross section. The distributor holes are
oriented upward. The outlet collector and vessel drain
pipes are specially constructed stainless steel and
provided with UOP Johnson screen. Reactor bottom
head is filled with concrete and epoxy resin coated.
The flow of the hydrocarbon, caustic and air is
charged downward through the bed. The sweetening
reaction takes place during, the course of movement
through the charcoal bed.
Particulates in the feed will be absorbed on and filtered
out by the charcoal bed. Hence a hot water washing
23 / 66
procedure for removing foreign materials absorbed by

the charcoal is done whenever required.
It is provided with following connections :

vent
1 No.
6 Inlet for Gasoline feed
1 No.
12outlet for Gasoline 1 No.
2 Air vent
1 No.
4 Drain.
1 No.
There are two safety valves located on the top of
the reactor PSV 101 A / B, which are set at 17.5 kg/cm2 g
pressure to safeguard the vessel from emergency.
Discharge of these PSVS are routed to LP Flare.
The purpose of reactor is to allow the catalytic oxidation of
mercaptans to disulfides. The vessels dimensions are 3100
mm I.D and a total tangential length of 6400 mm. The vessel
has got a inlet distributor (6) for the feed. The vessel is
provided with MEROX No. 8 catalyst . The height of the
packing is 5500 mm. Merox No.8 is charcoal impregnated
with Merox FB reagent. The vessel has got collector of 12
size. The vessel is designed for an internal pressure of 18.7
kg/cm2g at 70 deg C. The Vessels material of construction is
carbon steel. The outlet os the reactor pipe is provided with
a drain screen.
Drain Pot No.1 (V02, V22) :

The vessel dimenstions are 450 mm I.D and a total tangential
length of 900 mm. The vessels material of construction is
carbon steel. The vessel is designed for an internal pressure
of 18.7 kg/cm2g at 70 deg C.
Inhibitor Injection Tank (V51) :
The purpose is to store the UOP No. 5 inhibitor. The vessel
dimensions are 600 mm I.D and a total tangential length of
24 / 66
750 mm I. D . The vessels material of construction is carbon

steel. The vessel is designed for an internal pressure of 3.5
kg/cm2g at 70 deg C.
CHAPTER 4
PRECOMMISSIONING
ACTIVITIES
Before initial start up;
Each vessel is to be inspected for proper fitting of
internals, valves, pressure gauges, dial thermometer
25 / 66
All lines are to be checked to see that they conform to

the detailed piping drawing Attention should be given to
location of vents, drains, and Gauge Glasses. Each vessel
is to be flushed with water thoroughly to ensure complete
removal of construction debris, muck, rust etc.,
For initial commissioning adequate safety equipment,
fire extinguishers, fire hose connections, emergency eye
wash and showers are required to be provided at various
locations in the plant.
Personnel protective clothing like rubber gloves,
helmets, apron, gum boots, hand gloves, eye goggles, ear
muffs are to be supplied to the operating personnel
Reactor Charcoal Loading, initial Merox
catalyst
impregnation and reactor bed alkalination are to be done
prior to the start up.
4.1
REACTOR CHARCOAL LOADING
Before to loading the charcoal into the unit, all reactor

internals should be installed and inspected. The reactor ( R
01) is a vertical vessel designed to contain the charcoal bed
upon
which Merox catalyst is impregnated . The inlet
distributor spray pattern should be checked to ensure an
adequate distribution with cold condensate.
4.1.1
LOADING PROCEDURE
The Merox Reactor, must be isolated

from the
system
depressurised and blinded.
The top side
manways
opened. The holes in the inlet distributor
should be
protected from plugging during charcoal
loading by wrapping the distributor with canvas or plastic
covering.
A catalyst hopper with telescopic or segmented loading sock, that extends approx. to the level of the outlet
collector pipe, is mounted on the top manway for Merox
8 catalyst loading. The sack position and length are
26 / 66
adjusted as the Merox 8 catalyst loading progresses to

prevent any coning effect which could later cause
maldistribution of Hydrocarbon flow through bed by
channeling.
After the loading of Merox 8 catalyst has commenced
and the bed level is just slightly over the top of the
UOP Johnson screen collector pipe and assembly,
Merox 8 catalyst loading should be stopped. Once the
dust has settled, someone wearing a fresh air pack or
self contained breathing apparatus should enter the
reactor via the bottom side manway to verify that the
collector pipe assembly has been completely submerged
with Merox 8 catalyst and to make certain that there
are no unfilled spaces present underneath any of the
laterals.
The
reactor bottom side manway flange
faces should be checked and a new gasket should be
installed. After the manway is closed Merox 8 catalyst
loading can then be resumed, shortening the sock as
loading progresses.
When the top of the Merox 8 catalyst bed has risen
uniformly to within 750mm of the inlet distributor the
loading is stopped. Towards the end of the Merox 8
catalyst loading, the bed depth can be satisfactorily
gauged by dropping a probe through the reactor
manway. After the dust has settled and the bed is
visible.
Personnel entering the reactor should wear
scot air pack. If necessary additional charcoal may be
loaded to provide a level surface of 450 MM below the
inlet inlet distributor centre line .
A load in diagram is attached showing the appropriate
outages and a record should be kept of the weight,
volume of Merox 8 catalyst loaded.
When Merox 8 catalyst loading is completed
the
hopper and loading sack is removed. Also the Merox 8
catalyst bed is checked for cleanliness and extraneous
matter. The distributor pipe is uncovered and the top
manway positioned and secured on four sides.
27 / 66
4.1.2 DISPERSION
OF
MEROX CATALYST
IN
AMMONIA WATER
The following formula used is to calculate the quantity

of ammonia required for carrying out the reimpregnation.
A = 0.002 W (T - 0.2 L + D/6) (3.14 D2/4)
where
A
= Kg of NH3 required
D
=
Internal diameter of reactor in
meter
L
= Length of charcoal bed loaded in
meters
T
= Tangent length of reactor in meters
W
= Kg/m3 of water
It should be noted that some charcoals are washed with
acid during manufacture and may ultimately required as
much as 50% additional Ammonia.
Unhydrous Ammonia is used for impregnation
/reimpregnation before handling NH3, refer t Industry
Safety bulletins regarding the proper handling of this
toxic chemical. Install the cylinders as shown in figure .
The NH3 cylinder outlet connection should face up. This
will allow liquid NH3 to be drawn from the cylinder
through the internal dip leg. Adjust the NH3 rate into the
circulating water using the globe valve at the point of
addition to regulate the flow. PG 005 will indicate
pressure in cylinder. The rate of addition (observed by
cylinder weight loss), should be adjusted to add, the
required amount over a two hour period.
When the NH3 concentration is stabilised , verify that it
is a min of 0.2 Wt % by case analysis. A minimum NH3
concentration of 0.2 WT% required for good dispersion of
the Merox reagent. High concentration will not have
adverse effects but may present an odour problem.
Obtain the desired quantity of Merox FB reagent
prepare for impregnation as follows :
and
Into a clean 0.2 M3 drum add about 0.1 M3 of circulating

NH3 water.
A small air flow should be provided through the air
sparger to keep the catalyst in suspension. Do not
agitate too much as excessive foam will develop due
to too much air.
28 / 66
Shake the Merox FB container to disperse any reagent that may have settled and pour the contents
directly into the drum upto 15 Kg, 6 bottles of 2.5 Kg
each of Merox reagent may be added to the drum at one
time. If more than 15 Kg of reagent is required the
reagent should be added in equal batches of 15 Kg each.
The recommended quantity of Merox FB reagent, is
approx 1.4 Kg/cubic meter of effective reactor charcoal
inventory which is the charcoal bed volume above the
outlet collector assembly.
Once the reagent has been
transferred to the drum, begin adding it to the circulating
Ammonia water via the Eductor ( Y 51 ).
The total reagent required should be added at a uniform
rate over a four to eight hour period.
Note :
The Ammonia water effluent from the reactor outlet
should remain colurless throughout the initial Merox
catalyst impregnation procedure and this should be
verified by periodically inspecting a sample of reactor
outlet Ammonia water for colour. Should the Ammonia
water from the reactor become intensely blue in colour,
there is reason to suspect channeling of the charcoal
bed in which case the catalyst Impregnation should be
stopped and steps undertaken to remove the bed
channeling. The channeling may be due to several
reasons one being improper distribution by the
distributor pipe due to breakarage etc.,
During subsequent catalyst reimpregnations, a blue
colour will appear in the Ammonia water coming from
the reactor outlet. This is not unusual, since the old
aged charcoal may no longer be able to absorb all of
the Merox reagent. Particularly some of the more
soluble isomers. As little as 1 PPM of Merox reagent is
sufficient to give a faint blue colour to the Ammonia
water.
The following procedure must be used to remove
channels
block in the reactor inlet , outlet lines.
Inject a full amount of air for no longer than thirty

seconds to bubble or fluff the charcoal bed. ,
if convenient, somebody should observe at the

bubble patterns from the top manway.
Large
coagulated bubbles would be an indication of
29 / 66
channeling. A uniform bubble distribution would

be an indication that channeling no longer exists.
When the drum is nearly empty of Merox reagent, flush
it several times with carrier solution and educt this into
the reactor in order to get all the residual recycle/catalyst into the reactor.
Continue circulation of NH3 water
through the reactor for a min of 1 hour if time permits
the circulation should be continued over night, which will
aid in attaining a more even distribution of catalyst on
the charcoal.
At the conclusion of the catalyst
impregnation procedure, the NH3 water is stopped.
The reactor may now be drained using air or Nitrogen
to the sewer.
Open the reactor top manway and obtain an outage
measurement from the top of the bed. Also collect 8 10 spot samples of the impregnated. Charcoal from
predetermined representative
positions at the top
surface of the reactor bed, so as to enable future
determination of the lateral catalyst distribution profile,
if necessary.
These samples should be held
for
analysis in case trouble indicating maldistribution of
catalyst, should develop, when the unit is put into
operation.
Close the reactor manway and bring the reactor upto a
slight positive pressure with Nitrogen added through
vent line. The valves which were opened should be
closed and NH3 cylinder disconnected.
Now the bed is ready for alkalinization.
4.1.3
REACTOR BED ALKALINIZATION :

The reactor charcoal must be alkalinized with 3o Be
aqueous sodium hydroxide solution. Before this. we
have to remove the excess water that is remaining in
balance in the charcoal bed .
30 / 66
Suffficient caustic is to be injected to maintain a pH in

the range of 9 to 12 at the reactor drain pot outlet. The
caustic injection pump P01, P21 to be checked frequently
to assure that sufficient caustic is being pumped to the
reactors.
. The conventional fixed bed Merox reactor is now
prepared to receive some HC feed.
During continuous
operation of a conventional fixed bed or Merox 10 Unit,
the HC feed will gradually wash caustic out of the
charcoal bed. This caustic will collect in reactor water
drain or interface pot. When the caustic on the charcoal
become depleted, mercaptan conversion via the Merox
reaction will cease to take place. However, depletion is
gradual, not sudden. A regular lab analysis program to
determine mercaptan sulfur in the product will show a
gradual increase in mercaptan concentration with time.
This is largely
caused by loss of alkalinity and it
becomes necessary to realkalinize the bed periodically.
The amount of surface active material present:Both naturally occurring sulfonates and naphthenates
and synthetic corrosion inhibitor additives. i.e. if
prewashing to remove Naphthenates is inefficient
realkalinizing of the bed must be done more frequently.
4.1.5 INITIAL COMMISSIONING

Preliminary Inspection :
Inspection is the most
important step in start up preparation. All equipments
must be carefully inspected to see that it conforms in
all respects to the detailed drawing and specifications.
All respective lines should be traced to see that they
conform to the detailed piping drawing
and
specifications. Attention should be given to locations of
vents/drains/gauge glasses pressure gauges, sample
points, pressure gauge, temperature indicator, relief
valves to ensure that they are installed in accessible
locations.
Great attention must be given to installation of trays
packing supports and internal distributors.
Detailed
inspection criteria will be covered later along with
specific loading instructions.
31 / 66
Pressure Testing : After ascertaining by careful check

that all internal equipment is properly installed and all
vessels are clean and free of construction debris, vessel
manholes should be closed and the vessels and piping
should be pressure tested Hydraulically, using water in
accordance with the rating set forth in the pressure
certificate for the particular vessels. Blinds must be
installd in suitable locations to isolate vessels and
equipment which have a lower pressure rating than
the particular
vessel or equipment being tested.
Usually the Hydraulic pressure test is carried out at 1.5
times the design pressure, but the proper test pressures
must be ascertained for each vessel in question.
Very Important : All new pumps should be run for

sufficient time to properly wear in the packing , so that
bearings will not overheat when the pumps are finally
placed in service. In practice it is run for 24 hours,
suction strainers should be in place during this time
and for the first several days after commencing actual
operation. This is for the protection of the pump from
any dirt or construction debris.
Instruments : These must be carefully checked for
correct installation and calibration by a qualified
instrument personnel. All tests that can be performed
to simulate actual operating conditions should be carried
out to ensure that the instrument will operate properly.
All orifice plates should be checked to see that they
conform to the specifications.
32 / 66
CHAPTER 5
NORMAL START-UP
Before the feed is taken into the unit, it is necessary
to expel air from all equipments and pipelines, as it is a
potential fire hazard.
Air elimination can be done by Nitrogen purging.
Entire system is lined up and air elimination done by Nitrogen
purging.
Merox Reactor ( R 01 )
Reactor should be N2 purged to an Oxygen content of
less than 5% by lining up N2 through Reactor vent line.
Reactor inlet , outlet valves to be closed and drain pot exit
valve (i/v u/s of LV001) to be closed..
Ensure all the drains and vents are closed.
Nitrogen Purging should be carried out by
Pressurising the reactor with N2 to approx 15-20 Psig.
Depressurising to atmospheric pressure.
Again pressurising the reactor to 15 - 20 Psig.with N2 and
again depressurising it to atmospheric pressure.
This
method of pressurization and depressurisation should be
repeated until the oxygen content is less than 5 vol%.
Reactor to be pressurised with FG by opening the feed inlet
valve of the reactor.
Now the system is ready for receiving Gasoline.
Steps undertaken operation are ;
Check with blending people ( RTF) whether the designated
tank is ready to receive the product. Then open the B/L
valves. Inform FCC of starting the treatment of Gasoline.
When Gasoline product from FCCU is confirmed to specified
properties, route Gasoline to Merox Unit.
Caustic injection pumps P01A and P21 to be started and
caustic injection to be started at the maximum rate..
Gasoline flow through the unit is lined up as follows:
Gasoline feed ---- Gasoline feed cooler S52 --- HV 015 ---Reactor
(R 01) ---Designated Tank or slop tank.
Gasoline feed ---- Gasoline feed cooler S53--- HV 017
----Reactor(R 21) ---- Designated Tank or slop tank.
33 / 66
The Merox reactors are filled with Gasoline completely and

this is ascertained by overflow in vent line.
Wnem the reactor is full of hydrocarbon, reactor pressure to
be increased to operating pressure with the backpressure
controller.
Inform Kerosene Merox for want of air, open the air flow
indicating controller ( FIC 016 ) to R01 and FIC 018 to R21 to
a desired amount and switch over to automatic operation.
When aqueous effuluent apperas at the reactor water drain
or interface pot, the interface level controller (LIC 001) to be
commissioned and the caustic injection rate in increments to
obtain 9-12 pH drain effulent.
Start the Merox plus injection pump ( P 02 A and P22) to
inject Merox plus activator into the untreated Gasoline line.
The system pressure controlled at 3.5 Kg/cm 2g by PIC
001 for R01 and by PIC 002 for R21..
Sample product for doctor test. If negative, treated
product can be sent to storage tank .
34 / 66
CHAPTER 7
NORMAL SHUT DOWN

Usually normal shutdown takes place to carryout
scheduled turn around for maintenance jobs.
Just before shut down, inform
RTF to switch over
Gasoline rundown as there will be no more sweetening and
confirm, that Gasoline rundown switched over to some
other tank.
Cut off air injection to R01 reactor by closing FV 016 and
to R21 by closing FV018. Inform Kerosene Merox about the
shutdown.
Divert Gasoline flow to slop tank.
Block off Gasoline
Merox battery limit Valve. Depressure Merox Unit through
back pressure control. Then pump out through P 51 A to
slop tank.
Stop caustic injection pump (P 01 A and P21) to cut off in
caustic injection.
Stop Merox plus injection pump P 02A and P22 to cut off
the injection of catalyst activated.
Complete isolation must be attained between feed stock
line and injection lines of air and caustic soda by closing
each isolation valves located upstream of injection points.
7.1
TRANSFERRING INVENTORY LIQUID

Use the globe valve for caustic disposal and
monitoring the gauge glass and take care to ensure that
the Hydrocarbon does not go to spent caustic in tank.
Pump out the Gasoline in the following vessels to the
HC slop oil tank by using caustic circulation pump (P 51
A), Each vessel must be under a slight pressure to avoid
pulling a vacuum. This can be done by a small flow
stream of Nitrogen through the following vessels.
R 01
R21
Merox reactor
Merox Reactor
35 / 66
N.B : Permanent steam connection is provided for the

following vessels :
7.2
PREPARATION FOR MAINTENANCE

Steam out unit thoroughly
N.B. : (1) Reactor must be steamed out
from top to bottom inorder not to disturb the charcoal
bed.
Install isolation blind when required (as per
master blind list). Open vessels certify and condition
vessels for safe entry.
8.2
8.3
36 / 66
CHAPTER 8
EMERGENCY SHUT DOWN

PROCEDURES
An emergency shut down warranted if on or more
combinations of the following occurs.
FCCU upset/feed failure.
Power Failure
Instrument Air Failure
Steam Failure.
For all the above, the unit can be temporarily isolated, until
the failed service is brought back to normal condition, can
then be restarted simply by opening the isolation valve.
It should borne in mind to protect the product tanks, as
contamination should be avoided.
(1) FCCU Failure
Bypass Gasoline Merox and route the Gasoline to slop
immediately, to avoid off spec. Gasoline from coming in
contact and contaminating the Merox reactor beds. Return
the unit to service once upset is corrected and Gasoline
results are ok.
For the above close B / L isolation valve on the Gasoline feed
line and PIC 001 on treated Gasoline
line. Cut off air
injection by closing the XV 001 & FIC 016. Similarly cut off air
injection by closing the XV 002 and FIC 018. Isolate Gasoline
feed and Close PIC 002 on treated Gasoline line.
Stop the following pumps and close the discharge valves
P 01 A and P21 caustic circulation pump
P 02 A and P22
Merox Plus injection pump
(2) Power Failure
Gasoline feed pump, caustic injection and Merox plus
injection cease functioning. By pass the unit as above and
37 / 66
bottle up. As power is recovered restart pumps and return to

normal operation.
(3) Instrument Air Failure
In case of instruments air failure happens, all control
valves go to fail safe position. This results in all control
valves in the unit to shut down and isolate the unit. List of
instruments on FC/FO are given at the end of the manual.
Bypass unit until air is restored. Also close caustic injection,
Merox plus injection pumps.
(4)
Steam Failure
Even though no steam is used in Gasoline Merox in

normal operation, steam failure will affect the FCCU. There
is a danger that off spec. Gasoline may come to Merox Unit.
By pass Merox unit and bottle up until Gasoline comes on
spec. Keep RTF informed of the situation and confirm that
Gasoline is switched over. Once Gasoline comes on spec
inform to RTF to switch to product tanks.
CHAPTER 12
SPECIAL PROCEDURES
REACTOR BED HOT WATER WASHING

When adjustment of the operating variables is no
longer sufficient to maintain catalyst bed activity, the
charcoal bed can be hot water washed to remove sundry
organic compounds and caustic neutralization soaps which
have deposited in the charcoal pores or otherwise physically
blocked off the active catalyst surface. Since many of these
compounds are water soluble, catalyst bed activity will be
restored when they are flushed from the charcoal. Hot water
washing is also necessary to remove sodium soaps and
alkalinity from the charcoal prior to catalyst reimpregnation.
The phenomenon of charcoal pore plugging or coating is
gradual and, hence, allows the bed washing to be scheduled
with minimum inconvenience to general refining operations
38 / 66
and scheduling. Hot water washing may also be effective in

reducing or eliminating reactor bed pressure drop which
should never be allowed to exceed 0.7 Kg. The water used
for reactor washing should be either clean steam
condensate or deionized water that is free of dirt,
suspended matter, hardness, excessive salts, and active
chlorine as in hypochlorite.
The washing procedure is as follows
Stop the air injection and hydrocarbon flow to the reactor.
Provision should be made to pump - or pressure - out all
hydrocarbon from the Merox reactor under steam or nitrogen
pressure.
1. Fill the reactor with warm, 50C warm water. This should
be done by passing Cold Condensate through Y 52 and
opening LP steam after filling half of the vessel stop
water. Pump this wash water to spent caustic facilities.
Repeat this procedure. This step will greatly reduce the
alkalinity of the wash water discharged to the sewer
system and will also protect the vessel from caustic
attack.
2. After the hydrocarbon has been pumped from the
reactor and the major portion of the residual caustic has
been removed, begin steam injection downflow through
the bed via the water heater in the reactor. It will take
approximately one or two hours for this step to remove
most of the remaining hydrocarbon from high aromatic
feedstocks.
The reactor drain effluent is usually cooled
for safety using direct cold water quench of an effluent
heat exchanger.
3. Commission the water heater and introduce hot, 200 210F, (95 - 99) water via the reactor inlet distributor at
a
rate of approximately 0.65
M3/hr/cubic Meter of
activated carbon.
Initially the reactor drain valve is
closed. When the reactor is liquid full, open the reactor
drain valve and begin draining the hot water from the
reactor drain line to the sewer ( or an alternative disposal
point) at a rate approximately equal to the rate at which
hot, freshwater is flowing into the reactor.
4. During the initial stages of hot water washing, the reactor
effluent from the drain line will be highly discoloured,, e.g
black or dark brown, and foamy.
As the washing
proceeds, the water will lighten in shade and pass
through a series of colour hues.
(colour changes).
Eventually the water will become clear and essentially
colourless.
39 / 66
If the bed is being washed solely to reactivate the

catalyst by cleaning the charcoal pores, the washing is
completed when the wash water is clean and essentially
colourless. If the bed is being water washed prior to a
catalyst reimpregnation, hot water washing is continued
until the effluent water pH is reduced to between 8 and 9.
This will minimize acetic acid consumption in a later step.
6. Gradually stop the steam flow, but continue to introduce
cool condensate through the water heater into the reactor
to cool the heater into the reactor to cool the charcoal
bed down to a temperature of about 140F (60C).
Nitrogen can be used to maintain the reactor under
slight positive pressure.
7. After the bed is cooled, the water is displaced with
nitrogen pressure and all of the water in the reactor is
drained.
8. For a conventional fixed bed Merox Unit, the catalyst bed
must be alkalinized with fresh caustic (20 to 30 Be') as
discussed in _REACTOR BED ALKALINIZATION -- CONVENTIONAL FIXED BED UNITS section.
5.
CATALYST REIMPREGNATION
Requirements :
Catalyst reimpregnation is necessary only when hot
water washing is no longer effective in reactivating the
catalyst to provide long period of satisfactory mercaptan
oxidation. The internal between catalyst reimpregnation is a
40 / 66
function of proper operation HC and mercaptan types, crude

source, feed impurities etc and may vary from 3 months to
a year or even longer, when required the catalyst
reimpregnation is to be done.
Procedure
1.
2.
3.
4.
5.
The washing procedure has to be followed from steps 1 to

7. When effluent water pH is reduced to 8 to 9 or to a pH
which no longer seems to be dropping, stop washing,
while washing the reactor bed also flush out the circulation
pump suction and discharge lines to remove any residual
alkalinity with slight positive pressure on the reactor.
Please note that the water drained after acidification is
colored. This indicates the acid addition was effective in
releasing additional contamination from the catalyst
bed. Stop circulation when the level is below distributor
pipe. Approximately 20 M3 of water to be drained.
Close the reactor drain valve and fill the reactor with warm
50-60C Cold Condensate. Vent Nitrogen as required to
maintain a slight positive reactor pressure.
Stop the water and block in the water heater when the
reactor is full and catalyst bed is submerged.
Open the valves in the reactor drain and the side outlet
lines going to the circulation (caustic) pump (P 51 A )
suction. Line up the valves in the pump discharge back to
the reactor inlet line and into the reactor and start the
pumps and establish circulation.
The water is circulated in a closed loop system at a
maximum rate. Valves in the suction lines to the circulation pump from both the reactor bottom drain and the
reactor side outlet are open. Inject steam occasionally,
into the circulating water to maintain temp of 50-60C,
the water temperature can be satisfactorily estimated by
feeling the circulating pump casing/discharge piping.
Acidification of Charcoal Bed

Acidification of charcoal is important to assure liberation
of sodium salt of organic acid which were not removed
during hot water washing procedure. Hence after warm
water circulation is established, the last traces of alkalinity can be removed from the charcoal by educting
acid into the circulation wash system.
2. Glacial Acetic acid is recommended as it is readily
available and is much less corrosive than mineral acid.
1.
41 / 66
3.
Place about 28 lt of Acetic acid in to the acetic acid

addition pot provided. The acetic acid can be placed in
the drum used for catalyst impregnation or a rubber
hose can be put directly into the Acetic Acid container.
Educt the acid into the circulating water by regulating the
globe valve in the line from pump discharge into the
suction of the eductor. The glacial Acetic Acid should be
added to the system over a period of 5-10 minutes.
Note : 28 lts per reactor of commercial grade glacial

acetic acid required Acetic Acid is not required for the initial
impregnation of reactor. It is needed only for subsequent
Reimpregnation.
After circulating the acidified water for one hour, check
the water pH at the sample point in the circulation pump
suction line. If the circulating water pH exceeds 6.5, educt
another about 20 lt of Acetic Acid, as described above.
After another hour, again check pH of water from the
reactor outlet. continue this procedure until the water pH
is 6.5 or less. This provides on the bed slight acidic
medium.
5. Drain the acidified water from the reactor drain using
nitrogen to maintain a slight positive pressure on the
reactor. Note that the water drained after acidification is
coloured; this is an indication that acid addition was
effective in releasing additional contaminants from the
catalyst bed.
6. Once the bed is drained the reimpregnation is done as
disscussed in the impregnaiton procedure.
4.
42 / 66
CHAPTER 14
TROUBLE SHOOTING
The failure in mercaptan sweetening in the Merox inlet
can be attributed to one or more or combination of the
following;
a) Lack of caustic
b) Insufficient Air
c) Reactor channeling
d) Mechanical interference with the catalyst
e) Loss of catalytic activity
f) Emulsification and caustic entrainment.
(a) Lack of Caustic :

The presence of caustic is essential in the Merox
Reactor. When the Sodium Hydroxide is either consumed
out or weakened out, Mercaptan oxidation will no longer
proceed. This is evident by the increase in mercaptan sulfur
content in the treated Gasoline. Hence resaturation of the
catalyst bed must be carried out to restore the sweetening
process. Use of 20 Be fresh caustic is advised. Only by
operating experience frequency of saturation can be
determined. However a mere frequent caustic wash will
ensure sufficient alkalinity.
Sulfides may seriously impede caustic regeneration
due to oxidation of sulfide ion in preference to mercaptide
ion.
H2S + 2NaOH ---- Na2S + 2H2O.
Hence the source of hydrogen sulfide must be eliminated.

When all of the sulfide is oxidized, the catalyst will again
begin to oxidize mercaptan. Raising the catalyst concentration, caustic temperature and air rate may be used to speed
43 / 66
up elimination of sulfide interference. Hence two batch type

caustic prewasgh is employed in series. This will allow
greater utilisation of caustic without risking H2S leakage
into Merox Unit.
Up to
a certain point the presence of acid oils
improves extraction. When their presence interferes with
caustic flow in the extractor caustic entrainment may take
place.
Accumulation of regenerated acidic materials
may consume casutic,
by CO2 picked up from the
regeneration air. Only experience can determine the extent
to whcih spending the caustic with weak acid can be
tolerated before extracting efficiently drop off.
(b)
Insufficient Air
This often happens when there is an increase in

mercaptan sulfur, or the total Gasoline treated through this
unit. Air injection rate must be adjusted.
Accordingly to
accomodate these changes
in
air concentration is
generally kept at 150 - 200% of stoichiometric requirement,
higher conentration is possible as long as all the air is
dissolved.
Oxidation reactions other than that of
mercaptans will be promoted at higher concentration and
this must be considered when using a higher injection rate.
If insufficient air is suspected check the reactors
pressure to make sure all air is dissolved. Check the air flow
meter to see if air is going in at the right rate. Submit
Gasoline samples to analyse the mercaptans load and see if
there is any change. Adjust air rate accordingly.
(c)
Reactor Channelling
When the catalyst is new or known to have lost activity

and when it has been determined that adequate air is
present, channeling should be suspected. A separate air
phase will almost always induce channelling. Adjust system
pressure to dissolve the injected air.
Channelling can then
be corrected by fuffing the bed with air or nitrogen for 30-40
second. The air or Nitrogen hose should be connected to the
Gasoline outlet at the reactor bottom.
(D)
Mechanical Interference of Catalyst
44 / 66
The activated charcoal bed absorbs Naphthenic acids,

trace
compounds such as high molecular weight
Hydrocarbon,
particulates and Nitrogen compounds.
Accumulation of these materials will plug catalyst pores and
plug up active sites thus reducing the activity of the catalyst.
This is evident by observing the increasing pressure drop
across the reactor. The catalyst activity can be partially
recovered by hot water washing the reactor bed. If water
washing
is ineffective, the charcoal bed must be
impregnated.
(e)
Loss of Catalytic Activity
It is normal for the Merox catalyst to gradually lose its

effectiveness, as the unit ages.
The treated Gasoline
becomes more concentrated in mercaptan sulfur and does
not produce specification product. It is necessary to caustic
wash the reactor more frequently and more concentrated
caustic solution is to be used. Other means to help the
Merox reaction are to increase reactor temperature and the
oxygen content eventually mercaptan requirement can no
longer
be
made
despite
continuous
saturation,
reimpregnation will be required.
(f)
Emulsification and Caustic Entrainment
Merox catalyst in caustic solution does not increase

the tendency of caustic solution to emulsify with Hydrocarbons. It does however, increase the detergent properties of
caustic.
Scale and
dirt
will
be
almost
dislodged/absorbed by Merox catalyst.
completely
Finely diluted suspended material can stabilise emulsions.

It may be necessary to discard the first batch of
caustic if it picks up a big load of scale and dirt from used
equipment.
Part of this scale and dirt may be iron sulfide. It
appears that preferential oxidation of such sulfide may
prevent the catalyst from promoting oxidation of mercaptan.
45 / 66
46 / 66
CHAPTER 13
LIST OF SPECIAL EQUIPMENT

1.
2.
3.
4.
5.
Special check valve

Eductor
Air Mixer
Spray Nozzles
Desuperheater
Y
Y
Y
Y
Y 21
51
22
03,23
53
(1) Special Check Valve
(Y 03 )
The purpose of this piece of equipment is to prevent a

back flow of either caustic (Extraction Unit) or H.C.
(Sweetening Unit) to the source of air, whether it be a
dedicated compressor or the plant air system. It is installed directly on the air line just upstream of the injection
point into either the rich caustic or the sour H.C. stream.
The features of this
cracking requirement (0.14
spring loaded closing action.
100% fail safe, these valves
reliable over the years.
check valve include its low

- 0.28 Kg/cm2) and positive
Although no check valves are
have proven themselves quite
The valve must be installed in a vertical position, and

it is recommended to use stainless steel tubing on its inlet
side inorder to prevent extended pipe threads either
hindering the operation or damaging the valve internals.
Note : In the event of air failure H.C./caustic mixture may
be in contact with the check valve Internals:
(2) Eductor ( Y 01 )
This is used for catalyst and acetic acid injection.
Size
Motive force
ammoniated water
Inlet Pressure
:
:
1"
Water/0.2
5.27 Kg/cm2g
wt
47 / 66
Inlet Temperature
Liquid handled
:
38C
Glacial Acetic Acid and
Mixing of Air and
water
(3)
Air Mixer ( Y 04 )
Service
Hydrocarbon
Air Pipe Size
Tee Size
MOC
Carbon Steel, except SS filter
element
( 4 ) Spray Nozzles ( Y 03, Y23 )

Service
: For Caustic injection to the
hydrocarbon
Type
:
Removable
injection
nozzle
assembly
MOC
:
303 SS
Nozzle No. :
LNN SS14
Connection
:
(NPT)
Operating Conditions
Temperature
:
38C
Pressure Drop
:
21.1 Kg/cm2g
Operating outlet pressure
:
7.5 Kg/cm2g
Capacity
:
19.8 Lts/Hr.
( 5 ) Desuperheater ( Y 53)
Service
:
Type
:
Inlet steam
Flow rate :
Turndown :
Max. Temp. :
Normal Temp.
Outlet Steam
Press.
:
Reactor steam - out

Attemperator
2.527 T / h
5 to 1
232 oC
:
177 oC
1.5 kg/cm2g
48 / 66
Temp.
:
177 oC
Allowalbe temp. : 11 oC Variation
Desuperheater Water
Temp.
:
60 oC
Flow Rate :
0.11 m3/h
CHAPTER 10
LABORATORY REQUIREMENT
SCHEDULE
The ultimate objective of petroleum refining is to produce
product hydrocarbon streams which meet all specifications required for
their ultimate end use. To accomplish this objective, it becomes
necessary to characterize the important physical and chemical
properties of the various refinery streams utilizing specific laboratory
analytical testing procedures. Thus, satisfactory refinery operation
depends largely upon proper analytical procedures for quality control.
The sample point should be well purged to eliminate aged
material, water, dirt, etc., and assure withdrawal of sample
representative of the material in the pipe at that point in time. The
sample container must be adequate for the analysis to be obtained.
Once a proper sample has been obtained, it must be preserved
intact until analyzed. This require the preservation of its physical and
chemical changes in the sample.
49 / 66
10.1 SCHEDULES AND TEST METHODS
Suggested analytical schedule for the Gasoline Merox unit is

given below. These represent a minimum recommendation for an
adquate quality control program.
S.N. STREAM NAME & TEST
TEST METHOD
FREQUENCY
Once in a day
NAME
1 Gasoline Feed
Distillation
ASTM D 86
Hydrogen sulfide
UOP 163
Mercaptan Sulfur
UOP 163
Particulates
ASTM D 2276
Weekly
Gravity
ASTM D 1298
Daily
50 / 66
2 Fixed bed reactor inlet
Diagnostic
Drain Pot effluent
PH
UOP 314 or ASTM D1293
Daily
Total Alkalinity
UOP 210
Daily
Gravity
ASTM D 1429
Daily
Acid oils
UOP 743
As required
Reactor No.1 outlet

Diagnostic
Inhibited Product
Doctor Test
UOP 41
H2S
UOP 163
Mercaptan sulfur
UOP 163
Sodium
UOP 549
copper Strip corrosion
ASTM D 1266 or ASTM D
Distillation
1552
ASTM D 86
Oxidn stability induction

ASTM D 525
Lead content
Phosphorus
Benzene
ASTM D 3237
ASTM D 3231
ASTMD 3606
51 / 66
Octane Number
ASTM D 2699 and 2700
Oxygen Content
VOC
EPA formula
Toxics Reduction
EPA formula
Nox reduction
EPA formula
Existent Gum
ASTM D 381
52 / 66
Note:
The sampling and analysis same for Reactor No.2.
CHAPTER 16
SAFETY
All the rules of safety in the refinery operation apply to the operation of
the Merox Process. All employees and persons responsible for
operation of the Merox process should be familiar with applicable
safety practices. All necessary precautions should be taken to avoid
accidents.
16.1 INTERNAL FIRE
53 / 66
The presence of air and hydrocarbons in Merox Process

equipment, particularly the excess air vent line, is not considered to be
any more hazardous than other situations in refineries in which air and
hydrocarbons vapors exist.
Locations of Safety shower

1. North of MT-RF416-01 (Caustic Storage tank)
2. South of MT-RF416-02
Material Safety Data Sheet for Caustic :

Properties and characteristics:
Physical state
Turbid solution
Colour
Water white to slightly coloured
Water solubility
Complete
Molecular weight :
40.01
Flash point
Non flammable
Mode of entrance into body

Reactivity
Inhalation, ingestion and contact
54 / 66
The solution is stable in nature and

hazardous. It is slowly corrosive to iron and copper. Reacts violently
with many organic chemicals such as acrolein, acrylonitrile, alcohols,
chloroform, malei anhydride etc
Health Hazards :
Injury may result before one realizes that
chemical is in contact. It is toxic and damages tissures.
Inhalation
Injury to entire respiratory tract.
Prolonged exposure may lead to inflammation of lungs.

Skin
Destruction of tissues, burns and
Severe damage and may lead to
ulcerations.
Eyes
conjunctivitis, corneal burn etc.

Ingestion
Severe burns of the mucous
membranes of the mouth, throat,

esophagus and stomach.
Perforation of tissue may follow.
Fire and Explosion Hazards : Instances of violent decomposition of
organic materials have been recorded
following usuage of caustic soda solution
for cleaning production equipment.
Contact with water or moisture may
generate sufficient heat to ignite
combustible material.
Handling and Storage
For protection of
55 / 66
1. Respiration - Filters respirators

2. Hands
- Vinyl or neoprene
gloves
3. Eyes
Goggles. Face shield
4. Body
safety shoes, gum
boots & vinyl or rubber clothing.

Keep away from acids, metals,
explosives, organic peroxides and easily
ignitable materials. Emergency shower
etc., should be nearby where the
chemical is handled.
Spillage disposal
: Dilute the solution with large quantities

of water taking care not to splash the
material.
Neutralising Chemical
: HCl or other mineral acid solutions
Disposal
: Neutralize with dilute HCl acid.

Discharge into sewer with sufficient
water.
Fire Extinguishment
: Caustic soda is not flammable, however

fire extinguishing equipment and
adequate water for fire fighting should be
available in all process or storage areas.
First Aid
: In case of
Inhalation
: Leave the area, report for medical

evaluation.
56 / 66
Skin contact
: Emergency shower bath, followed by

removal of clothing while still under the
shower. See the physician.
Eye contact
: Irrigate for at least 15 minutes. Keep

eye lids apart and move eyes in all
directions and have irrigation continued.
Ingestion
: Drink lot of water/milk. Dont induce

vomiting unless advised by physician.
1% acetic acid solution can be given.
57 / 66
CHAPTER 15
CHEMICAL CONSUMPTION
15.1 CHEMICAL CONSUMPTION

1.
2.
3.
4.
5.
6.
UOP Merox 8 catalyst 44 m3/reactore

UOP Merox plus injection : Normal 1.5.Ltrs / hr &
Maximum 7.4 Ltrs/h. continuously to the reactor
charge.
Acetic Acid - 28 Litres/reactor
Commercial grade glacial acetic acid is used.
Not required for initial impregnation but required
for further reimpregnation.
Ammonia - 124 Kg/reactor
Liquid anhydrous ammonia in cylinders is used.
Caustic 10Be - 68 M3/3 days
Caustic 3Be - 0.02 m3/h
58 / 66
59 / 66
CHAPTER 11
EQUIPMENT DETAILS
S.NO
TAG NO
EQPT.
DESIGN
OPERATING
ID MM COLUMN
TITLE
1
2
MV RF416 REACTOR
V01
MV RF
NO. 1
REACTOR
416 V02
NO.2
MOC
TEMP
PRESS
TEMP
PRESS
DEG C
70
KG/CM2G
18.7
DEG C
38
KG/CM2G
70
18.7
38
3100
CARBON
3100
STEEL
CARBON
STEEL
60 / 66
VESSEL DETAILS
S.NO.
TAG NO
EQPT TITLE
DESIGN
OPERATING
ID
MM
TEMP
1
MV RF416-
DRAIN POT
V02
MV-RF416
INHIBITOR
V51
INJECTION
3*
MT-RF416-01 3
PRESS
TEMP
DEG C KG/CM2G DEG C

70
18.7
38
TANK
Be Caustic
70
3.5
70
254mmHg
PRESS
KG/CM2G
-450
38
600
Type = Cone Roof
Storage tank
* - Caustic Storage tank has got a partitioned section sized to hold
15% of Nominal tank capacity.
61 / 66
6800
PRESSURE RELIEF VALVES
S.
TAG SERVICE
NO
NO
SET PR
PRESS KG/CM2G
TEMP DEG C
KG/CM2G
BASIS OF
SELECT
101A Reactor 1
17.5
NORMAL
5.6
MAX
18.7
NORM
38
MAX
70
FIRE
vent
101B Reactor 1
17.5
5.6
18.7
38
70
FIRE
36
30
36
38
70
BLOCKEDO
vent
102 CSTC Pump
18.2
18.7
38
70
UTLET
FIRE
18.2
18.7
38
70
FIRE
18.2
18.7
38
70
FIRE
18.2
18.7
38
70
FIRE
outlet
121A Reactor 2
17.5
5.6
18.7
38
70
FIRE
vent
121B Reactor 2
17.5
5.6
18.7
38
70
FIRE
36
30
36
38
70
BLOCKED
discharge
110A Gasoline
Cooler 2
outlet
110B Gasoline
Cooler 2
outlet
111A Gasoline
Cooler 3
outlet
111B Gasoline
Cooler 3
10
vent
122 Caustic inj
pump 2 dis
OUTLET
62 / 66
S.
TAG SERVICE
NO
NO
11
SET PR
PRESS KG/CM2G
TEMP DEG C
BASIS OF
KG/CM2G
NORMAL MAX
NORMAL MAX
SELECT
151A Kero 1
24.6
14
24.6
38
70
BLOCKED
Caustic inj.
12
OUTLET
Pump A
151B Kero 1
24.6
14
24.6
38
70
BLOCKED
Caustic inj.
13
OUTLET
Pump B
152 Kero 2
24.6
14
24.6
38
70
BLOCKED
Caustic inj.
OUTLET
14
Pump
153 Air mixer out
15
to Reactor 1
154 Air mixer out
17.9
5.7
17.9
38
5.7
38
70
BLOCKED
70
OUTLET
BLOCKED
to Reactor 2
OUTLET
HEAT EXCHANGERS
S.NO TAG
NO
SIDE
SER
SURFACE
HEAT
MO
VICE
AREA
DUTY
TEMP DEG C
PRESS
KG/CM
M2/SHELL
MMK
1
S51
S53
S54
SHELL Gasoline
TUBE
CW
SHELL Gasoline
TUBE
CW
SHELL Hot Water
CAL/HR
2.43
CS
CS
5.04
CS
CS
0.82
CS
I/L
O/L DES NORM
112
32
102
32
93
38
49
38
49
54
63 / 66
IGN
140
120
130
120
120
8.16
3.5
9.0
3.5
4.7
wash
TUBE
effuluent
CW
CS
32
49
120
3.5
CENTRIFUGAL PUMPS
S.NO
TAG
SERVICE
SUC. PR
NO
MAX
1
RATED
KG/CM2G
P51A/B Ammoniate
1.05
1.05
PRESS
CAPACITY
KG/CM2G
M3/HR
DIS SHUTO NORM

5.27
FF
6.3
30
PO
RATED
HYD
30
3.5
d water
PROPORTIONATING PUMPS :
S.N TAG NO
SERVICE
SUCTION PR
CAPACITY L/HR
TYPE
KG/CM2G
3 oBe
P01,P21,
P31,P41
Caustic
P02,P22, Merox Plus
KG/CM2G
MAX RATED MAX MIN

0.75
0.07
99
9.9
--
0.07
DIS PR
7.37
0.74
Norm
MAX
19.8 DIAPHR
RATE
28.62
AGM
DIAPHR
28.62
1.5
64 / 66
P32,P42
P52,P53
3 Be
0.75
0.07
1356
136
678
Caustic
4
P03,P23,
UOP No.5
AGM
DIAPHR
13.3
AGM
0.07
6400
640
1600
6.75
P33,P43
65 / 66
66 / 66

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INDEX

Unit Protection System

Laboratory Requirements and Schedule

Equipments and Instruments Summary

Chemical Consumption During Initial and Normal

a mixture of substances that behaves as a single

represented by the general formula RSSR.

forming chain reaction (-OOH)

terminating a chemical reaction

having thiol functional groups represented by the

general formula RSH

carbon to metal bonds

entrained disulfide sulfur in regenerated caustic

hydrocarbon product from an extractor

periods of time in storage

This unit is designed to process 30,000 BPSD of Gasoline which will be

URG COMPONENTS (Light Mogas) ::

Naphtha Splitter Overhead stream (C5-105 deg C)

Depentaniser bottom stream (C6-105 deg C)

Deisohexaniser overhead stream (iC6)

RFG COMPONENTS: (Heavy Mogas) :

Naphtha Splitter sidecut stream (105 180 deg C)

Heavy cracked Naphtha stream (180-215 deg C)

2.9 UTILITIES DESCRIPTION

Refer P & ID :G 42 RF 416 101

A 6 header supplies LP steam to Desuper heater

The unit is also provided with 10 Nos. of LP steam utilities stations.

COOLING WATER SYSTEM

Refer P & ID :G 42 RF 416 121

A 8 Cooling water supply header is provided to Gasoline Cooler

A 6 Cooling water supply header is provided to spent wash water

POTABLE WATER DISTRIBUTION SYSTEM

Refer P & ID :G 42 RF 416 122

fountain through 3/4 line.

Safety Drinking water Shower & Eye wash ( PYWRF001) through 1

COLD CONDENSATE SYSTEM

Refer P & ID :G 42 RF 416 122

A 6 cold condensate header provided with battery limit isolation

The main header serves cold condensate to the following points.

A 4 line to water heater ( Y 52 )

A 4 line to Caustic storage tank ( MT RF416- 01 )

UTILITY WATER SUPPLY SYSTEM

Refer P & ID :G 42 RF 416 122

To pump seal P 01 A. ( line).

To pump seal P 01 B. ( line).

The unit is also provided with 10 Nos. of utility water stations.

FUEL GAS SYSTEM

Refer P & ID :G 42 RF 416 131

A 3 header supplies fuel gas to URG header for startup purposes.

A 2 header supplies fuel gas to LP flare header.

A 2 header supplies fuel gas to LP flare sub header.

PLANT AIR SYSTEM

Refer P & ID :G 42 RF 416 141

A 1 header is supplying air to Caustic storage tank(MT-RF416 -01)

Refer P & ID :G 42 RF 416 141

A 1 header supplies Nitrogen to Reactirs (R01,R21) and for R31 &

A 2 header supplies Nitrogen to LP flare header.

A 2 header supplies Nitrogen to LP flare sub header.

BREATHING AIR SUPPLY SYSTEM

Refer P & ID :G 42 RF 416 142

The unit is provided with 1 Nos. of breathing air utility stations.

INSTRUMENT AIR SUPPLY SYSTEM

Refer P & ID :G 42 RF 416 142

LP FLARE AND RELIEF SYSTEM