Fixed-Bed Platforming General Operating Manual Rev 6 PDF

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FIXED-BED PLATFORMING™
GENERAL OPERATING MANUAL
- LIMITED DISTRIBUTION -
This material is UOP LLC technical information of a confidential nature for use only by
personnel within your organization requiring the information. The material shall not be
reproduced in any manner or distributed for any purpose whatsoever except by written
permission of UOP LLC and except as authorized under agreements with UOP LLC.
February 2009
Revision 6
Fixed-Bed Platforming – General Operating Manual Table of Contents
TABLE OF CONTENTS
I. INTRODUCTION
A. The Platforming Process
B. The General Operating Manual
C. Nomenclature
II. PROCESS PRINCIPLES

A. Platforming Hydrocarbon Chemistry
1. Composition of Platforming Unit Feed and Product
2. Platforming Reactions
3. Relative Reaction Rate
4. Heats of Reaction
5. Equilibrium Considerations
6. Effects of Pressure and Temperature on Reaction Selectivity
7. Reactor Profiles: Commercial Platforming Data
B. Catalyst Chemistry
1. Dual Function Platforming Catalyst Chemistry
2. Effects of Pressure on Catalyst Design
3. UOP Platforming Catalysts
C. Catalyst Regeneration
1. Catalyst Regeneration Theory and Chemistry
2. Chloride Neutralization During Regeneration
III. PROCESS VARIABLES

A. Major Platforming Independent Variables
1. Catalyst Type
2. Reactor Temperature
3. Space Velocity
4. Reactor Pressure
5. Hydrogen/Hydrocarbon Ratio
6. Charge Stock Properties
7. Feed Additives
B. Platforming Dependent Variables
1. Catalyst Activity
2. Catalyst Selectivity
3. Catalyst Stability
4. Heat of Reaction
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This information is confidential. Do not disclose it to others, copy it, or use it for any purpose unless you have UOP’s written permission.
C. Catalyst Poisons
1. Sulfur
2. Nitrogen
3. Water
4. Metals
5. High Feed End Point
D Water Chloride Control
1. Function of Water and Chloride
2. Injection Philosophy
3. Pilot Plant Evaluation
4. Calculating Catalyst Chloride Level
5. Commercial Evaluation Tools
6. Summary
IV. PROCESS FLOW AND CONTROL

A. Process Flow
B. Control Systems
V. PROCESS EQUIPMENT
A. Reactors
1. Spherical Reactors
2. Down Flow Reactors
3. Radial Flow Reactors
4. Stacked Reactors
B. Heaters
C. Heat Exchangers
D. Recycle Compressors
E. Pumps
F. Product Separator and Recontact Drum
G. Net Gas Compressors
H. Chloride Treaters
I. Debutanizer/Depentanizer
J. Overhead Receiver
K. Fuel Gas Drum
L. Sulfur Guard Bed
VI. COMMISSIONING
A. Final Vessel inspection
1. Reactor Preparation Introduction
2. Reactor Inspection and Preparation (Before Reaction Section
Dryout)
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B. Cleaning and Servicing of Utility Systems

1. Steam Lines
2. Cooling Water Lines
3. Plant Air System
4. Instrument Air Lines
5. Raw Water
6. Firewater and Sprinkler Systems
7. Fuel Gas Lines
8. Fuel Oil System
C. Hydrostatic Pressure Testing and Flushing of Lines and Equipment
1. Hydrostatic Pressure Testing
2. Lines and Equipment Flushing
D. Inspection and Run-In of Pumps and Fans
1. Pump Inspection
2. Pump Run-In
3. Air Cooler/Condenser Fan Inspection
E. Leak Testing
1. General Guidelines
2. General Procedure
F. Run-In of Recycle and Net Gas Compressors
1. Inspection of Centrifugal Compressors
2. Centrifugal Compressors Startup
3. Centrifugal Compressor Operation
4. Centrifugal Compressor Shutdown
5. Reciprocating Compressors
G. Service and Calibrate Instruments
H. Dry Out Fired Heaters
1. Generalized Heater Dryout Procedure
2. Gas Fired Heaters
3. Oil Fired Heaters
I. Dryout of Reactor Section
2. Reactor Inspection After Reaction Section Dryout
J. Chemical Boil-Out of Steam Generation Facilities
1. General Notes
2. Boilout Chemicals
4. Post-Boilout Activities
VII. NORMAL STARTUP

A. Unit Preparation and Air-freeing
1. Unit Feed
2. Unit Hydrogen Specifications
3. Prepare Unit for Charging
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B. Air-Freeing
1. Purge and Start the NHT Stripper and Platforming Fractionation
Section
2. Evacuate and Purge the Platforming Reactor Section
3. Evacuate and Purge the Net Gas Recontact Section
4. Hydrogen Pressure the Platforming Reactor and Net Gas
Recontact Sections
C. Initial Operation
1. Start Hydrogen Circulation and Reactor Heat-up
2. Pre-Sulfiding
3. Feed In to the Reactor
4. Establish Separator Operation
5. Establish Normal Fractionation Section Operation
6. Start Chloride Adjustment Program
7. Increase Feed Rate and Temperatures
D. Stabilize Operations
1. Dry-Down
2. Octane Response Testing
3. Line Out to Start of Run Conditions
E. Sulfur Guard Bed
VIII. NORMAL OPERATIONS

A. Data Collection/Performance Monitoring
B. Water-Chloride Control
C. Catalyst Sampling
D. Fractionation
IX. ANALYTICAL
A. Laboratory Schedules
1. Platforming Unit
2. Catalyst Regeneration
B. Analyses of Streams
1. Liquid Streams
2. Gas Analyses
3. Catalyst Analyses
4. Regeneration Caustic Analyses
C. Sample Shipping Procedure
1. Procedure and Documentation
2. Sample Containers
X. TROUBLESHOOTING
A. Operation Troubleshooting
B. Scale Accumulation in Reactors
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XI. NORMAL SHUTDOWN
XII. EMERGENCY PROCEDURES

A. Power Failure
B. Partial Loss of Recycle Gas Flow
C. Total Loss of Recycle Gas Flow
D. Planned Repairs Which Require Stopping the Recycle Compressor(s)
E. Explosion, Fire, Line Rupture, or Serious Leak
F. Water Failure
G. Steam Failure
H. Instrument Air Failure
I. Emergency Situations During Catalyst Regeneration
1. Carbon Burn
2. Oxidation
XIII. SPECIAL PROCEDURES

A. Catalyst Loading
1. General Guidelines for Catalyst Handling and Loading
2. Radial Flow Reactors Catalyst Seal and Slump
3. Radial Flow Reactor Loading Guidelines
4. Downflow Reactors Loading Guidelines
5. Spherical Reactor Loading Guidelines
6. Recommended Sock Loading Procedure
7. Dense Loading
8. Stacked Reactor Catalyst Loading
B. Catalyst Unloading and Reloading
1. Partial Catalyst Unloading and Reloading
2. Unloading of Unregenerated Catalyst Containing Iron Pyrites
3. Catalyst Screening
C. Regeneration
1. Pre-Shutdown
2. Unit Shutdown
3. Carbon Burn
4. Proof Burn
5. Oxidation
6. Separator Flushing
7. Cooldown
8. Nitrogen Purge
9. Reduction – Catalysts Other Than R-72
10. Reduction – R-72 Catalyst
11. Sulfate Removal
12. Startup
13. Auxiliary Regeneration Piping
14. Chemical Requirements and Specifications
15. Calculations
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16. Regeneration Report

D. Compressor Washing
E. Column Water Washing
1. Unit Preparation
2. Reactor Preparation
3. Prepare Tower
4. Water Injection and Washing
5. Return to Normal Operation
6. Tankage
F. Acidizing Heater Tubes
1. General Instructions
2. Notes and Precautions
3. Equipment and Supplies
G. Turnaround
1. Inspection
2. Heaters
3. Reactors
4. Reactor Section Separator(s)
5. Combined Feed-Reactor Effluent Exchangers
6. Reactor Products Condensers
7. Monel Trim Valves
8. Condensate and Chloride Injection Points
9. Recycle Gas Compressors
10. General 30-Day Platforming Unit Shutdown - Inspection
Schedule
H. Mothballing
1. Electrical
2. Instrumentation
3. Piping & Equipment
4. Insulation
5. Protective Coating
6. Site Inspection and Maintenance Procedure During Idling
Period
7. Special Commissioning Procedures
XIV. SAFETY
A. OSHA Hazard Communication Standard
1. Written Hazard Communications Program
2. Training and Information
3. Labels and Other Forms of Warning
4. Material Safety Data Sheet (MSDS)
5. MSDS for UOP Platforming Processes
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B. Hydrogen Sulfide Poisoning

1. Acute Hydrogen Sulfide Poisoning
2. Sub-acute Hydrogen Sulfide Poisoning
3. Prevention of Hydrogen Sulfide Poisoning
C. Precautions for Entering a Contaminated or Inert Atmosphere
D. Safety for Vessel Entry
1. General Precautions
2. Positive Isolation
3. Vessel Access
4. Safety Harness
5. Manway Watch
6. Fresh Air
7. Vessel Entry Permit
8. Checkout Prior to Startup
9. Turnaround Inspections
10. Reactor Loading
11. Reactor Unloading
E. General Unit Safety Notes
F. Aromatic Hydrocarbons
1. Benzene
2. Toluene, Xylenes and Heavier Aromatics
3. Toxicity Information
4. Minimizing Exposure to Aromatics
5. Medical Attention
G. Safety Information for UOP Platforming Catalysts
1. Potentially Hazardous Substances
2. Handling Catalyst Spills and Deposited Catalyst Dust
3. Handling UOP Catalysts Safely
XV. EQUIPMENT EVALUATION
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Fixed-Bed Platforming - General Operating Manual Introduction
I. INTRODUCTION
A. THE PLATFORMING PROCESS
The catalytic reforming process has been a mainstay in most refineries throughout
the world for many years. The original function of this process was to upgrade low
octane number straight-run naphthas to higher-octane motor fuel blending
components by catalytically promoting specific groups of chemical reactions.
Naphtha boiling range products from other processes (thermal cracking, coking,
etc.) were soon being included in the charge to catalytic reforming units for octane
improvement. The reforming application was logically and rather quickly expanded
to include the production of specific aromatic hydrocarbons. High-purity benzene,
toluene, and mixed xylenes were made available to the chemicals industry from
petroleum fractions by the combination of reforming, aromatics extraction, and
fractionation. Hydrogen, the “by-product” from the aromatic producing reactions,
was found to be useful in supporting the operation of reformer feed preparation
units as well as other hydrotreating units. The light hydrocarbon gases, by-products
of the cracking reactions, were generally added to refinery fuel gas systems.
Butanes, other cracking by-products, were commonly used in adjusting vapor
pressures of gasoline pools. Thus, most refiners and many petrochemicals
manufacturers have found the catalytic reforming process an increasingly valuable
tool.
UOP’s catalytic reforming process, the Platforming process, has continually been
improved to meet the changing needs of the industry. Combined efforts in the areas
of catalyst and engineering development have increased the flexibility of the
Platforming process to meet the current and anticipated future needs of the
industry. Today more than 600 UOP Fixed Bed Platforming units are on stream.
A significant step in catalyst development was made in the late 1960’s. This was the
commercialization of bimetallic Platforming catalysts. UOP has commercialized a
series of Platinum/Rhenium catalysts: R-16 and R-18 series, the R-50 extruded
series, and the high stability R-60 series catalyst. These catalysts have been proven
to give better activity, stability, and selectivity than the all-platinum catalysts. In
many cases, they have allowed refiners to extend their Platforming operations to
higher charge rates and higher product octane levels than would have otherwise
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been practical. The most recently commercialized UOP Platforming catalyst is the
high-yield R-72 catalyst. This catalyst is stage-loaded with a Pt-Re catalyst to give
improved selectivity.
Due to the increased sensitivity of these catalysts to feedstock contaminants and

operational upsets, the refiner must now pay closer attention to the daily operation
to realize their full benefits. More precautions need to be taken to ensure clean,
continuous, upset-free operation. Even with these added requirements, refiners are
realizing better Platforming operations than ever before.
In 1971, a new Platforming unit started up which revolutionized the process. It was
the first Continuous Catalyst Regeneration (CCR) Platforming unit. Now extremely
high severities are obtainable without frequent shutdowns due to catalyst
deactivation. As of 1999, there are 156 such units on stream with many more in the
design and construction stages. New unit sales are almost exclusively of the CCR
design.
Non-CCR Platforming units were then called “Fixed-Bed” Platforming units to

distinguish them from the CCR type. These units are commonly referred to in
industry as “semi-regen” reforming units.
B. THE GENERAL OPERATING MANUAL
The purpose of this manual is to provide refining process engineers and unit
supervisors with the necessary information for successful operation of UOP
bimetallic Platforming catalysts. This manual does NOT provide detailed operating
instructions to be applied to any individual unit.
It is important to remember that UOP-issued procedures are general in nature. It is

the responsibility of the refinery engineer to develop procedures specific to his unit
from the general procedures presented in this manual. Operating personnel should
be supplied with well-detailed, specific procedures before they attempt catalyst
loading, startup, shutdown, or regeneration. Also, well-detailed emergency and
safety procedures (complying with all acceptable refinery practices and federal,
state and local codes) should be available to all operations personnel.
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C. NOMENCLATURE
1. Chemical Abbreviations and Symbols
A aromatic
A6 6 carbon number aromatic (benzene)
A7 7 carbon number aromatic (toluene)
etc.
Al2O3 alumina
B or BZ benzene
BTX benzene, toluene, xylene
C1 1 carbon number hydrocarbon (methane)

C2 2 carbon number hydrocarbon (ethane, ethylene)
etc.
CH cyclohexane
CH6 6 carbon number cyclohexane (cyclohexane)
CH7 7 carbon number cyclohexane (methylcyclohexane)
etc.
Cl, Cl- chlorine, chloride

CP cyclopentane
CP6 6 carbon number cyclopentane (methylcyclopentane)
CP7 7 carbon number cyclopentane (dimethylcyclopentane or
ethylcyclopentane)
etc.
Cr chromium
EDC ethylenedichloride
F, F- fluorine, fluoride
Fe iron
H2 molecular hydrogen
HC hydrocarbon
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MCP methylcyclopentane
Mn manganese
Mo molybdenum
N naphthene; nitrogen
N6 6 carbon number naphthene
N7 7 carbon number naphthene
etc.
Na sodium
Na2CO3 sodium carbonate (soda ash)
NaOH sodium hydroxide (caustic)
N2 nitrogen gas
Ni nickel
O olefin; oxygen
O2 molecular oxygen
P paraffin
P1 1 carbon number paraffin (methane)
P2 2 carbon number paraffin (ethane)
P3 3 carbon number paraffin (propane)
etc.
Pb lead
PDC propylene dichloride
PONA paraffin-olefin-naphthene-aromatic
Pt platinum
Re rhenium
S sulfur
T toluene
TCE trichloroethane
TEL tetraethyl lead
TML tetramethyl lead
X xylene
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R
aromatic ring compound
R
saturated 6-carbon-number ring compound (a cyclohexane)
S
R saturated 5-carbon-number ring compound (a cyclopentane)
—R a radical or side chain (for example - CH2CH3 an ethyl radical)
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2. General Platforming Unit Terms
Å — angstrom, 10-10 meter

ABD — average bulk density
activity — the temperature requirement needed by a catalyst to produce a
given octane Reformate at fixed operating conditions and
feedstock quality
acid site — a position or function of the catalyst needed to promote certain
of the desired reactions; generally provided by fluoride or
chloride
ASTM — American Society for Testing and Materials
attenuation — modification or tempering of the metal function of the catalyst
BPD — barrels per day

BPP — barrels of feed processed per pound of catalyst
BR — boiling range
caustic — sodium hydroxide

CCR — continuous catalyst regeneration
CS — carbon steel
DC4 — debutanizer
delta P (∆P) — pressure change
delta T ( ∆T) — temperature change (normally across a reactor)
EOR — end of run

EP — end point (of a distillation)
F-1 octane — Research octane (ASTM D-2699)

F-2 octane — Motor octane (ASTM D-2700)
FBR — full boiling range (about 170-400°F or 88-204°C)
GC — gas chromatography
GHSV — gas hourly space velocity
GLC — gas/liquid chromatography
G/O ratio — gas/oil ratio (total moles of recycle gas divided by moles of
fresh naphtha feed)
gph — gallons per hour
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H2/HC ratio — hydrogen/hydrocarbon ratio (moles of recycle hydrogen

divided by moles of fresh naphtha feed)
HC — hydrocarbon
HPS — high pressure separator
HR, ∆H — heat of reaction
IBP — initial boiling point
lean naphtha — a naphtha high in paraffin content, low in naphthene

content
LHSV — liquid hourly space velocity (volume of hourly naphtha
feed divided by catalyst volume)
LOI — loss on ignition: a laboratory test, see UOP Method 275
LPS — low pressure separator
LV-% — liquid volume percent
m or M — prefix for thousand

mm or MM — prefix for million
metal site — a position or function of the catalyst needed to promote
certain of the desired reactions; provided by the
Platinum and second metal, if any
micro octane — an octane determination made with small sample size
MON — motor octane number
MONC — motor octane number clear (unleaded)
MW — molecular weight
PONA — paraffin, olefin, naphthene, aromatic breakdown of a

hydrocarbon stream
ppb — parts per billion
ppm — parts per million
precursor — something which leads to a second object; i.e. a coke
precursor in the naphtha is a compound which directly
leads to coke formation on the catalyst
Platinum — the clustering or grouping of Platinum molecules on
agglomeration the catalyst surface
Rich naphtha — a naphtha high in naphthene content, low in paraffin

content
RON — research octane number
RONC — research octane number clear (unleaded)
RONO — research octane number clear (zero additives)
RVP — Reid vapor pressure
rx — reactor
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scallop — part of radial reactor internals

scf — standard cubic feet
scfb — standard cubic feet per barrel
scfh — standard cubic feet per hour
sch — schedule (measure of metal thickness)
seal catalyst — catalyst added to the top of a radial flow reactor to
prevent vapor bypassing
selectivity — the quality of a catalyst enabling it to produce high yields
of a specific product; generally a highly selective
Platforming catalyst is one which gives high C5+
reformate yields
severity — an overall measure (qualitative) of the difficulty of a
Platforming operation
SG — specific gravity
shield — part of radial reactor internals
skirt — same as shield
slump catalyst — extra catalyst added to the top of a radial flow reactor to
compensate for bed settling during operation
soda ash — sodium carbonate
SOR — start of run
stability — the quality of a catalyst enabling it to run for long periods
of time with almost constant yields and temperature
requirement
WABT — weighted average bed temperature (the sum of the

average reactor temperatures multiplied by the fraction
of catalyst in each reactor)
WAIT — weighted average inlet temperatures (the sum of the
reactor inlet temperatures multiplied by the fraction of
catalyst in the reactor)
wt, wt-% — weight, weight percent
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UOP P&I DIAGRAM ABBREVIATIONS

FUNCTIONAL IDENTIFICATION OF INSTRUMENTS
First Letter Subsequent Letters

Measured Variable Modifier Readout Output
A Analysis Alarm
B Burner Flame
C Compensated Control
D Differential
E Primary Element
F Flow Ratio (Fraction)
G Glass
H Hand (Manual)
I Current Indicate
J Power Scan
K Control Station
L Level Light
M
N
O Orifice
P Pressure, Vacuum Point (Test Conn.)
Q Quantity Integrate, Totalize
R Record
S Speed, Frequency Safety Switch
T Temperature Transmitter
U Multivariable
V Vibration Valve
W Weight Well
X Skin
Y Relay, Compute
Z Position
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INSTRUMENT ABBREVIATIONS
FIF FLOW INDICATOR FLOAT TYPE
LG-B GAUGE GLASS TUBULAR TYPE – VISIBLE LENGTH SHOWN
LG-R GAUGE GLASS REFLEX TYPE – VISIBLE LENGTH SHOWN
LG-RLT GAUGE GLASS REFLEX TYPE – VISIBLE LENGTH SHOWN – LOW TEMPERATURE
LG-T GAUGE GLASS THROUGH VIEW TYPE – VISIBLE LENGTH SHOWN
LG-TG GAUGE GLASS THROUGH VIEW TYPE – VISIBLE LENGTH SHOWN – GRAFOIL
LG-TK GAUGE GLASS THROUGH VIEW TYPE – VISIBLE LENGTH SHOWN – KEL-F
LG-TLT GAUGE GLASS THROUGH VIEW TYPE – VISIBLE LENGTH SHOWN – LOW
TEMPERATURE
OGV OMIT GAUGE VALVES
RTD RESISTANCE TEMPERATURE DETECTOR
WHEN INSTRUMENTS ARE DESIGNATED WITH AN ALARM
H INDICATES HIGH
L INDICATES LOW
HH HIGH-HIGH (INTERLOCK)
LL LOW-LOW (INTERLOCK)
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Fixed-Bed Platforming - General Operating Manual Process Principles
II. PROCESS PRINCIPLES
This section contains details of the chemistry of naphtha, catalyst and catalyst
regeneration involved in the Platforming process. The subjects of naphtha chemistry
and catalyst chemistry have been segregated as much as possible to make the
discussion easy to follow. However, the two subjects are necessarily and inherently
interrelated and some overlap of subject matter in the ensuing sections is
unavoidable. The subject material has been presented with the assumption that the
reader is familiar with basic organic chemistry and the concept of thermodynamic
equilibria.
A. PLATFORMING HYDROCARBON CHEMISTRY
1. Composition of Platforming Unit Feed and Product
Feed naphtha to a Platforming unit typically contains C6 through C11 paraffins,

naphthenes, and aromatics. The purpose of the Platforming process is to produce
aromatics from the naphthenes and paraffins, either for use as a motor fuel
(because of their very high octane ratings) or as a source of specific aromatic
compounds. In motor fuel applications the feed naphtha generally contains the
whole range of C6 through C11 hydrocarbons, essentially maximizing the amount of
gasoline produced from the crude run. In aromatics applications, the feed naphtha
generally contains a more select range of hydrocarbons (C6; C6-C7; C6-C8; C7-C8)
which serve as the source of the desired aromatic product. For either application the
basic naphtha chemistry is identical. However, aromatics processing, in most cases,
emphasizes C6 and C7 hydrocarbon reactions which are slower and more difficult to
promote.
Naphthas from various crude sources vary greatly in their “ease of reforming”. This
“ease of reforming” is primarily determined by the amount of the various
hydrocarbon types (paraffins, naphthenes, aromatics) contained in the naphtha.
Aromatic hydrocarbons pass through the Platforming Unit essentially unchanged.
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Most naphthenes react rapidly and efficiently to aromatics. This is the basic reaction
of Platforming. Paraffins are the most difficult compounds to convert. In most low
severity applications, there is only a small amount of paraffin conversion to
aromatics. In high severity applications, paraffin conversion is higher, but still slow
and inefficient.
Figure II-1 indicates the hydrocarbon conversion that must take place in a typical
Platforming operation on a “lean” naphtha (high paraffin, low naphthene content)
and on a “rich” naphtha (lower paraffin, higher naphthene content). For the richer
feed, less paraffin conversion will be necessary, making the operation much easier
and more efficient.
To provide a better understanding of Platforming hydrocarbon chemistry, the next

sections will detail the types of individual reactions, relative reaction rates, heats of
reaction, equilibrium constraints, and pressure and temperature effects involved in
these overall hydrocarbon conversions.
2. Platforming Reactions
The following reactions take place in the Platforming process to an extent

dependent on the severity of the operation, the quality of the feed, and the catalyst
type.
(a) Dehydrogenation of Naphthenes
The final step in the formation of an aromatic from a naphthene (either a

cyclohexane or a cyclopentane) is the dehydrogenation of a cyclohexane;
see Figure II-2. The reaction of a cyclohexane to the corresponding aromatic
is extremely rapid and essentially quantitative. Naphthenes are obviously the
most desirable feed components because the dehydrogenation reaction is
easy to promote and produces by-product hydrogen as well as the aromatic
hydrocarbons. This reaction is very endothermic. It is promoted by a metal
catalyst function and is favored by high reaction temperature and low
pressure.
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The discussion of catalyst acid and metal functions is contained in the

Catalyst Chemistry section. It is now important to only note which reactions
are catalyzed by the acid function and which ones are catalyzed by the metal
function.
(b) Isomerization of Naphthenes and Paraffins
(1) The isomerization of a cyclopentane to a cyclohexane, shown

in Figure II-3, must occur as the first step in converting the
cyclopentane to an aromatic. This isomerization involves ring
rearrangement and probability for ring opening to form a
paraffin is quite high. Therefore, the reaction of alkyl-
cyclopentanes to cyclohexanes is not quantitative. The reaction
is strongly dependent on the processing conditions.
(2) Paraffin isomerization, shown in Figure II-4, occurs readily in

commercial Platforming operations but at typical operating
temperatures the thermodynamic equilibrium is not strongly in
favor of the more desirable (higher octane) branched isomers.
In motor fuel applications this reaction does make a
contribution to octane improvement of the naphtha.
(3) Isomerization reactions result from carbonium ion intermediate

reactions. These reactions are promoted by an acidic catalyst
function, and are only slightly dependent on operating pressure.
(c) Dehydrocyclization of Paraffins
Dehydrocyclization of paraffins, shown in Figure II-5, is the most difficult

Platforming reaction to promote. It consists of a very difficult molecular
rearrangement from a paraffin to a naphthene. In the case of light paraffins,
equilibrium considerations limit this reaction.
The paraffin cyclization step becomes easier as the molecular weight of the
paraffin increases, because of increased statistical probability for the
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formation of the naphthene. Somewhat counteracting this effect is the

increased probability of the heavier paraffins to hydrocrack. Dehydro-
cyclization is favored by low pressure and high temperatures. Both metal and
acid catalyst functions are needed to promote this reaction.
(d) Hydrocracking
Because of the strained ring isomerization and ring formation reactions that
the feed alkylcyclopentanes and paraffins must undergo, and because the
catalyst needs to have an acid function, the possibility for acid-promoted
hydrocracking, depicted in Figure II-6, is strong. Paraffin hydrocracking is
relatively rapid and is favored by high pressure and high temperature. The
disappearance of paraffins from the gasoline boiling range via hydrocracking
does concentrate aromatics in the product and hence contributes to octane
improvement. The reaction does, however, consume hydrogen and result in
lower reformates yield.
(e) Demethylation
Demethylation reactions, shown in Figure II-7, generally occur only in very

severe Platforming operations (high temperature and high pressure). Under
certain conditions it may occur during the startup of a unit following catalyst
replacement or regeneration. The reaction is metal catalyzed and is favored
by high temperature and pressure. It can be inhibited by attenuation of the
metal catalyst function by addition of sulfur or a second metal (as in some
bimetallic catalysts).
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(f) Dealkylation of Aromatics
The dealkylation of aromatics, shown in Figure II-8, is similar to aromatic

demethylation, differing only in the size of the fragment removed from the
ring. If the alkyl side chain is large enough, this reaction can be visualized as
acid catalyzed carbonium ion cracking of the side chain. The dealkylation
reaction is also favored by high temperature and high pressure.
Because of the wide range of paraffins and naphthenes included in the

Platforming Unit feed, and because the reaction rates vary considerably with
the carbon number of the reactant, these reactions occur in series and in
parallel to each other forming the rather complicated overall reaction scheme
indicated in Figure II-9.
3. Relative Reaction Rate
In experimental pure component work, individual hydrocarbons were Platformed in

a pilot plant unit. Compounds studies were normal hexane, methylcyclopentane and
cyclohexane in the C6 hydrocarbon group, and normal heptane, methylcyclohexane
and dimethylcyclopentane in the C7 group. Operating pressure was varied between
70 and 300 psig (5 and 21 kg/cm2) and reaction temperature was varied between
840 and 1021°F (450 and 550°C). Hydrogen to hydrocarbon mole ratios were
nominally 5 to 7, using recycle hydrogen. Most runs were of short duration and were
designed to establish relative rates of reaction and the effect of operating conditions
on selectivity to aromatics.
Data from runs with pure compounds made at low conversion were used to
estimate the relative reaction rates for the various C6 and C7 hydrocarbon types
investigated. Adsorption effects, catalyst deactivation, and other factors would alter
the relative rates in a blend of compounds or in commercial naphtha feed, but this
analysis provides valuable insight into the basic Platforming kinetic mechanism. The
results of the kinetic analysis are summarized in Table II-1. The reaction rates are
reported relative to the rate of dehydrocyclization of normal hexane.
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Table II-1
RELATIVE REACTION RATES - C6 AND C7 HYDROCARBONS
Relative reaction rate 1

Hydrocarbon Type Paraffins Alkylcyclopentanes Alkylcyclohexanes
Carbon No. C6 C7 C6 C7 C6 C7
Isomerization
Paraffin 10 13
Naphthene 10 13
Dehydrocyclization 1.0 4.0
Hydrocracking 3.0 4.0
Decyclization
(ring opening) 5 3
Dehydrogenation 100 100
The primary reactions for the C6 and C7 paraffins proceed at significantly different
rates. The rate of dehydrocyclization for hexane is only one-third that of
hydrocracking so the fraction of the normal hexane converted to benzene is
relatively low. Normal heptane hydrocracks at about the same rate as normal
hexane so the faster rate of dehydrocyclization (about four times that of hexane),
leads to significantly greater fractional conversion to aromatics for normal heptane
in comparison to hexane. Both paraffins are isomerized rapidly to the various
possible isomers.
Reactions of the naphthenes show marked differences between the

alkylcyclopentanes and alkylcyclohexanes. Both cyclohexane types dehydrogenate
very rapidly and completely to aromatics. The cyclopentanes react at a much slower
rate and undergo both isomerization to form the corresponding cyclohexanes and
decyclization to form paraffins.
The ratio of the rate of isomerization to the total rate of reaction (isomerization plus
decyclization) is an indication of the expected selectivity to aromatics for the
alkylcyclopentanes. This ratio is 0.67 for the methylcyclopentane and 0.81 for
dimethylcyclopentane. The ease of isomerization increases with carbon number and
the C8+ alkylcyclopentanes have relatively high selectivities to aromatics.
1
Data determined from initial rates for pure components and mixtures of pure components. All
rates relative to rate of dehydrocyclization of normal hexane.
uop 117108-6 II-6
Thus, the paraffins show the lowest reactivity and the poorest selectivity for
aromatic formation. The alkylcyclopentanes, while more reactive and selective than
paraffins, still provide less than quantitative yields of aromatics. The alkylcyclo-
hexanes are converted very rapidly and quantitatively to aromatics.
4. Heats of Reaction
Generalized heats of reaction for the reactions of paraffin to naphthene, naphthene

to aromatic, and paraffin hydrocracking are shown in Table II-2.
Dehydrocyclization of paraffins and dehydrogenation of naphthenes are both very

endothermic as manifested commercially by the large temperature decreases
across the first two Platforming reactors. Generally, the last reactor is promoting a
combination of paraffin dehydrocyclization and hydrocracking reactions and the total
kinetics in this reactor may be either endothermic or exothermic depending on
processing conditions, feed characteristics, and catalyst.
Table II-2
TYPICAL HEATS OF REACTION
Reaction ∆H (Kcal/Mol H2)

Paraffin ⇒ Naphthene +10.5
Endothermic
Naphthene ⇒ Aromatic +16.9
Hydrocracking -13.5 Exothermic
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5. Equilibrium Considerations
Most modern fixed-bed motor fuel Platforming Units operate at conditions such that
the degree of conversion of the major components in the feed is not limited by
equilibrium. However, BTX naphtha feeds contain high concentrations of light
hydrocarbons, and for these feeds, the level of conversion is affected by
equilibrium. The least reactive and most strongly influenced by thermodynamic
factors are the six carbon number hydrocarbons. The effect of temperature and
hydrogen partial pressure on equilibrium conversion will be examined for this
system. A similar analysis would apply for seven and eight carbon number
hydrocarbon systems, but the degree of thermodynamic limitation would be much
lower.
The technique used to calculate equilibrium ratios for the various reactions is
illustrated by the following example. Consider the reaction of normal hexane
undergoing dehydrocyclization to form methylcyclopentane.
k1
nC6 MCP + H2
k2
where k1 and k2 are the forward and reverse reaction constants, respectively.
At equilibrium, the following equation is valid
k1 (PMCP) (PH2)
Kp = =
k2 (PnC6)
where Kp is the equilibrium constant and P is the partial pressure of the component.
The larger the value of Kp, the more favorable the reaction.
The equilibrium ratio for this reaction then becomes
(PMCP ) (KP )
=
(PnC6) (PH2)
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Values of Kp can be calculated from the thermodynamic properties of the reactants

and products and then the extent of equilibrium limitation established.
Figure II-10 shows the effect of temperature and hydrogen partial pressure on the
equilibrium ratio for the conversion of normal hexane to methylcyclopentane. It can
be seen that, in general, the equilibrium ratio is low, but it does improve rapidly as
temperature in increased and hydrogen partial pressure is decreased. It should be
noted that the level of MCP in the reactor must be reduced below the equilibrium
value before there will be any net conversion of hexane to cyclic materials. Since
the rate of hydrocracking is inhibited by lower hydrogen pressures, the selectivity of
the hexane to aromatics is greatly enhanced by low pressure, high temperature
operations.
The isomerization of methylcyclopentane to cyclohexane does not involve hydrogen

as a product or reactant, therefore the equilibrium ratio is a function of temperature
only. The effect of temperature on the equilibrium ratio of cyclohexane to
methylcyclopentane is illustrated in Figure II-11. The equilibrium ratio is quite low
over the normal Platforming temperature region and decreases slightly as
temperature is increased. This low equilibrium ratio inhibits conversion of
methylcyclopentane to cyclohexane because the cyclohexane concentration must
be reduced to very low levels before the forward methylcyclopentane reaction can
proceed. The complexity of the ring isomerization reaction and the unfavorable
thermodynamics combine to reduce the selectivity of methylcyclopentane to
benzene substantially below 100%.
The dehydrogenation of cyclohexane to form benzene is the most rapid and

simplest of the Platforming reactions. The effects of temperature and hydrogen
partial pressure on the equilibrium ratio for this reaction are illustrated in Figure II-
12. The formation of benzene is highly favored over the entire range of typical
Platforming operating conditions. Thus, this reaction is essentially irreversible and
thermodynamic factors have little effect on selectivity.
uop 117108-6 II-9
6. Effects of Pressure and Temperature on Reaction Selectivity
As an extension of the pure component equilibrium pilot plant studies, the effects of
pressure and temperature on the selectivity to aromatics for normal hexane,
methylcyclopentane, and normal heptane were investigated in detail. These
hydrocarbons have low selectivities, and thus optimization of operating conditions to
maximize the selectivity is the key to improved yields of aromatics.
The effect of operating conditions on normal hexane selectivity to benzene is

illustrated in Figure II-13. Here the selectivity to benzene is defined as the mole ratio
of hexane converted to benzene divided by the total moles of hexane converted
(conversion was based on disappearance of total hexane so that iso-hexanes in the
product were treated as unconverted normal hexane). This is, in essence, the
extent to which the dehydrocyclization of hexane is occurring. As shown in Figure II-
13, normal hexane selectivity to benzene increases with temperature at each
pressure. This is due to equilibrium shifting in favor of dehydrocyclization with
increasing temperature. Selectivity improvement with decreasing pressure is due to
the combined effects of improved equilibrium ratio and a suppression of the rate of
hydrocracking.
At a reactor temperature of 1000°F (540°C), decreasing the plant pressure from 200
psig (14 kg/cm2) to 130 psig (9 kg/cm2) increases the selectivity of normal hexane to
benzene by 33%, while a further decrease to 70 psig (5 kg/cm2) yields a 70%
improvement over the selectivity at 200 psig (14 kg/cm2). Benzene yields from
hexane precursors will be greatly enhanced by operating at high temperature and
low pressures. At these conditions, however, the rate of coke formation is very high,
and catalyst stability becomes a primary concern.
The effect of process conditions on the methylcyclopentane selectivity to benzene is

illustrated in Figure II-14. Methylcyclopentane shows the same trend of improved
selectivity with increased temperature and reduced pressure as noted for normal
hexane. At comparable conditions, however, the methylcyclopentane selectivity is
two to three times as large as the hexane selectivity. The best selectivity (about
70%) was obtained at 100 psig (7 kg/cm2) pressure and 1000°F (540°C) reactor
temperature. Increasing the pressure to one that many fixed bed BTX Platforming
uop 117108-6 II-10
Units operate at today, 300 psig (21 kg/cm2) lowered the selectivity to about 50%.
Thus a 40% improvement in methylcyclopentane selectivity to benzene is obtained
by operating at the lower pressure.
Figure II-15 summarizes the results obtained when normal heptane was processed
at various conditions. Heptane selectivity to toluene follows a pattern similar to that
found for normal hexane to benzene. Again, the improvement in selectivity as
temperature is increased and pressure decreased is due to the combined effects of
improved equilibrium ratio and a suppression of the rate of hydrocracking. For
example, at a reactor temperature of 1000°F (540°C), reducing plant pressure from
300 psig (21 kg/cm2) to 200 psig (14 kg/cm2) increased heptane selectivity to
toluene by 30% while a further reduction to 100 psig (7 kg/cm2) pressure provided a
selectivity 60% greater than that at 300 psig (21 kg/cm2) pressure. Heptane
selectivity to toluene is two to three times higher than hexane selectivity to benzene
at identical operating conditions.
The preceding pure component work indicates that the processing conditions
utilized can greatly affect the selectivity to aromatics for the C6-C7 paraffins.
Specifically, more aromatics are produced at low pressure, high temperature
conditions. Note, however, that the catalyst stability becomes a constraint as moves
are made toward conditions favoring increased aromatics production.
7. Reactor Profiles: Commercial Platforming Data
Having considered the relative rates of the various Platforming reactions,

equilibrium constraints, and heats of reaction, the overall Platforming process can
now be examined. Consider a modern, low pressure, motor fuel operation from the
aspects of hydrocarbon concentration, product quality, and temperature profiles as
the reactants pass through the reactor system.
The following data were obtained from a commercial, four reactor Platforming Unit.
Feed, product and inter-reactor samples were taken in such a manner as to follow
hydrocarbon conversion and product quality through the reactors. The profiles from
this unit vividly demonstrate the practical aspects of the hydrocarbon chemistry
discussed above.
uop 117108-6 II-11
Figure II-16 shows hydrocarbon types yield, expressed as moles of the particular
hydrocarbon type per 100 moles of feed, across the reactor system. The lines at
0.1, 0.25, 0.50, and 1.0 fraction of total catalyst indicate individual reactor
boundaries and points of sampling. Note that in this particular operation, aromatic
formation is 22, 10, 5.5, and 5.5 moles per 100 moles of feed respectively in
reactors 1, 2, 3, and 4. Because of their rapid reaction rate, 95 percent of the feed
cyclohexanes disappear in the first reactor. Slower to react, the cyclopentanes
disappear at rates of 4.5, 4.0, 1.0, and 0.5 moles per 100 moles of feed through
reactors 1 through 4. Paraffin disappearance on an absolute molar level is
comparable to cyclopentane conversion (4.0, 4.0, 7.0, and 6.5 moles per 100 moles
of feed) but on the basis of percent converted per mole of specific hydrocarbon
feed, the paraffin conversion is much lower.
Table II-3 quantifies the conversion of each hydrocarbon type based on the amount
of that hydrocarbon in the Platforming Unit feed.
Table II-3
PARAFFIN AND NAPHTHENE CONVERSION PER REACTOR
Conversion of Feed Hydrocarbon Type, Percent

Reactor No. 1 2 3 4 Total
Conversion
Cyclohexanes 95 3 0* 1* 99
Cyclopentanes 39 35 9 4 87
Paraffins 7 7 13 12 39
*Concentration too low to accurately measure.
Figure II-16 and Table II-3 demonstrate the rapid quantitative conversion of
cyclohexanes, the slower conversion of cyclopentanes, and the very slow paraffin
conversion. Note that isomerization is not included in paraffin conversion.
uop 117108-6 II-12
Figure II-17 demonstrates the effect of cyclopentane carbon number upon the rate
of conversion. In reactor 1 there is generally either no change at all, or actually an
increase, in absolute amount of methylcyclopentane. Such an increase would result
from cyclohexane isomerization and is generally observed in low severity units.
Figure II-17 shows the more rapid conversion of the heavier cyclopentanes; C9 and
heavier cyclopentanes are essentially completely converted in the first two reactors.
C8, C7, and C6 cyclopentanes react progressively slower.
Figure II-18 shows the paraffin content of the reactant stream (moles of paraffin per
100 moles of feed) across the reactor system. It is interesting to note that in the first
two reactors there is an increase in the absolute amounts of C6 and C7 paraffins
present. This is due to cracking of the heavy paraffins (note the rapid
disappearance of C9 through C11 paraffins) and possibly to decyclization of C6 and
C7 cyclopentanes back to corresponding paraffins. The more rapid conversion of
the heavier paraffins results from increased ease of ring formation,
dehydrocyclization, and increased rate of hydrocracking.
Figure II-19 shows the increasing isomerization in the C6 through C8 paraffin fraction
across the reactors. These iso/normal ratios approach but do not quite reach
equilibrium values. This isomerization plays a role in octane upgrading of the
remaining paraffin fraction.
One of the more interesting aspects of these results is demonstrated in Figure II-20.
This figure shows aromatic content by carbon number (again in moles of aromatic
per 100 moles of feed) across the reactors. The absolute amount of an individual
aromatic formed, of course, depends on the amount of precursors in the feed,
however, the rates at which the aromatics form are indicative of the kinetics of the
aromatic forming reactions. C10 and C11 aromatics are all formed in reactors 1 and
2; there is no net formation of these aromatics in the last two reactors. Figure II-18
does indicate conversion of C10 and C11 paraffins in reactors 3 and 4 and it is felt
that some of the converted paraffins are dehydrocyclizing, but that an offsetting
amount of dealkylation to lighter aromatics is occurring.
uop 117108-6 II-13
C7 through C9 aromatics continue to be produced throughout the reactor system.

Inspection of the previous figures show that very little C7-C9 aromatic production in
reactors 3 and 4 can be attributed to naphthene conversion, because most of these
naphthene precursors are converted in reactors 1 and 2. This aromatic production
must then be attributed to paraffin dehydrocyclization and dealkylation of heavier
aromatics. Finally, very little net benzene production occurs in reactor 3 and none
occurs in reactor 4. This is the result of rapid cyclohexane conversion in reactors 1
and 2, slower methylcyclopentane conversion in reactors 2 and 3, and minimal
hexane conversion. Hexane conversion at these moderate severity conditions was
low, as expected. More severe processing conditions are employed in modern BTX
Platforming designs to force higher conversions of hexane to benzene.
Figure II-21 shows octane increase across the reactors. Predictably, the octane
rating increases more rapidly in the first reactors, a result of the extensive
naphthene conversion. Octane upgrading in the last reactors results from the slower
isomerization, hydrocracking, and dehydrocyclization.
Finally, Figure II-22 shows the reactor temperature profiles. The inlet and outlet
temperatures can be measured commercially; the shape of the profile was
determined by a Platforming kinetic model.
Table II-4
PLATFORMING REACTIONS
Promoted By
Reaction Catalyst Temperature Pressure
Naphthene Dehydrogenation M High Low

Naphthene Isomerization A Low* —
Paraffin Isomerization A Low* —
Paraffin Dehydrocyclization M/A High Low
Hydrocracking A High High
Demethylation M High High
Aromatic Dealkylation M/A High High
* Low temperatures favor higher iso/normal ratios; rate of isomerization increases with increasing
temperature.
uop 117108-6 II-14
Figure II-1
uop
Hydrocarbon Types Volume Conversion in Platforming
• Conversion of lean and rich naphthas to moderate octane reformates

at constant operating conditions
Fixed-Bed Platforming - General Operating Manual
Lean Rich
Naphtha Reformate Naphtha Reformate
} Loss
117108-6
} Loss P
P
P
P N
N } From P
} From P N A From N
N }
A } From N
Legend A } From A A } From A
P = Paraffins Loss: Due to both cracking
N = Naphthenes and shrinkage
A = Aromatics F.B. Plat
117108 II-1
II-15
Process Principles
Figure II-2
Naphthene Dehydrogenation
R R
S + 3H2
Note:
S ,
S Denotes Saturated Rings (Naphthenes)
Denotes a Dehydrogenated Ring (Aromatic)
R, R', R" Denote Radicals or Side Chains

Attached to the Ring, for Example
-CH2CH3, an Ethyl Radical F.B. Plat
117108 II-2
Figure II-3
Naphthene Isomerization
R'
R S
S
F.B. Plat
117108 II-3
uop 117108-6 II-16
Figure II-4
Paraffin Isomerization
C
R-C-C-C-C-C-C R-C-C-C-C-C
F.B. Plat
117108 II-4
Figure II-5
Paraffin Dehydrocyclization
R'
S
+ H2
R-C-C-C-C-C-C
R"
S
+ H2
F.B. Plat
117108 II-5
uop 117108-6 II-17
Figure II-6
Hydrocracking
C C
R-C-C-C + H2 RH + C-C-C
H
F.B. Plat
117108 II-6
Figure II-7
Demethylation
R-C-C-C-C + H2 R-C-C-CH + CH4
and
R-C RH
+ H2 + CH4
F.B. Plat
117108 II-7
uop 117108-6 II-18
Figure II-8
Aromatic Dealkylation
R R'
+ H2 + R"
F.B. Plat
117108 II-8
uop 117108-6 II-19
uop
Figure II-9
Generalized Platforming Reaction Scheme
N-Paraffins
M or A
M/A
Cracked
Cracked A M M or A Lighter
Products
Products A Cyclopentanes Cyclohexanes Aromatics Aromatics
M or A M/A
Dealkylation
117108-6
Iso-Paraffins
Naphthene Dehydro- and
I II III Demethylation
Isomerization genation
Legend Predominent Active Sites

I = Hydrocracking
Demethylation (M) A = Acid
II M = Metal
= Paraffin Isomerization
III = Dehydrocyclization
F.B. Plat
117108 II-9
II-20
Process Principles
Figure II-10
Normal-Hexane/ Methylcyclopentane Equilibrium
1.2
1.0
Equilibrium Ratio
PMCP / PnC6
0.8
0.6
400°C (752°F)
0.4
600°C (1112°F)
0.2
500°C (932°F)
0.0
0.0 5 10 15 20
(71) (142) (213) (285)
Hydrogen Partial Pressure, kg/cm2 (psig
(psig)) F.B. Plat
117108 II-10
Figure II-11
Cyclohexane/Methylcyclopentane Equilibrium
0.14
Equilibrium Ratio
0.12
PCH / PMCP
0.10
0.08
0.06
0.04
400 450 500 550 600
(752) (932) (1112)
Temperature, °C (°F) F.B. Plat
117108 II-11
uop 117108-6 II-21
Figure II-12
Cyclohexane/Benzene Equilibrium
103
500ºC (932 ºF)

Equilibrium Ratio
102
PBZ / PCH
10 450ºC (842 ºF)
400ºC (752 ºF)
1
5 10 15 20
(71) (142) (213) (285)
Hydrogen Partial Pressure, kg/cm2 (psig
(psig))
F.B. Plat
117108 II-12
Figure II-13
Selectivity of Normal Hexane to Benzene
0.40
Hexane Selectivity to Benzene
5 kg/cm2 (71 psig)

psig)
Moles per Mole Converted
0.30 9 kg/cm2 (128 psig)

psig)
14 kg/cm2 (200 psig)

psig)
0.20
0.10
0.00
450 500 550
(842) (942) (1022)
Reactor Temperature °C (°F) F.B. Plat
117108 II-13
uop 117108-6 II-22
Figure II-14
Selectivity of Methylcyclopentane to Benzene
Per Mole MCP Converted 0.70 7 kg/cm2 (100 psig)

psig)
Moles Benzene,

psig)
0.60

psig)
0.50
0.40
0.30
400 450 500 550
(762) (842) (932) (1022)
Reactor Temperature °C (°F)

F.B. Plat
117108 II-14
Figure II-15
Selectivity of Normal Heptane to Toluene
0.80
Moles Per Moles Converted
7kg/cm2 (100 psig)

psig)
Heptane Selectivity
0.60
14kg/cm2 (200 psig)
psig)
0.40 21kg/cm2 (300 psig)

psig)
0.20
0.00
450 500 550
(842) (942) (1022)
Reactor Temperature °C (°F) F.B. Plat
117108 II-15
uop 117108-6 II-23
Figure II-16
Hydrocarbon Types Conversion Reactor Profile
60
A
Moles per 100 Moles of Feed
50
40 P
30
20
10 CP
CH
0
0.0 0.10 0.25 0.50 1.0
Fraction of Total Catalyst
F.B. Plat
117108 II-16
Figure II-17
Cyclopentane Conversion Reactor Profile
3
CP6
1 CP7
CP8 CP9
CP11 CP10
0 0.1 0.25 0.5 1.0
Fraction of Total Catalyst F.B. Plat
117108 II-17
uop 117108-6 II-24
Figure II-18
Paraffin Conversion Reactor Profile
14
12
P7
10
8 P6
6
P8
4
P9
2 P10
P11
0
0 0.1 0.25 0.5 1.0
117108 II-18
Figure II-19
Paraffin Isomerization Reactor Profile
5
C7/C8 i/n Equilibrium

4 P8
Iso / Normal Ratio
C6 i/n
3 Equilibrium P7
2
P6
0
0 0.1 0.25 0.5 1.0
117108 II-19
uop 117108-6 II-25
Figure II-20
Aromatic Formation Reactor Profile
20
A8
14 A9
A8
A7
12 A7
A9
8 A10 A10
A6 A6
4
A11 A11
0 0.1 0.25 0.5 1.0
117108 II-20
Figure II-21
C5+ Research Octane Rating Reactor Profile
100
Micro Research Clear Octane
90
80
70
60
0 0.1 0.25 0.5 1.0

117108 II-21
uop 117108-6 II-26
Figure II-22
Temperature Reactor Profile
Inlet
-20
Temperature Δ, °C(°F)
(-38)
-40
(-72)
-60
(-108)
-80
(-144)
0 0.1 0.25 0.5 1.0

Fraction of Total Catalyst
F.B. Plat
117108 II-22
uop 117108-6 II-27
B. CATALYST CHEMISTRY
1. Dual Function Platforming Catalyst Chemistry
Examination of the reactions listed in Figure II-9 shows that some of them are acid-
catalyzed while others are promoted by a metallic hydrogenation-dehydrogenation
catalyst function. As such it is necessary that a Platforming catalyst have a proper
balance between the metal and the acid function as represented in Figure II-23.
This is important to minimize hydrocracking while maximizing the dehydrogenation
and dehydrocyclization reactions. This balance is maintained by proper water-
chloride control during the cycle and proper regeneration technique.
The importance of water chloride control can be illustrated by imagining the catalyst
surface as a ball and stick model with alumina and oxygen atoms in a regular
pattern upon which hydrogen and hydroxyl groups are randomly arrayed as in
Figure II-24. The vapor phase HCl and H2O are in equilibrium with the surface
hydroxyl groups and chloride. Too much water in the vapor phase will force
chlorides from the surface leading to an underchlorided catalyst. While too much
chloride in the vapor phase has the reverse effect. Therefore, proper control of
water/chloride ratios is crucial in maintaining an active acid site.
On the other hand, the metal sites (and of course the acid site) are affected most
dramatically during the regeneration step. Using the ball and stick model, one can
imagine a platinum-chloride species somehow attached to the surface (i.e. through
an oxygen or aluminum atom). The presence of chlorides in an oxidizing
atmosphere is instrumental in redispersing the platinum on the surface.
Temperature also affects mobility of platinum and retention of chloride. (The impact
of temperature and water-chloride control during normal operations and
regeneration will be discussed in later sections.)
The classical picture of a dual function catalyst involves two separate and distinct
sites with the reacting molecule migrating from one site to another. Current thinking
leans toward a modified picture in which a single site or single complex is
responsible for the entire reaction sequence. It should be pointed out that presently
it is only a concept and is not supported by unequivocal evidence. It is known that
uop 117108-6 II-28
the method of catalyst preparation affects the activity to at least the same extent as
the absolute level of active ingredients, indicating that a specific juxtaposition or
arrangement is critical. In addition, since the rates of the reactions over a modern
Platforming catalyst are so high that one must question the mass transfer limitations
that would be involved in migration between separate sites.
The concept of a single complex site does not affect the innate dual-functional
nature of a Platforming catalyst. The surface must still possess both acidic and
metallic characters. The acidic character is mainly responsible for the formation of
carbonium ions by either extraction of hydride ions or addition of protons to double
bonds. Carbonium ions are, in turn, the intermediates in such reactions as
isomerization and hydrocracking. The metal function is responsible for the
extraction of hydrogen from hydrocarbons, the splitting of hydrogen molecules and
subsequent addition of hydrogen atoms to unsaturated species. Combinations of
these two functions into a single complex site allow these reactions to occur in a
concerted fashion.
2. Effects of Pressure on Catalyst Design
For special purposes, the acidity of a Platforming catalyst can be increased. The
best example of this is the R-15 LPG Platforming system, where the target is the
production of maximum propane and butane. This was accomplished by adding
another acidic component to a Platforming catalyst. Figure II-25 illustrates the effect
of such increased acidity on product distribution in the case of a relatively mild
processing of a mid-continent naphtha.
If this same catalyst system is now operated at a lower pressure, there is a dramatic
shift in product yields because the acidity or cracking nature of the catalyst is
significantly reduced. Figure II-26 illustrates the effect of lowering pressure on the
performance of an R-15 catalyst. At 100 psig (7 kg/cm2), R-15 behaves very nearly
like a standard Platforming catalyst.
The pressure effect translates to standard Platforming catalysts where lowering

reactor pressure reduces cracking tendencies and increases selectivities of
naphthenes and paraffins to aromatics (as previously discussed).
uop 117108-6 II-29
Figure II-27 illustrates the relationship between pressure and yield of light
hydrocarbons for a given Platforming system.
The source of the light hydrocarbons is the cracking of paraffins. The yield of
aromatics from paraffins (can increase by as much as 40% as the pressure is
decreased from 500 to 150 psig (35 to 11 kg/cm2). Figure II-28 shows that this is the
result of a substantial decrease in hydrocracking and an associated improvement in
the selectivity of these paraffins to aromatics.
With the increase in C5+ yield due to lowering reactor pressure, there is an increase
in the octane-barrel yield with the optimum occurring at higher octane severities*.
Figure II-29 illustrates that for a constant feedstock lowering reactor pressure from
300 psig (21 kg/cm2) to 100 psig (7 kg/cm2) the optimum octane for maximum
octane barrel shifts from around 96 RONC to about 99 RONC. Likewise in Figure II-
30, if pressure is held constant, as the feed N+2A content increases, the optimum
RONC for maximum octane barrel increases.
* Octane barrel yield is defined as C5+ volume yield (barrels) times C5+ RONC.
3. UOP Platforming Catalysts
The type of information presented above on the relationship between pressure and
yield encouraged UOP to focus attention on low pressure Platforming some time
ago. The yield advantages in that region are obvious, but the problem is catalyst
stability.
Figure II-31 illustrates the effect of increased octane and decreased pressure on
catalyst stability. Taking advantage of the optimum octane for maximum octane
barrel from Figure II-29 would result in a six-fold deactivation rate.
To achieve this objective, UOP is continually striving to develop more stable (and
higher yield) catalysts. The addition of rhenium to monometallic (platinum) catalysts
achieved a 4-6 fold increase in stability (R-16 series) and an activity improvement.
uop 117108-6 II-30
The R-50 catalyst gave a stability increase by a factor of 1.7 to 2.0 times over the
R-16 series catalyst with an activity improvement while maintaining equivalent
yields. The R-60 series catalyst further improved upon stability above that of R-50
while maintaining equivalent activity and yields. The introduction of R-56 gave
further increases in activity and stability of Platforming catalysts. With the addition of
R-72, the selectivity was increased at no deficit to activity or stability.
Figure II-32 compares the UOP Fixed-Bed Platforming catalysts to one another with
all-platinum catalysts as a reference point.
It should be pointed out that the bimetallic catalysts, because of their more precisely
controlled metal and acid functions, are much more sensitive to feedstock sulfur and
water levels. Many of the problems associated with bimetallic Platforming
operations, especially in older units, can be traced to excessive amounts of sulfur
and water in the unit. These contaminant problems and are discussed in detail
elsewhere.
A comparison of different UOP catalysts is made in Table II-5, which lists the major
properties of Platforming catalyst R-9 through R-86.
uop 117108-6 II-31
Table II-5a (English Units): UOP Platforming Catalysts – Fixed-Bed Operation
Sock
Nominal Loaded
Diameter Density Platinum Rhenium Chloride
Catalyst Inches lb/ft3 Wt.% Wt.% Wt.% State
R-9X 1/16 32.0 0.375 - 0.9-1.0 O

R-16F 1/16 32.0 0.20 0.2 0.9-1.0 R/S
R-16G 1/16 32.0 0.375 0.375 0.9-1.0 R/S
R-16H 1/16 32.0 0.375 0.20 0.9-1.0 R/S
R-50 1/16 x 1/8 (Ex) 52.3 (D) 0.25 0.25 0.9-1.0 R/S
R-56 1/16 x 1/8 (Ex) 52.3 (D) 0.25 0.40 0.9-1.0 R/S
R-62 1/16 44.3 0.22 0.44 1.0-1.1 R/S
R-72 1/16 44.3 0.30 - 1.0-1.1 R
R-86 1/16 x 1/8 (Ex) 41.2(45.0D) 0.25 0.40 1.05-1.15 R/S
R-98 1/16 x 1/8 (Ex) 41.2(45.0D) 0.25 0.25 1.05-1.15 R/S
Notes: Ex = Extrudate R-9X, R-16G and R-16H are also available

D = Dense loaded by machine as 1/8" diameter catalyst. These catalyst
R/S = Reduced and sulfided are designated with (l), i.e. R-16GL.
R = Reduced
O = Oxidized
Table II-5b (Metric): UOP Platforming Catalysts – Fixed-Bed Operation
Sock
Nominal Loaded
Diameter Density Platinum Rhenium Chloride
Catalyst mm kg/m3 Wt.% Wt.% Wt.% State
R-9X 1.6 513 0.375 - 0.9-1.0 O

R-16F 1.6 513 0.2 0.2 0.9-1.0 R/S
R-16G 1.6 513 0.375 0.375 0.9-1.0 R/S
R-16H 1.6 513 0.375 0.2 0.9-1.0 R/S
R-50 1.6 x 3.2 (Ex) 838 (D) 0.25 0.25 0.9-1.0 R/S
R-56 1.6 x 3.2 (Ex) 838 (D) 0.25 0.40 0.9-1.0 R/S
R-62 1.6 710 0.22 0.44 1.0-1.1 R/S
R-72 1.6 710 0.30 - 1.0-1.1 R
R-86 1.6 x 3.2 (Ex) 660(720D) 0.25 0.40 1.05-1.15 R/S
R-98 1.6 x 3.2 (Ex) 660(720D) 0.25 0.25 1.05-1.15 R/S
Notes: Ex = Extrudate R-9X, R-16G and R-16H are also available

D = Dense loaded by machine as 1/8" diameter catalyst. These catalyst
R/S = Reduced and sulfided are designated with (l), i.e. R-16GL.
R = Reduced
O = Oxidized
uop 117108-6 II-32
Figure II-23
Properly Balanced Catalyst
Desired
Metal-Acid
Balance
(Pt) (Cl)
Increasing Metal Increasing Acid
Function Function
Demethylation Cracking
Dehydrogenation
Dehydrocyclization
Isomerization F.B. Plat
117108 II-23
Figure II-24
Acid Site H H
O
H
Cl
H
H
O
Cl
Al
Al
O O O O
F.B. Plat
117108 II-24
uop 117108-6 II-33
Yield wt - % of Charge
117108 II-25
85
80
75
70
65
F.B. Plat
Standard Catalyst
C5+
Standard Platforming Catalyst vs. R-15
Comparative Yield Structures
C3 + C4
Figure II-25
C1 + C2
Midcontinent Naphtha
Product 95 RONC
H2
R-15-LPG
20
16
12
uop 117108-6 II-34
117108 II-26
F.B. Plat
90
80
50
70
60
40
30
7 kg/cm2(100 psig)
C5+
Effect of Pressure on Yield Structure
C4
of R-15 Catalyst
Figure II-26
C3
104.2
99.3
C2
RONC
42 kg/cm2(600 psig)
C1
42 kg/cm2
7 kg/cm2
H2
16
4
24
20
12
8
uop 117108-6 II-35
Figure II-27
Effect of Pressure on Yield Structure
100
Hydrogen
-%
wt-%
Product Yield, wt
90
C 1 + C2 + C3 + C4
80
C5+ Reformate
70
0 10 20 30 40
(143) (285) (428) (570)
kg/cm2 (psig
Pressure kg/cm (psig)) F.B. Plat
117108 II-27
Figure II-28
Effect of Pressure on Paraffin Conversion
45
Hydrocracked
Mole Percent of Feed Paraffins
40
To Aromatics
35
30
25
Remaining in Reformate
20
15
10 15 20 25 30 35 40
(285) (428) (570)
kg/cm2 (psig
Pressure kg/cm (psig)) F.B. Plat
117108 II-28
uop 117108-6 II-36
Figure II-29
Octane-Barrel Yield Response to Octane and Pressure
8400
Octane - Barrel Yield
8200
per 100 BBL Feed
P= 100 psig
8000 kg/cm2)
(7 kg/cm
7800 P= 200 psig

kg/cm2)
(14 kg/cm
7600
P= 300 psig
(Feed = Constant) kg/cm2)
(21 kg/cm
7400
0 94 98 102
RONC
F.B. Plat
117108 II-29
Figure II-30
Octane-Barrel Yield Response to Octane and Feed Composition
8,500
Octane - Barrel Yield
N + 2A = 80
per 100 BBL Feed
8,000
7,500 N + 2A = 60
7,000
(Pressure = Constant) N + 2A = 40
6,500
90 92 94 96 98 100 102 104
RONC
F.B. Plat
117108 II-30
uop 117108-6 II-37
Figure II-31
Effect of Octane and Operating Pressure
on Catalyst Deactivation
Relative Cycle Length = Catalyst Life
24
22
20
Catalyst Cycle Length
18
40
0
16
ps
ig
14 30
(2
0p
8
s ig
kg
12
/c
(2
m
1k
2)
10 200 g/c
m2
8 psi )
g (1
4k
6 g /cm 2
)
4 1 0 0 ps
ig (7 k
g/cm 2)
2
0
90 92 94 96 98 100 102
RONC
F.B. Plat
117108 II-31
uop 117108-6 II-38
uop 117108-6 II-39
C. CATALYST REGENERATION
A Platforming catalyst is manufactured with its various components optimized so

that the best process performance possible is realized. The catalyst has three
primary components:
1. The alumina support,

2. the acidity components, and
3. the metal components.
The alumina support must have a high enough strength and proper size so that
breakage and high bed pressure drop does not occur. The pore structure should
allow the charge stock availability to the active sites. The surface area should be
high in order to provide as many active sites as possible.
A very important feature of a catalyst is the dispersion of the platinum throughout

the alumina support. The platinum crystallites should be less than 35 angstroms in
size since only the surface atoms are available for reaction.
The object of a regeneration is to return the catalyst to a state as close to the fresh
catalyst state as possible. This means the regenerated catalyst must have the
following properties:
1. The surface area should be high;

2. the metals should be in the reduced state;
3. the metals must be highly dispersed;
4. the halogen/acidity must be at the proper level.
There are basic problems in retaining these properties during a regeneration. The
thermodynamics dictate that the system will always tend to its most stable state. For
the Platforming catalyst, well dispersed platinum on high surface area alumina is
much less stable than a single crystal of platinum and a single crystal of alumina
with no surface area, e.g. alpha alumina (Figure II-34). The conditions present
during the combustion of coke are those that will promote this transition to a more
stable system. Therefore, each step of the regeneration procedure is critical in
returning the catalyst system to its high performance nature.
uop 117108-6 II-40
Catalyst deactivation usually occurs due to coke formation that covers the active
sites of the catalyst. In addition to this, the deactivation may be caused by metal
agglomeration, catalyst poisons entering the system, or by damage to the base from
high temperatures. The activity of the catalyst may be restored if the deactivation
has occurred because of coke formation or from a temporary poison.
1. Catalyst Regeneration Theory and Chemistry
In order to regenerate the catalyst, the coke must be burned off, the catalyst
oxidized and finally reduced. These steps are diagrammatically shown below:
Plant Carbon
Shutdown Burn
Oxidation Reduction Plant

Start-Up
The coke burning reaction is exothermic and follows the approximate reaction
shown below:
4 CH + 5 02 4 CO2 + 2 H2O + heat
It is seen from the above reaction that the coke on the catalyst is assumed to
contain a carbon:hydrogen ratio of one.
Because the coke burning reaction is exothermic, care must be taken not to
overheat the catalyst when it is experiencing the burn. To keep the temperature of
the catalyst surface low, the oxygen content of the circulating gas is held low. At
high temperatures, platinum agglomeration and loss of surface area may occur. If
the temperature continues to rise, phase changes of the alumina base may occur
(Figure II-35).
Since the platinum crystals can grow at even moderate delta T’s, a step has been
included in the regeneration procedure to redistribute the platinum throughout the
catalyst surface. This redistribution step, or oxidation, is carried out subsequent to
the carbon burn. There are three key occurrences during the oxidation:
uop 117108-6 II-41
1. The metals are placed in their proper oxidation state prior to reduction.
2. The agglomerated metals are redistributed.
3. The correct chloride level is maintained.
It has been observed that chloride injection is effective in redistribution of the

crystallites and in maintaining their dispersion. During the oxidation step, the oxygen
content and the temperature of the circulating gas stream are increased. Depending
on the amount of agglomeration, the redistribution of platinum may be fairly slow to
accomplish. Therefore, adequate time is allowed at oxidizing conditions.
The presence of sulfates on the catalyst also promote platinum crystal growth. If it is
suspected that there are significant levels of sulfate present, (catalyst analysis,
sulfur history, sulfur present in the combustion gas during carbon burn step), then a
sulfate removal step is advisable. The basic reaction to form sulfates occurs during
the carbon burn step:
H2S + O2 SO2, SO3, SO4= + H2O
The SO2 and SO3 can cause platinum agglomeration. In addition to platinum
agglomeration, the sulfates tend to interfere with the catalyst’s ability to retain
chloride.
During the sulfate removal step, the sulfates are reacted to H2S, purged from the
catalyst surface, and finally scrubbed from the circulating hydrogen rich gas with
basic water.
After the sulfates have been removed from the catalyst, a re-oxidation is done to
ensure the metals return to a well-dispersed state.
uop 117108-6 II-42
The regeneration steps with sulfate removal are shown below:
Plant Carbon Shortened Sulfate

Shutdown Burn Oxidation Removal
Proof Carbon Oxidation Reduction Plant

Burn Start-Up
The final step of regeneration is the reduction of the oxidized metals to the metallic
state. This is best accomplished in as dry an atmosphere as possible. If the
atmosphere is wet, platinum crystal growth will occur. In order to accomplish this,
the water is drained from the plant before the cooldown and the reduction hydrogen
is circulated at as high a rate possible with the recycle gas compressor. This allows
rapid removal of the water formed by reduction from the catalyst particles.
Before the unit is placed in operation, it is necessary to assure that the catalyst is
sulfided. The purpose of the sulfur is to prevent exothermic reactions during startup
which are caused from the highly active metal components. Figure II-33 below
shows the temperature profile of a 300 psig catalyst system at startup that has not
been sulfided.
In Summary:
1. Each of the components of a Platforming catalyst is oxidized prior to

operation. Significant features are surface area, metals dispersions,
acidity:halogen level.
2. Conditions during regeneration are those that will lead to degradation of

these optimized factors.
3. The critical carbon burn step should be performed to control temperatures to

avoid surface area loss and platinum agglomeration.
uop 117108-6 II-43
4. The critical oxidation step should be performed at conditions that will allow
for metals redistribution. The injection of halogens is a key to success.
5. Reduction must be performed under dry conditions to maintain dispersion.
6. UOP regeneration procedures are designed to allow the refiner to come back
on stream with a catalyst that is as close to fresh as possible.
uop 117108-6 II-44
Figure II-33
Reactor Temperature Profile
Catalyst Not Sulfided
1000
900
800
7 00
Inlet Outlet
Bed Position
UOP PLT-R00-213
uop 117108-6 II-45
Figure II-34
Effect of Temperature on Pt Crystal Growth
Reduction of surface free energy
Pt Pt
Chemical interaction Al2O3

with Al2O3
Temperature reduces strength of interaction that stabilizes Pt on the
surface
Temperature increases rate of mobility of atom on surface

F.B. Plat
117108 II-34
Figure II-35
High Temperatures Can Cause Phase Changes
Relation Between Alumina Phase and Surface Area
300
Surface Area, m2/g
200 γ-Al2O3
δ-Al2O3
100
θ-Al2O3
α -Al2O3
0
600 800 1000 1200
(1100) (1475) (1800) (2200)
Treatment Temperature, °C (°F) F.B. Plat
117108 II-35
uop 117108-6 II-46
2. Chloride Neutralization During Regeneration
a. Carbon Burn and Oxidation Steps
In a sodium hydroxide/water system, the following reaction takes place as soon as

CO2 is available:
(1) 2NaOH + CO2 Na2CO3 + H2O
As this reaction progresses, the pH of the solution will change from 13 plus to 11.5
plus (being only slightly dependent upon concentration in the regime we employ).
With the production of additional CO2, the carbonate reacts to bicarbonate as
follows:
(2) Na2CO3 + H2O + CO2 2 NaHCO3
As the reaction progresses, the pH solution will change from 11.5 plus to about 8.5
(again assuming typical concentrations of about 1-5 weight percent for NaOH or
Na2O3). It is then the sodium bicarbonate that acts as the primary chloride
“scavenger” during carbon burn and oxidation steps:
(3) NaHCO3 + HCl NaCl + H2O + CO2
This reaction will occur gradually during the regeneration as chloride leaves the last
reactor. As the bicarbonate reacts with chloride, the pH of the solution will change
very slowly until almost all of the bicarbonate is consumed; a further small addition
of chloride rapidly decreases the solution pH to 4 and below. Proper, safe control of
basic water condition during carbon burn and oxidation must therefore involve
maintaining a bicarbonate solution having a safe “reserve” capacity for additional
chloride. Such a solution will have a pH of 7.5-8.5, but pH is of limited use as a
control parameter. For example, a bicarbonate solution of 5.0 weight percent
concentration NaHCO3 will have approximately an 8.5 pH and will have capacity to
react about 7.5 weight percent (as percent of solution) chloride; a bicarbonate
solution of 0.5 weight percent NaHCO3 will have perhaps an 8.0 pH but will have
uop 117108-6 II-47
capacity to react only 0.7 weight percent chloride. pH therefore, is a poor indicator
of the solution’s remaining capacity for chloride neutralization. An alternate
analytical tool to monitor basic water condition would be UOP Methods 209 or 210,
both of which measure total alkalinity of the solution (expressed as weight percent
NaOH equivalents). Use of one of these procedures would allow establishing a safe
minimal alkaline reserve of the basic water solution (perhaps 2 weight percent
NaOH equivalent). It is apparent that it is this reserve alkalinity and not pH that
should be monitored and kept at a predetermined, safe minimum.
The above discussion should clarify the point of increased caustic consumption
caused by maintaining too high of a pH during regeneration. If, for example, the pH
is maintained at 9 or higher, the discarded solution will contain some Na2CO3 which
is caustic (or carbonate) which has been totally unused for chloride consumption;
the major drop in pH from 11-13 down to 9 is caused by CO2 converting NaOH and
Na2CO to NaHCO3 and NaCl; hence, caustic (or carbonate) waste will be less.
Further control over the amount of usable caustic (or carbonate) discarded in the
drained solution is possible only by utilizing UOP Laboratory Method 209 or 210 to
measure total alkalinity of the circulating solution; draining and refilling can then be
performed when the available alkalinity reaches some low but safe level. If, for
example, 4 weight percent NaOH solution is used and draining/refilling is performed
when the total alkalinity is 1.5 weight percent NaOH equivalent, total caustic
consumption would be 4/2.5 × 100% or 160% of theoretical. A reserve such as 1.5
to 2.0 weight percent should be maintained to guard against chloride surges (such
as at the end of the last reactor burn and the heatup for oxidation) and any
unforeseen delays involved in draining and adding fresh basic solution.
Once the initial charge of basic solution has been converted to bicarbonate at the
start of carbon burn/oxidation steps, the solution will neutralize chloride as depicted
by equation (3). During the early stages of the carbon burn step, chloride is taken
up by the catalyst to a level of approximately 1.2 to 1.3 weigh percent. During this
time, the last reactor effluent HCl concentrations are low, and therefore bicarbonate
consumption is low. After reaching a high equilibrium catalyst chloride level,
however, total chloride leaving the reactors will equal total chloride added to the
reactors and bicarbonate consumption will increase. During a well-controlled carbon
uop 117108-6 II-48
burn-oxidation step, chloride addition will usually be relatively constant and

bicarbonate consumption will likewise be relatively constant. If this is the case, then
the frequency of adding fresh caustic or carbonate can be estimated by monitoring
chloride addition and adding one and one-half moles of sodium compound for each
mole of chloride added. This amounts to 2.25 weights of sodium carbonate per
weight of chloride, or 1.7 weights of sodium hydroxide per weight of chloride.
As previously mentioned, two periods will be notable exceptions to the above rule.
When the last reactor starts to burn, its outlet temperature will be increased by 80-
100°F, desorbing additional chloride from this reactor’s catalyst. This is somewhat
compensated for by adsorption of chloride by the previous reactor's catalyst as its
outlet temperature cools down to about 750°F. In addition, the burning wave itself
will displace even more chloride as it reaches the reactor outlet. The overall effect is
generally an increase in chloride leaving the last reactor toward the end of its burn.
A similar effect is noted when reactor inlet temperatures are increased from 750 to
950°F at the start of the oxidation.
b. Sulfate Removal Step
During the sulfate removal step, caustic will react with H2S as follows:
(4) 2NaOH + H2S Na2S + 2H2O
(5) Na2S + H2S 2NaHS
Reaction (4) is essentially irreversible and proceeds to completion. Reaction (5) is

equilibrium controlled and will proceed only to about 40% completion if complete
H2S removal from the vapor is maintained. Therefore, the overall reaction between
caustic and H2S is:
(6) NaOH + 0.7 H2S 0.4 NaHS + 0.3 Na2S + H2O
uop 117108-6 II-49
Competing for the NaOH will be the chloride leaving the last reactor. During a
typical sulfate removal step, most of the sodium (caustic) consumption is due to
chloride neutralization, not H2S removal.
(7) NaOH + HCl NaCl + H2O
This reaction does not, however, interfere in H2S removal, it merely removes some
of the available sodium hydroxide.
If Na2CO3 is utilized during a sulfate removal step, the reactions are much more
limited and less efficient with respect to sodium utilization. Sodium carbonate can
react with H2S as follows:
(8) 2NaCO3 + H2S NaHCO3 + NaHS + Na2CO3
However, the equilibrium limitations on this reaction are as severe as for reaction
(5), limiting the completion to about 40%. Furthermore, NaHCO3 cannot react with a
weak acid such as H2S. Thus, the best overall reaction possible is:
(9) Na2CO3 + 0.4 H2S 0.4 NaHS + 0.4 NaHCO3 + 0.6 Na2CO3
It is important also to note that as chloride is neutralized by the carbonate solution, it

is rapidly rendered useless for H2S removal. Carbonate reacts as follows with
chloride:
(10) Na2CO3 + HCl NaHCO3 + NaCl
Once the bicarbonate concentration reaches about 2/3 of the carbonate

concentration, the solution will no longer be able to completely remove H2S from the
gas. Thus, when Na2CO3 is used during sulfate removal, chloride not only
consumes some of the available Na2CO3 but consumes the small fraction of sodium
that would be otherwise available for H2S removal.
uop 117108-6 II-50
This limited ability for H2S removal (especially for a Na2CO3 solution) has been
recognized by our Treating Department. For H2S removal, they recommend
operation at a maximum 70% “spent” level. Definition of “% spent” is included in the
attached copy of UOP Method 210-76T. The following examples are given to
illustrate the relative effectiveness of NaOH and Na2CO3 for H2S/HCl removal, and
to show sample calculations of “% spent.”
Example II-1
Assume that 1 mole of NaOH reacts with ¼ mole of H2S; calculate the “% spent.”
NaOH + ¼ H2S ¼ Na2S + ½ H2O + ½ NaOH
The product solution would titrate as follows:
Bromthymol Bromphenol
compound
½ NaOH 1× ½ = ½ 1× ½ = ½
¼ Na2S ½× ¼× 2 = ¼ 1× ¼× 2 = ½
¾ 1
The total acid consumptions to the two end points are then used to calculate the %
spent condition of the solution:
(1 - ¾)
% spent × 100% = 25%
1
This solution is still usable for H2S removal (less than 70% spent).
Example II-2
Assume that ½ mole of Na2CO3 (1 mole of sodium) reacts with ¼ mole of H2S;
calculate the % spent.
½ Na2CO3 + ¼ H2S ¼ NaHS + ¼ NaHCO3 + ¼ Na2CO3

The product solution would titrate as follows:
uop 117108-6 II-51
compound
¼ Na2CO3 ½× ¼× 2 = ¼ 1× ¼× 2 = ½
½ NaHS 0 1× ½ = ½
¼ NaHCO3 0 1× ¼ = ¼
Total ¼ 1¼
(1¼) - (¼)
% spent = 100% × 100% = 100%
1
This solution would have exhausted its ability to completely remove H2S from the
circulating gas (less than 70% spent).
Example II-3
Assume that 1 mole of Na2CO3 has reacted with ¼ mole of HCl; calculate the %
spent to determine if this solution can completely adsorb H2S:
Na2CO3 + ¼ HCl - ¼ NaCl + ¼ NaHCO3 + ¾ Na2CO3
This product solution would titrate as follows:
Relative acid requirements to titrate to:
compound
¾ Na2CO3 ½× ¾ × 2 = ¾ 1× ¾ × 2 = 6
/4
½ NaHS 0 1× ¼ = ¼
7
Total ¾ /4
7/4 - 3/4
then % spent = = 57%
100% × 7/4
uop 117108-6 II-52
This solution has a small reserve left for complete H2S removal; note that only one-
eighth of the sodium has been utilized and the solution has only a very small
additional reserve for H2S removal.
UOP Method 210 is a simple analytical method that can be run by operators in a
control room. If the normality of the acid titrating solution and the amount of sample
are judiciously chosen and standardized, the calculations of % spent and total
alkalinity are very simple.
Obviously most refiners will continue to monitor pH only, because it is simple and it
usually provides a reasonable control parameter. The above discussion has pointed
out two severe limitations of pH indication: first, the total reserve to neutralize
chloride is not accurately indicated by pH and a sudden large surge of chloride may
result in a very rapid pH decline, with subsequent corrosion problems; second, H2S
removal is much more limited and less efficient that HCl neutralization, and NaOH is
much less limited in its ability to remove H2S. If either of these points is a major
concern during a particular regeneration, consideration should be given to using
UOP Method 210. If this method is used, total alkalinity should be maintained at
some safe level during carbon burn/oxidation (perhaps 1.5-2.0 wt-% NaOH
equivalents), and % spent should be maintained below 70% during sulfate removal
(total alkalinity will automatically be controlled at a safe high level by maintaining a
70% spent level).
c. Precipitation of Sodium Salts During Regeneration
There have been several cases in which refiners used too concentrated a solution
of caustic or carbonate for chloride neutralization during regeneration. Figure II-36
shows the problem with using high concentrations of caustic or carbonate. Based
upon previous discussion in this section, caustic and carbonate will be rapidly
converted to bicarbonate, which has a much lower solubility in water. If, for
example, an 8 weight percent NaOH solution is prepared and charged to the
Platforming Unit separator, the NaOH will be rapidly converted to NaHCO3 by CO2
present. Assuming negligible conversion to NaCl prior to complete conversion to
NaHCO3, the NaHCO3 weight concentration would become 8 × 84/40 = 16.8 grams
per 100 grams of water. Note that this is above the NaHCO3 solubility even at 50°C
uop 117108-6 II-53
(122°F). Figure II-37 gives the maximum allowable weight concentrations of NaOH
and Na2CO3 as a function of the coldest temperature in the cooler/separator. This
maximum allowable concentration of NaOH or Na2CO3 would be just sufficient to
produce a saturated NaHCO3 solution upon complete conversion of the caustic or
carbonate to the bicarbonate. Of course, in reality, some conversion to NaCl would
occur prior to complete conversion to NaHCO3, lowering the final NaHCO3
concentration attained. To provide a reasonable safety margin during Platforming
regenerations, the following are recommended as maximum caustic/carbonate
concentrations.
NaOH Na2CO3
g/100 g °Be g/100 g °Be
water water
Most regenerations 4 5.4 7 9.5
Winter regenerations in 3 4 5.5 7.5
winter climates
uop 117108-6 II-54
Figure II-36
Solubilities of Various Sodium Compounds
NaOH
60
50
Na2CO3
40 Na2S
NaCl
30
20
NaHCO3
10
0
0 10 20 30 40 50
(32) (50) (68) (86) (104) (122)
Temperature, °C (F)
UOP PLT-R00-211
uop 117108-6 II-55
Figure II-37
Maximum Allowable NaOH and Na2CO3 Concentrations
12
Na2CO3
10
8
NaOH
0
0 10 20 30 40 50
(32) (50) (68) (86) (104) (122)
Lowest Temperature in
Air / Water Coolers or Separators, °C (°F)
UOP PLT-R00-212
uop 117108-6 II-56
Fixed-Bed Platforming – General Operating Manual Process Variables
III. PROCESS VARIABLES
The purpose of this section is to discuss the major Platforming operating variables,
their relation to unit performance and the estimation of shifts in performance due to
operational changes.
The operating variables that are the most pertinent are shown in Table III-1. For
practical purposes, these variables are sufficient to define a Platforming operation.
Table III-1: MAJOR PLATFORMING VARIABLES
Independent Variables Dependent Variables
• Catalyst Type • Catalyst Activity

• Reactor Temperature • Reactor Effluent Yields
• Space Velocity • Product Quality
• Reactor Pressure • Catalyst Stability
• H2/HC Ratio
• Charge Stock Properties
• Feed Additives
Although there are inter-relationships between the variables (for instance the
reactor temperature, reactor pressure, and reactor effluent yield relationships
discussed in Section II), this section treats each independent variable separately
where possible.
A. MAJOR PLATFORMING INDEPENDENT VARIABLES
It is of interest at this point to discuss briefly and qualitatively the effects of the
major process variables on Platforming Unit operation.
uop 117108-6 III-1
1. Catalyst Type
Catalyst selection has most likely been tailored to the refiner’s individual processing
requirements. The UOP Platforming catalyst in your unit has been chosen to meet
the refiner’s yield, activity, and stability needs. As such basic catalyst formulation,
chloride level, platinum level, etc. are not discussed in this section.
There are some basic differences between individual catalysts that will be taken into
account in the calculations described below. For instance, catalyst type will affect
the temperature required to meet a particular product quality.
2. Reactor Temperature
The temperature at which the Platforming reactor catalyst beds are held is the major
control parameter the refiner uses to meet product quality requirements. Platforming
catalysts are capable of operation over a wide range of temperature with little
adverse affect on product yield and catalyst stability. However, very high
temperatures, above 1010°F (543°C), may cause thermal reactions which will
decrease reformate yield and catalyst stability.
Reactor temperature can be defined in two fashions, either Weighted Average Inlet
Temperature (WAIT) or Weighted Average Bed Temperature (WABT). These can
be calculated as follows:
WAIT = ∑ (C fr,i
w
i
x TIN )
⎡ fr,i
WABT = ∑ ⎢Cw
(T i
IN
+ T OUT ⎤
i
⎥
)
⎢⎣ 2 ⎥⎦
where:
fr,i
C w
= weight fraction of total catalyst in reactor i
i
T IN
= Inlet temperature of reactor i
i
T OUT
= Outlet temperature of reactor i
uop 117108-6 III-2
The WAIT is primarily used in the calculations (because of ease of calculation)

although the WABT is a better measure of the average catalyst temperature or
reaction conditions. As such there is a WAIT-WABT criterion imposed for the
calculation of activity.
3. Space Velocity
Space velocity is a measure of the amount of naphtha that is processed over a

given amount of catalyst over a set length of time. When the hourly volume charge
rate of naphtha and the volume of catalyst are used, the term is liquid hourly space
velocity (LHSV). When weights are used, the term is weight hourly space velocity
(WHSV). Either is applicable in following a Platforming Unit operation when a set
catalyst density and volume is involved. LHSV, hr-1, is commonly used by UOP
since most refiners define their charge rate on a volume basis, and hourly rates
yield conveniently sized numbers.
Space velocity has a major effect on product quality (example: octane number). The
higher the space velocity the lower the product RONC or the less the amount of
reaction allowed at a fixed WAIT. Increased reactor temperatures will offset this
effect. Within normal Platforming Unit design parameters, space velocity has little
effect on product yields and catalyst stability (on a barrel per pound basis). At very
low velocities, thermal reactions can occur to a sufficient degree to decrease
reformate yields. While there is no known upper limit on space velocity, reactor
temperatures have to be increased in order to maintain the product quality and
above a certain point, this can again cause unfavorable thermal reactions that will
lower selectivity.
4. Reactor Pressure
Because of its inherent effect on reaction rates, hydrogen (or hydrocarbon) partial
pressure is the basic variable, but for ease of use, the information which follows has
been adjusted so the total reactor pressure can be used and the hydrogen purity is
not needed.
uop 117108-6 III-3
Reactor pressure is most accurately defined as the average catalyst pressure.

Since 50% of the catalyst is usually in the last reactor, a close approximation is the
last reactor inlet pressure. Separator pressure, as an operating parameter, is of
limited value since the pressure drop from unit to unit can be considerably different
and even within the same unit, the pressure drop will vary considerably with charge
rate, recycle gas rate, recycle gas gravity, etc.
The reactor pressure affects the Platforming Unit yields, reactor temperature
requirement, and catalyst stability. Reactor pressure has no theoretical limitations,
although practical design limitations have an effect. Reactor pressures as high as
700 psig (49 kg/cm2) and as low as 80 psig (5.6 kg/cm2) have been run
commercially.
Decreasing the reactor pressure will increase the hydrogen and reformate yield,
decrease the temperature requirement to make the product quality, and shorten the
catalyst cycle (increase catalyst coking rate).
5. Hydrogen/Hydrocarbon Ratio
Hydrogen/hydrocarbon (H2/HC) ratio is defined as the moles of recycle hydrogen

per mole of naphtha charged to the unit.
Recycle hydrogen is necessary in the Platforming Unit operation for purposes of

catalyst stability. It has the effect of sweeping the reaction product and condensable
materials from the catalyst and supplying the catalyst with readily available
hydrogen.
An increase in H2/HC ratio will move the naphtha through the reactor at a faster rate
and supply a greater heat sink for the endothermic heat of reaction. The end result
is increased stability with little effect on the product quality or yields.
uop 117108-6 III-4
6. Charge Stock Properties
The charge stock properties that are pertinent to this discussion of Platforming
variables are as follows:
Property Laboratory Method
Source of Stock -
Initial boiling point (IBP)

Mid boiling point (50%) ASTM D-86 Distillation
End boiling point (EP)
Paraffin Content (P)

Naphthene Content (N) UOP 880 (Hydrocarbon Types)
Aromatic Content (A)
Generally, the computation procedures described later on are based on correlations

of pilot plant and past commercial data. The preferred PONA analysis is UOP
Method 880. The UOP Method 273 will tend to give inaccurate naphthene results
for full boiling range feedstocks because of the presence of polycyclic naphthenes.
The UOP Method 777 is the method of choice if the olefin content is high (>2 LV%).
These correlations are to be used to characterize straight run naphthas only.

Estimation of other feeds such as FCC and coker naphthas fall outside the range of
these correlations. In the Catalyst Stability section of this Process Variables
Chapter, coking rate adjustment factors for FCC and coker naphthas as well as
Raffinate processing are discussed.
Charge stocks with low IBP’s [less than 170°F (77°C)] will generally contain a
significant amount of C5+ material. The pentanes in the feed cannot be converted to
aromatics and, therefore, these pentanes will pass through unconverted, isomerized
and/or cracked to light ends. Because of their low octane, they will dilute the overall
reformate octane and result in a higher than anticipated (C6+) octane-severity in the
uop 117108-6 III-5
Platforming Unit. On the next page is an example of the effect of C5’s on

Platforming Unit severity.
Charge stocks with low EP’s have C6 and C7 hydrocarbons concentrated. These
are the most difficult species to reform. On the other hand, charge stocks with high
EP’s cause higher catalyst coking rates. They also contribute significantly to high
reformate endpoint.
The following example helps to illustrate this dilution effect and provide a means to
estimate the new RONC severity (needed for the proceeding correlations for
activity, stability and yields).
Example III-1
a. Process Conditions
Feed Rate 10,000 BPD (1,590 m3/day)

Reformate C5+ Yield, LV-% 82.08
Reformate C5+ RONC 98.2
Total Pentanes in Feed (From Feed GC) 3.0 LV-%
n-Pentane 1.7 LV-%
i-Pentane 1.0 LV-%
Cyclopentane 0.3 LV-%
If individual pentanes are not known, assume 40% of total is iso-pentane and 60%
is n-pentane.
b. Compute Total Product Octane-Cubic Meters (Octane-Barrels)
Feed x Yield x RONC
1,590 m3 x .8208 x 98.2 = 128,144 octane-m3
(10,000 BBL x .8208 x 98.2 = 806,026 octane-barrels)
uop 117108-6 III-6
c. Compute Product C5 Octane-Cubic Meters (Octane-Barrels)

(Assume 90% of C5 in Feed Goes to Product)
Feed x (C5 Fraction to Product) x RONC contribution of that species

n-pentane 1,590 x (0.017 x 0.9) x 63.0 = 1,532 octane-m3
(10,000 x (0.017 x 0.9) x 63.0 = 9,639 octane-barrels)
iso-pentane 1,590 x (0.010 x 0.9) x 92.3 = 1,321 octane-m3

(10,000 x (0.010 x 0.9) x 92.3 = 8,307 octane-barrels)
cyclo-pentane 1,590 x (0.003 x 0.9) x 101 = 434 octane-m3

(10,000 x (0.003 x 0.9) x 101 = 2,727 octane-barrels)
total C5’s 1,532 + 1,321 + 434 = 3,287 octane-m3

(9,639 + 8,307 + 2,727 = 20,673 octane-barrels)
d. Compute Total Octane-Cubic Meters (Octane-Barrels) Produced in

Reactor
Total Product - Total C5’s from Feed = Total Produced in Reactors
128,144 - 3,287 = 124,857 octane-m3

(806,026 - 20,673 = 785,353 octane-barrels)
e. Compute Total Cubic Meters (Barrels) Produced in Reactor
Total Product - Total C5’s from Feed = Total Produced in Reactors
(1,590 x .8208) - (1,590 x .03 x .9) = 1,262 cubic meters

((10,000 x .8208) - (10,000 x .03 x .9) = 7,938 barrels)
Total Octane Produced in Reactors

f. Compute Actual RONC =
Total Product Produced in Reactors
124, 857 octane - m3

= 98.9 RONC
1, 262 cubic meters
uop 117108-6 III-7
785, 353 octane - barrels

( = 98.9 RONC)
7, 938 barrels
Therefore, the octane that should be used for yield, activity, or stability
calculations in this case is 98.9 rather than the reported 98.2.
The effects of C5 in feed will be greater as the product octane and/or pentane
in feed increase.
7. Feed Additives
It is assumed that chloride and water additions to the feed are sufficient to maintain
the chloride balance on the dual-function UOP Platforming catalyst. Chloride control
will be discussed in detail in the Water-Chloride Section.
Catalyst poisons and feed contamination will also be covered in the Catalyst
Poisons Section.
B. PLATFORMING DEPENDENT VARIABLES
In this portion of the Process Variables section, the effects of the Platforming
independent variables on the major dependent variables will be discussed. More
importantly, methods for estimating the effects of operating changes on one or more
of the dependent variables will be illustrated.
1. Catalyst Activity
Catalyst activity is a term used to describe the temperature at which a particular

catalyst must be operated to produce a given product quality. In this discussion, the
catalyst temperature will be defined exclusively as the WAIT or weighted average
inlet temperature. Product quality as it applies to motor fuel operations will be
defined as the RONC or research octane number clear.
uop 117108-6 III-8
The WAIT requirement to meet a given RONC is obviously affected by many things.
At the outset of a run with fresh catalyst, one would expect that the WAIT required
would only be affected by: the feed characteristics, RONC desired, and the catalyst
type. Things are only this simple one time, because as a Fixed-Bed unit run
progresses, the catalyst deactivates due to gradual coke laydown increasing the
necessary WAIT to achieve the desired octane. Also, any operational upset can
affect the water-chloride balance and the apparent catalyst activity can change. The
list goes on and on.
There is a simple calculation procedure for estimating the Start-Of-Run WAIT

requirement. This SOR WAIT is the temperature at which a fresh catalyst loading
would operate in order to produce a certain RONC from a feed characterized by a
certain N and A content and charged at a given LHSV. There are at least two (2)
important ways at which this estimate can be put to use:
i. Fixed-Bed Platforming Unit startup WAIT target.
ii. Fixed-Bed “Delta WAIT” (Predicted WAIT minus actual SOR WAIT) for
tracking catalyst deactivation on a normalized basis.
The first use, (i), is fairly straightforward. The calculation enables the process
engineer or supervisor to estimate the WAIT required to meet product requirements
following a fresh catalyst loading and, in many cases, following a Fixed-Bed unit
catalyst regeneration.
The second use requires some explanation, but the reader will note that the concept
is simple. The basic idea is to determine a number (Delta WAIT) which puts the
catalyst temperature requirement on a consistent or normalized basis for comparing
day-to-day operation. This would not be necessary, of course, if the Fixed-Bed Unit
ran at the same conditions (Feed N and A, RONC, LHSV) all the time. Of course,
this is seldom the case.
What “Delta WAIT” does, then, is normalize reactor temperature data with respect
to Platforming Unit feed N and A, RONC and LHSV. It is defined as the difference
uop 117108-6 III-9
between the WAIT at which the Platforming Unit is operating, given the three
parameters above, and the fresh catalyst WAIT requirement for the same
parameters. It is the activity difference between the real catalyst and a hypothetical
“perfect” catalyst.
Tabulation or graphical plotting of “Delta WAIT” is a natural followup. In maintaining

a plot, the process engineer can track Fixed-Bed Platforming activity decline with
catalyst life (usually barrels per pound or m3 per kg of catalyst) due to coke
laydown. Perhaps near the end of run, a prediction of when the catalyst will need
regeneration can be made. Disruptions in and recovery of the water-chloride
balance can be tracked using the “Delta WAIT” calculation and plot.
The SOR WAIT requirement calculation will now be explained. The calculations for
Fixed-Bed applications is shown below. The figures used are not meant to cover all
variables that can affect the apparent fresh catalyst activity. Predictions of the SOR
WAIT requirements from the figures should, however, be within plus or minus 3°C
(5°F) of the actual requirement.
Below is an outline of how the calculation proceeds, with reference to the

appropriate Tables and Figures for Fixed-Bed applications:
Parameters Needed Source of Data
1. RONC
- N and A (N+3.5A) -Actual Unit Operating Data-
- LHSV
- Catalyst Type
2. Estimate SOR WAIT at 1.0 LHSV Figure III-1
3. Estimate Correction for actual LHSV Figure III-2
4. Estimate Correction for Actual Catalyst Type Table III-2
5. Add the results of 2,3,4 to give SOR WAIT -
The following numerical examples are presented in order to give the refiner a guide
for calculating the SOR WAIT requirement.
uop 117108-6 III-10
Example III-2
1. Process Conditions
Catalyst R-62
RONC 95
LHSV, hr-1 1.5
Feed N, LV-% 20
A, LV-% 10
N + 3.5A = 20 + 35 = 55 LV-%
2. From Figure III-1
SOR WAIT at 1.0 LHSV = 944°F (507°C)
3. From Figure III-2
Correction 1.0 to 1.5 LHSV = +18°F (+10°C)
4. From Table III-2
Catalyst Correction for R-62 = -25°F (-14°C)
5. SOR WAIT requirement
SOR WAIT = 944 + 18-25 = (507 +10-14)

= 937°F = 503°C
Suppose now that the Fixed-Bed Platforming unit for the day in question was
running an actual WAIT of 950°F (510°C). The engineer would tabulate and plot for
this day the following “Delta WAIT” (predicted-actual):
Delta WAIT = 937-950°F = -13°F (= 503-510°C = -7°C)
In other words, the catalyst has lost a total of 13°F (7°C) activity from fresh catalyst.
Day-to-day calculations would allow the engineer to assess the catalyst deactivation
on a normalized basis and determine whether it is along the lines that would be
expected.
uop 117108-6 III-11
Figure III-1 has a “Basis” or guideline associated with its usage. Basis #5 puts a
constraint on the WAIT-WABT delta. When this delta is exceeded, an additional
step must be employed to adjust for a (WAIT-WABT) delta greater than the
constraint.
If the WAIT-WABT = 30°F (17°C) from current commercial operations, then the
SOR prediction would need to be adjusted upward by (30°-25°=) 5°F or (17°-15°=)
2°C. Note the ‘25°F (15°C) term’ comes from the Basis #5 constraint in Figure III-1.
If for the above samples, the Fixed-Bed Platforming WAIT-WABT was 30° (17°C),
then the predicted SOR’s would now become:
SOR = 937 + 5°F = 942°F (= 503 + 2°C = 505°C)
The temperature-octane response for a Platforming unit is shown in Figure III-3.

This chart can be used to estimate the changes in the WAIT required to switch daily
operations from one RONC to another. It could also help provide some insight into
the water-chloride balance. This will be discussed in the water-chloride section.
2. Catalyst Selectivity
Selectivity is defined as the tendency of a given Platforming catalyst and the

operation of that catalyst to produce the most desired material. In most Platforming
Unit operations, the most desired material is reformate or more specifically the yield
of C5+ liquid. Also, for the purpose of this section and those to follow, product
quality will continue to be defined as RONC, the research octane number clear.
The selectivity of a Platforming catalyst and operation is dependent upon several

variables. The effects of Platforming Unit feedstock characteristics (N and A content
and 50% point), product quality (RONC), and reactor average pressure on
selectivity to C5+ liquid will be discussed.
uop 117108-6 III-12
A preliminary glance at the selectivity curves allows the following general

conclusions to be made:
1. C5+ yield increases with a decrease in average reactor pressure.

Furthermore, comparing the pressure effect at two octane levels and
constant N+2A shows the higher the octane, the larger the increase in yield
as pressure decreases.
2. C5+ yield decreases as octane is raised at constant reactor pressure and

feed N+2A.
3. C5+ yield generally increases with an increase in feed naphtha N+2A at

constant pressure and RONC. The effect becomes less pronounced as feed
changes occur at high N+2A value.
It is important to realize that in the following procedure absolute yields are not
calculated. The estimate gives the shift in yield in going from a base condition (the
current Platforming Unit operation, for instance) to a new case.
A sample calculation of the C5+ yield change estimate is given for Fixed-Bed
Platforming operation:
Example III-3
1. Base Case Case A
RONC 93 95
N/A, LV-% 40/10 34/10
N+2A, LV-% 60 54
Feed 50% point 260°F (127°C) 240°F (116°C)
Avg. Rx. Pres., psig (kg/cm2) 450 (31.5) 330 (23.1)
2. Averages:
RONC 94
N+2A (60 + 54) = 57
uop 117108-6 III-13
3. RONC Effect, Figure III-4
A. C5+ yield decrease = -0.83 LV%/RONC
B. Yield Delta = (-0.83)x(2) = -1.66 LV%
4. N+2A Effect, Figure III-5
A. C5+ yield increase = 0.25 LV%/N+2A
B. Yield Delta = (0.25)x(-6) = -1.50 LV%
5. Pressure Effect, Figure III-6
A. C5+ yield increase =1.4 LV%/100 psi

(1.4 LV%/7 kg/cm2)
B. Yield Delta = (1.4)(120)/(100) = 1.4 (8.4)/(7)

= 1.68 LV% = 1.68 LV%
6. 50% Point Effect, Figure III-7
C5+ yield change = -0.7 LV%
7. Overall Yield Change
Net yield = (-1.66)+(-1.50) + (1.68) +(-0.7)

= -2.18 LV% Total
3. Catalyst Stability
Catalyst stability is a measure of the coke formation on a given catalyst. For Fixed-
Bed Platforming Units, stability is measured as deactivation rate, because the coke
laydown requires that the WAIT be increased to maintain product quality.
uop 117108-6 III-14
(a) Effect of Process Variables on Stability
The rate at which a given catalyst forms coke is set by the process variables listed
below. The five figures to be used are listed below:
Relative
Process Variables Deactivation Rate
RONC Figure III-8

Feed Naphtha N+A Figure III-9
Feed Naphtha End Point Figure III-10
Avg. Rx. Pressure Figure III-11
Hydrogen/Hydrocarbon Ratio Figure III-12
These curves are based on a combination of pilot plant and commercial data. The
data are normalized to eliminate inter-relationships between variables as much as
possible. The figures, therefore, give the relative deactivation in terms of single
variables (e.g., Figure III-8, Relative Deactivation Rate versus C5+ RONC).
The following numerical examples will illustrate how the stability measures for
Fixed-Bed mode of operation is estimated.
Example III-4: Relative Deactivation Rate
This Fixed-Bed Platforming example demonstrates how to estimate the relative

deactivation rate between the base case and case "A."
a. Case Base A
RONC 93 95
N+A, LV-% 50 44
Feed EP °F (°C) 360 (182) 385 (196)
Avg. Rx Pressure, psig (kg/cm2g) 450(31.5) 330 (23.1)
H2/HC 7.0 5.2
b. From Figure III-8: Case A/Base = 1.8/1.3 = 1.4

From Figure III-9: Case A/Base = 0.95/0.83 = 1.1
uop 117108-6 III-15
c. The overall relative deactivation rate is the product of the five individual
relative deactivation rates.
(1.4)x(1.1)x(1.3)x(1.5)x(1.55) = 4.7
Thus, case "A" will deactivate 4.7 times faster than the base case. If the base case
had shown at 30°F deactivation in WAIT requirement over 100 BPP catalyst life,
then case "A" would show a 30° WAIT deactivation over only 21 BPP catalyst life.
(b) Effect of Non-SRN on Catalyst Stability
As mentioned previously, these coking/deactivation factors are for straight-run

naphthas (SRN’s). For situations where, other stocks such as FCC and coker
naphtha are included as part of the feed, a rough approximation can be made of
their impact on coking or deactivation. But to do this, one must have a
characterization of the feeds that went into the Platforming Unit feedstock blend so
as to evaluate each one separately and sum up their effects to get the overall
impact.
The deactivation rate relative to a SR naphtha will increase by a factor of about 1.6
for an FCC naphtha and by 2.0 to 2.8 for a coker or thermally derived naphtha,
depending on endpoint. To minimize the deactivation effect, the coker naphtha
endpoint should be constrained to a maximum of 350°F (177°C) with a desired
endpoint of about 320°F (160°C).
The yields on FCC naphtha will be comparable to a SRN of the same

characteristics. But because of the nature of a coker naphtha (produced in a
hydrogen-deficient environment) the C5+ yields will generally be worse than a SRN
of comparable PONA. The difference appears to be in the C5/C6 naphthene ring
distribution with coker naphthas having more of the less selective C5 naphthene
rings.
Hydrocracked naphthas have deactivation rates and yields similar to SR naphthas

and as such can be treated like SRN.
uop 117108-6 III-16
(c) Raffinate Processing
Raffinate processing in a Fixed-Bed Platforming unit is difficult because of the poor

selectivity of C6 and C7 paraffins to aromatics at typical Fixed-Bed Platforming
operating pressures. As mentioned previously, lower pressure improves the
selectivity of paraffins to aromatics and as a result, a CCR Platforming Unit is more
ideally suited for raffinate processing.
For illustrative purposes, Figure III-13 shows the pilot plant yields for a raffinate of
the following composition:
IBP/50/EP: 152/172/250°F
P/N/A: 88.4/10.8/0.8 LV-%
P6/P7: 49.5/35.2 LV-%
This figure illustrates the poor C5+ yield on raffinate at typical Fixed-Bed Platforming
pressures. Of course, even higher pressures will result in even lower yields. Note
that lowering the pressure from 250 psig to 75 psig improves the yields by 10-15
LV% at an octane of 85.
Estimating stability and yields for a raffinate blend is beyond the scope of these
discussions. But it should be noted that the estimation technique is iterative and
involves looking at the raffinate stream as independent from the SRN. The raffinate
stream is like C5’s in the feed in that it drags down the product RONC requiring the
SR naphtha to be processed at a higher severity to compensate (i.e., if target blend
RONC was 98, then the SR portion of feed may require 101 RONC to offset the
RONC achieved, say of 90, on the raffinate at a fixed WAIT).
4. Heat of Reaction
The final portion of this section will address an estimating procedure for the
endothermic heat of reaction for a given Platforming Unit operation.
uop 117108-6 III-17
The endothermic heat of reaction, when regularly calculated for a fairly constant
charge stock PONA and reformate octane number, may be used as an indication of
catalyst deactivation. The decreasing heat of reaction shows the decreasing
aromatics forming ability of the catalyst. These curves do not correct heat of
reaction for charge stock composition or product octane number because of the
complexity of these relationships. If these values vary, the heat of reaction will also
vary.
The total delta T over the catalyst is directly related to the total heat of reaction.
While the heat of reaction is not a function of the H2/HC mole ratio, the total delta T
is, due to the “diluent effect” of the recycle gas. LHSV does not materially affect the
heat of reaction.
Using Figures III-14a and 14b or Figures III-15a and 15b, the heat of reaction may
be determined when the following are known:
Recycle gas purity (mole percent hydrogen)

H2/HC mole ratio
Total delta T
Charge stock molecular weight
The heat of reaction value as calculated from these graphs indicates the
aromatization ability more accurately than total delta T.
The following sample problem demonstrates the use of the figures in calculating the
heat of reaction.
1. Total delta T (all Platforming reactors) 145°F

Hydrogen/Hydrocarbon Ratio 6
Recycle Gas Hydrogen Purity 75%
Charge Stock Molecular Weight (MW) 110
2. From Figure III-14A
Total heat of reaction (HR) = 153(145/100) = 222

(Btu/lb of naphtha)
3. From Figure III-14B
uop 117108-6 III-18
MW correction = +8 (145/100) = +12
4. The correct heat of reaction:
Corrected heat of reaction = 222 + 12
= 234 Btu/lb of naphtha
uop 117108-6 III-19
Table III-2
Fixed-Bed Platforming Catalyst Corrections – SOR WAIT Requirements
Catalyst Correction
°F °C
R-5, R-7, R-8 +10 +6
R-9, R-10, R-11, R-12, R-14 - -
R-16 Series -5 -3
R-30 Series -20 -11
R-50 Series -25 -14
R-56 -33 -18
R-60 Series -25 -14
R-86 -28 -16
R-98 -31 -17
Notes: 1) Figures in the above table are based on the activity of all-platinum
catalyst, such as R-9.
2) For staged loadings with R-72, use the correction for the Pt-Re catalyst
used with R-72.
uop 117108-6 III-20
Figure III-1
SOR WAIT Requirement at 1.0 LHSV
°F
1000 °C Bases:
530
980 All Platinum
1. R-20 Series or All
RONC 520 Platinum
Catalyst Catalysts
960
104 510 2. 200-600 psig
940 Average Reactor
500
100 Pressure
920
490 3. Standard Water
900 480 and Chloride
95
880 Levels
470
90 4. 100-165°C (210-330°F)
860 460
85 ASTM 50% Point
840 450 on Charge
80
820 440 5. (WAIT - WABT)
30 50 70 90 110 less than 15°C
(25°F)
Hydrotreated Naphtha N + 3.5A Content, LV-%
PLT-R01-148
uop 117108-6 III-21
Figure III-2
WAIT Requirement Correction for LHSV
°F °C
35
60
30
50
25
40
20
30
15
20
10
10 5
0 0
-5
-10
0.75 1 2 3 4
LHSV, hr. -1
PLT-R01-149
uop 117108-6 III-22
Figure III-3
Temperature - Octane Response
8
4
7
6
3
5
4
2
3
75 80 85 90 95 100
C5+ Reformate RONC
PLT-R01-150
uop 117108-6 III-23
Figure III-4
Effect of Octane Number on C5+ LV% Yield
Good For:
1. Full Boiling Range Straight Run Naphtha

2. 300 psig (21 kg/cm2) Average Reactor Pressure
5.0
4.0
30
40
3.0 50
60
70
2.0 80
90
1.0
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
80 85 90 95 100 105
C5+ RONC
PLT-R00 -186
uop 117108-6 III-24
Figure III-5
Effect of Cyclic Content on C5+ LV% Yield
Good For:

2. 300 psig (21 kg/cm2) Average Reactor Pressure
0.8
0.7
0.6
0.5
0.4
0.3
RONC
105
0.2
100
95
0.1 90
85
80
0.0
30 40 50 60 70 80 90
N + 2A, LV-%
PLT-R00-187
uop 117108-6 III-25
Figure III-6
Effect of Reactor Pressure on C5+ LV% Yield
Good For:

2. Average Reactor Pressure 8.5 to 42.0 kg/cm2 (125-600 psig)
4.0
3.5
30
40
3.0 50
60
70
2.5 80
90
2.0
1.5
1.0
0.5
0.0
80 85 90 95 100 105
C5+ RONC
PLT-R01-153
uop 117108-6 III-26
Figure III-7
Effect of Boiling Range on C5+ LV-% Yield
uop 117108-6 III-27
Fi gure I I I -8
Rel ati ve Deacti vati on Rate - C5+ RONC
Hydrotreated Straight Run Naphtha
16.0
15.0
14.0
13.0
12.0
11.0
10.0
9.0
8.0
7.0
6.0
PLT-R00-188
5.0
4.0
3.0
2.0
1.0
0
75 80 85 90 95 100 105
C5+ RONC
uop 117108-6 III-28
Fi gure I I I -9
Rel ati ve Deacti vati on Rate - N+ A
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
30 40 50 60 70
N + A (LV-%)
PLT-R00-189
uop 117108-6 III-29
Figure III-10
Relative Deactivation Rate -Charge Endpoint
1.4
1.2
1.0
0.8
0.6
Basis: IBP - 82°C(180°F)
0.4
149 160 171 182 193 204

(300) (320) (340) (360) (380) (400)
ASTM EP °C (°F)
PLT-R00-190
uop 117108-6 III-30
Figure III-11
Relative Deactivation Rate - Reactor Pressure
2.6
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
7.0 14.0 21.0 28.1 35.1 42.1
(100) (200) (300) (400) (500) (600)
Average Reactor Pressure, kg/cm2 (psig)

PLT-R00-191
uop 117108-6 III-31
Figure III-12
Relative Deactivation Rate - H2/HC
2.5 7.3
2.4 7.0
6.7
2.3
6.4
2.2
6.1
2.1 5.8
2.0 5.5
1.9 5.2
4.9
1.8
4.6
1.7 4.3
1.6 4.0
1.5 3.7
3.4
1.4
3.1
1.3 2.8
1.2 2.5
1.1 2.2
1.0 1.9
1.6
0.9
1.3
0.8 1.0
0.7 0.7
4.0 5.0 6.0 7.0 8.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
H2/HC MOLE Ratio H2/HC MOLE Ratio
PLT-R00-192
uop 117108-6 III-32
Figure III-13
Pilot Plant Studies
C5+ Yield vs. Octane
uop 117108-6 III-33
Figure 14a
Total Heat of Reaction from Total Delta T
English Units
260
240
H2/HC
220
200
180
160
140
120
100
80
60 70 80 90 100
Mole % Hydrogen in Recycle Gas
PLT-R00-168
Figure III-14b
Molecular Weight Correction
to Heat of Reaction
English Units
+40
Parameter
HR/100°F T
+20
0 100
150
-20 200
250
100 120 140
Charge Molecular Weight
PLT-R00-169
uop 117108-6 III-34
Figure III-15a
Total Heat of Reaction from Total Delta T
Metric Units
110
Parameter
H2/HC
100
90
80
70
60
50
40
30
6 7 8 9 10
Mole % Hydrogen in Recycle
PLT-R00-170
Figure III-15b
Molecular Weight Correction
to Heat of Reaction
Metric Units
20
16
12 Parameter
HR/100°C T
40
0 60
80
100
10 12 14
Charge Molecular Weight
PLT-R00-171
uop 117108-6 III-35
C. CATALYST POISONS
The purpose of this section is to discuss bimetallic Platforming catalyst poisons with
respect to:
1. Maximum allowable contaminant level

2. Methods of detection
3. Process symptoms
4. Suggested operational response
5. Possible sources of contamination
6. Consequent mechanical problems
Above the recommended maximum levels of feed stock contaminants, catalyst

performance will be measurably and negatively affected and steps should be
immediately taken to rectify the problem. In the cases of sulfur and nitrogen, UOP
strongly recommends operation at as low a severity as possible and not at the
maximum allowable levels. Such minimization of known poisons will help assure
maximum selectivity and stability of a Platforming operation.
The listings of possible sources of contamination, typical process symptoms, and

possible mechanical consequences have been compiled from operating experience
of hundreds of Platforming units. As always, UOP is interested in receiving refinery
feedback on these subjects so that we may add to our understanding and
awareness of current operational difficulties. This also provides for sharing of
effective solutions to process and mechanical problems among refiners.
The suggested operational responses to the presence of poisons are those

responses that, in general, minimize catalyst and equipment damage. It often
occurs that other considerations such as product octane level, production quotas,
shutdown schedules, etc., are in conflict with the suggested operational response. If
this does occur, the refiner must weight the alternatives of additional catalyst and/or
mechanical damage versus the economics of the situation.
uop 117108-6 III-36
1. Sulfur
(a) Maximum Allowable Concentration
Maximum allowable concentration in the naphtha feed is 0.5 weight ppm. Operation
at 0.1 to 0.2 weight ppm in the feed is normally possible with most Naphtha
Hydrotreaters and will provide added assurance of realizing maximum catalyst
stability and selectivity.
(b) Methods of Detection
(1) Feed naphtha sulfur analyses:
Nickel Reduction Method: UOP 357

- Good for reducible sulfur
may not give total sulfur
Microcoulometric Method: UOP 727
- Good down to 0.1 ppm
Tracor (Houston) Atlas: ASTM D-4045

- Preferred
- Good down to 50 ppb
NOTE: Neither a lamp sulfur method nor a doctor test is adequate for
this purpose. Also, experimentation has shown that the highly
hindered (thiophenic) sulfur compounds are unreactive under the
conditions of the Nickel Reduction procedure. As a result this method
may not give total sulfur results (especially for high endpoint feeds).
(2) Sniffer tube H2S determinations to quantify H2S levels in the recycle
and stabilizer overhead gas. Note that a rule of thumb estimation is 1
wt-ppm sulfur in feed = 3 mol-ppm in recycle gas = 10 mol-ppm in
stabilized overhead gas.
uop 117108-6 III-37
(c) Process Symptoms
Sulfur contamination in the Platforming unit results in attenuation of platinum

activity. This in general means that the hydrocracking (acid catalyzed) reactions will
increase relative to the dehydrogenation and dehydrocyclization (metal catalyzed)
reactions. Resulting observable effects include:
(1) Decreased hydrogen production;

(2) Decreased recycle gas hydrogen purity;
(3) Increased hydrocracking (higher C3 and C4 yield);
(4) Reduced delta T’s;
(5) Lower C5 plus yield;
(6) Lower catalyst activity in more severe cases;
(7) Increased catalyst coking rate (decreased stability).
(d) Suggested Operational Response
Catalyst damage will be minimized by maintaining reactor temperatures as low as

possible. [There is no need to go below 900°F (482°C).] In no case should reactor
temperatures be increased to compensate for decreasing RONC if sulfur is present
in the recycle gas as this will rapidly accelerate coke laydown.
Every attempt should be made to eliminate sulfur from the feed. Once low sulfur
naphtha feed has been restored, the sulfur will gradually desorb from the catalyst.
When the recycle gas H2S content has decreased to 1-2 ppm, normal operation
may be resumed. Slightly increased chloride addition (perhaps double normal
addition rate) during the time in which sulfur is present in the recycle gas will
improve the rate of sulfur desorption from the catalyst as sulfur and chloride
compete for the same sites on the catalyst.
uop 117108-6 III-38
(e) Possible Sources
(1) Inadequate naphtha hydrotreating: this can result from low

activity hydrotreating catalyst or from simply running at too low
of a hydrotreating reactor temperature.
(2) Recombination sulfur from NHT: combinations of high

hydrotreater temperature and low hydrotreater pressure can
promote recombination of hydrogen sulfide with trace quantities
of olefins. Such problems can normally be solved by lowering
the hydrotreater temperature below 650°F.
(3) Hydrotreater stripper upsets: these may result in incomplete

stripping of H2S. Generally, water as well as H2S will come over
from the stripper that also aggravates the situation.
(f) Possible Mechanical Problems
(1) Increased iron sulfide formation throughout the unit;
(2) Extra regeneration steps will probably be required in order to

completely remove the sulfur from the catalyst.
2. Nitrogen
The maximum allowable concentration of nitrogen in the naphtha feed is 0.5 weight
ppm. Every attempt should be made to absolutely minimize the nitrogen content of
the naphtha. A real level of 0.5 weight ppm nitrogen in the feed to a 10,000 BPD
Platforming unit will result in the deposition of 1814 pounds (823 kilogram) per year
of ammonium chloride deposits in the recycle gas circuit and stabilizer column
overhead. Also, every 0.1 wt-ppm of nitrogen in the feed ties up 0.25 wt-ppm
chloride (injected in the feed) which must be made up otherwise the catalyst
chloride level will fall.
(b) Methods of Detection: Analyze Naphtha Feed
uop 117108-6 III-39
Kjeldahl Nitrogen method: UOP 384

Chemiluminescense: ASTM D-4629

(Dohrman Apparatus)
Nitrogen is an acid function poison. Organic nitrogen that enters the Platforming unit
will be converted to ammonia. This ammonia will react with chloride on the catalyst
to form volatile ammonium chloride. The overall effect is to reduce catalyst chloride
level producing the following symptoms:
(1) loss of catalyst activity;

(2) increased hydrogen production;
(3) increased hydrogen purity;
(4) increased reactor delta T’s.
During the period that nitrogen is entering the Platforming unit, an attempt should be
made to maintain proper catalyst chloride level. Of course, the first priority should
be to isolate the source of nitrogen and eliminate it from the Platforming unit feed. If
accurate feed nitrogen analyses are available, an added amount of chloride to offset
the nitrogen contamination can be added to Platforming unit charge to help maintain
the proper chloride level on catalyst. This extra chloride addition should be limited to
5 wt-ppm of naphtha charge. It must be remembered that operation for more than a
few days with such feed contamination is almost certain to produce serious
mechanical problems from ammonium chloride fouling. Also, during the period of
nitrogen contamination, do not raise temperature to maintain octane, since
increased coking may result from “pushing” an operation with unbalanced catalyst
acid/metal functions.
uop 117108-6 III-40
(1) Inadequate naphtha hydrotreating: Most virgin straight run

naphthas contain very little nitrogen. Consequently,
hydrotreaters processing such naphtha can be designed at
lower pressures than would be required if the naphtha
contained higher nitrogen levels. The difference in design
pressure is normally 200 to 400 psi (14 to 28 kg/cm2) and
cannot be compensated for after the unit is designed.
Therefore, it is necessary to avoid processing higher nitrogen
content naphthas in hydrotreaters originally designed for lower
nitrogen naphtha. The hydrogen partial pressure is not
sufficient to accomplish complete nitrogen removal.
(2) Inclusion of cracked naphthas in the Platforming unit charge:

Most cracked naphthas will have a high nitrogen content.
(3) They must, therefore, be hydrotreated at high pressure in

preparation for inclusion to Platforming unit feed. A stream of
cracked naphtha, even though small relative to total Platforming
unit charge, should not be included to Platforming unit charge if
only low pressure hydrotreating is available.
(4) Improper use of inhibitors: Use of filming and neutralizing

amines as corrosion inhibitors throughout the refinery can
sometimes lead to inadvertent naphtha nitrogen contamination.
Areas of caution are crude system overhead, hydrotreater
stripper overhead, and hydrotreater reactor effluent in addition
to any other refinery units processing a naphtha which will be
sent to the Platforming unit. Carefully monitored ammonia and
increased water injection is often a less expensive and less
dangerous solution than inhibitor injection. Where inhibitor
uop 117108-6 III-41
usage is absolutely necessary, strictly adhere to the

recommended dosage.
(5) As the NHT catalyst loads up with metals it's ability to remove
organic nitrogen compounds falls off. Since nitrogen is more
difficult to decompose than sulfur or metals, it will be the first to
show up in the stripper product as the NHT catalyst fails.
Ammonium chloride deposits will accumulate in the Platforming unit products

condenser, separator, recycle compressor suction lines, and stabilizer column. This
can result in decreased cooling capacity in the products condenser, possible
compressor damage (especially during regeneration when high water levels move
the deposits onto the compressor wheels or valves), and erratic stabilizer operation.
Moreover, extreme care must be taken when ammonium chloride contaminated

equipment is to be opened or inspected. Such equipment must first be thoroughly
washed to remove the ammonium chloride deposits. Otherwise, the hydroscopic
deposit will adsorb atmospheric moisture and cause serious corrosion problems.
3. Water
A Platforming unit performs best when the feed to the unit is essentially dry and the
water-chloride balance is maintained via injection systems. The optimum
performance of the catalyst is a function of several variables. One of which, the
catalyst chloride level, is set by the reactor conditions and the water/chloride
injection rates. If an unknown source of water enters the system, the long-term
effects can be a shorter catalyst life and a decrease in yield and activity.
uop 117108-6 III-42
A recycle gas water content of 30 mol-ppm indicates excessive water, dissolved

oxygen, or combined oxygen in the feed to the Platforming unit. Moisture levels at
or above this level may lead to excessive hydrocracking and coke laydown.
Additionally, the chloride will be stripped from the catalyst upsetting the catalyst
balance.
(1) Suggested on-stream moisture analyzers:

Ametek Recycle Gas
Panametrics 3000 Feed/Recycle Gas
Mitsubishi Water Analyzer CA-03 Feed
(2) HCl in recycle gas by Dräger Tube.
Water tends to act as a metal function poison (much like sulfur) and enhance the
acid function. Water also strips chloride from the catalyst to form HCl in the recycle
gas. In the short terms, this high level of HCl accentuates the acid function, most
notably hydrocracking. Therefore, the short-term observable effects include:
(1) Decreased hydrogen production

(2) Decreased recycle gas hydrogen purity
(3) Higher C3 and C4 yields
(4) Reduced delta T’s
(5) Lower C5 plus yield
(6) Increased catalyst coking rate
(7) Increased recycle gas HCl levels
If feedstock with a high water content is charged to a unit over a long period of time,
the catalyst will become chloride deficient. The extent of this deficiency will
determine whether the catalyst damage is reversible within the remaining catalyst
life.
uop 117108-6 III-43
Catalyst damage will be minimized by maintaining reactor temperatures as low as

possible. [There is no need to go below 880°F (471°C).] Failure to lower
temperatures could result in a substantially shorter catalyst life.
Locate the source of the water contaminant and either remove it outright, or make
the appropriate process adjustments to the feed pretreating units. When the recycle
gas water has decreased to less than 30 ppm, re-establish normal operating
temperatures.
(1) Inadequate hydrotreating of feed may allow unconverted

oxygen compounds to enter the Platforming unit.
(2) Further, any properly hydrotreated feed that is not completely

stripped will allow water and other catalyst poisons to enter the
Platforming unit.
(3) Other possible sources are leaks in upstream steam or water

exchangers.
(4) Platforming unit water injection system.
(5) NHT stripper feed effluent exchanger leaks.
The excessively high HCl in the net gas from the Platforming unit will be corrosive to
downstream equipment and users.
uop 117108-6 III-44
4. Metals
(a) Maximum Allowable Concentrations
Because of the quantitative and irreversible effects of Platforming catalyst metal

contamination, there should be no detectable levels of metals in the Platforming unit
charge. Also, it’s possible to get metals poisoning during regeneration so it’s
important to properly do the regeneration.
(b) Method of Detection
For small concentrations in the naphtha feed there are some specific methods that
are improvements over AAS (Atomic Adsorption Spectroscopy) or more recently
ICP (Induction Coupled Plasma):
Detectability
Limit
Arsenic in Petroleum Naphthas: UOP 946 1 wt ppb

UOP 296 1 wt ppb
Trace of Concentrations of Lead UOP 952 10 wt ppb

in Gasoline or Naphtha: UOP 350 20 wt ppb
Copper in Gasoline and Naphtha: UOP 962 5 wt ppb

UOP 144 2-3 wt ppb
Silicon in Petroleum Distillates UOP 787 0.1 wt ppm
For analysis of a catalyst sample for possible metal contamination:
Impurities in Alumina Base

Catalysts by Spectrography: UOP 303
uop 117108-6 III-45
Most metals are poisons to the platinum function of the catalyst. In general, metal
poisoning occurs chromatographically throughout the reactors, completely loading
up the first reactor’s catalyst before breaking through to the following reactor. The
first reactor, therefore, assumes the burden of metal poison damage.
The observable effects will be less severe loss in the effected reactor's delta
temperature and a loss of overall catalyst activity and selectivity as more and more
catalyst is contaminated.
Periodic checks for meal content should be made of the naphtha hydrotreater
charge. Any periods of significant metal content in the hydrotreater feed should be
documented in an attempt to quantify the total weight of metals going to the
hydrotreater. Normally, UOP hydrotreating catalyst can still function effectively up to
a total metals loading of 2 to 3 weight percent. If the hydrotreating catalyst has been
exposed to sufficient metals to approach this 2 to 3 weight percent level, strong
consideration should be given to replacing the hydrotreating catalyst. Likewise, if
any detectable metals levels are found in the hydrotreated naphtha and increased
hydrotreater temperature does not eliminate the problem the hydrotreater catalyst
should be changed. Any metals that do enter the Platforming unit will irreversibly
damage the catalyst, but quick detection and subsequent metal contaminant
removal on the refiner’s part can often limit the damage to only the first Platforming
reactor.
(1) Some virgin naphthas contain measurable levels (ppb) of

arsenic.
uop 117108-6 III-46
(2) Lead can be introduced by either reprocessing of off-spec

leaded gasoline or contamination of Platforming unit feed tanks
with leaded gasoline.
(3) Corrosion of products:
Corrosion of plant hardware can result in migration of the

corrosion products into the reactors. Iron is the most common
such corrosion contaminant; molybdenum, chrome, and copper
are other possibilities. Especially in the case of iron, these
corrosion contaminants are better tolerated by Platforming
catalysts than are organic metals. These corrosion products
often enter the first Platforming reactor as sulfide scale from the
charge heater, combined feed exchanger and hydrotreater. The
scale will accumulate in the first Platforming reactor and may
cause flow distribution problems. Catalyst regeneration
provides an opportunity for liberation of sulfur from scale and
may hinder proper oxidation and reduction of the catalyst.
(4) Separator level control and foaming problems during

regeneration can provide carryover of sodium hydroxide or
sodium carbonate through the recycle gas circuit to the
reactors.
(5) Water treating compounds containing zinc, copper,

phosphorus, etc., have at times been mistakenly added to
Platforming unit charge.
(6) Some cracked (coker) naphthas can contain silicon, added as

an antifoaming agent elsewhere in the refinery.
(7) Excessive injection of corrosion inhibitors on NHT strippers can

result in the inhibitor getting into the stripper bottoms. This is
especially of concern when there is no overhead liquid draw on
the stripper.
uop 117108-6 III-47
Metallic scale migration into the Platforming reactors may cause flow distribution
problems if the scale accumulation is great enough. These problems include fines
accumulation in the catalyst bed, scale accumulation on the scallops, scale
accumulation in the scallops, and top of the bed in downflow type reactors.
5. High Feed End Point
A Platforming unit is designed to product aromatic hydrocarbons. This aromatic

production apparently cannot occur without some very small amount of single ring
aromatic condensation into multi-ring polycyclic aromatics. These polycyclic
aromatic hydrocarbons are direct coke precursors. Once they are formed, they are
strongly held to the catalyst surface and will further convert to what is typically
referred to as coke on the catalyst. The rate of natural formation of coke on the
catalyst is fortunately very slow at typical Platforming operating conditions. As
discussed in the Process Variable Section, coke formation does increase
significantly as Platforming unit pressure and hydrogen circulation are decreased
and/or temperature (octane) is increased. These are all changes that would favor
further aromatic condensation to coke. One other operating variable that was shown
to have a significant effect on catalyst deactivation (coke formation) was naphtha
feed end point. As the feed end point approaches 400°F (204°C), increased levels
of naturally occurring polycyclic aromatics are carried with the naphtha. The
absolute amount will probably vary significantly with crude type and with
fractionation efficiency since these compounds are still present in ppm ranges even
at 400°F (204°C) naphtha end point. Since they are direct coke precursors, these
compounds can be considered as a catalyst poison. Once deposited on the
catalyst, they can only be removed by regeneration.
uop 117108-6 III-48
400°F (204°C) is a critical temperature regime for the naphtha cut point. Above this
end point (based on an ASTM D-86 distillation), the concentration of polycyclic
aromatics in the feed naphtha will increase rapidly. UOP does not recommend
operation above this end point.
Measure the ASTM D-86 end point of each feed stream to the Platforming Unit or
hydrotreater. In some instances where blends of various feed types are used, a GC
or True Boiling Point endpoint may indicate a “tail” not picked up by the ASTM
endpoint.
The effect of more rapid coke deposition will be more rapid overall catalyst
deactivation, with decreasing catalyst activity and selectivity.
Analyze each feed stream for ASTM D-86 end point once per shift and adjust the
fractionation to maintain each stream's end point below 400°F (204°C). Maintain
sufficient reflux to minimize "sloppy" end points on all appropriate columns.
If the Platforming unit feed is coming from multiple refinery sources (e.g., straight
run naphtha, hydrocrackate, coke naphtha), each stream should individually be
analyzed for compliance with the 400°F (204°C) end point limitation. Blending of a
high end point stream with a low end point stream will “mask” the high boiling
fraction of the heavy stream. The polycyclic aromatics will still be present, but will
not be indicated or detected by the ASTM D-86 end point.
uop 117108-6 III-49
There are no mechanical consequences other than more frequent catalyst

regeneration.
D. WATER-CHLORIDE CONTROL
1. Function of Water and Chloride
(a) Chloride
The two biggest catchwords in Platforming operation are under-chlorided and over-
chlorided. Obviously, everyone would prefer the middle ground of optimum chloride.
So, to aid in achieving this middle ground, some understanding of the two extremes
may prove helpful.
The primary purpose of chloride injection is to maintain acidic reaction sites within
the catalyst structure. In general, these acid sites are responsible for the
dehydrocyclization reactions along with isomerization reactions, which are
desirable, but there are also dealkylation (cracking) reactions which are
undesirable. Bearing in mind that aromatics have much higher octane numbers than
either isoparaffins or normal paraffins and that isoparaffins generally have higher
octane numbers than paraffins, a decrease in dehydrocyclization reactions results in
decreased octane number. When an under-chlorided situation such as this occurs,
one is led to conclude that overall catalyst activity has decreased. In practice, most
units are operated to maintain a specified octane number. Therefore, identification
of an under-chlorided situation is indicated by an increase in the reactor inlet
temperature, which is required to maintain a specified octane number.
Over-chlorided catalyst is commonly identified by noting an increase in the cracking

reactions. However, from the discussion above, it can be concluded that the
desirable dehydrocyclization reactions would also increase. In fact, both types of
reactions do increase and, in order to hold a constant octane number, lower catalyst
uop 117108-6 III-50
temperatures would be required. But, along with this seeming benefit of lower
reactor inlet temperatures, comes the detrimental side effects of cracking. Cracking
reactions reduce the reformate yield and add coke to the catalyst at an increased
rate.
The middle, or optimum, chloride level represents a balance of the benefits of

increasing catalyst activity and product octane versus the drawbacks of decreasing
product yield and catalyst stability. Catalyst characteristics and performance
actually determine an optimum chloride level. As chloride injection brings the
catalyst to this optimum, the incremental benefits of increasing chloride upon activity
decrease. Then, after the optimum chloride level of the catalyst is satisfied, any
excess chloride results in the detrimental effects of cracking.
(b) Water
The function provided by water injection is to redistribute the chloride through the
whole catalyst bed. In theory, both water and chloride could be minimized if the
proper relative ratio were maintained. However, from a practical standpoint, the
response time or lag time required to effect a change throughout the catalyst bed
becomes excessive as the water injection rate is decreased. Therefore, a serious
effort should be made to maintain the recycle gas or injection water level at the level
specified for a given catalyst.
2. Injection Philosophy
During the typical Platforming operation cycle, a refiner generally encounters three
different situations for which water and chloride injection rates need to be
determined. Those three situations are startup, normal equilibrium operation, and
recovery of normal equilibrium following the identification of poor operation.
(a) Startup
During startup, a significant amount of water may be released via two mechanisms.
During reduction, water is produced from a chemical reaction of the catalyst, metal
uop 117108-6 III-51
oxides, and hydrogen. Also, as the catalyst is heated, it releases water that has
been adsorbed physically. To minimize the effects of water formed during a
reduction, special care should be taken to drain as much as possible from all low
points in the reactor circuit prior to feed cut-in. Then, to minimize the effect of
adsorbed water being released, it is especially important to follow the recommended
temperature and chloride injection program. The chloride injection is reduced
stepwise as water is eliminated from the recycle gas. See chapter VII “Normal
Startup” for those schedules.
These schedules are based upon a normal startup drydown situation (which may be
assumed to last 4-5 days). However, it is important to note that chloride injection
schedule is a function of the water level in the recycle gas and is not based upon
any time period following feed cut-in. If abnormal circumstances are encountered,
the program may require modification. For instance, if the feed is known to be wet
or if the catalyst has been exposed to excessive moisture, then the chloride
injection should be increased to compensate. Likewise, if excessive nitrogen
contamination is expected, then the chloride injection should be similarly increased.
(b) Normal Operation
The primary objective during normal equilibrium operation is to maintain the catalyst
chloride level at its target level. In this situation, the current catalyst activity level is
satisfactory and no improvement is needed. Figures III-29~32 present graphs which
show the normal chloride injection rates for normal operation. These rates need
only be adjusted as catalyst temperatures are adjusted during the course of a
typical catalyst cycle. For staged loadings with R-72, use the injection rate for the
Pt-Re catalyst used with R-72.
Sufficient water should be injected to maintain 5 wt-ppm total water in the feed.
Adequately stripped feed can be estimated to contain 0.5-1.0 wt-ppm dissolved
water. Therefore, the normal water injection rate would be 4-4.5 wt-ppm based upon
feed.
uop 117108-6 III-52
In normal operation, following these injection philosophies should result in 15-25

ppm H2O in the in the recycle gas and the proper level of HCI in the recycle gas for
the particular catalyst, as shown in Table III-7. Note that water injection rate
changes should not be made based on H2O analyzer; the rate should be set and
maintained.
(c) Recovery of Normal Equilibrium
If operating data show a need to increase or decrease the amount of chloride on the
catalyst, that may be accomplished simply by following the curves shown in Figures
III-29~32 labeled "increase" or "decrease" chloride. However, the real problem is
identifying that the equilibrium catalyst chloride level is not in fact normal.
The most important measure that may be used to verify that the catalyst is at or
near its optimum chloride level is the octane adjusted activity level. This measure
has less error inherent in its determination than other measures of optimum catalyst
chloride level. This is because it depends only upon gathering the following data
accurately:
Reactor LHSV
Catalyst WAIT
Feed PONA
Product RONC
It does not require the calculation of an accurate component balance. Using the
figures in the Process Variables Section, an estimated start-of-run weight average
inlet temperature (SOR WAIT) should be determined for actual operating conditions.
This SOR WAIT should be compared against the actual operating WAIT to obtain
the "delta WAIT." "Delta WAIT" is the measure of activity loss from the theoretical
start-of-run conditions. This "delta WAIT" should then be plotted against catalyst life
daily over the course of the run.
To determine whether activity is normal, an assumption must be made as to the

expected cycle length. Cycle length is defined as the catalyst life (time) interval over
uop 117108-6 III-53
which the catalyst may be expected to deactivate 30-40°F (17-22°C). If operating

conditions are nearly the same as design conditions, then the design cycle length
should be used. If operating conditions are significantly different than design, then
an estimate of relative cycle length should be made from the figures that correlate
relative deactivation rate earlier in this Process Variables section. Alternatively, past
experience may provide a basis from which cycle length may be estimated.
Periodically, test data should be assembled for the specific purpose of verifying that
the water-to-chloride ratio is being maintained at its normal equilibrium level. A unit
material balance should be prepared. Any data that is outside a 98-102 wt-%
closure should not be utilized. A total C5+ yield should be determined for
comparison with the operating severity.
Trend data should be plotted daily. These can be expected to vary significantly on a
daily basis. However, often with time, a major upset can be detected early by
diligent attention to trend data. It is extremely important to watch for any sudden
persistent increase or decrease in the following:
HCl content of recycle gas and stabilizer overhead gas

H2O content of recycle gas
Reactor differential temperatures for all reactors
Net hydrogen gas production
In gathering trend data for the recycle gas water-to-chloride ratio, the sampling
method is extremely important. See Chapter IX “Analytical” for a discussion of the
use of gas sampling tubes.
Several other factors can influence the water-to-chloride ratio. The water and
chloride injection pumps should be checked regularly to verify intended injection
levels. Adequate naphtha stripping efficiency must also be maintained to ensure
that the feed does not contain an excessive amount of water. Indeed there have
been cases where extensive feed preheat has reduced the required vapor
generation at the bottom of the stripper and allowed an increase in the amount of
water exiting in the stripper bottoms. Also, while on-stream water analyzers are
uop 117108-6 III-54
extremely useful for trend data, they are frequently not accurate in measuring the
absolute water level.
For all of the injection rates recommended, it is assumed that there is a minimum
nitrogen contamination in the feed entering a Platforming Unit. If the feed is
extremely clean, these rates may be slightly high. However, in the event of a
sudden dramatic increase in the nitrogen concentration, a significant amount of
chloride can be lost from the catalyst since 1 wt-ppm nitrogen can react with 2.5 wt-
ppm chloride to form ammonium chloride. If such an increase occurs, it will be
necessary to increase the chloride injection accordingly. This adjustment should be
based on loss of catalyst activity, not absolute value of nitrogen, as nitrogen
analysis may not be absolutely correct.
3. Pilot Plant Evaluation
The following pilot plant data explores the effect of low and high chloride levels and
a "high" water environment on the activity, yields and stability of R-50 and R-62.
These pilot plant evaluations are high severity tests designed to deactivate or
explore the response of the catalyst over a one to two week period. The effects
exhibited in these tests also apply to other Platforming catalysts besides R-50 and
R-62, as the metal and acid balance (common on all Platforming catalysts) is being
altered.
(a) High Chloride R-50 Yield-Octane Evaluation
An R-50 with a catalyst chloride level of 1.4 wt-% was evaluated versus a reference
R-50 with a catalyst chloride level of 1.08 wt-% chloride, at 95 and 100 octane. The
300 psig (21 kg/cm2) Yield Octane (Y/O) conditions are listed in Table III-3. The Y/O
test is a yield evaluation at various octanes while maintaining a constant catalyst
stability through the use of a high H2/HC ratio (about 10/1).
uop 117108-6 III-55
Figure III-16 illustrated that:
(1) The 1.4 wt-% chloride R-50 needed about 15-20°F less
temperature than the reference to achieve the octanes of 95
and 100;
(2) the high-chlorided R-50 gave 1 to 1.5 LV-% less C2+ yield at
equivalent conditions; and
(3) the high chlorided R-50 also showed up to about 200 SCFB
less H2.
(b) High Feed Chloride Level on R-50 AST Evaluation
Figure III-17 is an Accelerated Stability Test (AST) evaluation of an R-50 catalyst

with 8 ppm chloride in the feed compared to a reference with 1 ppm chloride in the
feed. End of Run chlorides on the two catalysts were 1.0 and 1.4 wt-% for the
reference and high chlorided tests, respectively. (Note that both catalysts started off
at 1.08 wt-% chloride.) Table III-4 gives the processing conditions for the two 300
psig AST’s.
The results illustrate that the over chlorided catalyst had better activity 5 to 8°F (3 to
5°C) poorer C5+ yield of about -1 LV-%, and poorer H2 yield of -100 to -200 SCFB
(15-30 Nm3/m3) than the reference. It also appeared that the rate of deactivation
began to increase faster after middle-of-run for the high chloride test as the catalyst
chloride increased up to 1.4 wt-% at end of run.
(c) Low Chloride R-62 AST Evaluation
Figure III-18 is a 250 psig AST evaluation of the effect of low catalyst chloride level
(0.76 wt-%) on R-62 on activity, yields, and stability. Table III-5 gives the processing
conditions.
uop 117108-6 III-56
The results illustrated that with low catalyst chloride, the activity or temperature
needed to make RONC was 15-20°F higher than reference R-62. Comparing the
deactivation slopes of the low chlorided R-62 to reference R-62 showed that the low
chlorided R-62 deactivated approximately 30% faster. There was an improvement in
yields though for the low-chlorided R-62, with the C5+ yield being about 0.5 to 1.0
LV-% higher and the H2 about 30-40 SCFB (5-7 Nm3/m3) higher.
UOP would not recommend operating with low chloride, not only because of the
loss of activity and stability, but because there is less chloride buffer for operational
upsets.
(d) High Water AST Evaluation
AST’s were performed using R-50 and R-62 to determine the effect of high water
levels in the feed (and recycle gas). A pilot plant test with 60 ppm H2O in the recycle
gas was compared to a reference with about 10 ppm H2O in the recycle gas. For
the high water tests in Figures III-19 and 20 the gas/oil ratio was raised from 2.0 to
3.0 to anticipate the increased deactivation rate.
The effect of high water levels was the same for both catalysts: loss of 1-2 lv-% C5+
and 50-100 SCFB (8-17 Nm3/m3) H2 and a 60% increase in deactivation rate.
UOP's guidelines for bimetallic catalyst are for 10-20 ppm H2O in the recycle gas or
about 5 ppm water in the feed.
4. Calculating Catalyst Chloride Level
Proper catalyst chloride level is achieved through optimum control of the water-
chloride balance in the reactors during normal operation as well as during
regeneration. The water-chloride balance is an equilibrium between water and
chloride in the vapor phase, and the chloride and hydroxyl groups on the catalyst.
Figure III-24 is a ball-and-stick model of a catalyst and helps illustrate this water-
chloride equilibrium. Water in the vapor phase forces water to the catalyst surface
and drives off chloride. Thus, if there is too much water in the vapor phase, this
forces more water to the catalyst surface and drives off the chloride. Vice versa, too
uop 117108-6 III-57
much chloride in the vapor phase forces more chloride to the surface of the catalyst.
Therefore, chloride control is primarily a function of the molar water/chloride ratio in
the vapor phase above the catalyst.
Calculation of this important (combined feed) molar water-chloride ratio, R, is

accomplished by using the equation in Table III-6 and Figures III-25 through 28. (An
example is shown later in this section.) Or a short-cut calculation can be performed
that is accurate to with + 10%. That equation is:
wt - ppm H2O in the feed

R = 1.8 ×
wt - ppm chloride in the feed
where the "wt-ppm water in the feed" is what is injected plus what comes in with the
feed from the stripper – this is generally about 1 ppm for a properly operating NHT
stripper.
Having calculated the combined feed water-to-chloride ratio, R, Figure III-24 can be
used to determine the anticipated steady-state chloride level on the catalyst. Figure
III-24 highlights the chloride effect for the different Fixed-Bed Platforming catalyst
types at 950°F (510°C). The R-50 and R-62 have superior chloride retention
qualities over the R-16 and R-20 series catalyst and, therefore, require less chloride
injection to maintain 1.0 wt-% chloride at equivalent conditions (i.e., for 1.0 wt-%
chloride: R-16 catalyst would require12-1 H2O-Cl vs. R-50/60 series which would
require only 23/1 H2O-Cl).
Note that the catalyst chloride level from Figure III-24 is for a Weight Average Bed
Temperature (WABT) of 950°F (510°C). This value, therefore, must be adjusted for
the Weighted Average Bed Temperature. Platforming catalyst will hold more
chloride at lower temperatures. To adjust this calculated chloride level to the actual
WABT requires adding .0018% per every 1.0°F (or .0032% per 1.0°C) if WABT is
less than 950°F (510°C), or subtracting if WABT is higher. This adjustment is
applicable to all catalyst types.
uop 117108-6 III-58
This water-chloride ratio (vs. wt% catalyst chloride level) applies equally in reactor
(H2 and hydrocarbon) or regenerative (oxygen) atmospheres. Figures III-21a and b
illustrate that the necessary water-chloride ratio for a desired chloride level is the
same regardless of a hydrogen or oxidative environment. This relationship also
holds regardless of catalyst type.
Unfortunately, there are secondary factors that can impact on the validity of this
calculated chloride value and cast doubt on its accuracy. These factors include:
a. Reactor temperatures
b. Coke level
c. Catalyst surface area
d. Feed contaminants and upsets
(a) Reactor Temperatures
UOP's catalyst chloride target is about 1 wt% average. But there is always an
average WABT gradient from the first to the last reactor, with the first reactor having
the lowest WABT. As a result, there is a chloride gradient from the first to the last
reactor, with the first reactor having the highest chloride level. For most catalysts
this delta chloride gradient is about 0.2-0.3 wt%. As a result, catalyst chloride levels
can vary from 1.4 to 0.8 wt% chloride in the reactors and still give acceptable
results. In fact, there is a "window" of acceptable average chloride levels. That
window is from 0.9-1.2%.
(b) Coke Level
Figure III-22 illustrates the effect of coke level on chloride retention at 950°F
(510°C). As coke deposits on the surface it covers hydroxyl sites. As a result, a
coked catalyst requires a lower water-chloride ratio (more chloride) to maintain the
desired chloride level. Generally, the middle-of-run (MOR) curve is used when
determining the chloride level throughout the cycle as it represents an average coke
level of 6-8 wt-%. (Further confounding the picture is the fact that coke level, like
chloride level, varies from reactor to reactor with the highest in the last.)
uop 117108-6 III-59
(c) Surface Area
As the surface area of the catalyst declines (from regenerations), a lower

water/chloride ratio is needed (much like the effects of coke deposition). Figure
III-23 shows that at equivalent water-chloride conditions, the chloride on catalyst will
decrease as the surface area declines. With R-16 catalyst at equivalent water-to-
chloride ratio, there would be 0.1 wt% less chloride on the catalyst for every 20
m2/g loss of surface area as shown in Figure III-23. To offset this effect, the chloride
injection rates need to be increased appropriately. If regenerations are done within
UOP's guidelines, the loss of surface area should be constrained to within 5-10
m2/g per regeneration. But nonetheless, after several regenerations of a catalyst, it
may, therefore, become necessary to increase the chloride injection rates (lower
H2O/Cl ratio) during the oxidation-chlorination step of the regeneration. This effect
would come into play regardless of catalyst type.
(d) Feed Contaminants and Upsets
Feed contaminants (such as nitrogen) and sulfur and water upsets will have an
impact as the calculated chloride level is for a steady-state condition. Nitrogen will
strip chloride out of the gas phase or off the catalyst, whatever is needed to satisfy
the ammonium-chloride stoichiometric ratio. 0.1 ppm nitrogen will scavenge 0.25
ppm chloride and eventually result in a low catalyst chloride level.
Sulfur and water (as in a stripper upset) will also strip chloride off the base and
impede chloride pickup resulting in a low catalyst chloride level. At the low levels of
chloride injection for bimetallic catalysts, it can take from 30 to 60 days to change
the chloride level by 0.1 wt%. An operational upset can strip greater than 0.1 wt%
chloride in a matter of hours or days.
5. Commercial Evaluation Tools
As discussed above, calculation of the combined feed water-chloride ratio and

subsequent catalyst chloride level is not sufficient to give us a good handle on unit
uop 117108-6 III-60
performance. As a result, we must utilize other tools to gauge the water-chloride

balance.
(a) Catalyst Sampling
A catalyst sampler, such as UOP’s shown in Figure IX-2, inserted into the bottom of
the last reactor (or even the first and last reactor) is the best way to track the
catalyst chloride. See Chapter IX “Analytical” for a discussion of the use of the
catalyst sampler.
Unfortunately, not all refiners have catalyst samplers and, therefore, must rely on
additional tools in their unit evaluation kit. The key is to utilize as many of these
tools as possible to make the most informed decision. Other tools or information
that should be monitored are discussed below.
(b) Water and Chloride Injection Rates
Control of water and chloride injection rates is best achieved by holding the water
injection rate constant and as necessary adjusting the chloride injection rate up and
down. Table III-7 gives typical water and chloride injection ranges for UOP’s
catalysts.
To fit in with UOP’s constant water/variable chloride injection rate, a series of

chloride injection rate curves versus WABT have been generated. Using the
shortcut water-chloride calculation method and a curve fit of equations for Figure III-
23, it was possible to generate chloride injection rate curves as in Figures III-29
through 31. These three figures assume 5 wppm water in the feed (4 ppm H2O
injection plus one from the stripper). The curves give approximate chloride injection
rates to maintain from 0.9 to 1.1 wt-% chloride. The "normal" curve is for an average
of 1.0 wt% chloride on catalyst. The "increase" and "decrease" curves are for
changing the catalyst chloride by 0.1 wt%. Note that these curves are a good
starting point. The chloride injection should be adjusted if necessary as your
operating experience improves on the catalyst system.
uop 117108-6 III-61
(c) Water and Chloride in the Recycle Gas
The water and chloride in the feed should end up in the recycle gas. For water, 1
ppm in the feed should result in about 3 ppm in the recycle gas. UOP generally
targets for 10-20 ppm H2O in the recycle gas with trace to 0.5 chloride in the recycle
depending on catalyst type. Typical recycle gas values for UOP’s catalysts are
shown in Table III-7 with the injection ranges.
The amount of H2O and chloride to be expected in the recycle gas as a function of
feed levels can be calculated from the equilibrium curves (Figures III-25~28). These
can then be compared to the water measured by the recycle gas water analyzer
and the chloride measured by Dräger or sniffer tubes.
The water-chloride verification curve in Figure III-32 plots (predicted water in the
recycle gas)/(water the feed) versus (chloride in the recycle gas)/(chloride in the
feed). If these ratios (using measured values) do not fall on this line, it could mean
the moisture analyzer is reading incorrectly or the measured chloride by Dräger
tube is incorrect. At the end of this section, there is an example using this curve.
(d) Chloride and H2S in the Stabilizer Gas
Monitoring the HCl and H2S in the stabilizer gas is another handle for monitoring
chloride and sulfur in the feed and then comparison to the recycle gas values. The
concentrations in the stabilizer gas can be up to ten times higher than those in the
feed or three times higher than the recycle gas. But measurement of the stabilizer
gas is more difficult because it’s a cooler stream. (In some R-62 operations, it has
been found to be more beneficial to monitor the stabilizer gas for H2S and HCl as in
some cases HCl and H2S do not readily show up in the recycle gas.) A properly
hydrotreated feed should result in H2S levels in the stabilizer gas of less than 5
ppm.
uop 117108-6 III-62
(e) Unit Mass Balance
Mass balancing the unit enables a refiner to normalize their data (via the Process
Variable curves) and track activity and yield changes. By normalizing and plotting
activity and yields, fluctuations in feedstock and processing conditions can be
eliminated allowing a refiner to see changes associated with a catalyst metal/acid
imbalance.
UOP uses a proprietary computer program called CDOTS to collect, store and
process a refiner’s operating and laboratory data. CDOTS can normalize and plot
delta activity and yields and much more. CDOTS can be installed on a refiner’s PC
so that data analysis can be performed daily. The data can also be sent
electronically to UOP for review. In CDOTS format, data can be much more easily
processed and reviewed by UOP thus giving a more timely turnaround.
(f) Light Gas Yields
Along the lines of delta C5+ and H2 yields, ratios of “reactor effluent” basis light gas
yields can provide insight into an imbalanced catalyst system (i.e., wet/dry and/or
over/under-chlorided.)
There are two light gas ratios that UOP employs:
(1) The Molar Methane Ratio (CH4):
C1
C1 + C2 + C3
(2) The Molar Light Ends Product (LEP):
C1 + C2
C3 + C4
uop 117108-6 III-63
There is some confounding of these two ratios as a wet system can lead to
increased C3 and C4 yields much like an over-chlorided catalyst. As such, these two
ratios may tend to track each other. On the other hand, the LEP ratio may be more
sensitive to the over-/under-chlorided system as it also incorporates the butane
production. Generally, a high catalyst chloride content leads to increased
hydrocracking which is responsible for the production of C3 and C4’s. On the other
hand, a reduced catalyst chloride level results in diminished hydrocracking.
Just plotting the "reactor effluent" basis light gas ratios can be misleading in that
these ratios are also a function of feedstock and processing conditions. In Tables
III-8 and 9 can be found "five-variable" models to predict the Methane and LEP
ratios as feedstock and processing conditions change. Utilizing the actual and
predicted ratios, the delta (actual-predicted) ratios should be plotted as such:
The plotted deltas should be scrutinized for trends and excursions outside the 95%
confidence intervals given with the prediction equations in Tables III-8 and 9.
(g) Recycle Gas Density
The recycle gas density can also provide some insight to sudden changes in
hydrocracking activity. Over the course of a cycle, the recycle gas density will
gradually increase as H2 purity decreases and more light ends are made. But any
sudden increase in density could indicate an increased cracking function as the
result of a sudden water slug (feed “wet” from storage) or a slug of chloride.
(h) Reactor Temperatures
The reactor fractional delta temperatures
Reactor i (in - out)

Total Platformin g Reactors Delta Temperatur e
are a measure of the reactions taking place in each reactor. These fractional delta
T’s for each reactor should be fairly constant over the life of the catalyst. Any
uop 117108-6 III-64
changes in the fractional delta T’s can indicate changes in the catalyst environment
(sulfur and/or water poisoning, unbalanced chloride levels, metal poisoning, etc.).
There may be some gradual changes in these delta T’s as the catalyst ages. This
may appear as a gradual deterioration of the back reactor(s) fractional delta T.
(Note that the total reactor delta temperature drop will also gradually decrease as
the catalyst ages.)
(i) Temperature-Octane Response
Figure III-3, from the Dependent Variables section, enables one to gauge if a
change in reactor inlet temperatures results in the proper change in the reformate
octane. If the change in reactor inlet temperatures result in an expected RONC
shortfall, this might indicate an under-chlorided catalyst (and vice versa might be an
over-chlorided catalyst).
Example III-5
Initial Conditions:
WAIT = 930°F (499°C)
RONC = 93
Final Conditions:
WAIT = 950°F (510°C)
RONC = 97
950 − 930°F 20°F
= 5°F/RONC
97 − 93 4 RONC
From Figure III-3 at an average RONC of 95
°F/RONC = 5.5°F (3.1°C)
The actual temperature-octane response is close to actual and may at worse

indicate a slightly over-chlorided catalyst.
uop 117108-6 III-65
6. Summary
Optimal or proper control of catalyst chloride requires knowledge of the Platforming

unit operations. The refiner should endeavor to collect as much data as possible
and in as timely a fashion as possible.
Unfortunately, probably not all of the data collected will lead one to the same
conclusion. As such, the data must be weighted based on a refiner’s opinion of its
validity. If a refiner feels a number of pieces of data are questionable, then this is an
area that needs future attention.
Monitoring the naphtha hydrotreater is also important as minimum levels of

feedstock contaminants will result in smoother Platforming Unit operations.
Example III-6: Water/Chloride Ratio Calculated from Typical Injection Rates
Unit Conditions
Product separator press., psig (kg/cm2) 350 (24.6)

Product separator temp., °F (°C) 100 (38)
Net separator gas, SCFB (Nm3/m3) 1000 (170)
Gas/Hydrocarbon ratio, molar 5
Water injection, wt-ppm in feed 4
Chloride injection wt-ppm in feed 0.5
Assume
1 wt-ppm of water in feed before injection

molecular weight of the feed is 115
From Figures III-27 and 28
for HCl, K = 1.95 and 1.78 mol-ppm HCl in recycle gas/1 wt-ppm in feed then
recycle gas HCl = (0.5)(1.78) = 0.89 mol-ppm
uop 117108-6 III-66
From Figures III-25 and 26
for H2O, K = 1.3 and 3.2 mol-ppm H2O in recycle gas/1 wt-ppm in feed then
recycle gas H2O = (4+1)(3.2) = 16.0 mol-ppm
Calculation of water/chloride ratio
(16)(5) + (4 +1)(115/18)
R = = 18.4
(0.89)(5) + (0.5)(115/35.5)
Example III-7: H2O - Cl Verification
Assume
Sep Pres : 300 psig (21 kg/cm2)

Sep Temp : 100°F (38°C)
Net Gas Yield : 1300 SCFB (225 Nm3/m3)
H2O in Feed : 4 wt-ppm
Chloride Inj : 0.5 wt-ppm
Recycle Gas : 14 mol-ppm H2O

0.4 mol-ppm Cl
0.4 14
Chloride Ratio = = 0.8 H2O Ratio = = 2.8
0.5 4 +1
From Equilibrium Curves (Figures III-25~28)
Chloride Ratio = 1.5 H2O Ratio = 2.6
Therefore, it appears that the water numbers are correct but there is concern about
the validity of the chloride numbers. So one would question either the chloride
injection or the measurement of the recycle gas chloride. Another possibility is that
there is nitrogen in the feed. 0.1 ppm, N2 will consume 0.25 ppm chloride. If the feed
contains 0.1 ppm N2 then only half of the injected chloride will end up in the recycle
uop 117108-6 III-67
gas. Therefore, the 0.4 ppm HCl in the recycle gas is indicative of only (0.5-0.25=)
0.25 ppm chloride injection
0.4 ppm HCl in RG

Chloride Ratio = = 1.6
0.25 ppm Cl injection
uop 117108-6 III-68
Table III-3
Yield-Octane Study of R-50 with High Catalyst Chloride Level
Pilot Plant Test Conditions
Catalyst Chloride Level Normal High

Pressure, psig 300 300
kg/cm2 21 21
-1
LHSV, hr 2.0 2.0
H2/HC, molar ratio 10 10
Target RONC 95/100 95/100
Catalyst Chloride, wt% Cl (SOR) 1.08 1.40
Table III-4
Accelerated Stability Test for R-50 with a High Feed Chloride Level
Feed Chloride Level Normal High

kg/cm2 21 21
-1
LHSV, hr 2.0 2.0
Target RONC 100 100
Feed Chloride, wt-ppm Cl 1.0 8.0
Feed Water, wt-ppm H2O 2.5 2.5
Catalyst Chloride, wt% Cl (SOR) 1.08 1.08
(EOR) 1.00 1.38
Table III-5
Accelerated Stability Test for Low Chloride R-62
Feed Chloride Level Normal Low

kg/cm2 17.5 17.5
LHSV, hr-1 2.5 2.5
Target RONC 98 98
Catalyst Chloride, wt% Cl 1.03 0.76
uop 117108-6 III-69
Table III-6
Calculation of Catalyst Chloride Level
Necessary Data
XF = Wt-ppm of Chloride into the fresh feed
YF = Wt-ppm of water in the fresh feed (1)
MWF = Molecular Weight of the fresh feed
XR = Mole ppm HCl in the Recycle Gas (2)
YR = Mole ppm Water in the Recycle Gas (3)
G = Gas Ratio (Moles Recycle Gas / Mole Fresh Feed)
(1) The value normally used is the wt-ppm water injected into the fresh feed plus
an additional 0.5 to 1.0 wt-ppm assumed to be in the fresh charge
(2) The HCl content of the recycle gas can be estimated from Figures III-27 and
III-28 (Equilibrium Recycle Gas HCl Content).
(3) The water content of the recycle gas can be estimated using the value of YF
times the multiplier obtained from Figures III-25 and III-26 (Equilibrium
Recycle Gas Water Content).
Calculation
R = Water / Chloride mole ratio in combined feed (fresh charge plus

recycle gas).
⎡ ⎛ MWF ⎞⎤
YR G + ⎢ YF ⎜⎜ ⎟⎥
⎟
⎣⎢ ⎝ 18 ⎠⎦⎥
R=
⎡ ⎛ MWF ⎞⎤
X R G + ⎢ X F ⎜⎜ ⎟⎥
⎟
⎢⎣ ⎝ 35.5 ⎠⎥⎦
uop 117108-6 III-70
Table III-7
Typical H2O, Chloride, Sulfur Values
Catalyst H2O Chloride Recycle Gas Content, vol- Stabilizer Gas

Type Injection*, Injection, ppm Content, vol-ppm
wt-ppm wt-ppm
H2O HCl H2S H2S
R-16
4.0 1.5 10~20 0.5+ <1.0 5.0
series
R-50 Trace –
4.0 0.5 10~20 <1.0 5.0
series 0.2
R-62
4.0 0.7~0.8 10~20 0.5+ <1.0 5.0
series
R-86 Trace –
4.0 0.5 10~20 <1.0 5.0
series 0.2
R-98 Trace –
4.0 0.5 10~20 <1.0 5.0
series 0.2
All- 3 x feed 8~12 x feed
11 1.5 30~40 1~2
Platinum content content
* - Assumes there will be 1 wt-ppm H2O in feed from stripper.
uop 117108-6 III-71
Table III-8
Methane Ratio Correlation (Based on Pilot Plant Data)
5 Variable Model
MR= -0.805 + 0.000257A – 1.252B + 0.671C + 0.0125D + 0.00188E
Where
A = (average reactor pressure – 283), psig
⎡ (Total Feed Naph, lv% − 29.86 ) + 2(Total Feed Arom, lv% − 8.72)⎤
3
B=⎢ ⎥
⎣ 100 ⎦
⎡ (131.5 + Feed API)

−1
⎤
C=⎢ − 0.744 ⎥
⎣ 141.5 ⎦
⎡ (D90% − 309.8 ) − (D50% − 255 ) ⎤

D = ABS ⎢ ⎥
⎣ 100 ⎦
E = (LHSV – 1.29)-1
NOTES:
1. 1 standard deviation (67% conf. level) = 0.022
2. 2 standard deviations (95% conf. level) = 0.044
3. Ratio calculation becomes unstable at 1.29 LHSV. Near this value, use 1.25 or
1.35 LHSV (if in between those values) whichever is closer.
4. Distillation in °F
uop 117108-6 III-72
Table III-9
Light Ends Product Ratio Correlation (Based on Pilot Plant Data)
5 Variable Model
LEP= -1.088+ 0.00987A + 0.0011B + 0.00237C + 0.00549D - 0.00383E
Where
A = (Total Feed Naphthenes, lv%) - 29.86
B = (Average Reactor pressure) – 283, psig
C = Predicted SOR, °F
D = (Feed 90% Point) – 309.8°F
E=
(Feed EP, °F − 350.9°F) − (Feed IBP, °F − 191.3°F)
100
1 standard deviation (67% conf. level) = 0.135

2 standard deviations (95% conf. level) = 0.27
uop 117108-6 III-73
Figure III-16
Yield Octane Study of R-50
With High Catalyst Chloride Level
H2 Yield, SCFB
H2 Yield, nm3/m3
1200 200
190
1100 180
1000 170
160
900 150
140
800
82
80
C5+ Yield, LV-%
78
76
74
72
70
68
66
95 RONC 100 RONC
Block Temperature, °C
Block Temperature, °F
1000
990
530
980
970 520
960
Symbol R-50 Chloride
950 1.08 Wt% (vf
(vf)) 510
940 1.40 Wt% (vf
(vf))
Lean Feed @ 95 & 100 RONC 500
930
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
(0.175) (0.351) (0.526) (0.701) (0.876) (1.052) (1.227)
Catalyst Life, BPP (M3/kg)
F.B. Plat
117108 III-16
uop 117108-6 III-74
Figure III-17
300 psig Accelerated Stability Test
for R-50 Catalyst With a High Feed Chloride Level
H2 Yield, nm3/m3
H2 Yield, SCFB
1200
180
1000
160
800 140
120
600
74
C5+ Yield, LV-%
72
70
68
66
64
1020
540
1010
Block Temperature °F
Block Temperature, °C
1000
530
990
980
520
970 Symbol Catalyst Feed Cl
R50 1.0 wt-ppm
wt-ppm
960 R50 8.0 wt-ppm
wt-ppm 510
Lean Feed @ 100 RONC
950
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
(0.175) (0.351) (0.526) (0.701) (0.876) (1.052) (1.227)
Catalyst Life, BPP (m3/kg)
F.B. Plat
117108 III-17
uop 117108-6 III-75
Figure III-18
Low Chloride AST Test - R-62
1210
200
1180
H2 Yield, SCFB
1150
nm3/m3
190
1120
1090
180
1060
1030
1000 170
80
79
Adjusted C 5+,
LV-% FF
78
77
76
75
Adjusted Block Temp., °F
1010
1000
990
980
970
960
Low Chloride R-62
950 Reference R-62
940
0 2 4 6
Catalyst Life, BPP (m3/kg)
F.B. Plat
117108 III-18
uop 117108-6 III-76
Figure III-19
High Water AST Test - R-50
1200
200
H2 Yield, SCFB
1100
nm3/m3
180
1000
160
900
140
800
80
78
Adjusted C5+
Yield, LV-%
76
74
72
70
1010
1000
990
980
970
960
R-50 Reference
950
R-50 HI Water (40 ppm FF)
940
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Adjusted Catalyst Life, BPP
F.B. Plat
117108 III-19
uop 117108-6 III-77
Figure III-20
High Water AST Test - R-62
1200
H2 Yield, SCFB 200
1100
nm3/m3
180
1000
160
900
140
800
80
Adjusted C5+
78
Yield, LV-%
76
74
72
70
1010
1000
990
980
970
960
950 R-62 Reference

R-62 High Water (40 ppm FF)
940
0.0 0.8 1.6 2.4 3.2 4.0 4.8
Adjusted Catalyst Life, BPP
F.B. Plat
117108 III-20
uop 117108-6 III-78
Figure III-21a
H2O/Cl Equilibrium
R-50 at 950°F (510°C)
1.5
1.4
1.3
Chloride, Wt-%
1.2
1.1
1.0
0.9
R-50 in H2
0.8
R-50 in Air
0.7
0 20 40 60 80 100
H2O/Cl
O/Cl Molar Ratio
F.B. Plat
117108 III-21a
Figure III-21b
H2O/Cl Equilibrium
R-50/R-62 at 950°F (510°C)
1.5
1.4
1.3
Chloride, Wt-%
1.2
1.1
1.0
R-62 in Air
0.9 R-62 in H2
0.8 Curve Fit of R-50 Data
0.7
0 20 40 60 80 100
H2O/Cl
O/Cl Molar Ratio
F.B. Plat
117108 III-21b
uop 117108-6 III-79
Figure III-22
H2O/Cl Equilibrium
R-50/R-62 at 950°F (510°C)
1.5
R-62/50 at SOR
1.4 R-62/50 at MOR
1.3
Chloride, Wt-%
1.2
1.1
1.0
0.9
0.8
0.7
0 20 40 60 80 100
H2O/Cl
O/Cl Molar Ratio
F.B. Plat
117108 III-22
Figure III-23
H2O/Cl Equilibrium
Surface Area Affect for R-16 Series Catalysts
1.1
36/1 H2O:Cl
H2O:Cl
61/1 H2O:Cl
H2O:Cl
1.0
91/1 H2O:Cl
H2O:Cl
Chloride, Wt-%
0.9
0.8
0.7
0.6
[ 0.1 wt-% Cl
17 m2/g ]
0.5
160 180 200 220
Surface Area, m2/g
F.B. Plat
117108 III-23
uop 117108-6 III-80
Figure III-24
Water - Chloride Equilibrium Curve
950°F (510°C) Weighted Avg. Catalyst Bed Temperature
1.3
Chloride on Catalyst, wt%
1.2
1.1 R-50, 56, 62, 72, 86, 98
1.0
0.9
R-16 & R-20
0.8
Temp. Correction = Cl/100oF
-0.18% Cl/100
0.7 Cl/100oC
-0.32% Cl/100
0.6
0 5 10 15 20 25 30 35 40
H20/HCl
0/HCl Mole Ratio in Combined Feed to Reactors
F.B. Plat
117108 III-24
Figure III-25
Equilibrium Constant, K, of Water in Recycle Gas
Separator Temperature, °F (°C)
2.0
3.0
4.0
1.0
5.0
(49) 120
8.0
(43) 110
(38) 100
7.0
(32) 90
(27) 80
6.0
(21) 70
50 100 150 200 250 300 350 400 450 500 550 600
(3.5) (7) (14) (21) (28) (35) (42)
Separator Pressure, psig
(kg/cm2-g)
F.B. Plat
117108 III-25
uop 117108-6 III-81
Figure III-26
Equilibrium Recycle Gas Moisture Content
8
Mol--ppm Water in Recycle Gas

ppm Water in Fresh Feed
10
7.0
Equilibrium K
5.0
6
3.0
2.0
1.5
4
wt-ppm
1.0
wt-
Mol
600 800 1000 1200 1400 1600
(107) (142) (178) (214) (249) (284)
Net Separator Gas Flow SCFB (Nm3/m3) F.B. Plat
117108 III-26
Figure III-27
Equilibrium Constant, K, of Hydrogen Chloride in Recycle Gas
Separator Temperature, °F (°C)
10
7
6
5
8
9
2
4
(49) 120
(43) 110
(38) 100
(32) 90
(27) 80
(21) 70
50 100 150 200 250 300 350 400 450 500 550 600
(3.5) (7) (14) (21) (28) (35) (42)
Separator Pressure, psig
(kg/cm2-g) F.B. Plat
117108 III-27
uop 117108-6 III-82
Figure III-28
Equilibrium Recycle Gas HCl Content
4
Mol--ppm Chloride in Recycle Gas

ppm Chloride in Fresh Feed
10
7.0
5.0
Equilibrium K
3
3.0
2.0
1.5
2
1.0
wt-ppm
wt-
Mol
1
600 800 1000 1200 1400 1600
(107) (142) (178) (214) (249) (284)
Net Separator Gas, SCFB (Nm3/m3)
F.B. Plat
117108 III-28
Figure III-29
Chloride Injection Rate
5 wt-ppm H2O (R-16 Catalysts)
1.7
Chloride Injection Rate,
1.5
1.3
ppm
Wt-ppm
Increase
1.1
Wt-
Normal
0.9
0.7
Decrease
0.5
840 860 880 900 920 940 960 980
Weight Average Temperature, °F
455 470 490 510

WABT, °C
F.B. Plat
117108 III-29
uop 117108-6 III-83
Figure III-30
5 wt-ppm H2O (R-50/R-56 Catalysts)
0.9
Increase
0.8
0.7
ppm
Wt-ppm
Normal
0.6
Wt-
0.5
Decrease
0.4
0.3
840 860 880 900 920 940 960 980
450 470 490 510

WABT, °C
F.B. Plat
117108 III-30
Figure III-30 A
5 wt-ppm H2O (R-86/98
(R-50/R-56 Catalysts)
Catalyst)
00.9
.9
Increase
00.8
.8
00.7
.7
ppm
Wt-ppm
Normal
00.6
.6
Wt-
00.5
.5
Decrease
00.4
.4
00.3
.3
840 860 880 900 920 940 960 980
450 470 490 510

WABT, °C
F.B. Plat
117108 III-30
uop 117108-6 III-84
Figure III-31
5 wt-ppm H2O (R-62 Catalyst)
1.1
Chloride Injection Rate, Increase
1.0
Normal
0.9
ppm
Wt-ppm
0.8
Wt-
0.7
Decrease
0.6
0.5
840 860 880 900 920 940 960 980
Weight Average Bed Temperature, °F
450 470 490 510

WABT, °C
F.B. Plat
117108 III-31
Figure III-32
Water and Chloride Ratio Verification
6
5
Recycle Gas mol ppm
ppm
wt-ppm
4
Water Ratio,
Fresh Feed wt-
0
0 0.4 0.8 1.2 1.6 2.0 2.4 2.8
Chloride Ratio,
Recycle Gas, mol-
mol-ppm/Fresh
ppm/Fresh Feed wt-ppm
wt-ppm
F.B. Plat
117108 III-32
uop 117108-6 III-85
Fixed-Bed Platforming – General Operating Manual Process Flow and Control
IV. PROCESS FLOW AND CONTROL
A. PROCESS FLOW
The reactions that take place in the UOP Platforming Process are mostly
endothermic (require heat input), and must occur at elevated temperatures in a
hydrogen atmosphere to obtain optimum catalyst life and product yields. If the
conditions are unfavorable, product yields and/or catalyst life will be poor. Unit
designs may vary depending upon processing conditions, optimum capital
investment, desired yield structure and operating costs (based on information
projected at the time of the unit’s design). But all Platforming units have certain
basic components as illustrated in Figure IV-1:
1. The feed must be properly hydrotreated to lower the sulfur and nitrogen
contents to below 0.5 ppm, saturate all olefins, and to remove metals,
halogens and oxygenates. The naphtha boiling range has a minimum IBP of
170°F (75°C) and a maximum endpoint of 400°F (204°C).
2. The preheater section would include the combined feed exchanger(s) and
the charge heater. Its function is to raise the temperature of the feed plus
recycle H2 to reaction temperatures (900°F [482°C] or higher). The combined
feed exchanger(s) can be (listed in increasing order of efficiency):
a. A bank of horizontal exchangers in series;

b. One to four vertical exchangers in parallel; or
c. Plate exchangers (such as offered by Packinox).
The vertical and plate exchangers have low pressure drop and are now
preferred over the horizontal exchanger. The cost for replacing banks of
horizontals with one or two vertical exchangers can have a payback time of
less than one year just in energy savings (exclusive of the yield realized from
the lower pressure). The charge heater part of the preheat will be deferred to
until the reheat section.
uop 117108-6 IV-1
3. The reactor section can be 3 to 5 reactors in series separated by reheat

sections or interheaters. The reactors can be side-by-side or stacked one on
top of the other. For Fixed-Bed applications, the reactor types can be:
a. spherical
b. downflow
c. radial downflow centerpipe
d. radial upflow centerpipe
Most reactor designs are now radial flow because of the low pressure drop
across them versus types a and b. (All CCRs utilize stacked radial flow
reactors, types c and d.) The radial upflow is UOP's latest CCR Platforming
stacked radial flow reactor design with the hydrocarbon flow going up the
centerpipe rather than down. For further details on all of these reactors, see
Chapter V: “Process Equipment”.
Design operating conditions on Fixed-Bed Platforming Units cover pressures

of 150 to 600 psig (10.5-42.2 kg/cm2) and temperatures of 880°F to 1000°F
(471-538°C). Most CCR Platforming Units operate at pressures from 175
psig to 50 psig (12.3-3.5 kg/cm2) and temperatures of 900-1010°F (482-
543°C) with a design of 990°F (532°C).
4. The reheat or interheaters section (including the charge heater) can be

individual heaters, circular updraft or horizontal cabin type or a partitioned
heater box with a cell for the charge heater and each interheater. The
partitioned multi-cell heater is used on CCR Platforming Units because of its
low pressure drop. For further details on these heaters, see Chapter V:
“Process Equipment”.
The fuel used can be oil only, gas only, or oil and gas combination. The type
of fuel utilized will determine the type of burner to be used. The type of fuel
will also have an impact on whether the burners will be floor or side-mounted
figure and whether the tubes (in the multi-cell heater) will be upright U-type,
inverted U-type, or a straight tube crossover.
uop 117108-6 IV-2
These heaters can be:
a. natural draft
b. forced draft
c. hi-intensity
The metallurgy of the heaters’ tubes is usually 2¼%Cr-1%Mo or 9%Cr-

1%Mo depending on tube wall temperatures (1125 or 1175°F, respectively).
Most heaters have a convection section for the waste heat that’s used for
steam generation or more recently column reboiling duty.
5. The gas/liquid separation section, whose function is to separate the C5+

aromatic rich hydrocarbons from the net H2, can be:
a. a single separator;
b. low pressure and high pressure separators which may involve total or
net gas recontacting; and/or
c. a chiller section.
As the pressure of the unit decreases, the flash across a separator becomes
less efficient and more hydrocarbons will end up in the net H2 stream. This
increases the load on the recycle compressor (more gas to compress for the
same H2/HC ratio), and on the heating and cooling equipment (more mass
flow to heat and cool). It also increased the duty on the fractionation system
since there is more hydrogen with respect to the amount of light ends in the
separator liquid, which require additional reflux and reboiling.
To improve this separation efficiency, a high pressure separator is added.

This recontact step improves recovery of the C3+ material from the net H2
stream and also boosts the pressure up to that necessary for downstream
users such as the naphtha hydrotreater.
uop 117108-6 IV-3
6. The stabilizer section may be one or two columns (stabilizer and reformate
splitter such as on an aromatics unit) used to produce a C5+ or C6+
reformate stream or fractionate out the aromatics. These columns are usually
steam fired, or in some instances, reactor effluent reboiled.
Figures IV-2 and 3 show a typical flow scheme for a UOP Fixed-Bed
Platforming, side-by-side reactors, single separator unit, and a UOP CCR
Platforming unit with two stage countercurrent recontact, respectively.
B. CONTROL SYSTEMS
Most of the control schemes used in a Platforming unit are easy to understand.
Most are either straight XRC loops or XRC reset by YRC loops, where X and Y are
generally T (temperature), P (pressure), F (flow), or L (level).
1. Heater Firing
One system that is sometimes difficult to understand is the shutdown system for
heater firing. Figure IV-4 shows the general design of the most recently adopted
system. In general, the heater firing is stopped automatically if:
(1) recycle gas flow (in a reactor circuit) or reboiler circulation flow (in a
reboiler) is lost on two separate orifice meters; or if
(2) pilot gas pressure drops below a safe level. In addition, if atomizing
steam is lost, fuel oil firing will be stopped.
If low process flow or low atomizing steam pressure shuts down the firing, the pilots
will remain on. But if low pilot gas pressure occurs, the pilot gas supply will also be
isolated. All of the solenoid valves used must be manually reset to avoid problems
that would be encountered if they were to be reset by the panel operator.
uop 117108-6 IV-4
2. Reactor Pressure
Another complex control system is often the Platforming reactor section pressure
control system. If the control is not a straight or split range system PRC (pressure
recorder controller), the system is usually one of these shown in Figures IV-5
through 7. In Figure IV-5 there is a booster compressor between the Platforming
unit and hydrotreater with a PRC on the Platforming unit separator and a PRC on
the hydrotreater. The sequence of events is as follows:
(1) as pressure on the hydrotreater rises, the hydrotreater PRC opens

valve 3 to control the pressure
(2) as pressure on the hydrotreater falls, its PRC will close valve 3 and
when valve 3 is fully closed, will attempt to close valve 2;
(3) as the Platforming Unit pressure rises, its PRC will attempt to close
valve 2, and if the pressure still rises, will open valve 1.
The signals from each PRC to valve 2 are compared by a low signal selector, which
chooses the lowest signal to actuate valve 2. The purpose of this arrangement is to
keep the booster compressor compression ratio at or below the normal ratio.
As it operates, the system will let the hydrotreater pressure fall off if there is not
enough gas to supply its requirements, while holding the Platforming unit pressure
steady. Excess gas will be vented from the hydrotreater if the compressor capacity
is greater than the gas production, or from the Platforming unit (or the Platforming
unit and hydrotreater) if the compressor capacity is less than the production.
Figure IV-6 shows the same type of system for a dual separator Platforming unit. In
cases where no flow is expected from valve 1, the line comes from the low pressure
separator. If flow is normal for valve 1, the line comes from the high pressure
separator. The reason is that it is desirable to vent from the low pressure separator
in the case of an upset (loss of recycle compressor, pressure surge, etc.), but if a
constant stream is to be vented, less C5 plus material will be vented in the gas from
the high pressure separator than in the gas from the low pressure separator.
uop 117108-6 IV-5
Figure IV-7 shows a system similar to the one shown in Figure IV-5, but for a multi-
stage booster compressor. Each stage is protected from an excessive compression
ratio, just as in the system shown in Figure IV-7.
3. Fractionation
One other unusual control loop may be encountered on reboiler control system (see
Figure IV-8). This utilizes a PDRC (pressure differential recording controller) to
control reboiler heater firing instead of a TRC (temperature recorder controller).
The reason for using a PDRC is that in some cases there is a very small
temperature increase across the reboiler (i.e., narrow boiling range feeds). In this
case, an absolute temperature setting would not give good control. The PDRC is
utilized to control the amount of vaporization occurring in the reboiler, rather than
the temperature.
This system will work regardless of the temperature rise across the heater, but it is
not often used, unless it is necessary, due to the higher cost of the installation
compared to a TRC.
Figure IV-10 shows another UOP approach to stabilizer control. In the past, the
overhead receiver level controlled the rate of overhead liquid to storage and reflux
was on temperature control. But the new control scheme is self-compensating. As
the column tray (#7) temperature rises, the control valve on overhead liquid to
storage closes. This will result in a level increase in the overhead receiver. Then the
reflux control valve will open allowing more reflux and lowering the top temperature.
uop 117108-6 IV-6
Aromatics Stream
5. Gas / Liquid
117108 IV-1
Reformate or
F.B. Plat
6. Stabilizer
Separation
Liquid
Basic Platforming Process Flow
Gas
3. Reactors
4. Reheat
Figure IV-1
H2
2. Preheater
1. Feed
uop 117108-6 IV-7
117108 IV-2
LPG
F.B. Plat
Fuel Gas
H
UOP Fixed-Bed Platforming Process
Reformate
M
M
E
D
B
Net Gas
M
Figure IV-2
E
S
P
Combined Feed Exchanger

C
E
F
M
H
Rx
Debutanizer
Feed
Separator
H
Reactor
Heater
Rx
Legend
DEB
CFE
Rx
SEP
Rx
H
uop 117108-6 IV-8
Figure IV-3
Platforming Process with Two-Stage
Counter-Current Recontact
Fresh Net Gas
Catalyst
R R
Rx S C C
C E
F P
Rx E
Rx
REC
Spent H H H
Feed
Catalyst LPG
Legend D
E
SEP = Separator B
RC = Recontact Drum
DEB = Debutanizer Reformate CON H
REC = Receiver
CON = Convection Section
uop 117108-6 IV-9
Figure IV-4
Heater Shutdown System
Fuel Gas to Burners

Fuel Gas F
PIAL
Pilot Gas to Pilots
Fuel Oil to Burners Heater
Atomizing Steam
Return to Burners
Fuel Oil
Supply E
PIAL
Atomizing
E
Steam AND
Low Flow Shutdown
AND
Process Stream OR
uop 117108-6 IV-10
Figure IV-5
Reactor Pressure Control
Scheme I
Fuel Gas Split

Split Range
Range
1 Booster PRC
Compressor
PRC
H
3
Low Signal
Selector
S
2
Legend
S = Separator
H = Hydrotreater
FB Plat
117108 IV-5
uop 117108-6 IV-11
Figure IV-6
Pressure Control
Scheme II
Split Range Fuel Gas

1
Recycle Booster
PRC Compressor Compressor
To Hydrotreater
From Hydrotreater
PRC
LPS Low Signal

HPS 2
Selector
Recycle Gas
Legend
LPS = Low Pressure Separator
HPS = High Pressure Separator
FB Plat
117108 IV-6
uop 117108-6 IV-12
Figure IV-7
Pressure Control
Scheme III
Split
Range
Split Booster Compressor
Range
PRC
PRC
Stage 2
PRC Stage 1
H
Low Signal
Split Selector
Range
S
Low Signal For three or more stages,
Legend Selector duplicate as required
S = Separator
H = Hydrotreater
FB Plat
117108 IV-7
uop 117108-6 IV-13
Figure IV-8
Reboiler Firing Control
PDRC
TR
C
FRC
RH
Reboiler
Pump
Product Legend
C = Column Fuel
RH = Reboiler Heater
*Eccentric orifice to allow liquid to flow through the pipe
uop 117108-6 IV-14
Figure IV-9
Eccentric Orifice Flow
100%
% Vaporization
75%
50%
25%
Reboiler
Return
Orifice
Design Point
ΔP
7 Units of Flow
% Design Flow to
Reboiler
uop 117108-6 IV-15
Figure IV-10
Stabilizer Control
PRC
FR
LC
TRC
FRC
Stab FRC
Feed Reformate
Overhead
As TRC ↑, FRC closes then LC increases
causing FRC CV to open (more reflux)
uop 117108-6 IV-16
Fixed-Bed Platforming – General Operating Manual Process Equipment
V. PROCESS EQUIPMENT
A. REACTORS
In general, the purpose of the Platforming reactors is to allow the feed to contact the
catalyst at reaction conditions while not allowing the catalyst to leave with the
product. Catalyst containment is one of the primary goals of the design.
The more modern designs of Platforming Units employ reactors that are radial flow
in design. Since the history of the Platforming process is fairly long, this reactor
choice is as a result of design evolution. A brief description of this evolution follows.
1. Spherical Reactors
The first Platforming units were designed for high pressures. A spherical reactor
shell design was adopted for these reactor conditions since the wall thickness could
be less than with a cylindrical reactor at the same pressure. The reactors were
downflow reactors with ceramic material in the bottom of the vessel and on top of
the catalyst bed. A feed distributor was attached to the inlet elbow and an outlet
basket fit into the outlet nozzle. See Figure V-1.
Careful attention had to be paid to the reactor loading of these units to avoid flow
maldistribution. Even when the reactor was loaded correctly, the non-uniform cross-
section along the flow path led to an inherent flow maldistribution and consequent
under-utilization of the catalyst.
2. Down Flow Reactors
As Platforming catalysts improved over the years, particularly with respect to the
catalyst stability, the reactor pressure could be reduced. Lowering the reactor
pressure made the flow maldistribution problem in the spherical reactors even
worse. With a lower reactor pressure, however, the cylindrical reactor could be
adopted without excessive wall thicknesses. Hence the second generation of
reactors developed. See Figure V-2.
uop 117108-6 V-1
These cylindrical vessels were still in a downflow configuration with ceramic

material in the bottom of the vessel and on top of the catalyst bed. A feed distributor
was attached to the inlet elbow and an outlet basket fit into the outlet nozzle.
Since there was now a constant cross-section to the flow path, the flow distribution
was much improved. This configuration does not give true plug-flow in practice due
to inconsistencies in catalyst loading and wall-effects during fluid flow.
Some reactors incorporated an insulating layer inside the reactor shell. This
decreased the reactor wall temperature and hence metallurgy requirements. An
example of these internally insulated or cold wall reactors is shown in Figure V-3.
3. Radial Flow Reactors
As catalysts improved still further, operating pressures were decreased in line with
the improvements to take advantage of the increased C5+ and hydrogen yields at
lower operating pressures. At lower pressures, the pressure drop though the reactor
circuit became an important consideration.
The third generation of Platforming reactor was developed which gave increased
flow distribution at a decreased pressure drop. The Radial flow reactor has
combined feed entering at the top, being distributed to the vessel walls where it
enters a series of scallops (or baskets). The combined feed flows vertically down
through the scallops (or baskets) and, by equal pressure drop, horizontally out of
the scallops and into the catalyst bed. The combined feed flows horizontally through
the annular catalyst bed radially inwards to a centerpipe which collects the reactor
products and directs them downwards to the reactor outlet. See Figure V-4.
Further improvements in reactor design have led to the commercialization of the

radial upflow reactor in the 1980s. This is essentially the same as the original radial
flow reactor except that the flow is directed upwards through the centerpipe to the
reactor outlet which is at the top of the reactor. This configuration gives even better
flow distribution at an even lower pressure drop. There are other distinct
advantages to this configuration in the CCR stacked reactor arrangement. Field
assembly is also simplified. See Figure V-5.
uop 117108-6 V-2
4. Stacked Reactors
Stacked reactors are used in UOP’s Continuous Catalyst Regeneration units. Some
Fixed-Bed Platforming Units are constructed with stacked reactors with the intent of
a future revamp to add a CCR unit. Radial flow reactors are constructed one on top
of the other such that catalyst flows by gravity from reactor No. 1 (at the top of the
stack) through to the last reactor (at the bottom).
An additional design criteria of these reactors is that the reactor internals should be
of such manufacturing quality that the catalyst is not damaged while flowing through
the reactor. All surfaces that come in contact with catalyst are designed to be very
smooth.
Process vapors enter the catalyst bed from the vapor space inside the scallops and
flow horizontally through the catalyst bed to the centerpipe. Process vapors then
flow through the centerpipe and out the reactor. Flow through the center pipe can
go either up or down depending on the design (Figure V-5). CCR Platforming units
were originally designed with flow down through the centerpipe, but recent designs
have incorporated an upflow centerpipe. The temperature of the process vapor
drops rapidly in going through the catalyst bed, since the reactions are very
endothermic. Therefore, they must be reheated before they enter Reactor No. 2 to
support further reactions. After reheating, the vapors go to the No. 2 reactor where
the process is repeated.
In the upflow centerpipe design (Figure V-5), the centerpipe is bolted to an internal
expansion joint which in turn is bolted to an internal elbow which is bolted to the
outlet nozzle inside the reactor. The expansion joint has a shroud with a ring that is
used to support the coverplates. The reason the expansion joint is needed is that
during heat-up and cool down, the stainless steel centerpipe will expand or contract
at a different rate than the 1¼ Cr - ½ Mo or 2¼ Cr - 1 Mo vessel walls.
The centerscreen is made up of a profile wire screen placed over a perforated rolled
plate. The screen prevents catalyst from exiting the reactor with the product. The
holes in the rolled plate provide the pressure drop required to maintain good flow
distribution through the catalyst bed.
uop 117108-6 V-3
To help keep the scallops in place, expander rings are used. These rings are made
up out of three or four sections that bolt together. Each ring is supported by lugs
welded to the vessel walls. There are four to five rings from top to bottom in each
reactor.
B. HEATERS
Heaters are used to supply sufficient heat to the combined feed so that the desired
reactions can be obtained with the Platforming catalyst in the reactors. In the overall
reactions, heat is used up, so that the effluent material from each reactor generally
emerges at a lower temperature than the inlet. For this reason, interheaters are
used before each reactor in the chain. Small temperature changes have
considerable effect on the extent of the reactions and, therefore, it is important that
reactor inlet temperatures be maintained at the specified values.
A drawing of a typical UOP Platforming heater appears in Figure V-6. This heater
contains three or four separate cells, each of which heats the combined feed prior to
its entry into individual reactors. A typical refinery heater has a radiant section in
which the radiant tubes are positioned against a refractory wall; the burners are
positioned on one side of the tubes (single fired). The typical Platforming heater
contains tubes that are fired on both sides (double fired). In this manner, the total
tube surface can be better utilized; a double-fired arrangement can allow a 60%
greater heat pickup per length of tube than a single fired arrangement.
Each cell is composed of several tubes connected to inlet and outlet manifolds.
Each tube is arranged in a "U" with burners situated in the center of the "U" and on
either side of the straight lengths of tubes. The center burners are designed to
provide 50% of the total heat load while the burners on either side of the "U" supply
25%.
At design conditions, the Platforming heaters operate at temperatures at or in the

vicinity of the maximum allowable for their respective tube metallurgy. At firing rates
in each cell of 25%, 50% and 25% on the inlet side, center, and outlet side,
uop 117108-6 V-4
respectively, the metal temperatures should be acceptable. If one burner is

removed from service or pinched down, the proper heat distribution would be
disrupted causing the remaining burners to fire harder than initially intended. This
may cause the tubes to exceed their maximum allowable temperatures and suffer
oxidation or a reduction in tube life. The above condition should not pose a problem
for the short-term (periods of burner adjustment or replacement) but should not be
allowed to occur for extended periods.
Since Platforming heaters are designed to operate near or at their maximum

allowable tube wall temperatures, the firing pattern of the burners should be closely
observed, and adjusted if necessary. As in all heaters, but more importantly in such
high temperature heaters, flames impinging on the tubes should be avoided. A
slightly negative pressure at the bridgewall should be present to provide adequate
draft at the burners. If inadequate draft is available at the burners, insufficient air
may be available through the burner to complete combustion. This could cause a
loss of efficiency, ballooning flame dimensions or afterburning. As excess air to a
burner declines below acceptable levels, flame dimensions increase; unburned
hydrocarbon will travel a greater distance to come in contact with oxygen and ignite.
Ballooning flame dimensions can cause a maldistribution of heat or flame

impingement. A further decrease in available air may result in incomplete
combustion. Unburned fuel is useless and lowers efficiency. Unburned fuel can also
ignite in other than burner areas where air can enter the furnace (i.e., tube sheets,
inspection doors). This is known as afterburning and can cause tube damage (if
ignition occurs in tube areas), refractory damage or structural damage.
There are three (or four) gas fired heaters in a typical Platforming unit, one charge
heater and two interstage heaters. Each heater is a radiant-convection, box-type
heater with U-type process tubes. This design provides a low pressure drop across
the heaters. Feed passes through the radiant section only. Waste heat is recovered
in the convection section generally for steam generation or column reboiling. The
charge heater and the Interheaters all share a common convection section. See
Figure V-7.
uop 117108-6 V-5
Each heater is equipped with fuel gas-fired burners mounted on the end walls of the
heater box. Fuel gas flow to the burners is generally adjusted by a TRC controlling
heater outlet/reactor inlet temperature. A snuffing steam connection is provided on
each heater for purging out any combustible gases from the firebox before lighting
pilots during startup, after the burners are shut off, and during an emergency.
Additional comments on the reheat section can be found in Section IV.
Due to the high temperatures required in the reactors, the heater tubes in the
radiant section are usually constructed from 9 Cr-1 Mo. In the convection section,
some of the hot oil tubes have fins or studs for better heat transfer. Because most
heaters fire only fuel gas, permanent soot blowers are not provided for regular
removal of soot from the fins and studs. Generally, frequent soot removal is
required only if fuel oil is burned.
Draft through the heater is controlled by dampers located in the stack above the
convection section. Draft gauges (vacuum gauges) are installed in the radiant
sections, convection inlets, and before and after the dampers to monitor draft
through the heater. A negative pressure must be maintained for safe, efficient
heater operation.
C. HEAT EXCHANGERS
Heat exchangers are used to heat and cool many streams in the Platforming Unit.
Each Platforming unit has combined feed/effluent exchanger(s). This exchanger is
either a shell and tube type or welded plate type, Figures V-8 and V-9, respectively.
The combined feed/effluent exchangers (CFE) allow the hot effluent of the last
reactor to add heat to the Platforming feed before the first heater. The last reactor
effluent is then cooled further so that hydrogen can be separated from the unit
product reformate. The last reactor effluent is condensed by an air cooler and trim
cooler.
uop 117108-6 V-6
D. RECYCLE COMPRESSORS
All Platforming units have one or more recycle compressors. The recycle
compressor circulates hydrogen-rich gas through the Platforming reactor circuit.
Without hydrogen circulation, large amounts of coke will form on the catalyst that
will prevent the desired catalytic reactions. It is important to maintain recycle gas
flow when feed is being charged to the unit. Platforming recycle compressors can
be either reciprocating or centrifugal type with centrifugal most common.
E. PUMPS
There are many types of pumps used in the Platforming unit. Generally, centrifugal
pumps are used to supply feed to the reactor section. Proportioning pumps are
used for chemical injection. High head pumps such as a multi-stage are used to
pump the Separator liquid into the Recontact Section which is at a much higher
pressure than the Separator.
F. PRODUCT SEPARATOR AND RECONTACT DRUM
All catalytic units having a recycle gas stream will have a low pressure separator. A
low pressure separator is designed primarily to separate hydrogen from
hydrocarbon. There are one or two nozzles on top of the Separator. In the case of
two nozzles, one nozzle routes hydrogen rich recycle gas to the Recycle
Compressor. The other nozzle routes hydrogen rich net gas to the first stage
suctions of the Net Gas Compressor. Some unit designs use the recycle gas
compressor as the first stage of net gas compression. In this case there is a single
nozzle for the total gas outlet.
One of the basic components of the separator is a mesh blanket used as a demister
pad and which is constructed of Monel. It is enclosed in a horizontal baffle in the top
of the separator to coalesce, or help remove entrained hydrocarbon droplets from
the gas stream. There is an inlet distributor, generally located somewhere in the
uop 117108-6 V-7
middle of the vessel, and it will help to distribute the gas evenly through the entire
vessel. A level glass shows the hydrocarbon level. A level controller will control the
flow of hydrocarbon from the separator to the separator liquid pumps. Maintaining a
liquid seal in the bottom of the separator is important.
The liquid outlet line will generally have a vortex breaker. In the cases where liquid
is pressured out, there is no vortex breaker required. Because there will be some
corrosive products, the vessel will be made of killed carbon steel.
The Recontact Drums are essentially the same design as the Separator but
generally smaller in dimension.
G. NET GAS COMPRESSORS
All Platforming units have one or more net gas compressors. The hydrogen-rich gas
from the Product Separator which is not recycled back to the Platforming reactor
circuit via the recycle gas compressor (i.e., the hydrogen which is produced in the
Platforming reactors) is exported from the unit via the net gas system. This excess
hydrogen is compressed in the net gas system and exported to the plant hydrogen
header. Platforming net gas compressors can be either reciprocating or centrifugal
type with reciprocating most common. The main user of this hydrogen is the
Naphtha Hydrotreating Unit. Some units incorporate a purification unit downstream
of the net gas system to increase the hydrogen purity of the net gas stream.
H. CHLORIDE TREATERS
In order to remove the HCl in the net gas, a chloride treater is installed. Chloride
treaters are carbon steel vessels containing a bed of activated or promoted alumina.
The chloride is absorbed onto the alumina. Net gas flows from the Recontact Drum
downflow through the chloride treater. The outlet of the treater should be sampled
about once a week to check for HCl breakthrough.
uop 117108-6 V-8
I. DEBUTANIZER/DEPENTANIZER
When the Platforming Unit is operated in the gasoline production mode, this column
will act as a Debutanizer. The Debutanizer is used to control the vapor pressure of
the gasoline by fractionating all but a predetermined amount of C4s (butanes)
overhead. The amount of butane left in the gasoline will help determine the vapor
pressure of the gasoline.
In aromatics production mode, the column will act as a Depentanizer. The

Depentanizer will remove C5s (pentanes) overhead so that the bottoms of the
column will contain essentially all C6 material.
J. OVERHEAD RECEIVER
All fractionating columns have receivers to collect condensed overhead vapors. An

overhead receiver can be the same diameter as the column. Generally, the tangent
length of the receiver will be three times the diameter. The inlet has a distributor,
slotted to permit proper mixed phase distribution. The hydrocarbon outlet line has a
standpipe. The standpipe will permit a small liquid level but relatively large inventory
of water to build in the overhead receiver before it would enter the hydrocarbon
outlet line. There is a level glass and a level control bridle nozzle for the
hydrocarbon phase. There is a gas outlet nozzle to permit non-condensable gas to
go overhead and a valve is provided to permit the gas to be sent to flare, if
necessary. If the system is totally condensing, the column pressure controller would
be on the overhead vapor stream before the condenser.
A hydrocarbon drain with a vortex breaker is used on the hydrocarbon outlet line to
protect net overhead and reflux pumps. The material of construction on this vessel
is the same as would be used on the stabilizer column, killed carbon steel.
The overhead receiver design temperature is much higher than its operating
temperature. The receiver is designed to withstand temperatures that may develop
if the overhead condenser should fail.
uop 117108-6 V-9
K. FUEL GAS DRUM
A fuel gas drum is a vessel under pressure, designed to remove condensable

material. A Monel mesh blanket is installed to remove entrained liquid. The liquid
that gets knocked out can be drained manually to the relief header.
L. SULFUR GUARD BED
The sulfur guard bed adsorber is designed to remove from liquid Platforming Unit
feeds low levels of recombination-type sulfur compounds by chemisorption. At
ambient temperatures, adsorption is usually caused by intermolecular forces
(physical adsorption) rather than by formation of new chemical bonds. At higher
temperatures, above 400ºF, the activation energy is available to make or break
chemical bonds, and if such a mechanism prevails, the adsorption is called
chemisorption.
Typically, the adsorber feed should contain no more than 10 wt. ppm sulfur. Higher
values up to 20 wt-ppm might be considered, depending on the situations
economics. The adsorber product stream will contain usually wt. ppb of sulfur.
The guard bed is not intended to replace or augment the desulfurization normally
done in a Naphtha Hydrotreater. While H2S and mercaptans can be removed,
thiophenes and other such sulfur compounds that survive hydrotreating are not. The
adsorber will also not successfully remove sulfur compounds above a 350-360°F
boiling point.
The liquid adsorber might be installed in the following instances:
1. When a hydrotreated feedstock is the sole source of feed to the Platforming

Unit.
2. When there are numerous stripper section upsets in NHT unit.
uop 117108-6 V-10
3. When feed contains typically more than the UOP maximum of 0.5 wt. ppm
sulfur. These sulfur compounds must be recombination types, H2S or
mercaptan. Better NHT and stripper operation may resolve this problem,
however, without resorting to a guard bed.
4. On a hydrocracked naphtha stream being used as all or part of the

Platforming Unit feed and where sulfur is present as H2S and mercaptan.
This option represents the most current practical application.
In every case, careful analysis to situation and type of sulfur compounds in the
Platforming Unit feed is necessary prior to considering a guard bed installation.
ADS-11L is a 0.0625" (1.59mm) diameter extrudate containing approximately 58

wt.% nickel. To retain stability for shipping and handling, ADS-11L is sold in a partly
reduced, partly oxidized state. ADS-11L cannot be sold 100% prereduced. The high
nickel content makes it unstable when exposed to air.
Normally, two guard bed adsorbers would be installed with piping arranged so that
feed flow is always downflow. The vessels may be valved for either parallel or
series flow. Series flow is performed because the second bed will check
breakthrough of sulfur from the first bed and permit continuous operation while
reloading with fresh absorbent. The guard beds are normally located after the
Platforming Unit charge pump but before vessel circuit.
uop 117108-6 V-11
Center
117108 V-1
F.B. Plat
Line
D = Bed Depth
Distributor
D/2
D/2
Spherical Reactor Design
1/16” Catalyst
Figure V-1
1/8” CSM
3/4” CSM
1/4” CSM
3/4” CSM
1/4” CSM
uop 117108-6 V-12
Figure V-2
Downflow Reactor Design
Inlet
Inlet distributor
Catalyst
1/4” (6 mm) and
3/4” (19 mm) CSM
Elephant stool
Unloading nozzle
Ceramic balls (CSM)
and valve
1/8” (3 mm)
1/4” (6 mm)
3/4” (19 mm)
Outlet screen Outlet
F.B. Plat
117108 V-2
uop 117108-6 V-13
Figure V-3
Radial Flow Reactor
Internally Insulated - Cold-Wall Reactor
Concrete
insulation
Inlet distributor
Deflecting baffle
Shell
3/16” Liner
Mineral Perforated scallop

fiber
Mineral fiber
F.B. Plat
117108 V-3
uop 117108-6 V-14
Figure V-4
Radial Flow Reactor Design
Coverdeck
Scallops
Shield Catalyst level
3/4” (19 mm) CSM

Seal and slump
1/4” (6 mm) CSM catalyst
Center pipe
1/4” (6 mm) CSM
Ceramic fiber
F.B. Plat
117108 V-4
uop 117108-6 V-15
Figure V-5
Stacked Radial-Flow Reactors (Rx #2 Shown)
Downflow Centerpipe Upflow Centerpipe
Manway
Reactor #2 Feed
Reactor #2 Feed
Reactor #1 Effluent Manway Reactor #2
Effluent
Centerpipe
Expansion
Scallops Bellows
(or outer
Catalyst Scoops baskets)
or Flow Cones
Expansion
Annular
Bellows Reactor #3 Feed Catalyst
Withdrawal
Reactor #2 Effluent Reactor #3 Feed
Catalyst
Transfer Lines Reactor #3
Effluent
= Hydrocarbon Flow
F.B. Plat
117108 V-5
uop 117108-6 V-16
Figure V-6
Vertical Heater
Stack
Damper
Sample Connection DGC
Inlet from Process
Convection Section
Tube Pulling Door Heating Tube
Cross Over
Tube
Radiant Section
Heating Tube
Snuffing Steam Snuffing Steam
Outlet Cast Burner

Burner Block
F.B. Plat
117108 V-6
uop 117108-6 V-17
Figure V-7
Platforming Heaters
U-Type Tubes with Common Firebox
Header
Burners
Process
Firewall
Coils
Interheater No.2
Charge Heater Interheater No.1
F.B. Plat
117108 V-7
uop 117108-6 V-18
Figure V-8
Vertical Combined Feed Exchanger
Tube Outlet
Shell Inlet
Girth Flange
Shell
Tubes
Tubesheet
Orifice Distributor Plate

Expansion
Bellows Shell Outlet
Drain - must be at the lowest

point in the shell cover Tube Inlet
F.B. Plat
117108 V-8
uop 117108-6 V-19
Figure V-9
Packinox Welded Plate Combined Feed Exchanger
New uop
uop PACKINOX Design
Coventional
Exchanger Duty,
MMBTU/hr (GJ/hr) 145 (153) 145 (153)
Surface Area, ft2 (m2) 54896 (5100) 39827 (3700)
Plot Area, ft2 (m2) 1076 (100) 807 (75)
Bundle Height, ft (m) 65.6 (20) 32.8 (10)
Total Weight, Tons (MT) 82 (74) 36 (33)
Installed Cost, (1988) MM$ 2.5 1.7
Cold End Approach, °F (°C) 45 (25) 45 (25)
Tube / Plate Length, ft (m) 54 (25) 35 (10.7)
Weight, Tons (MT) 159.8 (145) 45.2 (41)

Maximum Throughput Per Shell,
bbl/day (m3/hr) 18,000 (120) 30,000 (200)
F.B. Plat
117108 V-9
uop 117108-6 V-20
Fixed-Bed Platforming - General Operating Manual Commissioning
VI. COMMISSIONING
During and following the final stages of construction, a large amount of pre-startup
preparatory work on the Platforming Unit must be done by operating personnel in
cooperation with others at the job site. These activities should not be treated lightly.
Careful and thorough preparatory work is a prerequisite for satisfactorily unit
performance and a trouble-free, on-schedule startup. In addition, performance of
this work will enable operating personnel to become familiar with specific pieces of
unit equipment.
The primary scope of the preparatory work should be directed toward ensuring that
unit construction was done exactly as specified by the Piping and Instrument
drawings, detailed drawings, standard specifications and project specifications. The
installation, orientation, and cleanliness of vessels, vessel piping, vessel internals
and linings should be checked carefully. Particular attention should be given to
exchanger supports, piping, reactor transfer piping, ladders and service lines to
insure that there is sufficient room for expansion once the unit is heated up. All
rotating equipment, i.e. compressors, fin fans, pumps, etc. should be checked for
correct piping, speed instrumentation, rotational direction, horsepower requirements
and construction material. Unit safety and operability should always be kept in mind.
Generally, a representative of UOP will be on site to observe, advise and aid
operating personnel with this preparatory work, especially the inspection phase.
This section covers the work required in preparing the unit for operation, i.e.,
readying for oil-in, prior to its first startup. Most of the items may be considered as
construction details, in as much as they are generally carried out only once.
Subsequent plant startups will not require these checks. After major turnarounds,
however, it may be necessary to repeat some procedures.
uop 117108-6 VI-1
A. FINAL VESSEL INSPECTION
All vessels should be inspected before final closure for conformity to design details
as specified in the unit project specifications.
After this mechanical inspection and any necessary repairs have been completed,
i.e., all internal dimensions, nozzle and distributor orientations, tray specifications,
downcomer orientation, weir heights, reactor internals, vortex breakers, vortex
risers, thermowell locations, sight glass baffles, etc. meet specifications, a final
check should be made for completeness and cleanliness prior to final vessel
closure. Extreme care should be taken to ensure that no foreign materials, i.e. tools,
rags, trash, scaffolding, etc., are left in the vessels.
1. Reactor Preparation Introduction
Inspection, preparation, and loading of the Platforming reactors are three very
important activities. They are important because they help ensure that the reactors
and the catalyst will perform as expected after startup.
To do these activities correctly, the refinery personnel must:
a. Pay close attention to the reactor design drawings.
b. Be sure all materials used in the reactors meet or exceed design

specifications.
c. Plan ahead carefully.
d. Work effectively.
e. Load catalyst properly.
uop 117108-6 VI-2
There are recommendations in this section for the inspection and preparation
activities of the Platforming reactors. These recommendations cover four general
process areas of inspection, including checks on:
a. critical dimensions,
b. catalyst containment,
c. surface smoothness (more important for CCR application)
d. cleanliness.
These areas are important for the performance of the reactors and the catalyst. But
these areas do not cover the scope of a complete mechanical inspection of the
reactors. These checks are written with the assumption that a thorough mechanical
inspection has been done already.
In this section, many aspects of inspection, preparation, and loading of a

Platforming reactor area covered in some detail. It must be understood that these
are general procedures and are not meant to strictly apply to one particular reactor.
The purpose in preparing these procedures is to assist the refiner in developing
more detailed procedures for his particular unit.
The dimensions and tolerances cited are typical and may not apply to all reactors.
Those shown in the UOP Project Specifications take precedence over any cited
herein.
2. Radial-Flow Reactor Inspection and Preparation (Before Reaction

Section Dryout)
a. Check that all shipping supports are removed, including:
(1) Tie bolts on expansion bellows.

(2) Bracing rings around scallops.
(3) Centering supports for centerpipe.
(4) Stiffening I-beams for shell.
uop 117108-6 VI-3
b. For upflow centerpipe reactors only, check the centerpipe support for:
(1) No burrs and weld slag on the catalyst baffles and nozzles.
(2) Good condition of gasket between support and bottom head
(3) Proper tightness of support ring bolts. Bolts should be double-
nutted beneath.
(4) Washers under the top nuts in good condition and covering bolt
holes.
(5) Tightness of centerpipe holddown bolt. Nut and bar stop should
be tackwelded at top, and bolt should be double-nutted at
bottom.
c. For downflow centerpipe reactors only, check the centerpipe split ring
assembly for:
(1) Good condition of gasket between split ring No. 2 and bottom
head.
(2) Good condition of gasket between halves of split ring No. 2.
(3) Good condition of gasket between split ring No. 2 and
expansion joint flange.
(4) Proper tightness of all bolts of split rings.
(5) Proper assembly of split rings No. 1 and No. 3 inside
centerpipe base.
d. Check the centerpipe for:
(1) No distortion of wires.

(2) No cracked welds between sections of centerpipe screen. No
sharp edges or burrs.
(3) Slot openings should be 0.61 mm +/- 0.05 mm (0.024 +/- 0.002
inches). Maximum is 1.0 mm (0.040 inches). Minimum is 0.46
mm (0.018 inches).
(4) Verticalness (plumbness).
uop 117108-6 VI-4
(5) For upflow centerpipe reactors only: Gap between centerpipe

base and centerpipe support. Minimum gap should be less than
1.0 mm (0.039 inches), except there should be no metal-to-
metal contact. Maximum gap is 4.0 mm (0.157 inches). Good
gasket condition.
(6) For downflow centerpipe reactors only: Gap between
centerpipe base and split ring No. 2 should be less than 1.0
mm (0.039 inches).
(7) For downflow centerpipe reactors only: Centerpipe manway
gasket seated correctly.
(8) For downflow centerpipe reactors only: Centerpipe guide collar
or pipes not binding.
(9) Proper number, arrangement, and size of centerpipe holes.
Screen support bars should not block centerpipe holes.
(10) Top of slot openings in centerpipe should be at some elevation
as top slots in scallops.
(11) Cleanliness. No plugging of slots and holes.
e. Check scallops for: (if applicable)
(1) Straightness. Fitup distance from scallop to the reactor wall

should be less than 12.7 mm (0.5 inches).
(2) No cracked welds between sections of scallop. No sharp edges
or burrs. Good, smooth welds with minimum offset.
(3) Equal spacing of scallops. Tackweld (one per scallop) to
scallop support ring (on one side only). Levelness of support
ring.
(4) Slot openings should be 1.0 mm x 12.7 mm (0.040 inches x
0.500 inches) spaced 15.9 mm (0.625 inches) on end centers
and 3.2 mm (0.125 inches) on side centers.
(5) Cleanliness. Keep risers covered during inspection and
preparation activities.
uop 117108-6 VI-5
f. Check the expander rings for: (if applicable)
(1) No warping of ring sections. No cracked welds.

(2) Position the joints of the expander ring sections in-between
scallops.
(3) Do not overtighten the expander rings. Once the scallops are fit
up to the reactor wall, the recommended ring tension is so the
gap between the ring and all scallops is 1.6-4.8 mm (0.0625-
0.1875 inches).
g. Check outer basket screen for: (if applicable)
(1) No distortion.
(2) Slot openings should be 0.64 mm +/- 0.13 mm (0.025 inches
+/- 0.005 inches).
(3) No cracked welds between sections of screens. No sharp
edges or burrs. Good, smooth welds with minimum offset.
(4) Verticalness (plumbness).
(5) Remove shipping bolts from bottom flange. Replace with
shoulder bolts, washer and nut. Nut should be only finger tight.
(6) Measure the gap between outer basket bottom flange and the
base ring (for the record).
(7) Cleanliness. No plugging of slots.
h. Check the outlet lines for:
(1) Expansion joint and shroud should be specified length.

(2) Lateral offset of expansion joint should be minimal.
(3) Proper fitup of miter elbow.
(4) Internal sleeve of expansion joint in place.
(5) Proper tightness of bolts and seating of gaskets.
uop 117108-6 VI-6
i. Check the ventilation screens for:
(1) Slot openings should be 0.89 mm +/- 0.13 mm (0.035 inches

+/- 0.005 inches).
(2) Cleanliness. No debris behind ventilation screens or plugging
slots of screens.
j. Check the coverplate for the following:
(1) Good coverplate fitup. Wedge pins or bolts tight. Gaps between
sections should be less than 1.0 mm (0.040 inches). INSURE
THERE ARE NO “LINE OF SIGHT” OPENINGS IN
COVERDECK TO CATALYST BED.
(2) Seal plates flat. Gaps between seals plates and coverplates
should be less than 1.0 mm (0.040 inches). Tackwelds not
broken.
(3) Clearance between seal plates and risers should be 0.61 mm
+/- 0.10 mm (0.024 inches +/- 0.004 inches). (Each riser and its
seal plate is a machined pair.)
k. For upflow centerpipe reactors only: Remove bottom head from

integral catalyst collector. Replace after checking for:
(1) Position and centering of distributor.

(2) No burrs and weld slag.
(3) Cleanliness.
l. Measure critical reactor dimensions including but not limited to:
(1) Reactor I.D. and tangent length.

(2) Overall length of screen wire openings of centerpipe.
(3) Overall length of slot openings in either scallops or outer basket
screen, whichever applies.
uop 117108-6 VI-7
(4) Distance from bottom of coverdeck to:

(a) shoulder of scallop
(b) top of centerpipe slots
(c) top row of scallop slots
(5) Riser height.
(6) Centerpipe O.D.
(7) Catalyst bed width from centerpipe O.D. to either scallop face
or outer basket screen, whichever applies.
(8) Centerpipe centering with the catalyst bed.
(9) Outer basket screen centering without the catalyst bed (if
applicable).
(10) Overall dimensions of slot openings in ventilation screens.
(11) Catalyst collector I.D. and tangent length (if applicable).
m. Check for correct metallurgy:
(1) Bolts and nuts for internal flanges on process elbows,

centerpipe, expander rings, transfer pipes, etc.
(2) Coverplates, wedges, seal plates, expander rings, etc.
n. Check for correct gasket materials for all flanges.
o. Reinstall coverplate sections and transfer pipes with the correct

gaskets, nuts, and bolts.
p. Remove all debris from coverplate, reactor heads, inlet nozzles, and
from inside scallops.
q. Close all reactor manways and prepare for reaction section dryout.
r. Based on actual reactor measurements, compute the following:
(1) Reactor catalyst volumes.
uop 117108-6 VI-8
(2) Available catalyst seal heights. Advise UOP immediately of

discrepancies compared to design values.
(3) Total reactor catalyst volume.
(4) Mechanical and thermal slump expected on startup.
B. CLEANING AND SERVICING OF UTILITIES SYSTEMS
Following construction, the various utilities such as steam, cooling water, air, etc.
must be put in service. Prior to commissioning, the various lines must be tested for
leakage and cleared of debris and construction trash. The latter may be done by
water circulation and steam or air blowing techniques, depending on the particular
utility service. Such techniques are generally described below for each type of utility
system.
1. Steam Lines
Once steam is available in the refinery, the steam system can be warmed up and
blown free of all debris. Before putting steam into the system all steam traps, control
valves, turbines, heaters, instruments, vacuum ejectors and strainers should be
removed or blanked off from the system. The steam headers, one header at a time,
should be slowly warmed up while expansion of the line is observed. Special
attention should be given pipe support shoes. Condensate must be drained
manually as it forms to prevent steam hammering.
When the headers are warm, the drain and vent valves should be opened and the
lines blown vigorously for a few moments before reclosing the valves. This
procedure should be repeated 5 to 10 times to move material along the headers to
the drains. On lines leading to turbines special attention to detail is critical. All debris
including scale must be removed from these lines otherwise there will be damage to
the turbine blades. Blow these lines clean using high velocity steam and alternative
the temperature of the lines so scale on the pipe walls is removed. Usually a lead
impingement plate is installed at the opening where the steam is being vented.
When no indents are noted on the plate the line is clean.
uop 117108-6 VI-9
Also care must be taken that debris or scale is not blown into a line that has already
been cleaned. Condensate lines may be cleaned in the same manner as steam
lines, but close observation of the pressure on the condensate line is necessary
since the working pressure and temperature of the condensate lines is generally
lower than that of the steam headers.
When blowdown of the steam system is complete, traps and other equipment that
were removed prior to the blowdown may be reconnected. Steam turbine alignment
should be rechecked. The system can then be reheated and placed in service.
2. Cooling Water Lines
Cooling water lines should be flushed with makeup water. Cooling water tanks or
pits should be thoroughly cleaned by hose and by hand, if necessary, before they
are filled with clean water. Suction strainers of 20 mesh should be installed in the
pump suctions. This screening can generally be fitted around a 5 mesh permanent
pump suction screen. All coolers, condensers, sample coolers, lube oil coolers at
pumps and cooling water to case jackets of rotational equipment should be
disconnected from the system. The inlet lines should be flushed, one at a time,
using flow from the cooling water pumps. When all inlet lines are flushed, reconnect
the lines. Disconnect the cooling water outlet line from the user. Flush through the
users; then reconnect the outlet lines. When all outlet lines are connected, flush the
return line.
3. Plant Air System
Clean out the plant air blower(s) suction lines. Disconnect the blower discharge(s)
line from any downstream equipment; i.e., driers, oil separator, exchangers. Start
the blower(s) and verify it works correctly. At the same time the discharge line is
blown clean. Shutdown the blower(s) and reconnect the lines. Restart the blower(s),
pressure up the entire blocked in plant air header and start blowing down each
header one at a time starting with the main header. Then do each branch header
individually. Do not blowdown any lines through instruments or equipment. Always
disconnect and make sure the line is clean to that point before moving on.
uop 117108-6 VI-10
4. Instrument Air Lines
Disconnect the air line from the instrument air regulators. Remove any other
regulators from the line. Blow down each individual air line, then make up the line.
5. Raw Water
Raw water lines to safety eyewashes, showers, drinking fountains should be flushed
then left running to remove and dilute any harmful substance. Analyses of the water
should be made at points of human consumption to ascertain whether the water is
fit for human consumption.
6. Firewater and Sprinkler Systems
After removing all nozzles, each fire hydrant and monitor should be flushed. Since
this may be the first time the firewater pump has operated, the pump s operation
should be observed carefully. Replace all monitor nozzles when flushing is
complete. Before flushing sprinkler systems remove all sprinkler heads; then flush
the entire system. When clean, replace heads. Inspect each head before installation
to make sure it is clean. Try each piece of equipment with its head installed.
7. Fuel Gas Lines
The fuel gas lines may be blown clear with steam. All regulators and control valves
should be rolled out of the lines prior to such blowing. All gas burners piping should
be opened. Once the main fuel gas system has been steam blown (start from the
knockout drum and work out). Steaming may then be resumed up through the
burners to check their orientation and confirm that all nozzles are free and clear.
The entire system should then be air dried before replacing regulators and control
valves. Care must be taken during both the steam blowing and the air drying not to
exceed the relief valve settings.
uop 117108-6 VI-11
8. Fuel Oil System
The fuel oil system may be blown clean with steam, however all condensate
introduced must be removed before it is put in service. All regulators, control valves,
and atomizing steam pressure taps should be first rolled out or isolated. All oil guns
should also be disconnected. The system should be steamed until it is clean and
hot. The fuel oil guns may then be reconnected and steamed up through. Following
steaming, the entire system should be air dried. A similar procedure may be used
on the atomizing steam system.
C. HYDROSTATIC PRESSURE TESTING AND FLUSHING OF LINES AND

EQUIPMENT
1. Hydrostatic Pressure Testing
Hydrostatic pressure testing of the unit after final construction completion to prove
the strength of the materials and weld integrity is normally the contractor’s
responsibility. The hydrostatic pressure test is made by completely water filling the
equipment to be tested and increasing the pressure to 1½ times the design
pressure of the lowest pressure-rated piece of equipment in the circuit being tested.
For a successful test, the system loss should not exceed 2% of the test pressure
per hour. If the system fails the test, i.e. has a greater loss than 2%, evidence of
water at flanges, welds, pipes, etc. will indicate the leaking areas to be repaired.
NOTE: Hydrostatic pressure testing should not be confused with the less severe
“tightness test” that will be conducted generally by operations personnel during leak
checking.
Hydrostatic pressure testing the entire unit and all of its equipment simultaneously is
normally not practical. Generally, therefore, the unit will be divided into sections as
governed by the location of the various items of equipment and the test pressures to
which each item will be subjected. Suitable blinds must be made up for insertion on
nozzles and between flanges to isolate the various sections of equipment as
uop 117108-6 VI-12
required. Normally, the exchangers, receivers, etc., for the various towers will be
tested together with the main vessels. Test pressures will be determined from the
pressure vessel summary for the unit. During pressure testing, all safety valves
must be blinded off, since normal relieving pressure will be exceeded.
In general, Platforming Unit reactor sections utilizing stacked reactors are not field
hydrostatically tested because of structural support considerations and the
probability of internal reactor system damage. The reactor vessels should have
been shop tested hydrostatically by the manufacturer. Since the Platforming Unit
stacked reactors are housed in the same vessel shell, if field hydrostatic testing is
desired, precautions must be taken to prevent overstressing or rupture of the
intermediate heads and expansion joints, which are generally designed only for a
maximum differential pressure of 16 psig (1.1 kg/cm2).
If the stacked Platforming reactors are to be pressure tested, it probably will be

most convenient to test the reactors and the heaters in one group. As the heaters
are normally tested at a higher pressure (code hydrostatic testing) than the
reactors, the simplest method is to blind off the heaters, test the heaters first, and
then test the entire system at the reactor test pressure. Blinds can be provided with
connections for the introduction of water for testing and for venting of air as the
system is filled with water. It may be necessary to use thermowell connections and
pressure taps for additional vents in the reactor system.
General guidelines for hydrostatic testing are:
a. An air pressure test may be placed on the sections of the plant prior to
hydrostatic pressure testing so that any open lines or flanges may be
located and repaired before the test.
b. All equipment in the section of the plant to be tested should be rated

for the test pressure.
c. The test pressure gauge should be installed at the bottom of any

vessel to include any liquid head effects.
uop 117108-6 VI-13
d. Differential test pressures between the tube and shell side of all heat
exchangers, coolers, condensers and combined feed exchangers
must be taken into consideration and proper testing procedures used.
Generally, both the tube and shell side are raised to the lowest test
pressure at the same time. Then while maintaining the lower test
pressure on its respective side the higher test pressure is developed
and maintained on its respective side. Any equalization of pressure
indicates a leak.
e. Safety valves, relief valves, and rupture disks must be isolated or

removed from the tested system, since their normal relieving pressure
will be exceeded.
f. If the safety and relief valves are removed, the time during the
hydrostatic test period can be utilized to bench test and set the valves.
g. The sections of the plant to be pressure tested must be isolated from

the remainder of the unit by blinds inserted between flanges. Blinds
must be rated for the test pressure.
h. All spring hangers should be in the pinned position. Piping should be

checked to ascertain if there is sufficient support to withstand the
weight of water.
i. All vessel foundations must be checked to ensure their ability to

support the vessel when full of water.
j. Hydrostatic pressure testing should not be carried out at vessel wall

temperatures below 60°F (15°C), to prevent metal embrittlement. If
necessary, the testing medium should be warmed to attain this
temperature.
uop 117108-6 VI-14
NOTE: Sometimes because of ambient temperature considerations or unit dryness

considerations, it is advantageous to use naphtha instead of water for testing. Of
necessity, this procedure should be reviewed with regard to safety procedures and
expected benefits at the time of the initial startup.
k. The water used must be clean and contain less than 50 wt-ppm
chloride.
l. Never include compressors or pumps in the hydrostatic pressure test.
2. Lines and Equipment Flushing
Upon completion of final mechanical inspection of the unit for variations from design
specifications, the unit is handed over to the operations group. One of the first tasks
they have to do beside familiarizing themselves with the unit is flushing. During
flushing all piping and equipment not previously cleaned is flushed with clean water
(typically). All reactors, vessels and heaters have already been cleaned as part of
the final mechanical inspection. While it is all right and even desirable to flush
through these pieces of equipment special care should be taken that no trash is
flushed into them. Always flush away from vessels.
If desired the pumps that can operate on water can be run-in after most of the trash
has been removed from the piping.
Just like during hydrostatic testing the water used must be clean and contain less
than 50 wt-ppm chloride.
NOTE: No water flushing should be carried out in the compressors the compressors
should be blinded off at the suction and at the discharge before line flushing is
started.
uop 117108-6 VI-15
The following guidelines are generally observed for flushing operations:
a. All possible lines should be used during the flushing operation to

facilitate complete system cleanout.
b. The fire water system should be flushed first and can be used to
supply water for flushing the rest of the plant.
c. Flush pump suction and discharge lines while disconnected from the
pump casing.
d. Screens should be placed in the suction lines of all pumps before any
liquid is allowed to pass through them. If this is not done, scale, weld
metal or slag, stones, etc., may freeze or damage centrifugal pump
impellers. The screens also act to trap such dirt in a place where it can
be conveniently removed. The screens should be placed in a flange
between the suction valve and the pump so that the screen may be
removed without depressuring any vessels. The flow through the
screen should preferably be downward, or horizontal. Precautions
should be taken to place the screen in a location where the dirt
particles will not drop into an inaccessible place in the line when the
flow through the pumps is stopped. If this should happen, it would not
be possible to remove the dirt upon removal of the screen.
e. When practical, lines should always be flushed away from a vessel

rather than into a vessel. Any vessel flushed into, should be opened
and manually cleaned following flushing.
f. Always flush from highest elevation to lowest elevation.
g. Vessels and systems must be vented when filling or emptying. This is

especially true for towers not rated for vacuum or high pressure.
uop 117108-6 VI-16
h. All lines not flushed by vessel drainage or pump circulation must be

flushed independently.
i. In flushing, maximum volume and velocity should always be used to

insure thorough cleaning. Regulate rate of flushing medium at the
source.
j. Control valves and thermowells must be the piping system during

flushing to prevent damage.
k. Orifice plates should only be installed after flushing is completed.
l. Instruments, i.e. pressure gauges and transmitters, differential flow

meter transmitters, moisture and other inline analyzers, etc., must be
isolated from the system during flushing.
m. Flush through all drains and vents to check for blockage.
n. Where possible, flush through open end lines. Do not restrict flow.
o. Flush lines in the following sequences where possible; first, the main
header; second, each lateral header; and third, each branch line.
p. Always flush through a bypass to an open end before flushing through

equipment.
q. Do not flush lines into exchangers. Spread the inlet flange, cover the
exchanger nozzle and flush the line clean. If flushing through an
exchanger is necessary, open the exchanger and clean when flushing
is complete.
r. Continue flushing each line or piece of equipment until the exiting

water is clear.
uop 117108-6 VI-17
s. Use a unit piping flow diagram as a cleaning checkoff record to ensure

that all lines are flushed including lines to and from tankage. This
helps ensure that a line that has already been cleaned is not
contaminated by later flushing a dirty line into it.
t. Avoid flushing from a large pipe to a smaller one. At the completion of

the flushing operations, keep the water in the unit to facilitate pump
run-in if this was not done during the flushing operation. If pump run-in
has been completed or is not to follow the flushing operation
immediately drain all water from the unit. When necessary, break
flanges at low spots to facilitate drainage and air blow as required to
remove as much water as possible. All orifice plates should be
installed in the lines at the end of this step or step D as is convenient.
They must all be installed prior to leak checking.
D. INSPECTION AND RUN-IN OF PUMPS AND FANS
Prior to unit startup, all pumps and air cooler/condenser fin fans must be thoroughly
checked and properly broken in to insure trouble free performance once the plant is
in operation. This may be accomplished in connection with flushing, if convenient.
1. Pump Inspection
All centrifugal pumps should be inspected and run-in by techniques similar to the
following guidelines.
a. Check to see that all necessary water piping has been made to
stuffing boxes, bearing jackets, pedestals and quench glands. Ensure
that all necessary lube oil piping is installed, and that this piping is not
mistakenly connected to the water system.
uop 117108-6 VI-18
b. Check arrangements to vent the pump for priming, if the pump is not
self-venting. See that special connections such as bleeds and drains
are properly installed.
c. Check strainers in pump suction lines. Strainers must be installed

before aligning pumps. A three or five mesh strainer is provided for
each pump suction line during startup. To avoid pump damage during
flushing with water, the strainers should temporarily be lined with 20
mesh screen, or as specified by the pump manufacturer. Remove this
screen after water flushing is completed. All strainers should be
flagged, and a list similar to the blind list should be kept, so as to
prevent a “lost” screen from plugging and upsetting unit operation.
NOTE: On new units, the fine mesh strainer screens are sometimes left in service
for the first run on all locations where spare pumps are provided.
d. Check that power or steam is available for running in the pump. Check
that pressure gauges and any special instrumentation are in working
order.
e. Before lubricating oil-lubricated bearings, check bearing chamber in

pumps to see that no slushing compound or shipping grease is left in
the chamber. Mechanical seals should be flushed with water prior to
pump operation.
f. It is extremely important that the proper type and viscosity oil and
proper grade of grease is used to lubricate the equipment. Refer to
manufacturer’s instructions and refinery lubricating schedule for this
information.
g. See that the driver rotates the pump in the direction indicated by the
arrow on the pump casing. Rotate the pump by hand to see that it is
clear before starting.
uop 117108-6 VI-19
h. After lines and vessels have been flushed with water, pumps should
be run in on water. Couple up and align the pumps, then check for
cooling water availability and start flow of cooling water to the pumps
requiring external cooling, before they are run in.
NOTE: Multistage, centrifugal pumps should not be run in with water to prevent
equipment damage.
2. Pump Run-In
a. Open pump suction valve and close discharge valve (crack discharge
valve for high capacity, high head pumps).
b. Flush pump through casing drain and vent to remove any particulate
and ensure that the pump is liquid full.
c. Warm up the turbine of turbine driven pumps without shaft rotation.

Turbines may be warmed up by opening the exhaust valve wide and
bleeding a small amount of steam through the turbine case. Be sure to
condensate-free the steam line first and to drain any condensate from
the turbine case prior to startup.
d. Start pump. If motor driven, pump will come up to speed; if turbine

driven, pump must be brought up to speed as quickly as possible.
Immediately check discharge pressure gauge. If no pressure is
shown, stop the pump and find the cause. If discharge pressure is
satisfactory, slowly open the discharge valve to give the desired flow
rate. Do not run pump with discharge block valve closed, except for a
very short time. Note any unusual vibration or operating condition.
NOTE: Water circulation with motor driven hydrocarbon pumps designed for light
hydrocarbons can result in motor overload. For equipment of this type, pump
capacity must be reduced by throttling the discharge to restrict flow. An ammeter
can be used to determine the required throttling.
uop 117108-6 VI-20
e. Check bearings of pumps and drivers for signs of heating. Recheck all
oil levels. Check stuffing box for heating. Loosen or tighten packing
gland as required. It is desirable to allow considerable leakage in the
stuffing box at the beginning, to permit packing to run-in. Heating of
pump casing may be attributed to internal rubbing.
f. Run pump for approximately one hour, then shut off to make any
adjustment necessary and check parts for tightness. Since it is not
possible to run pump at operating temperature, final check of
alignment must be made during normal operation by switching to
spare pump.
g. Start pump and run for at least four hours. Shut down and pull
strainers. Clean strainers and replace in line.
h. Replace temporary packing (if used) with normal service packing.
3. Air Cooler/Condenser Fan Inspection
Prior to placing the air cooler/condenser fans in operation, the following items
should be accomplished:
a. Check the fan motor for proper rotation and grounding.
b. Set the fan blade pitch to the manufacturer’s specs. Once the fan is in
operation, if motor amperage is too high or low, pitch readjustment
may be required.
c. Set the vibration shutdown switches to give the permitted safe

vibration level.
d. If the fan is belt driven, adjust the drive bolts for proper tension and
check belt condition.
e. Confirm the fan safety shields are in place.
uop 117108-6 VI-21
Once the above items are completed, the fans should be ready for run-in. Note any
unusual vibrations or noise when the fans are placed in operation. Run each fan for
at least four hours to insure a good run-in.
After all lines and equipment have been flushed and all pumps and fans have been
run-in, water should be completely drained from the unit and all lines blown clear
with air. Lines containing low spots should be broken at the low spot, if no drain is
provided. If the vessels are to be left standing for a long period of time before steam
drying or before operation, and inert gas such as nitrogen should be introduced into
the vessels as the water is displaced to prevent rusting of the internals from oxygen
in the air.
E. LEAK TESTING
Leak testing is performed typically with air or nitrogen. It is usually performed on

sections of the unit rather than the whole unit at one time. When leak checking it is
important the personnel involved stay organized and document leaks found. The
easiest way to accomplish this is by flagging any leaks noted and have a repair
team follow closely behind the leak checkers.
1. General Guidelines
The following is a list of guidelines to keep in mind when preparing for and leak
checking.
a. Have on hand a large quantity of soap, squirt bottles and colored

tagging tape. A couple of five-gallon buckets are also needed.
b. Break the unit up into sections to be tested. This way when a leak is
found that cannot be fixed while still under pressure only that section
needs to be depressured. Leak checking on other areas can continue.
uop 117108-6 VI-22
c. STAY ORGANIZED. Start at one end of a section and work your way
through to the other end, checking all flanges, valves, fittings,
instruments, etc.
d. Tag each leak found. Also log the location of the leak on a list to make
it easier for maintenance and the next shift to find it. Maintenance
crews should work along with the leak checking teams as much as
possible.
e. Check pumps and compressors independently. Because they have

packing leaks which could interfere with the pressure gauge check on
the rest of the unit.
f. Use large quantities of soapy water when testing.
g. It is preferable that leak checking be done shortly before startup. This

will minimize the chance of new leaks developing through additional
maintenance.
The following is a generalized procedure to be used when leak checking:
a. Isolate the section of the unit from the rest of the unit to be tested. Do
not add additional blinds to do this. Block valves should be sufficient.
b. Slowly pressure the section to 25 psig (1.8 kg/cm2) with nitrogen or

air. Listen for large leaks or open valves. Walk through the entire
section.
c. Hold at here for 1 hour while monitoring a low range pressure gauge.
If the leaks are minor less than 1 psig should be last, then continue. If
the leak rate is greater than 1 psig check the block valves and blinds
isolating this section from others. Also, start leak checking.
uop 117108-6 VI-23
d. Slowly pressure the section to be tested to 100 psig or design

pressure if less.
e. Monitor an appropriate range pressure gauge for a loss in pressure.
f. Start systematically, leak checking the unit with plenty of soapy water.
g. After all leaks have been repaired and the pressure gauge holds
within 2% of the test pressure for one hour the test is complete.
h. As was mentioned earlier leak check the compressor and pumps

separately. Typically, many small leaks are found on new
reciprocating compressors.
i. Depressure the section rapidly through low point valves to maximize

water removal from the unit.
NOTE: It is very important that a good tightness check be performed. Otherwise

during normal operation hydrogen which leaks out of the unit could result in a
almost invisible flame. Also at a given pressure a hydrogen leak will be greater than
a air or nitrogen leak. Since hydrogen is an important product from the Platforming
Unit any leaks represent a loss in valuable product.
F. RUN-IN OF RECYCLE AND NET GAS COMPRESSORS
The recycle gas compressor is operated to maintain the desired recycle hydrogen
rate to the Platforming reactors. The net gas or booster gas compressors are
operated to provide makeup gas to the Platforming Unit Catalyst Regeneration
section, if installed, and other hydrogen users such as the naphtha hydrotreater,
etc. and the net gas recontact section. Since maintaining these gas flows at all
times is very important, all refinery operating personnel must be familiar with startup
and operation of these compressors. The compressors should be started and
operated according to the manufacturer’s instructions.
uop 117108-6 VI-24
NOTE: Whenever compressors are to be placed in service when the plant contains
hydrogen or hydrocarbons, they must be freed of air before filling with hydrogen.
Before air can be reintroduced into any compressor that has contained hydrogen or
hydrocarbons, the machine must first be isolated, depressured, and purged with
nitrogen.
These compressors can be driven by electric motors, steam turbines, gas turbines,
or gas engines. When steam turbines are used, the exhaust steam may be sent to a
low pressure steam system or may be totally condensed in a surface condenser.
With the turbine exhausting to a surface condenser, the exhaust system operates at
a vacuum created by the rapid condensation of the steam and hence enhances the
operating efficiency of the compressor. Any inert gases present are expelled
through steam-jet ejectors to atmosphere. The condensed steam (condensate) is
pumped to the refinery low pressure condensate system on surface condenser level
control.
1. Inspection of Centrifugal Compressors
Before initial unit startup, it will be necessary to check the operation of the recycle
and net gas compressors. Depending upon the state of construction, this checkout
may possibly be carried out in connection with the subsequent Platforming reactor
section drying operation. In any event, preliminary compressor operation should
also be as recommended by the manufacturer.
In general, a manufacturer’s representative will precheck the compressors, drivers,

the lube oil system and seal oil (centrifugal compressors only) system prior to initial
machine run-in. Some of the items he will cover are:
a. Checking compressor-driver alignment, both hot and cold.
b. Checking for proper base grouting and equipment support.
c. Removing slushing oils from bearings and seals.
uop 117108-6 VI-25
d. Checking all seal and bearing clearances.
e. Evaluating suction and discharge piping for proper vibrational support.
f. Acidizing and flushing lube, seal, and hydraulic oil systems, as

necessary.
g. Adjusting centrifugal compressor seal oil system for smooth operation

including alarm instrumentation.
h. Installation of orifices in the sour oil trap vent and oil receiver purge
lines.
i. Run-in of main and auxiliary lube and seal oil pumps.
j. Establishing normal oil levels in all lube and seal oil systems.
Once the precheck is completed, the compressors should be ready for operation.
Since these machines are important and expensive pieces of process equipment,
their proper operation cannot be overemphasized. Manufacturer’s recommenda-
tions should be consulted for a more thorough discussion of any item mentioned
here.
2. Centrifugal Compressors Startup
Generally, the recycle gas compressor will be a single or multi-stage centrifugal

compressor driven by a steam turbine or an electric motor coupled through a gear
box for speed control. Occasionally, a centrifugal booster or net gas compressor will
also be provided, although usually a large number of stages are required for such
service and a reciprocating machine is more economical.
Startup, operation and shutdown of any centrifugal compressor installed in the unit
will be covered in detail in the manufacturer operating instructions provided with the
machine. These should be studied thoroughly by operating personnel prior to
uop 117108-6 VI-26
machine initial operation. Generally, however, such instructions will contain the
following guidelines:
NOTE: Because of the high speeds involved with this machine’s operation, it may
be desirable to leave a coarse suction screen in the machine for the duration of the
first run to guard against the possibility of superfluous material left over from the
construction entering the compressor during operation.
The general startup procedure for centrifugal compressors is as follows:
a. Check the rotating element of the compressor for free rotation by

turning slowly by hand. If the rotor rubs, rotation should be stopped
immediately and the difficulty located and repaired.
b. Line up (include a filter and cooler) and start the seal and lube oil
circulation systems to make certain that the bearings of the
compressor and driver are well lubricated. The manufacturer’s
instructions will give the proper values for the lube oil pressure and the
seal oil differential, as well as other necessary settings. Generally, the
minimum inlet lube oil pressure to each bearing should be about 10
psig (0.7 kg/cm2). The seal oil pressure will initially be low, and will not
rise to normal operating pressure until the compressor is operating at
loaded conditions. Typically, the seal oil pressure will be slightly
greater than the suction pressure the usual differential between the
two pressures is about 5 psig (0.35 kg/cm2).
NOTE: The seal oil system should be in operation whenever any pressure is on the
compressor case, even though the machine is idle. This is necessary to prevent
depressuring the compressor case to the seal oil reservoir and to keep any possible
hydrogen sulfide or hydrogen chloride in the process gas away from the bearings.
Too high a differential pressure between the seal oil system and the suction
pressure will force oil past the seals into the compressor case, and thence into the
recycle gas stream. This is generally undesirable although there will be a certain
uop 117108-6 VI-27
amount of seal oil leakage from the system. This oil is called sour oil and should not
be reused. A careful check between makeup oil and seal oil loss should be made
periodically; any oil not accounted for is oil that has leaked through the seals into
the process stream.
c. Remove any suction or discharge line blinds.
d. Close the sour oil vent valve to minimize gas losses until the
compressor is on stream.
e. Purge air from the compressor with nitrogen for one minute; then
pressurize the compressor to 100 psig (7 kg/cm2) with nitrogen and
leak test the compressor.
f. Blow down all compressor casing drains.
g. Pressure the compressor to the line pressure. During dry-out the unit
might be pressured with nitrogen or hydrogen or a mixture of both
depending on the recycle compressor driver limitations (operating
specific gravity). For unit startup pressure with hydrogen.
h. Unblock the compressor suction and discharge.
i. Put stand-by seal and lube oil pumps on auto-start.
j. If the compressor driver is a condensing steam turbine, commission

the surface condenser system and warm up the turbine. Warmup
should be extended evenly over a thirty-minute period. During
warmup, the high pressure steam should be checked to ensure that all
condensate is out of the system.
k. Start the compressor rotating using the inlet steam block valve for
control (startup is best done on manual control) and bring the
machine’s speed to 500 RPM. If the compressor is motor driven
uop 117108-6 VI-28
throttle the suction butterfly valve to the minimum opening as was set
for surge protection and start the motor. Note any excessive vibration
or noise. If either occurs, shutdown immediately and locate the
problem.
NOTE: With a flexible shaft, multistage turbine driver, the startup acceleration
places considerable torque strain on the coupling, and startup heating effects can
warp the shaft. To minimize this situation, the machine should be brought up to
operating speed in several steps.
l. Allow the compressor to run at the specified rpm until the seal and
lube oil rise to near normal operating temperature, usually about
120°F (50°C). Start cooling water flows to the oil cooler to maintain
seal and lube oil temperatures at the desired level. This is usually
controlled automatically.
m. If the machine is turbine driven, increase the compressor speed

stepwise to above the critical speeds being sure to increase the speed
smoothly and rapidly through the critical speeds. Put the compressor
on governor control and establish the desired recycle gas flow rate.
n. Crack open the vent valve on the sour oil pot.
o. Make any necessary adjustments as required in the manufacturer’s

instructions for continuous operation.
3. Centrifugal Compressor Operation
Normal operation of a centrifugal compressor is essentially automatic and will

require little operator action. However, frequent checking of all temperatures,
pressures, oil levels and vibration monitors should be done to ensure satisfactory
operation. In addition, there are a number of other items that require special
attention or precautions during operation:
uop 117108-6 VI-29
a. Due to the high operating speed of a centrifugal compressor, special

attention must be paid to the problem of vibration. Misalignment is
usually the main source of vibrational troubles. However, vibrational
problems may also result from operation at or close to the machine’s
critical speeds. All high speed centrifugal equipment have critical
speeds at which a shaft vibration can set up extreme equipment
vibrations. The shaft may be operated above or below the critical
speeds without vibration. Operation of the compressor at a critical
shaft speed for even a short period of time will result in equipment
damage. Thus, it is important when increasing or decreasing speed to
pass the critical speeds quickly.
b. If insufficient gas is being pumped at any given set of speed and

pressure conditions, surging can result. Surging will rapidly overhead
and damage the compressor. If surging is detected, the speed of the
compressor must be reduced until stable operation is obtained.
Operation at the critical speeds should, of course, be avoided. If
compressor surging cannot be stopped, the unit must be shut down
until the source of the surging can be located. A careful check of unit
conditions prior to the onset of surging should be made. Under some
conditions, a low molecular weight gas will cause a compressor to
approach surge conditions; the gravity of the recycle gas will show
this. Once the surge cause has been located and corrected, the
compressor should be restarted carefully while closely observing its
operation to insure that no previous damage has resulted. On motor
driven machines adjustments to the suction butterfly valve stops might
be necessary.
c. The centrifugal compressor will have discharge temperature indicators

and high discharge temperature shutdown alarms. These discharge
temperatures should be monitored to see that they do not approach
the maximum allowed by the manufacturer and thus cause
unnecessary shutdowns. Poor vacuum on the turbine exhaust, if total
condensing, or high inlet steam temperature can cause high turbine
discharge temperatures. High compressor discharge temperatures
uop 117108-6 VI-30
can also be caused by too high a suction temperature, too high a

compression ratio, or surging.
d. Under no circumstances should a centrifugal compressor be operated

with the suction or discharge block valves closed. With the
compressor blocked in, severe overheating will occur within a few
seconds.
e. Frequent checks of the compressor suction equipment should be

made to ensure that no liquid enters the compressor. At the high
speeds involved, great damage will result from liquid entry.
f. If foaming causes trouble in the lube oil system, a foam depressant

may be utilized.
g. The viscosity of the seal oil must be watched after the plant is on
stream. The seal oil may be diluted by heavier ends from the process
gas and, if unchecked, the viscosity may drop so low that the seal oil
pumps are unable to maintain system operation.
h. Hydrogen from the compressor case can be absorbed in the seal oil
and carried back to the oil reservoir. If the reservoir were vented to the
atmosphere, an explosive mixture with oxygen from the air could be
formed. This danger is minimized by maintaining a nitrogen blanket
above the oil reservoir.
4. Centrifugal Compressor Shutdown
NOTE: If the compressor is the recycle gas machine, the unit charge must be cut
out, all reactor section heater fires extinguished, and the reactor outlet temperatures
cooled to below 200°F (90°C) prior to compressor shutdown (750°F if it is a
temporary shutdown or are preparing to regenerate the catalyst).
uop 117108-6 VI-31
Usually a centrifugal gas compressor is shut down by a procedure similar to the

following:
a. Trip the overspeed trip on the turbine if turbine driven or shut down the
electric driver.
b. If turbine driven, reset the overspeed trip and establish a slow roll of
the turbine at about 500 RPM for one hour to permit cooldown, then
block in the steam inlet and exhaust.
c. Close the vent valve on the sour oil pot.
d. If the shutdown is to be for a short time, maintain seal and lube oil
system operation. If the shutdown is to be for an extended period,
block in the compressor suction and discharge valves and depressure
and purge the case. Shut down lube and seal oil system and block in
cooling water flows when the bearing outlet oil temperatures are the
same as the inlet temperatures.
e. Shut down the surface condenser system, if installed.
5. Reciprocating Compressors
In Platforming process units reciprocating compressors can have cylinder

lubrication. However, special types of synthetic oil must be used as specified in the
project specifications. Limits and injection rates are also given. These requirements
are necessary to avoid unacceptable levels of contaminants contacting the catalyst.
Such machines are generally used as net-gas or booster gas compressors.
Normally a spare machine is provided.
Reciprocating compressors should be started and operated according to the

manufacturer’s instructions supplied with the machines.
uop 117108-6 VI-32
Special attention should be paid to those instructions regarding barring or hand-

jacking of the machines prior to startup. This operation insures that all moving parts
are free.
The general startup procedure for most reciprocating compressors will usually be
similar to the following:
a. Startup Procedure for the first compressor
(1) Purge the compressor with nitrogen through the suction purge
valve to the atmospheric vent line.
(2) Roll the machine over to ensure complete purging.
(3) After nitrogen purging of the machine, introduce hydrogen to

the compressor via the hydrogen pressuring line or by cracking
open the suction block valve.
(4) After partially pressuring the compressor with hydrogen, roll the
machine over and vent the hydrogen to the atmospheric vent to
displace nitrogen in the machine.
(5) Gradually open the compressor suction valves to pressure up

the machine to line pressure.
(6) Start steam to the steam tracing or the in-line jacket heater.
Drain the suction line and snubbers of any liquid.
(7) Make sure that there are no restrictions to the gas flow from the
net gas compressors. Open any upstream flow control valves
or spillback control valve prior to starting the machine.
(8) Start cooling water flow to the compressor. Check

temperatures, pressures and levels as required. Many big
machines have dedicated cooling systems.
uop 117108-6 VI-33
(9) Start the compressors auxiliary lube oil pump. Check pressures
and flows as required.
(10) If the machine is fully equipped with suction unloader valves,

start up the machine as follows:
i) After the machine is pressured with hydrogen, close the

small bypass vent line, unload all of the suction valves
and unblock the compressor discharge lines.
ii) Check the compressor’s lubricating oil level in the crank

case or reservoir.
iii) Start the compressor and check the oil pressure.
iv) Let the compressor idle for a few minutes while closely
watching the suction temperature. Then, close the
suction valve loaders to put the machine on line. Follow
the manufacturer’s loading sequence, if one is specified.
v) Verify that the oil lubricators for the seals, packing and
cylinders are working. Fill the reservoir with the correct
type of synthetic oil. Adjust the drop rate as specified.
b. Startup Procedure for the second compressor
The second compressor can be started up using the same procedure as was
given for the first compressor startup. Follow steps 1 through 11 given in the
proceeding pages. Since the compressor discharge valves will act as check
valves, the gas from the operating machine will not flow back to the suction
of the unblocked idle machine.
uop 117108-6 VI-34
G. SERVICE AND CALIBRATE INSTRUMENTS
Normally, instrument lead lines will be tested hydrostatically up to the first block
valves coming off the pipe, vessel or piece of equipment when the unit is
hydrostatically tested. Hydrostatic test pressure should not be applied on
instruments which normally handle gas, and no pressure measuring element should
be subjected to test pressures above its range. The remaining piping and
instrument are pressure tested with either air or water independently from the rest
of the unit by the instrument inspection team. However, when the unit is leak tested
during precommissioning by the operations group all instruments should be include
in this final integrity test.
All instrument air piping should be tested at 100 psig (7 kg/cm2) with compressed
air. Soap should be used on all joints to check for leakage. Care should be taken to
ensure that this high air pressure is not put on any instruments or control valve
diaphragms. Likewise when pressure testing the unit, care must be taken that any
fuel gas pressure balance valves are blinded off to keep high pressure off the
diaphragm.
All control valves should be checked for operability, i.e. stem travel, action on air
failure, etc. Special attention should be devoted to split range systems to insure
their proper installation and operation. All radioactive level indicators should be
calibrated and prepared for normal operation.
After line flushing and pump run-in are complete, all orifice plates should be
calibrated and installed. The orifice plates must be checked for proper size, weep
hole, tag and plate direction on installation.
Before startup, all instruments should be serviced and calibrated. Transmitter and
board mounted receiver readings for each instrument should be synchronized.
uop 117108-6 VI-35
H. DRY OUT FIRED HEATERS
Before a heater is put into service for the first time, it will be necessary to slowly
expel the excess moisture from the insulating concrete (setting) by gradually raising
the temperature. To be assured of a long heater life with minimum maintenance,
this procedure must be done with extreme care. Except under special
circumstances, completion of the heater dryout procedure without any material
flowing through the process tubes is preferable as this ensures a more equal heat
distribution in the firebox. If the heaters are UOP heaters, a suitable dryout
procedure is recommended in UOP Standard Specification 2-18 or 2-19 (whichever
applies). If they are non-UOP heaters, the manufacturer’s recommended drying
procedures should be followed. However, if a specific procedure is not supplied, a
procedure similar to the following may be utilized:
1. Generalized Heater Dryout Procedure
a. Make a temporary installation of thermocouples through the pipe

sleeves in the hip section of the heater. The tips of these
thermocouples should extend 6 inches (150 mm) beyond the inside of
the insulating concrete, but should not contact the tubes.
b. It is preferable to use gaseous fuel (refinery gas or LPG) for drying out
the heater. If no gas is available, liquid fuel may be used, but it should
be free of sediment and heated as required to give the proper
viscosity (about 200 SSU) for good atomization and clear combustion.
c. Before starting to light any burners, all individual burner and pilot block
valves are to be closed, and the firebox steamed out to remove any
gas accumulation. Open all dampers.
d. Light all pilots. Verify they all work.
e. Light one or more burners, as required, in each section of the heater

and fire slowly so that the temperatures as indicated by the hip
thermocouples increases about 25°F (14°C) per hour until a level of
900-950°F (482-510°C) is reached. While increasing the temperature,
uop 117108-6 VI-36
rotate the burner operation frequently to distribute the heat as evenly

as possible throughout the heater firebox. Setup a timetable with
burner numbers so there is no confusion shift to shift. Problems with
the burners can be corrected as found.
f. Maintain 900-950°F (482-510°C) on the hip thermocouples for 10

hours or two hours per inch of refractory thickness if more than 5
inches of refractory wall thickness exists. Rotate burner operation
frequently during this hold period to assist in equal distribution of heat.
g. After the ten-hour hold period, all burners and pilot should be shut off
and the heater refractory allowed to cool slowly by keeping the air inlet
registers and stack dampers closed. Close all pilot and burner block
valves.
h. After cooldown is complete, the temporary hip thermocouples should

be removed, and the plugs replaced in the stack pipe sleeves. If the
heater has been dried out as outlined above, the heater temperature
may be subsequently raised or lowered at rates consistent with the
safe operation of the heater and unit. If the heater has been shut down
for a prolonged period of time it may be necessary to repeat the
drydown procedure.
2. Gas Fired Heaters
Generally, heaters in the Platforming units are gas fired; however, depending upon
fuel availability, heaters may be designed to fire on gas only, oil only, or a
combination of both.
General rules applying to gas fired heaters are as follows:
a. When the unit is shut down, always blind off the fuel gas supply line,
because gas may leak through the block valves into the heaters and
fill a furnace.
uop 117108-6 VI-37
b. Before starting to light any burners, see that all individual burner block
valves are closed, and steam out the firebox to remove any gas
accumulation. Make sure the dampers are opened. Continue steaming
until a steady plume of steam is visible rising from the stack. Then
stop steaming and pinch in the dampers.
c. Light each pilot individually by opening its gas valve slowly after
inserting a lit torch in front of the pilot head or light using the push
button ignition system if installed. When the pilot ignites, open its gas
valve completely; gas flow to the pilot head is controlled by an orifice
in the pilot assembly.
d. Once all pilots are lit, light the required number of gas burners from
their respective pilots. After a few burners are lit, it may be necessary
to open the damper more to provide enough draft to light additional
burners.
e. Burners should be fired to produce a blue flame with a yellow tip,

obtained by regulating the primary and secondary air supply. The
heaters should be checked frequently for dirty burners that might give
either too long, too short, or a misdirected flame. There must be some
excess of air to the burners so that an increase in fuel gas flow will
have sufficient air to produce complete combustion.
f. If, for any reason, the fires in a heater go out, then:
(1) Shut off the gas supply immediately by closing the block valves
at the fuel gas control valves. Bypass and pilot lines that might
be located upstream of the fuel gas control valve’s block valve
must also be closed.
(2) Open stack dampers and air registers to purge air through the
firebox.
uop 117108-6 VI-38
(3) Close all individual burner and pilot valves.
(4) Only after the heater has been properly purged it can be
restarted.
g. As in all heaters, care should be taken that no flame impingement on

the tubes is permitted.
3. Oil Fired Heaters
General rules applying to oil fired heaters are as follows:
a. When the unit is shut down and before entering heaters, always
double block the oil supply line on both the supply and return headers
and pull the oil guns from the burners as oil may leak through the
block valves at the heaters and fill a furnace.
b. Before starting to light any pilot burners, see that all individual oil guns
are removed from the burners, and steam out the firebox to remove
any gas accumulation. Make sure that the dampers are opened.
c. Always light the gas pilots first. Have fuel oil circulating through the
fuel oil return at normal operating temperature before attempting to
light any oil burners. The recommended steps for safely lighting an oil
burner are:
(1) Push the oil gun forward, and then turn on steam by fully
opening the steam block valve and the steam control valve.
Close off when the steam is dry.
(2) Make sure the oil block valve is closed, then open the steam
bypass valve to clean and warm the burners.
(3) When condensate has been removed and the steam is dry (dry
steam is invisible), close the bypass steam valve.
uop 117108-6 VI-39
(4) Adjust atomizing steam valve for a small flow of steam.
(5) Open oil block valve gradually until the oil starts burning. The
oil will ignite from the pilot flame. Take care to see that
unburned oil is not put into the firebox. Accumulated unburned
oil will become hazardous as the firebox heats up.
(6) Adjust the atomizing steam valve and oil valve to obtain correct
flame pattern. Never let the flame touch the tubes.
d. Oil burners should be fired to produce a yellow flame with a good

pattern obtained by regulating the primary and secondary air supply.
The furnaces should be checked frequently for dirty burners that might
give either too long, too short, or a misdirected flame. There should be
some excess air to the burners so that an increase in fuel flow will
have sufficient air to produce complete combustion.
e. If, for any reason, the fires in the furnace go out.
(1) Shut off the fuel supply immediately. Do this by closing the
main block valve in the fuel supply to the furnace. This will take
care of any bypass lines that might be open around the control
valves.
(2) Put snuffing steam in the firebox.
(3) Block in the pilot gas line. Close individual burner and pilot
valves.
(4) Only after the heater has been properly purged can it be
restarted.
f. As in all heaters, care should be taken that no flame impingement the

tubes is permitted.
uop 117108-6 VI-40
I. DRYOUT OF REACTOR SECTION
Before loading catalyst into the reactors, it is necessary that the lines and
equipment be dried to remove any traces of water that might have remained from
the construction and flushing. This step is normally carried out by using the recycle
compressor(s) and the heaters to circulate hot nitrogen through the normal process
circuit and draining condensate from the separator(s). If a waste heat recovery
system for steam generation is installed in the convection zone of the Platforming
Unit heaters, this system can be thoroughly cleaned out using the procedure
detailed in Section J of this chapter at this time.
On units equipped with centrifugal recycle compressors or lubed reciprocating

compressors, the use of air for this dryout procedure is not recommended because
of the possibility of an oxygen-seal oil explosive mixture in the compressor at
elevated temperature. The nitrogen gas is heavier than the normal recycle gas but
the compressor should be rated for the Regeneration case which will allow it to
perform reactor dryout with nitrogen.
Precautions must be taken during the dryout procedure to avoid overheating of the
heater tubes, which might cause oxidation or scaling on the outer surface. The
external condition of the tubes should be observed frequently during the dryout
period to assist in early identification of any tube overheating. If the heater is
equipped with a waste heat recovery steam generation section, normal operation
should be established on this section during the dryout procedure.
All of the reactor internals should be installed prior to the dryout operation. This will
minimize work to be done in the reactors after dryout and provide an opportunity for
identification/correction of any possible heatup stresses, etc. on internals during the
preloading inspection.
The following procedure outlines a satisfactory method for carrying out this drying
operation:
uop 117108-6 VI-41
Line up the reactor and recycle gas compressor circuit for dryout.
a. Block-in the recycle and net gas compressor suction and discharge
lines.
b. Line up valves through the entire system to isolate the Platforming

reactor system from the fractionation section and all other units.
Ensure that all drains and vents are closed and capped. If there is a
booster gas or net gas recontact section in the unit include it in the
dryout. It is a good opportunity to run-in the reciprocating machines
and verify the split range pressure controls work.
c. Air-free the unit as is described in Chapter VII (Normal Startup).
NOTE: When nitrogen is used for dryout, set the unit pressure at a value consistent
with the safe operation of the compressors. Consult the compressor vendors for this
information.
d. After the unit is air free, purge the recycle compressor and net gas
compressors with nitrogen to remove air. Once the compressors
pressure equals the unit pressure line them up to the unit.
e. Establish normal operation of the reactor products condenser(s) and

the reactor products trim cooler(s).
f. Start the recycle gas compressor and net gas compressors. Establish
circulation through the system at a rate compatible with the
compressor discharge temperature and pressure differential. Slowly
increase the net gas section to the limit recommended by the
compressor vendor. The pressure controls should be in auto.
NOTE: High gravity gas such as nitrogen will result in much higher compressor
discharge temperatures.
uop 117108-6 VI-42
g. Drain all free water from any low points in the system. This should be
done both before pressuring up and also during the heatup and drying
period.
h. Light a few burners in each Platforming heater and bring the

temperature up at 100-150°F (55-83°C) per hour until the reactor
inlets reach about 500°F (260°C). Maintain this temperature level until
water drainage from the separator(s) and plant low points reaches an
acceptable level (several gallons/hour). During this period the entire
reactor section should be inspected closely for expansion, and
problem areas noted for observation later during the high temperature
phase of the dryout.
i. Establish flows through all lines.
j. Once water drainage is reasonable, raise reactor inlet temperatures at

100-150°F (55-83°C) per hour until all inlets reach 950°F (510°C);
maintain this temperature level until the drying is complete. This will
be indicated by a constant, low water drawoff rate from the
separator(s) and other low points. The water drawoff rate should be
less than 100 ml per hour.
k. When drying is judged complete, the heater fires can be cut. Gas
circulation by means of the recycle gas compressors, however, should
be continued until all reactor temperatures have cooled to less than
130°F (55°C).
l. After the reactors have been cooled, shutdown the compressor(s) and
depressure the reactor section to a slight positive pressure in
preparation for loading catalyst as described in Section IV. If hydrogen
and/or fuel gas was used during the dryout depressure to the flare and
change to a nitrogen atmosphere as is detailed in Chapter XI (“Normal
Shutdown”). Before catalyst can be loaded into the reactors the
atmosphere must be changed to a dry air.
uop 117108-6 VI-43
2. Reactor Inspection After Reaction Section Dryout
a. Complete the following in each reactor. Matchmark all parts before

disassembling.
(1) Inspect all seal plates around risers for signs of binding.
(2) Remove one coverplate section in each reactor to access each

reactor’s catalyst bed area, where possible.
(3) Clean the scallops or the outer basket screen (whichever

applies). Clean the centerpipe screen and the ventilation
screens. Use a wire brush and vacuum as needed.
(4) Inspect all the scallops and the expander rings or inspect the
outer screen (whichever applies). Inspect the centerpipe.
Recheck verticalness.
(5) Inspect for cracked welds and broken tackwelds. Repair as
needed.
(6) For upflow centerpipe reactors:
(a) Recheck condition of gasket between centerpipe support

and bottom head.
(b) Recheck the gap between centerpipe base and

centerpipe support. Recheck condition of gasket.
Recheck tightness of centerpipe holddown bolts.
(7) For downflow centerpipe reactors:
(a) Recheck condition of all gaskets around split rings.

Recheck tightness of all bolting of split rings (if
applicable).
uop 117108-6 VI-44
(b) Recheck gap between centerpipe base and split ring No.
2 (if applicable).
(c) Reset to finger tight all shoulder bolt nuts of outer basket
screen. Tackweld nuts to bolts (if applicable).
(d) Install seal band at outer basket screen base ring.

Maximum gap is 0.030 inches (0.76 mm). Target gap is
0.000 inches (0.00 mm) (if applicable).
(e) Install ceramic fiber rope in crevice between centerpipe

socket and collar (if applicable).
(8) Install ceramic balls in catalyst unloading nozzles.
(9) Vacuum bottom head in catalyst bed thoroughly clean.
b. Proceed with catalyst loading activities as detailed in chapter XIII,

“Special Procedures”.
J. CHEMICAL BOIL-OUT OF STEAM GENERATION FACILITIES
If a waste heat recovery installation for steam generation is provided in the

convection section of any of the unit heaters, a thorough cleaning of this installation
will be required following construction. Such cleaning is generally done by
performing a boil-out after all physical inspections and checkout procedures have
been performed and just prior to bringing the unit on stream. This boil-out is usually
done with chemical enhancement to ensure complete removal of all oil and other
deposits that may have accumulated on internals during fabrication and erection of
the system components. Complete removal of any oil, grease or oily scale from the
inside of the pressure parts is required to avoid foaming and priming during
subsequent operation.
uop 117108-6 VI-45
1. General Notes:
a. The heater refractory dry-out, plant dry-out and chemical boil-out

procedures can be combined in the interests of saving time. It is likely,
however, that the heat input during either the heater refractory or the
unit dry-out procedures may be excessive for controlled chemical boil-
out. Therefore, combining the two or three operations may require a
temporary interruption of the drying-out procedure while the flushing
operation is completed, and the steam generation facilities made
completely operational.
b. The drying-out and boil-out periods present an opportune time to

check out the operation of auxiliary equipment and instrumentation.
2. Boilout Chemicals
Several combinations of chemicals may be used to achieve a satisfactory job of

cleaning during the boil-out. Commercial mixtures are also on the market which are
designed to do a very thorough and complete job of cleaning. These latter should
be used strictly in accordance with the manufacturer's recommendations. Two
satisfactory mixtures for chemical boil-out are the following.
1. A mixture of soda-ash (Na2CO) and Caustic Soda (NaOH) in equal

proportions for a total of 50 lbs. of chemicals per 1,000 gallons of boiler
water.
2. An equal mixture of Trisodium Phosphate and Caustic Soda for a total of 40

lbs. of chemicals per 1,000 gallons of boiler water.
These chemicals should be well mixed and thoroughly dissolved in hot water and
are best introduced into the steam drum through the chemical feed connections. If a
portable pumping system is not available, the chemical solution may be fed directly
into the drum through the manway prior to boil-out.
uop 117108-6 VI-46
If possible, it is desirable to introduce part of the chemical solution into the feed line
leading to the boiler feed water preheat coil in order to obtain some cleaning action
in the preheat coil itself.
With the system in readiness and the chemical solutions prepared, the actual boil-
out can begin.
The following suggested sequence may be used.
a. Fill the system to normal drum level, using the feed-water pump and
the regular feed connections. Introduction of some chemical
compound into the feed water, as outlined above, would be desirable.
The feed water should be limited to approximately 180-200°F (82-
93°C).
b. Make certain that the superheated steam line is closed to the refinery
steam system. Ensure that the superheated steam coil outlet vent and
drain lines are open to the atmosphere and leave them partially open
during boil-out. This will assure flow through the superheater tubes
and avoid any accumulation of condensate. It may be necessary to
blow steam through the superheater tubes to protect them from over-
heating until sufficient steam is being generated.
c. Open the vent valve on top of the steam drum.
d. Start one of the water circulation pumps to provide flow through the
steam generating coils.
e. Light fires in the heater. The boil-out procedures can be combined

with the refractory dryout or the unit reactor section dryout. Bring the
heater firebox temperature up 100°F (55°C) per hour maximum until
the steam drum pressure is established at approximately 50 to 100
psig (3.5 to 7.0 kg/cm2). Care must be taken to maintain a level in the
steam drum at this time.
uop 117108-6 VI-47
f. Flow must be maintained through the boiler feed water preheat coil.
Since steam will be venting to atmosphere, this will be accomplished
by charging make-up water to maintain the level in the steam drum. If
possible, a temporary line should be connected from the discharge of
the water circulating pumps to the boiler feed water preheat coil inlet
line to provide chemical to clean this section out, also.
g. Approximately once each shift, the unit should be blown down using
the blowdown connections. The water should be dropped to the
bottom of the gauge glass and then fresh water added to bring the
water back to the normal operating level. Chemical solution should be
added through the chemical feed connection to maintain the
concentration in the boiler water as close to the recommended levels
as possible.
During each blowdown period, the superheater drains should also be opened wide
to assure that no condensate has accumulated in the coil or outlet header.
The waste heat circulating pumps should be operated in rotation to make certain
that there will be no difficulties during final startup.
The duration of boil-out will normally vary between twenty-four (24) and seventy-two
(72) hours, depending on the type and initial cleanliness of the unit, as well as the
chemical concentration and temperature maintained during boil-out. It is to be
expected that twenty-four (24) to thirty-six (36) hours should suffice to prepare the
system for satisfactory operation.
Blowdown water condition is one indication of whether the boil-out has achieved
satisfactory results. The only conclusive determination of boil-out effectiveness,
however, is by a visual internal inspection of the steam drum.
Upon completion of boil-out, the fires should be extinguished and the unit permitted
to cool. After drum pressure has reached zero, open vent valves and completely
drain unit of chemical solution.
uop 117108-6 VI-48
After draining, the unit should be refilled with clean, fresh water to high drum level
and flushed through the drum blowdowns, bottom drains, and the steam generation
coils. After flushing, open the steam drum for internal inspection to check on the
effect of the boil-out. The flushing procedure should remove practically all residual
chemicals and any accumulation of sludge.
If the interior of the drum is adequately clean, the boil-out may be considered
complete. If cleaning is not adequate, the boil-out should be repeated. It must be
emphasized that the satisfactory operation of this section unit depends, to a
considerable extent, on a complete and thorough job of chemical cleaning.
4. Post-Boilout Activities
After chemical cleaning is complete, the following steps should be taken:
a. The gauge glasses should be removed, cleaned and reassembled.

Care should be taken to be sure that all connections between the
drum, gauge glasses, and water columns are unobstructed.
Note: If desired, spare gauge glasses may be used during boil-out to be

replaced by new glasses prior to normal operation.
b. All manhole and other gaskets which were exposed during inspection,
blinding, etc., should be replaced with new operational gaskets.
c. All connections and closures, which were opened after hydrotesting,

should be checked and tightened securely. All such connections
should be watched carefully for leakage when the unit is brought on-
line later for normal operation.
uop 117108-6 VI-49
Fixed-Bed Platforming – General Operating Manual Normal Startup
VII. NORMAL STARTUP
This section describes the precommissioning activity and startup of the Platforming
unit with a fresh load of catalyst. Variations in the startup procedure described are
possible on subsequent startups, depending upon how complete a shutdown has
previously been made. If a less extensive shutdown has been made, various
omissions in the following procedure may be made as determined by the unit
supervisor.
NOTE: This procedure is general in nature and is not intended to cover every
possible mechanical and process combination. Before proceeding with a startup,
each individual unit should be examined and a detailed procedure prepared for that
specific unit. Particular care should be taken not to exceed equipment limitations.
Prior to startup, the Platforming reactor section should be dry to minimize loss of
chlorides from the catalyst during the startup sequence. Any water that has
collected in the system during the shutdown should be drained. The wet areas of
the unit should be blown dry if possible. For the initial unit startup the unit should
have been dried out before the catalyst is loaded. In those cases where the unit
has been shutdown for catalyst change-out and equipment has been filled with
water for testing, circulation of hot gas through the reactor section prior to catalyst
loading is also advisable. A dryout procedure will ensure a dry plant for catalyst
loading.
Oil or flammable gas should never be charged into process lines or vessels
indiscriminately. If the lines or vessels have contained air, suitable purging must be
performed. Similarly, air should not be allowed to enter lines or vessels that have
contained hydrocarbon until proper safety precautions have been taken. At no time
should wet air (ambient or plant air) or refinery fuel gas be purged through the
catalyst bed. The moisture in the air and fuel gas will leech the chloride from the
catalyst. Also, the fuel gas could contain other catalyst poisons such as sulfur. The
following procedure for purging and preparing the unit for startup should be closely
followed. If varying the purge procedure appears necessary, the unit supervisor's
approval should always be obtained.
uop 117108-6 VII-1
uop
Figure VII-1
Fixed-Bed Platforming Start-Up Procedure Sequence
Complete catalyst Air-free and Change to H2, Start recycle Heat-UP

Heat-Up
R.G. Pre-Sulfiding
loading/regeneration and Preparation pressure pressure up and leak gas reactors to
650°F (343°C) H2S?
all mechanical work test test circulation 650°F No
Yes
Fixed-Bed Platforming – General Operating Manual
Increase feed rate to design

Heat-UP
Heat-Up Check feed R.G. H2O
reactors Cut-in feed to Separator and Start chloride
reactorstoto contaminants if un- <300m-ppm? hold
(371°C) reactors column control injection
700°F700°F Increase
Increase reactor
reactortemperatures
temperaturesto treated No
(471
880 °Fto 880°C)
or or 900 °F (482
900°F
°C)
Yes
117108-6
Yes Yes No
Decrease R.G. H2O Decrease Increase
Increase reactor
R.G. H2O Decrease R.G. H2O
chloride <200m-ppm? chloride temperatures to
temperatures to chloride hold
<100m-ppm? <30m-ppm?
injection injection 900°F (482°C)
900 or 920°For injection
920°F (493°C)
No Yes
No
hold hold
Decrease Yes Increase reactor Yes

Octane Octane R.G. H2O Start water NORMAL
chloride response OK? temperatures to <15m-ppm?
response test injection OPERATION
injection SOR
No
No
Adjust
hold
chloride
VII-2
Normal Startup
injection
A. UNIT PREPARATION AND AIR-FREEING
Before attempting to put the unit on stream, all necessary details with regard to the
mechanical condition of equipment, availability of utilities, etc., and reactor catalyst
loading should be complete. Other areas of the refinery which may feel the effects
of the startup and subsequent plant operation, such as the boiler house, units
receiving products from the Platforming Unit, and fuel and water facilities should be
notified of the pending startup.
The detailed startup procedure outlined in Figure VII-1 is divided into several
sections. The timing of some sections and steps is a matter of convenience, while
others may fall into a necessary sequence. Some of the sections and steps can or
must be carried out simultaneously.
The outline in Figure VII-1 is expanded on in the following pages in more detailed
steps which cover each operation.
1. Unit Feed
Hydrotreated naphtha should be available for the unit startup. If there is hydrogen
available the naphtha hydrotreater unit can be placed on-line before the Platforming
Unit. Otherwise, previously treated naphtha taken from storage can be used.
Typically, such feed will have the following contaminant levels:
Boiling Range As per design

Total Sulfur 0.5 wt-ppm maximum
Total Nitrogen 0.5 wt-ppm maximum
Chlorides *(0.5 wt-ppm)
Fluorides *(0.5 wt-ppm)
Lead *(20 wt-ppb)
Arsenic *(1 wt-ppb)
Water + Dissolved Oxygen + Combined Oxygen = Low enough to produce

less than 5 mole ppm water in the recycle gas with no water injection.
* Below the lower limit of detection for the analytical method used;
parenthetical values are current UOP laboratory method limits.
uop 117108-6 VII-3
If hydrotreated feed is not available, startup may be done on non-hydrotreated

straight run naphtha providing it meets the following limitations:
Total Sulfur 100 wt-ppm maximum

Total Nitrogen 1 wt-ppm maximum
Arsenic 5 wt-ppb maximum
Lead 25 wt-ppb maximum
Halides 1 wt-ppm maximum
End Point 400°F (204°C) maximum
Bromine No. 1 maximum
The startup operating period on this feedstock must be limited to a maximum of

twelve hours and all reactor inlet temperatures must be maintained below 900°F
(482°C) or 880°F (471°C) for R-50 series and R-62, R-86 and R-98 catalysts during
this period.
NOTE: Regardless of whether previously hydrotreated or untreated straight run

naphtha is used for the Platforming unit startup, the feed must be routed through a
stripping column for adequate water removal prior to being charged to the
Platforming unit.
2. Unit Hydrogen Specifications
Make-up hydrogen of electrolytic or reformer quality should be available consistent

with the following specifications:
Source
Catalytic Reforming Electrolytic
Hydrogen purity, mol % 75 min. 99.5 min.
Carbon oxides (CO2 & CO), mol ppm Nil 20 max.
Nitrogen, mol % Nil 0.5 max.
Oxygen Nil Nil
Chlorine & Chlorides, mol ppm 50 max. Nil
Total Sulfur, mol ppm 5 max. Nil
uop 117108-6 VII-4
NOTE: Hydrogen from refinery hydrogen manufacturing plants is normally not

acceptable because of the inherently high moisture content.
3. Prepare Unit for Charging
a. Check that all blinds have been removed and that all safety valves are
installed.
b. Check that all utilities are available where required.
c. All instruments should be ready for service.
d. If it is a new unit run-in, the pumps on water whenever possible. An

alternate method would be to run-in the pumps on oil before the
reactor section is started, i.e., the reboiler and reflux pumps on
fractionation columns. If possible, run-in the reciprocating
compressors before heating up the reactor section. The centrifugal
compressor is typically run-in during the reactor section heatup.
e. Leak check all sections of the unit. Slowly pressure to 100 psig with
either nitrogen or air (instrument air in the reactor section). Check for
leaks at all flanges, valves and fittings as required. Also monitor the
individual section pressures. If no leaks are found and system
pressure holds for one hour with no more than 2 psig loss corrected
for temperature change, then the leak test has been successful. The
pumps and compressors should be isolated from the rest of the unit
during the leak test. They can be leak checked separately. On new
units, reciprocating compressors usually have many small leaks.
B. AIR-FREEING
1. Purge and Start the NHT Stripper and Platforming Fractionation Section
uop 117108-6 VII-5
a. If the fractionation section has been washed or hydrostatically

pressure tested prior to startup, dry the columns with steam. If the
columns have not had water in them prior to startup, the towers can
be purged with an inert gas such as nitrogen until oxygen-free (less
than 0.3% oxygen).
b. To dry the columns with steam, pressure up to any safe pressure with
steam, while venting air from the high points and draining condensate
from the low points. When all air has been vented, discontinue
venting, and allow the equipment to approach the steam temperature.
Stop the steam flow once the vessel is hot, and open all vessel drains
and vents. The rapid depressurization of the column will vaporize and
blow-out any condensate left in the tower. When the column
approaches atmospheric pressure, the remaining hot steam vapors
should be purged out with nitrogen or sweet fuel gas before the steam
has an opportunity to condense. The vent valves should be closed
and the drain valves regulated to remove any condensate. Personnel
should not leave the tower unattended during these final steps. Only
after all of the tower valves have been closed and the tower is safely
pressured with nitrogen or fuel gas can the startup personnel move on
to the next task.
NOTE: Gas should always be admitted to a vessel immediately after

stopping the steam depressuring to avoid creating a vacuum in the vessel.
Most fractionation columns are not designed for vacuum.
c. If the column and its equipment are to be purged with nitrogen,

introduce the gas at low points. The towers should be purged from
connections at the base and vented at the highest point. All reflux and
charge lines should also be purged as well by using connections on
the reflux and charge pump piping for introduction of the gas.
Continue purging until the vent gases escaping through the vents on
top of the tower and on the overhead receiver are oxygen free. Also
be sure all dead legs have been properly purged.
uop 117108-6 VII-6
d. Prior to fractionation section startup, establish column pressures at

design operating pressure or maximum sweet fuel gas header
pressure, whichever is less.
e. Line up startup naphtha to the stripper tower.
f. Bypass the Platforming reactor section by closing the block valves on

the charge line(s) from the stripper bottoms product line to the
Platforming combined feed exchanger(s). Do not flush hydrocarbons
into the Platforming reactor section.
The startup naphtha is now lined up to the NHT stripper and then onto the
Platforming Unit fractionation section bypassing the NHT and Platforming
reactor sections.
g. Start a flow of startup naphtha to the fractionation sections through the

normal charge lines using the reactor section bypass lines
(Platforming unit and NHT unit).
h. When a good working level has been established in the first column
bottoms, start heatup of that column. Continue in similar fashion on
other columns in the fractionation section.
NOTE: If there is any chance that water is in the towers heatup very slowly. If
water vaporizes too quickly, the pressure surge could damage the trays.
i. Continue the startup naphtha flow until an adequate inventory has

been established in all columns, then discontinue flow.
j. Establish reflux on each column when adequate overhead receiver

levels appear. Raise or lower column heat inputs, as necessary, to
maintain reasonable reflux to feed ratios. It may be necessary to
uop 117108-6 VII-7
operate the towers at less than design pressure in order to establish

reflux.
k. If circulation between columns is possible, establish such circulation at
approximately 50% of normal rate.
l. Drain water from overhead receivers and system low points, as

necessary.
m. Rotate pumps and commission instruments to test as much equipment

as possible before cutting charge into the Platforming reactors.
2. Evacuate and Purge the Platforming Reactor Section
a. Close all drain and vent valves in the reactor system.
b. Block in all instrument taps in the reactor section.
c. Close all isolation block valves including those on the compressor(s)

and all valves and vents necessary to isolate the reactor section from
other sections of the unit and from other units.
d. Connect the vacuum ejector to the Platforming Unit Product

Separator.
e. Evacuate the reactor section to a minimum of 24 inch. (600 mm )Hg

vacuum. If this requires over an hour, there is excessive system
leakage, a valve is open, or the steam ejector is not functioning
properly.
f. When maximum vacuum is attained, block in the ejector and hold the
vacuum for an hour. If the unit is tight, there should be little or no loss
of vacuum at the end of the hour.
uop 117108-6 VII-8
g. Break the vacuum to a positive pressure of 5 psig (0.35 kg/cm2) with

nitrogen introduced at the discharge of the recycle gas compressor.
NOTE: In all cases, while adding nitrogen or hydrogen to the Platforming
reactor system, normal direction of flow through the catalyst beds should be
used. This reduces the danger of any catalyst displacement in the reactors.
CAUTION: To avoid the danger of pulling air into the compressors, no vacuum
should be put on the compressor cases. The compressors should be purged
separately with nitrogen from the suction through the discharge and out the
vent line.
h. Repeat evacuation. Break the vacuum with nitrogen to 5 psig (0.35

kg/cm2).
i. Evacuate the Platforming reactor system to 24 inch. (600 mm) Hg

vacuum. Break the vacuum to 1 psig (0.1 kg/cm2) using electrolytic or
reforming hydrogen consistent with the specifications given earlier in
this chapter.
3. Evacuate and Purge the Net Gas Recontact Section
a. Close all drain and vent valves in the net gas recontact section.
b. Block in all instrument taps, isolate the reciprocating compressors,

and block in all valves and vents necessary to isolate the net gas
section from other sections of the unit and from other units.
c. Connect the vacuum ejector and evacuate this section to 24 inch.

(600mm) Hg vacuum. If it requires over half an hour, there is probably
a leak or an open valve.
d. When the vacuum is attained, block in the ejector and hold the
vacuum for an hour. If the unit is tight, there should be little or no loss
of vacuum at the end of the hour.
uop 117108-6 VII-9
e. Break the vacuum to a positive pressure of 5 psig (0.35 kg/cm2) with

nitrogen. The nitrogen should be connected so as to maximize purging
of all the piping in this section. It may be necessary to purge with
nitrogen at more than one location. All dead legs must be properly
purged.
f. Repeat evacuation. Break the vacuum with nitrogen to 5 psig (0.35

kg/cm2).
g. Evacuate a third time and break the vacuum with hydrogen. It must be
the same quality as that used in the reactor circuit. Pressure to 1 psig
(0.1 kg/cm2).
h. Line-up the reactor section to the net gas recontact section.
i. Unblock all instrument taps in both the reactor and net gas recontact
sections.
4. Hydrogen Pressure the Platforming Reactor and Net Gas Recontact

Sections
a. Gradually bring the Platforming reactor and net gas recontact systems
up to 125 psig (8.8 kg/cm2) minimum hydrogen partial pressure or
normal operating pressure, whichever is lower, with additional
hydrogen meeting the above specifications.
b. As pressure is increased, continue surveying the system for possible

leakage.
NOTE: Do not exceed design operating pressure of the product separator.
uop 117108-6 VII-10
C. INITIAL OPERATION
1. Start Hydrogen Circulation and Reactor Heat-up
a. Be sure the recycle gas compressor has been purged with nitrogen
first and then hydrogen. Any oxygen present from air will be displaced
out the compressor discharge vent line by admission of nitrogen into
the compressor suction. The admission of hydrogen by the same
route will purge out the nitrogen.
b. Check the compressor suction and discharge lines for liquid. Check
the separator(s) and any drains in the recycle gas circuit for liquid.
c. Establish normal operation of the Product Condenser and any trim

coolers in the recycle gas circuit.
d. Start the recycle gas compressor using the manufacturer's suggested

procedure or the guidelines presented elsewhere in this manual.
e. With recycle gas flowing, purge the Platforming reactor charge heater
and inter-heaters as per normal refinery practices, light fires, and
begin raising the reactor inlet temperature to 700°F (371°C). The
heat-up rate must be limited to 55°F (30°C) per hour for stacked
reactors, 75 to 100°F (42 to 55°C) for side-by-side radial flow reactors,
and 125 to 145°F (69 to 80°C) for downflow reactors. Due to the light
heat load, only a limited number of burners will be required in the
heaters during the heat-up period. Maintain maximum recycle gas
circulation and line up charge to the unit.
f. While the reactors are being heated to 700°F (371°C), commission the
net gas reciprocating compressors per the manufacturer's suggested
procedure. Load the machines and slowly increase their discharge
pressure. Pressure control, including operation of spillback control
uop 117108-6 VII-11
valves, should be in automatic while the pressures are brought up. Do

not exceed design pressure.
g. Water circulation should be established in the steam generation

section of the waste heat recovery system, if installed, on the heater
prior to heater firing. Similarly, process flow should be established
through any process tubes, if any, installed in the heater convection
section.
NOTE: In order to preserve the optimal properties of fresh catalyst, the period of
time required to heat the catalyst to 700°F (371°C) should not exceed 12 hours.
2. Pre-Sulfiding
Sulfur is a catalyst poison but a small amount is needed to attenuate the initial
activity of the fresh (or freshly regenerated) catalyst and passivate the unit
metallurgy. For all catalysts that are supplied in a sulfided state (see the “UOP
Platforming Catalysts” section of Chapter II, “Process Principles”), there should be a
detectable amount of H2S in the recycle gas when the reactors have been heated
up.
a. When the reactor inlet temperatures reach 650°F (343°C), sample the
recycle gas for H2S with a Dräger-type sniffer tube.
NOTE: If a Reduction step (see chapter XIII “Special Procedures”, sections B. 9

and B. 10) has just been completed, it is NOT necessary to cool the reactor inlet
temperatures to 650°F (343°C) in order to sample the recycle gas for H2S or to pre-
sulfide. Proceed to sample and pre-sulfide, if necessary, at 700°F (371°C).
b. If H2S is detected, proceed to the next section.
c. If no H2S is detected, proceed to inject organic sulfur compound to the

inlet of the reactors using the regeneration chemical injection system.
uop 117108-6 VII-12
Start sulfiding chemical injection into the lead reactor. If capable

injecting sulfiding chemical into individual reactors would be preferred.
d. Set the injection rate to deliver a maximum of 0.05 wt-% sulfur based
on the catalyst loading over a 2-hour period.
e. Stop injection when H2S is detected in the recycle gas or when the
total amount of organic sulfur compound (0.05 wt-% S based on
catalyst loading) has been injected. H2S samples taken at the outlet
of an individual reactor are to be done in accordance to refinery best
practice.
NOTE: It is not necessary to sulfide R-72 catalyst. With an R-72 staged-loading, if

possible, inject the sulfide compound only to the reactors that contain the Pt-Re
catalyst.
3. Feed In to the Reactor
a. Check the start-up naphtha to ascertain if it is clean, water white

(clear), and suitable for feed to the reactors.
NOTE: The columns should be warmed up, at or near operating pressure,

and on total reflux before charge is cut into the reactor section.
b. When the reactor inlet temperatures reach 700°F (371°C), charge

start-up naphtha to the Platforming reactors at approximately one-half
design rate. Close the startup bypass line around the Platforming
reactor section if it was being used for fractionation section circulation.
NOTE: Manpower should be available to light additional burners in the

Platforming charge heater and inter-heaters to pick up the increased heat duty
when charge is introduced.
uop 117108-6 VII-13
c. Adjust firing on the charge heater and the inter-heaters to hold 700-
750°F (371-399°C) on the reactor inlet temperatures until separator
operation has been established.
d. Adjust charge rate as soon as possible to achieve a minimum of 0.75

LHSV.
e. Care should be taken to prevent the hydrogen-to-hydrocarbon mole

ratio from dropping below design during charge-in operation. This
H2/HC ratio should be maintained as the hydrogen production
commences and the unit pressure stabilizes.
4. Establish Separator Operation
a. When condensed reactor effluent has reached a satisfactory level in

the separator, start the separator pump, unblock the separator level
control valve, and commission the level control instrument.
b. After starting hydrocarbon flow from the separator, a level will quickly
build in the next downstream vessel, i.e., net gas recontact separator
drum or fractionation column, and this equipment should be
commissioned in a similar manner to the previously described vessel.
5. Establish Normal Fractionation Section Operation
a. As soon as hydrocarbon flow reaches the fractionation section, line

out of the columns. The columns should already be warm and on total
reflux so this should require only adjusting the column reflux rates and
heat inputs to obtain the desired products.
b. Care should be exercised to ensure that material that has passed

through the Platforming reactor is not recycled to these reactors.
uop 117108-6 VII-14
6. Start Chloride Adjustment Program
Since the unit will normally be “wet” during a fresh catalyst start up or following a
regeneration, extra chloride must be added during the start-up to maintain the
catalyst chloride level. Chloride addition must begin once feed is cut in. The catalyst
chloride level is in equilibrium with the recycle gas water content. If the feed chloride
injection rate is too low, the recycle gas moisture will remove chloride from the
catalyst to equilibrate itself. This then decreases the catalyst chloride level and
affects catalyst performance. Proper control of feed chloride injection will maintain
the recycle gas water-chloride ratio, and thus not leach any chloride from the
catalyst. See the “Water-Chloride” section of Chapter 3, “Process Variables” for
details. During this period, the reactor inlet temperatures are held at lower levels
until the recycle gas water and H2S levels reach a low value in order to limit the
coke deposition on the catalyst.
a. As soon as feed is charged to the reactor, begin injecting an organic

chloride compound into the feed for catalyst chloride adjustment by
the programmed method. The chloride injection rate designated by
this method is dependent on recycle gas moisture content, as
illustrated below. Choose the injection rate based on the catalyst type
in the unit. If using an all platinum catalyst, follow the R-16 injection
rates. For R-72 staged loadings, follow the schedule for the Pt-Re
catalyst in use.
Recycle Gas Moisture

Chloride Addition Rate (Wt-ppm on Feed)
(Mole ppm)
R-16 R-50 Series R-62 Series R-86 & R-98
Over 500 50 10 25 10
300-500 30 6 12 6
200-300 20 4 8 4
100-200 10 2 4 2
30-100 5 1 2 1
<30 Normal Normal Normal Normal
uop 117108-6 VII-15
NOTE: The recycle gas moisture analyzer should not be commissioned until at least
24 hours after feed has been cut in to the Platforming unit. After this time, test the
recycle gas for HCl with sample tubes. When less than 15 mol-ppm HCl is indicated
in the recycle gas, the moisture content should be approximately 300 mol-ppm and
the analyzer can be commissioned. It is not advisable to commission this analyzer
sooner, as damage to the sensor cell may occur due to high HCl content in the
recycle gas or the probe could become saturated due to high moisture content in
the recycle gas.
b. Typically, the unit will not contain less than 500 ppm moisture in the
recycle gas on start-up. Therefore, the highest organic chloride
injection rate should be the initial rate in most cases.
c. Platforming Process Units with recycle gas driers: The drier

should not be placed in service until after feed cut-in. The drier should
be removed from service within 36 hours of feed cut-in, or when the
recycle gas moisture content drops below 30 mole ppm H2O,
whichever occurs first. The chloride injection rate during this first 36
hour period after feed cut-in should be the NORMAL injection rate as
indicated in the “Water-Chloride” section of Chapter 3, “Process
Variables” used when the recycle gas moisture is 30 mole ppm H2O
or less, as required to obtain the proper recycle gas chloride (HCl)
level. This injection rate will be unit specific as it depends on the
system moisture content, catalyst condition, etc.
If the NORMAL chloride injection rate for the unit is greater than 1 wt-
ppm, a 1 wt-ppm injection rate should be used during this first 36-
hour period after feed cut-in. Once the recycle gas drier has been
taken out of service, readjust the chloride injection rate as required to
attain the proper recycle gas chloride (HCl) level, i.e. increase the
chloride injection rate above 1 wt-ppm should that be required.
7. Increase Feed Rate and Reactor Temperatures
uop 117108-6 VII-16
Once operation of the separator(s) and downstream column(s) is established, the

reactor inlet temperatures may be increased.
a. After feed is introduced to the unit and has been increased to a

minimum of 0.75 LHSV, the feed rate should then be further increased
stepwise over a two-hour period to the desired rate.
b. At the same time, begin raising the reactor inlet temperatures at 55°F
(30°C) per hour. The inlet temperatures should be limited to the lower
of 900°F (482°C) or (880°F (471°C) for R-50 series, R-62, R-86 and
R-98 catalysts, or the temperature that produces a reformate octane
(RONC) of 92. This is to minimize the initial coke laydown.
D. STABILIZE OPERATIONS
1. Dry-Down
The water in the system (absorbed by the catalyst during loading, remaining from
the reduction step of the regeneration or remaining in piping or equipment from any
cleaning or testing) will slowly be driven off as feed is processed through the
reactors. Inlet temperatures should not be increased until the recycle gas moisture
content decreases sufficiently. The chloride injection rate must also be decreased
commensurate with the recycle gas moisture content.
a. If the unit was started on untreated straight run naphtha the

Platforming reactor inlet temperatures can slowly be raised to
produce the hydrogen needed for start-up of the NHT unit. The
Platforming reactor inlet temperature should not be increased any
higher than necessary to produce the needed hydrogen quantity.
NOTE: Platforming unit feed must be properly hydrotreated within 12 hours of

admitting feed to the reactors.
uop 117108-6 VII-17
b. When the feed meets all the contaminant specifications detailed

earlier in this procedure, check that the recycle gas moisture is below
200 mol-ppm, the sulfur content of the feed is 0.5 wt-ppm or less and
the hydrogen sulfide content of the recycle gas is below 2 ppm.
c. Increase the reactor inlet temperatures to 920°F (493°C) or 900°F

(482°C) for R-50, R-62, R-86 and R-98 series catalysts.
d. As the unit continues to dry out, continue the chloride adjustment

operation as per the program given earlier in this chapter.
e. If the recycle gas moisture analyzer is not operating properly or cannot

be properly calibrated, the following time schedule can be used as a
guide to adjusting reactor temperatures and chloride injection rates:
(1) Assume 2 days are required for the recycle gas moisture
content to be reduced to 200 mol-ppm.
(2) Assume an additional 2-3 days are required for the recycle gas
moisture content to be reduced to 30 mol-ppm.
f. However, for a unit with recycle gas dryer, if the recycle gas moisture
content does not decrease below 30 mol-ppm H2O within the first 36
hours after feed cut-in, then revert to the chloride injection schedules
as detailed earlier in this procedure. Inspection of the dryer and
adsorbent material should be made. A properly functioning recycle
gas drier should lower the system moisture level to 30 mol-ppm H2O
within this period of time.
2. Octane Response Testing
When the recycle gas moisture content is less than 30 mol-ppm and reactor inlet
temperatures are at 900°F (480°C) for R-50, R-62, R-86 and R-98 series catalysts
or 920°F (493°C) for all others, the octane response should be checked. See the
uop 117108-6 VII-18
discussion in the Water-Chloride section of Chapter III, “Process Variables” for

further details.
a. Increase reactor WAIT by 10°F (5.5°C).
b. After the unit has stabilized, sample the reformate for RONC.
c. The response should be at least one clear octane number per 4-5°F
(2-3°C) increase in reactor inlet temperatures (WAIT). If so, continue
to the next section.
d. If not, this is an indication that the catalyst chloride content is low. In

this event, perform one of the following:
(1). Increase the organic chloride injection rate several ppm for
several days. Remain at a reduced severity until the octane
response is back to normal.
(2). Decrease the reactor inlet temperatures back to 900°F (482°C)

(880°F (470°C) for R-50 series, R-62, R-86 and R-98 catalyst)
and, while still maintaining sufficient hydrogen production to
keep the hydrogen users in operation, inject 0.1 to 0.2 wt-%
chloride into the inlet of each reactor based on the mass of
catalyst in that reactor over a minimum of 4 hours. This
operation should be closely supervised.
e. Before increasing severity recheck the unit octane response as

discussed above.
3. Line Out to Start-Of-Run Conditions
a. When the recycle gas moisture content is less than 30 mol-ppm and
the octane response is good, the reactor inlet temperatures may be
increased to achieve the desired product octane.
uop 117108-6 VII-19
b. At the same time, the chloride injection rate should be reduced to

normal. The normal chloride injection rate will be dictated by the
Platforming Unit recycle gas moisture content and unit performance.
See the “Water-Chloride” section of Chapter III, “Process Variables”
for details.
uop 117108-6 VII-20
c. When the recycle gas moisture content decreases below 15 mol-

ppm, the injection of water (as clean steam condensate, or an easily
dissociated alcohol such as methanol or isopropyl alcohol) to the feed
should be established to maintain the proper moisture content of the
recycle gas. Typically 1 wt-ppm water in the feed equates to 3 mole
ppm moisture in the recycle gas. Assuming there is 0.5 to 1.0 wt-ppm
dissolved water in the stripper bottoms product, the normal water
injection rate would then be 4 to 4.5 wt-ppm based on the feed. The
target moisture level in the recycle gas is 15 to 25 mole ppm.
E. SULFUR GUARD BED
For units with a sulfur guard bed, it can be put on-line when the unit charge is
stable. The Platforming unit feedstock should be thoroughly dry before passing
through the guard bed. Proper stripper operation should ensure there is <2 ppm
moisture in the naphtha.
1. Crack open the valves at guard bed outlet to fill up the vessel. Vent gas
around the safety valve bypass. Care should be used to control liquid rate so
as not to disturb the bed.
2. Watch the level sight indicator (possibly installed on the PSV bypass) to
confirm that the vessel is full. Close the outlet valve.
3. Open the inlet valve on the guard bed, then the outlet valve. Close the
bypass valve around the guard bed to establish normal flow.
4. Frequently analyze at the outlet of first guard bed (if two in series) for sulfur
breakthrough.
uop 117108-6 VII-21
Fixed-Bed Platforming – General Operating Manual Normal Operations
VIII. NORMAL OPERATIONS
During normal operation, the unit must be operated so that two main objectives are
achieved. These are the production of the various product streams at proper
specification and the protection of the Platforming Catalyst. These objectives can
only be achieved on a long term basis if good control is exercised on the unit. Such
control requires that the unit weight balance (100 ± 2 wt.%), accurate analyses be
reported on feed and product streams, the feed be properly treated to remove
contaminants, and unit operation be smooth at proper catalyst water/chloride
balance with a minimum of upsets.
A. DATA COLLECTION/PERFORMANCE MONITORING
Commercial experience on numerous Platforming units has shown that, with good
installation and a proper program for preventative maintenance of instrumentation,
an adequate unit weight balance can be achieved on a routine daily basis. Similar
experience using modern up-to-date laboratory equipment and techniques has also
proven the feasibility and value of accurate stream analyses. Most refiners have few
problems with either of these items. However, adequate feed pretreating to remove
contaminants and stable unit operation have eluded many refiners because both
items are very susceptible to the mechanical condition of the unit and the quality of
operation and operating personnel.
Most refiners find that daily operating plots are the best technique for unit
performance evaluation. The following data is generally plotted:
Reactor inlets as WAIT, °C (°F)

Total delta T, °C (°F)
Reactor delta T, %
C5+ yield, LV% of charge
Stabilizer bottoms octane, F-1 clear
Stabilizer bottoms aromatic content, LV% (Aromatics units only)
uop 117108-6 VIII-1
Stabilizer offgas, Nm3/m3 (SCFB of charge)

Stabilizer overhead liquid, LV% of charge
H2 production, Nm3/m3 (SCFB of charge)
LHSV
Molal H2/HC ratio
Separator pressure, kg/cm2 (psig)
Recycle gas purity, mol % H2
Chloride injection, ppm by wt.
Water injection, ppm by wt.
Water in recycle gas, molal ppm
Catalyst carbon, wt-%
Catalyst chloride, wt-%
From such daily operating plots, any change in unit performance that is not
accounted for by a corresponding change in unit operating variables may be readily
recognized and corrective action taken, if necessary.
UOP uses a proprietary computer program called CDOTS to collect, store and
process a refiner’s operating and laboratory data. CDOTS is very useful for tracking
process performance and for predicting future operation and regenerations. CDOTS
can be installed on a refiner’s PC so that data analysis can be performed daily. The
data can also be sent electronically to UOP for review. In CDOTS format, data can
be much more easily processed and reviewed by UOP thus giving a more timely
turnaround.
B. WATER-CHLORIDE CONTROL
Control of the catalyst chloride-water balance for optimum catalyst selectivity and
maximum product octane or maximum aromatics production is one of the most
critical areas of Platforming unit operation. A good technique for obtaining this
objective (control) is important for smooth operation, since such control must take
into account all factors affecting unit performance. Typical factors involved are:
uop 117108-6 VIII-2
• Charge stock quality

• Average reactor pressure
• LHSV
• Product aromatics content or octane
• Recycle gas water content
• Hydrogen/hydrocarbon ratio
A change in any one of these factors can affect the unit operation sufficiently to
cover up a change in the catalyst chloride level. The unit performance interpretation
technique must, therefore, be chosen such that these factors are normalized before
performance is evaluated.
The water and chloride injection amounts may seem to be insignificant by virtue of
their size, but are actually very important items in the maintenance of the unit
chloride-water balance and hence proper unit operation and catalyst activity.
Uncontrolled injection rates of either water or chloride will severely handicap stable
operation. The water and chloride injection tanks and gauge glasses should be
rigorously calibrated, chloride blends carefully prepared, and injection rates
frequently checked. Under normal conditions, the injection rates may vary from
week, but, in most cases, will be continuous.
The water and organic chloride injection rates will be determined by monitoring the
recycle gas water and hydrogen chloride contents, the chloride and water content of
the naphtha charge and the selectivity of the catalyst (aromatics in the product
primarily). The HCl content of the recycle gas should be monitored once a shift with
gas tubes, i.e., HCl Dräger tubes. With the proper water injection rate the HCl in the
recycle gas should be as discussed in the Water-Chloride section of Chapter III,
Process Variables. The moisture content of the recycle gas can be obtained on a
continuous basis through use of the moisture analyzer installed on that stream. A
general rule of thumb for correlation of water in the recycle gas is that one weight
ppm of water in the charge will give approximately three molal ppm water in the
recycle gas. The continuous moisture analyzer operation should be frequently
cross-checked with this rule of thumb to insure its continued proper performance.
Any discrepancies on laboratory analyses should be checked. See chapter III
“Process Variables” section D for a full description of water-chloride functions,
injection rates and evaluation methods.
uop 117108-6 VIII-3
As the catalyst ages, its chloride retention decreases. To maintain catalyst chloride
level and hence catalyst activity, it is necessary to increase the chloride injection
rate. A general relationship between catalyst age and the required water-chloride
ratio to be maintained in the recycle gas is represented in Figure VIII-1. The
relationship represented in Figure VIII-1 is a general guideline and should be
adjusted commensurate with any data from actual catalyst chloride analytical results
and unit performance.
Substantial variation in catalyst surface area versus the number of regenerations

exists due to the following factors:
• Care in controlling the mol-% oxygen and the delta T across the reactor
during the carbon burn
• Duration of the carbon burn, which depends largely on the coke level on the
catalyst at the end of each cycle
• Degree of maldistribution in the reactor leading to higher temperature
exposure for some of the catalyst during the proof burn and the start of the
oxidation step
• Differences in the water vapor content of the circulating regeneration gas
during the carbon burn, which is largely a function of the separator
temperature and pressure.
In addition, there is sometimes substantial variation in the catalyst surface area

between the catalyst in the first reactor compared to catalyst in the last reactor due
to the differing coke levels and, consequently, the duration of the burns. Some
refiners rotate their catalyst during dump and screening to try to keep the surface
area relatively even throughout the inventory.
Increasing the chloride injection rate in this manner will increase the HCl in the
recycle gas. The actual increases in HCl content could be so low that it may be
difficult to detect them analytically (with a sniffer tube in the recycle gas stream). It
is therefore most important to monitor process performance as detailed in the
“Commercial Evaluation Tools” sub-section of the “Water Chloride Control” section
of Chapter III, “Process Variables” to insure that the proper catalyst chloride level is
maintained.
uop 117108-6 VIII-4
Figure VIII-1
Approximate Water-Chloride Ratio Requirements with
Catalyst Age
210 1
205
Approximate Catalyst Cycles

Catalyst Surface Area, m /kg
200
2
2
195
190
3
185
4
180
5
175 6
7
170 8
165 10
10 12 14 16 18 20
Molar Water-Chloride Ratio
uop 117108-6 VIII-5
C. CATALYST SAMPLING
During normal operation catalyst is sampled as frequently as necessary to establish

and maintain optimum catalyst chloride content and monitor carbon laydown rate.
Typically, catalyst is sampled every one to two weeks after a regeneration until
normal chloride levels are established and then every one to two months thereafter.
Catalyst should also be sampled after a severe upset to check the effect of the
upset on chloride and carbon content. See Chapter 9, “Analytical” for further details.
D. FRACTIONATION
On a typical Platforming unit, the liquid product is stabilized in a fractionation

column prior to transfer to storage or additional splitting. Since this fractionation
column may be a depropanizer, debutanizer, or depentanizer, the operating
pressure and other conditions must be adjusted within tower design limits to obtain
the desired bottoms product. Analytical results on the overhead and bottoms
products are generally used as the basis of such adjustments, i.e., changes to
reboiler temperature and reflux flow rate.
uop 117108-6 VIII-6
Fixed-Bed Platforming - General Operating Manual Analytical
IX. ANALYTICAL
The UOP Platforming Process depends heavily upon various analytical methods for
control and protection of the process, the catalyst, and the equipment. Since there
is an almost bewildering number of analytical methods available to laboratory
personnel, some guidance is necessary in order to obtain laboratory results which
will be meaningful to the operator and his supervisor.
A. LABORATORY SCHEDULES
Following are typical laboratory schedules for a Platforming unit during normal
operation and during Regeneration that outline some of the more common
procedures.
1. Platforming Unit – Typical Laboratory Test Schedule
Test Name Test Method / Number Frequency

Normal Startup
Platforming Unit Charge (Stripper Bottoms)
Relative Density ASTM D 4052 or 3/D 3/D
ASTM D 1298
API ASTM D 287 3/D 3/D
Distillation ASTM D 86 3/D 3/D
Color ASTM D 156 3/D 3/D
Sulfur ASTM D 4045 or D 5453 1/D 1/D
Chloride UOP 395 or 588 1/W 1/D
Nitrogen ASTM D 4629 1/W 1/D
Composition (PONA) UOP 880 1/W 1/D
Paraffins UOP 690
Aromatics UOP 744
Naphthenes UOP 870
Composition (C6-) UOP 551 As Req. 1/D
Arsenic UOP 296 or 946 1/M 1/W
Lead UOP 350 or 952 1/M 1/W
Copper UOP 144 or 962 1/M 1/W
Water Content UOP 481 As Req. 1/W
uop 117108-6 IX-1

Normal Startup
Bromine Index UOP 304 1/M 1/W
Silicones UOP 787 1/M 1/W
Fluoride UOP 619 1/M 1/W
Mercury UOP 938 As Req, As Req,
* Active Oxygen ASTM E 299 1/M 1/W
* Dissolved Oxygen UOP 678 1/M 1/W
* Carbonyl UOP 624 1/M 1/W
* Trace Metals UOP 391 or UOP 389 1/M As Req,
* - When downstream of non-UOP NHT unit only

Normal Startup
Recycle Gas
Relative Density UOP 114 1/D 3/D
Composition UOP 539 1/D 1/D
HCI Detector Tube 1/D 3/D
H2S Detector Tube 1/D 3/D
H2O UOP 344 On Line Analyzer
Net Gas
Stabilizer Off Gas (Debutanizer Gas)

HCl Detector Tube 1/D 1/D
Stabilizer Overhead Liquid (Debutanizer OVHD Liquid)

Relative Density ASTM D 1657 1/D 3/D
H2S UOP 212 1/D 1/D
Bromine Index UOP 358 1/W 1/D
Residues in LPG ASTM D 2158 1/W 1/D
Chlorine UOP 910 1/W 1/D
uop 117108-6 IX-2

Normal Startup
Stabilizer Bottoms (Debutanizer Bottoms or Reformate)
ASTM D 1298
Reid Vapor Pressure ASTM D 323 or 3/D 3/D
ASTM D 5191
Octane Research ASTM D 2699 1/D 1/D
Color ASTM D 156 1/W 1/D
Composition (C5-) UOP 551 1/W 1/D
Paraffins UOP 690
Aromatics UOP 744
Naphthenes UOP 870
Bromine Number UOP 304 1/W 1/D
Gums ASTM D 381 As Req. As Req.
Deheptanizer Off Gas (Reformate Splitter Off Gas)

Composition UOP 539 As Req. 3/D
Deheptanizer Overhead Liquid (Reformate Splitter Overhead Liquid)

Relative Density ASTM D 1657 1/D 3/D
Distillation (if require) ASTM D 86 1/D 3/D
H2S UOP 212 (w/LPG) 1/D 1/D
UOP 163 (Stable Liquid)
Deheptanizer Bottoms (Reformate Splitter Bottoms)

ASTM D 1298
Color ASTM D 156 1/D 1/D
Paraffins UOP 690
Aromatics UOP 744
Naphthenes UOP 870
Bromine Number UOP 304 2/W 1/D
Heater Flue Gas

Oxygen Content Orsat As Req. As Req.
uop 117108-6 IX-3

Normal Startup
Reforming Unit Steam Generation Continuous Blowdown

Total Hardness (as CaCO3) ASTM D 1126 As Req. As Req.
Ca Hardness (as CaCO3) ASTM D 1126 As Req. As Req.
Mg Hardness (as CaCO3) ASTM D 1126 As Req. As Req.
Potassium ASTM D 4192 As Req. As Req.
Sodium ASTM D 4191 As Req. As Req.
Copper ASTM D 1688 As Req. As Req.
Iron ASTM D 1068 As Req. As Req.
Total Alkalinity (as CaCO3) ASTM D 1067 3/D 3/D
M Alkalinity (as CaCO3) ASTM D 1067 As Req. As Req.
P Alkalinity (as CaCO3) ASTM D 1067 As Req. As Req.
Chloride ASTM D 512 As Req. As Req.
Sulfate ASTM D 516 As Req. As Req.
Silica ASTM D 859 As Req. As Req.
Total Dissolved Solids APHA 2540C As Req. As Req.
Total Suspended Solids APHA 2540D 3/D 3/D
pH ASTM D 1293 3/D 3/D
Specific Conductance ASTM D 1125 3/D 3/D
Dissolved Oxygen ASTM D 888 As Req. As Req.
Turbidity ASTM D 1889 As Req. As Req.
Phosphates ASTM D 4327 3/D 3/D
Oil ASTM D 3921 As Req. As Req.
Hydrazine ASTM D 1385 1/D 1/D
On-Stream Catalyst Samples

Carbon (after Carbon Burn) UOP 703 As Req. As Req.
Carbon on spent catalyst UOP 602 and UOP 703 As Req. As Req.
Chloride UOP 291 and UOP 275 As Req. As Req.
or UOP 949
Sulfur UOP 864 As Req. As Req.
uop 117108-6 IX-4
2. Catalyst Regeneration – Typical Laboratory Test Schedule

Carbon Burn
Each reactor outlet
SO2 Detector Tube At peak of burn wave
HCl Detector Tube Twice during burn of each
reactor
Separator (Circulating Caustic)

Water pH ASTM D 1293 (pH Meter) Every 30 mins
or Litmus Paper
Solids concentration Boil Away Every 30 mins
Caustic solution (Total UOP 209 and UOP 210 Every 30 mins
Alkalinity)
Iron ASTM D 1068 Every 3~4 hours
Compressor discharge (and last RX inlet if parallel burn)

O2 Portable Anal. Continuous
Oxidation
All reactor outlets
SO2 Detector Tube Every 3~4 hours
HCl Detector Tube Every 3~4 hours

or Litmus Paper
Alkalinity)
Iron ASTM E 291 Every 3~4 hours
Compressor discharge (and last RX inlet if parallel burn)

Cool Down
All reactor outlets and reactor #1 inlet
SO2 Detector Tube At reactor outlet temps. of
900, 700 and 500°F
HCl Detector Tube At reactor outlet temps. of
900, 700 and 500°F
Compressor discharge
uop 117108-6 IX-5

Nitrogen Purge
Compressor suction, discharge and all dead-end lines
SO2 Detector Tube Every 15 mins. On forward
and back purges
CO2 UOP 172 Every 15 mins. On forward
and back purges
Reduction
All reactor outlets and reactor #1 inlet
H2S Detector Tube At reactor outlet temps. of
900, 700 and 500°F
HCl Detector Tube At reactor outlet temps. of
900, 700 and 500°F

Measure water volume - At reactor outlet temps. of
drained 900, 700 and 500°F
Water pH ASTM D 1293 (pH Meter) At reactor outlet temps. of
or Litmus Paper 900, 700 and 500°F
Sulfate Removal
All reactor outlets
H2S Detector Tube Every hour
HCl Detector Tube Every hour

or Litmus Paper
Alkalinity)
Iron ASTM E 291 Every 3~4 hours
Compressor discharge
H2S Detector Tube Every hour
H2 On-Line Continuous
Suggested sniffer tube inventory:
Type Without Sulfate Removal With Sulfate Removal

SO2 35 tubes 50 tubes
HCl 50 tubes 100 tubes
H2S 25 tubes 60 tubes
uop 117108-6 IX-6
B. ANALYSES OF STREAMS
This section discusses the various methods of analyzing the major process streams
in the Platforming Unit.
1. Liquid Streams
The following are the most common tests performed on liquid streams; feed and
reformate.
a. PONA – UOP 880
This method, “Hydrocarbon Types in Low Olefin Distillates by GC”, is a procedure

for calculating paraffin, olefin, naphthene and aromatic hydrocarbon types in
hydrocarbon fractions, such as reformer feeds and reformates, having endpoints of
200°C or less (C3 through C11). C12 paraffins and naphthenes at concentrations
totaling less than 3% can be determined. Olefins must be less than 2%. C6 minus
can be reported individually or by carbon number. C7 through C12 paraffins and
naphthenes are determined by carbon number. Aromatics through C10 can be
determined individually or by carbon umber with C11+ aromatics determined as a
composite. Olefins are reported undistributed. Results are reported in mass-percent
(mass-%) or liquid volume-percent (LV-%).
The sample is analyzed by three gas chromatographic methods: UOP Methods

690, 744 and 870. Data are combined from each analysis to report the total
composition of the sample. The sample is analyzed by UOP Method 690 to
determine the individual C8 minus paraffin and naphthene distribution. The total C8
minus olefins are also determined by this method. The sample is then analyzed by
UOP Method 870 to determine the total paraffins, naphthenes and aromatics by
carbon number. Finally the C6 through C10 aromatics distribution and the C11+
aromatic composite are determined by UOP Method 744.
uop 117108-6 IX-7
(1) Naphthenes - UOP 690
This method, “Octanes and Lower Boiling Hydrocarbons in Olefin-

Free Gasolines by Gas Chromatography”, is for determining C8 and
lower boiling paraffins, naphthenes, benzene and toluene in olefin-free
gasolines having a maximum final boiling point of 260°C. Certain non-
aromatic components of interest are reported as composites and C8
aromatics are not quantitatively determined.
(2) Paraffins - UOP 870
This method, “Carbon Number Distribution of Paraffins, Naphthenes

and Aromatics by Gas Chromatography”, determines the P, N, A
distribution in hydrocarbon fractions having a maximum final boiling
point of 200°C (C3-C11). C12 paraffins and naphthenes at
concentrations less than 3% can be determined. C9+ aromatics are
reported as a group. Olefins, if present, are hydrogenated and the
resultant saturates are included in the paraffin and naphthene
distribution. Many samples that fit the scope of UOP 777 can be
analyzed by this automated method, which requires only one injection
into the gas chromatograph.
(3) Aromatics - UOP 744
This method, “Aromatics in Hydrocarbons by Gas Chromatography”,

is a method for determining individual C6 through C10 aromatic
compounds in petroleum distillates or aromatic concentrates having a
final boiling point of 210°C or lower. C11 and heavier aromatics are
reported as a group. C10 and heavier non-aromatics, if present in
appreciable quantities, may interfere with the determination of
benzene and toluene. When this occurs, benzene and toluene can be
determined by UOP Method 394 or ASTM Method D 4420. Other
applications include assay of certain aromatics, namely, benzene,
toluene, mixed xylenes and O-xylene. This method may also be used
to provide a distribution of C8 aromatics and/or C9 and heavier
aromatics to a value determined by a different method. When used for
uop 117108-6 IX-8
any of the above applications, the lower limit of detection for a single
aromatic component is 0.05 mass- or liquid volume-%.
b. Poisons
For details of analyses for common catalyst poisons, see the “Catalyst Poisons”
section of chapter III, “Process Variables”.
c. Composition (C6-)
UOP Method 551 is for determining benzene, individual hexanes and lower boiling
point hydrocarbons in olefin-free gasoline having a final boiling point of 260°C or
lower. Results are reported in mass-% or lv-%. The lower limit of detection for a
single component is 0.05 mass-%.
d. Distillation – ASTM D86
This method covers the distillation of motor gasolines, and similar petroleum
products. A sample is distilled under prescribed conditions and systematic
observations of thermometer readings and volumes of condensate are made.
e. Density and API Gravity
(1) API Gravity - ASTM D287
Using a glass hydrometer, the API gravity of crude petroleum and petroleum
products which have a Reid Vapor Pressure under 26 lbs can be determined.
Gravities are determined at 60°F by means of standard tables. Conversion tables
are not applicable to non-hydrocarbons or essentially pure hydrocarbons such as
the aromatics.
uop 117108-6 IX-9
(2) Relative Density - ASTM D4052
This test method covers the determination of density or relative density of petroleum
distillates and viscous oils that can be handled in a normal fashion as liquids at test
temperatures between 15 and 35°C. Its application is restricted to liquids with vapor
pressures below 600 mm Hg (80 kPa) and viscosities below about 1500 cSt (mm/s)
at the temperature of test.
f. RONC – ASTM D2699
This method determines the knock characteristics of motor gasolines, intended for
use in spark-ignition engines. A Research Octane Number (RONC) of 100 or lower
is the volume percent of iso-octane in a blend with n-heptane that matches the
knock intensity of the unknown sample. For numbers above 100, a comparison is
made to iso-octane and milliliters of tetra-ethyl lead required to match the knock
intensity. Knock intensity is measured by an electronic detonation meter on a
testing unit consisting of a single-cylinder engine.
g. Reid Vapor Pressure – ASTM D323, D5191
This method determines the absolute vapor pressure of volatile crude oil and
volatile non-viscous petroleum products, except LPG. The gasoline chamber of the
testing apparatus is filled with a chilled sample and connected to the air chamber
section which should be at 100°F. The container is then immersed in a constant-
temperature bath and shaken periodically until the equilibrium is reached. A
manometer attached at the end of the cylinder-like apparatus is read and corrected
if the air chamber temperature is initially at something other than 100°F.
h. Color – ASTM D156
This method covers the determination of the color of refined oils such as undyed
motor and aviation gasoline, jet fuels and kerosine. A sample of the liquid is added
to a tubular column through which a light source is seen. The color is compared
with specific glass standards. The height of the liquid sample is decreased by levels
uop 117108-6 IX-10
until the color of the sample is lighter than that of the standard. The color number
above this level is reported. The range of number is +30 (lightest) to –16 (darkest).
Color standards correspond to sample depth and color number.
2. Gas Analyses
a. Sniffer Tubes
Through a great range of experience using various "sniffer" tubes, we have found
the Dräger Multi Tester to be the easiest "sniffer" apparatus to use and read. Since
both H2S and HCl analysis of the separator and fractionator gas streams are for unit
control purposes, it makes sense to do the samples at the unit, if this is possible.
The various "sniffer" tube devices are all applicable at the unit and give rapid results
(much quicker than a laboratory test).
In gathering trend data for the recycle gas water-to-chloride ratio, the sampling
method is extremely important. Since the concentrations of both water and chloride
are very low, small changes in temperature as gas flows through a sample line can
change the concentration. To obtain a representative recycle gas sample, the
sample should be taken at the recycle gas compressor discharge (where the gas is
hotter), through a very short and well-purged sample connection. Tygon is the
preferred material for the connecting tube. The tube should definitely not be copper.
The sample should not be taken until the sample line reaches the same
temperature as the compressor discharge line. In addition, to eliminate
contamination of the sample with ambient air, a special connection such as the one
shown in Figure IX-1 should be made. For gas detector tubes (Dräger, MSA, or Gas
Tech), it is important not to create a positive pressure at the inlet to the tube, since
the tube is calibrated for a fixed volume of sample gas.
uop 117108-6 IX-11
Figure IX-1
Recycle Gas Sampling
Minimum Length Flexible

Plastic Tubing
Glass Tee
Compressor Discharge Piping
Gas Sniffer Tube
PLT-R00-217
uop 117108-6 IX-12
b. Composition – UOP 539
This method is for determining the composition of a wide variety of gaseous

hydrocarbon mixtures obtained from refining processes or from natural sources,
including minor concentrations of the composite of C5 olefins and C6+
hydrocarbons. 1-Butene is not resolved from iso-butylene and argon is determined
as a composite with oxygen.
c. Gas Density – UOP 948
This method is for calculating the relative density of gas mixtures, generated by
typical refinery processes run under typical conditions, from their composition as
determined by UOP Method 539 or any other suitable method. This method can be
used in place of UOP Method 114. The relative density of air is defined as unity
(1.00).
3. Catalyst Analyses
UOP’s catalyst sampler takes only a small volume of catalyst so as not to disturb
the bed. (Note that caution must be exercised in sampling frequently from a radial
flow first reactor as too much sampling can have an adverse effect on catalyst seal.
Additional catalyst should be loaded in the seal area when a catalyst sampler is
employed.) See Figure IX-2.
The sampling device works on the principle of a gas lift from reactor to the sample
receiver. The sample receiver is connected to the probe while under a slight
nitrogen pressure. When the final block valve is opened, the surge of gas that
equalizes the pressure in the sample receiver fluidizes a small amount of catalyst
transferring the catalyst to the receiver. The amount of catalyst withdrawn from the
reactor is controlled by the volume of gas vented to the sample receiver that in turn
is controlled by the size of the sample receiver. See Figure IX-3. There follows a
generalized procedure for the operation of the UOP Catalyst Sampler; for a
detailed procedure of a particular sampler, please contact UOP PIC Systems.
uop 117108-6 IX-13
a. Clearing the Catalyst Sampler
To insure that any residual hydrocarbon, catalyst and/or air is removed from the
sampling system, proceed as follows:
(1). Open up the nitrogen cylinder

(2). Vent any pressure in the sampler.
(3). Drain any liquid from the sampler.
(4). Pressure the sample receiver with nitrogen.
(5). Depressure the sample receiver to the vent.
b. Testing the Integrity of Valve #1
This valve isolates the sampling system from the reactors so it is vitally important
that it functions correctly.
(1). Close valve #1

(2). Open valve #2
(3). Monitor the pressure of the sample receiver
(4). Any appreciable increase in pressure could mean that valve #1
is passing and so sampling should not be attempted.
(5). If integrity is acceptable, purge nitrogen through the sample
receiver to the vent.
c. Clearing the Sample Probe
To insure that any residual hydrocarbon and/or catalyst is removed from the
sampling probe, proceed as follows:
(1). Pressure the sample receiver with nitrogen to 10~20 psig less
than the reactor pressure.
(2). Slowly open valve #1 until the receiver pressure equalizes with
that of the reactor.
(3). Close valve #1
uop 117108-6 IX-14
(4). Slowly vent the pressure from the sample receiver

(5). Purge the sample receiver with nitrogen
(6). Drain any material from the sample receiver
d. Collecting a Catalyst Sample
To collect the sample, proceed as follows:

(2). Pressure the sample receiver with nitrogen to establish the
required ΔP with the reactor for the size of catalyst sample
required (see Figure IX-3).
(3). Open valve #1 for 10~20 seconds then close.
(4). Depressure the sample receiver to the vent
(6). Collect the catalyst from the bottom of the sample receiver.
e. Securing the Catalyst Sampler in Stand-By Condition
When the sampling is complete,
(1). Replace the cap on the receiver drain valve.

(2). Ensure that valve #1 is securely closed
(3). Block in the nitrogen cylinder.
uop 117108-6 IX-15
Figure IX-2
UOP Catalyst Sampler
Existing Special Catalyst

Flame Arrestor Sampling Probe
Vent to Nozzle
Atmosphere Catalyst Bed
Reformer Reactor
Valve #1
Relief Valve
Valve #2 Special Ball

Valves
Pressure Gauge
Pressure Regulator
Sample Receiver
Nitrogen
Cylinder
F.B. Plat
117108 IX-2
uop 117108-6 IX-16
Figure IX-3
Catalyst Sampler Transfer Capacity
uop 117108-6 IX-17
a. Carbon Content
The analytical procedure employed depends on the state the catalyst is in when the
sample was taken. A spent catalyst sample may still contain some hydrocarbon
residue and method UOP 602 must be employed first to remove the residue before
UOP 703 can be performed to determine the carbon content. Catalyst Samples
taken after carbon burn can be analyzed directly by UOP method 703.
(1) UOP 602
This method, “Soxhlet Extraction of Catalyst” is for separating hydrocarbons from

catalyst by extraction with a volatile solvent. This extraction is used to obtain a
hydrocarbon a water-free catalyst sample for carbon determination by UOP Method
703. It can also be used to determine the non-volatile hydrocarbon content of the
sample, or to provide an extract for subsequent organic types analysis.
(2) UOP 703
This method, “Carbon on Catalysts by Induction Furnace Combustion and Infrared

Detection”, is for determining total carbon on catalysts and in other inorganic
materials using a high temperature induction furnace analyzer. The method is
generally applied over a range of 0.01 to 20 mass-% carbon; however, up to 100
mass-% carbon can be determined with appropriate calibration. On spent catalyst,
the carbon may be present as coke and/or hydrocarbons. If only the present as
coke is desired, hydrocarbons are removed as described in UOP Method 602.
Analysis of catalysts containing light hydrocarbons can be problematic due to
thermal loss of the hydrocarbons before controlled combustion occurs. For such
materials, other methods, such as carbon, hydrogen and nitrogen by ASTM D5291,
should be utilized. The presence of halogens in the sample has been shown to
cause corrosion damage to the instrument, therefore a trap consisting of antimony
metal and potassium iodide must be utilized.
uop 117108-6 IX-18
b. Chloride
(1) UOP 949
The latest method, “Total Chloride in Catalysts by X-Ray Fluorescence”, is for

determining the total chloride content of fresh alumina and silica-alumina catalyst or
catalyst base and regenerated or spent alumina and silica-alumina catalyst, by X-
Ray Fluorescence (XRF) Spectroscopy. The test is quantitative over a range of 0.01
to 3 mass-% on samples containing less than 10 mass-% water.
(2) UOP 291
This method, “Total Chlorine in Platforming Catalysts by Digestion and

Potentiometric Titration”, is a procedure for the determination of total chlorine and
bromine in Platforming catalysts. The catalyst is leached with hot, dilute sulfuric
acid. Chloroplatanic acid, if present, is reduced. The chloride is titrated
potentiomentrically with silver nitrate solution.
c. Sulfur – UOP 864
This method, “Sulfur in Organic and Inorganic Materials by Combustion and IR

Detection”, is for determining the total sulfur in petroleum products, and other
organic/inorganic materials using a LECO Sulfur Analyzer. The detection range is
from 100% down to a lower limit of 0.005 mass-% sulfur. Nitrogen and halogens do
not interfere unless they are present in concentration ten times higher than that of
the sulfur.
d. Other Analyses
Many refiners may be capable of running carbon and chloride on catalyst samples.
There are other analyses that also provide insight into unit performance that UOP
can provide. These other analyses, in addition to carbon and chloride that UOP's
laboratory can perform, include:
uop 117108-6 IX-19
1. Surface area, Pore Volume and Diameter

2. Platinum dispersion by x-ray diffraction
3. Trace metals on the catalyst by ICP
4. Alumina types by x-ray diffraction
4. Regeneration Caustic Analyses
Other than simple pH testing of the circulating caustic during catalyst Regeneration,
determination of the total alkalinity is also required (see discussion in the
Regeneration Chemistry section of chapter II, “Process Variables”). The following
two methods can be used to do this. One is rigorous and the other more
convenient.
a. UOP Method 210-76T
This method, “Caustic Solution Analysis – Double Indicator Method”, is a

convenient, though not rigorous, test for the plant control of refinery caustic
solutions used to remove hydrogen sulfide, mercaptans and certain other weak
acids from petroleum products. The method is also applicable to Merox circulating
caustic. The results are significant only when correlated with plant experience.
While the Double Indicator Procedure may be a convenient procedure to use, a

potentiometric procedure is more accurate and can distinguish between strong
basis; i.e., sodium phenolate and sodium hydroxide. See UOP Method 209.
This method uses two indicators to distinguish strong bases from weak bases
present in the sample. Strong bases in the sample are titrated with standard acid to
the bromthymol blue endpoint. Strong plus weak bases in a second sample are then
titrated with standard acid to the bromphenol blue endpoint to determine total
alkalinity.
uop 117108-6 IX-20
b. UOP Method 209-83
This method, “Potentiometric Analysis of Used Refinery Caustic Solutions”, is for

determining the strong base, weak base (spent caustic) and total alkalinity of used
refinery caustic solutions. A titration for determining the concentration of sulfur
present as sodium sulfide and as sodium-mercaptide is also included.
While this potentiometric procedure may be a more accurate procedure to use to

distinguish between strong bases, i.e., sodium phenolate and sodium hydroxide,
UOP Method 210, "Caustic Solution Analysis–Double Indicator" is also available for
a convenient, although not rigorous, test for the plant control of refinery caustic
solutions used to remove hydrogen sulfide, mercaptans and certain other weak
acids from petroleum products.
The strong base, weak base and total alkalinity are determined by titrating with
standard acid using a potentiometric procedure. The titration of the strong bases to
an endpoint in a pH range of from 9 to 6 includes sodium hydroxide, one-half of the
sodium carbonate, one-half of the sodium sulfide, sodium alkyl mercaptides and
sodium phenolates. The titration of the weak bases from a pH of about 6 to an
endpoint in a pH range of from 4 to 3, includes sodium bicarbonate, sodium
bisulfide, sodium naphthenates and sodium thiophenolates (sodium aryl
mercaptides).
C. SAMPLE SHIPPING PROCEDURE
1. Procedure and Documentation
Included at the end of this chapter are the standard procedures and forms to be
used when shipping any samples to UOP for laboratory analyses.
uop 117108-6 IX-21
2. Sample Containers
a. Octane Loss
It has been found that sample collection in clear bottles, which are left exposed to
sun light (or ultraviolet lighting) either direct or indirect, and whether or not the
sample has been treated with oxidation inhibitors, will result in a severe loss of
octane rating within a very short time. Every effort must therefore be made to see
that only the brown or amber sample bottles are used for daily samples and more
important that all samples shipped to UOP for analysis are taken in amber bottles,
are kept in a cool dark place until packaged for shipment, and are shipped as soon
as possible after sampling.
It appears the mechanism for octane loss is peroxide formation. When air saturated
samples are exposed to ultraviolet light, peroxides are formed. Peroxides are pro
knock compounds that thermally decompose at temperatures lower than the
desired combustion temperatures in engines.
b. Plastic
It has been found that hydrotreated kerosene sample when stored in a plastic
sample bottle would have 2 to 3 times the sulfur content after 10 days than it had
the first day. It appears the plastic container increased the sulfur content of the
sample. Therefore, plastic containers should be avoided for sampling naphtha
streams.
c. Polyethylene Caps
There have been found to be problems associated with the shipment of liquid
samples shipped in standard laboratory vials with conical polyethylene caps. It has
been found, through controlled tests, that samples cannot only permeate out of the
containers in the question, but that the samples can actually cross- permeate
between samples.
uop 117108-6 IX-22
Tests were performed with the type of vials generally available in the laboratory
using caps with liners of various materials. In a typical test, a vial containing only
benzene and a vial containing only orthoxylene were placed together in a sealed jar
for a period of time. The jars were heated to 40°C (a very possible shipping
temperature) to speed the permeation. Tests were done both with the vials in an
upright position and with the vials lying on their side so that the liquid would contact
the caps. The common conical polyethylene lined caps cross-permeated from 0.50
to 4% under these conditions. Paper lined caps produced terrible results. Corks and
Teflon linings worked well until they were tipped over, at which point these
containers also produced terrible results. The best caps found thus far are the foil
lined caps. The aluminum foil lined caps cross-permeate only slightly and the tin foil
lined caps do not cross-permeate at all.
The following recommendations are made: If possible, keep the samples cool.
Temperature does affect the permeation rate through some materials. Use tin foil
lined caps when available and keep the samples as far apart as possible so they
will have less tendency to cross-permeate.
uop 117108-6 IX-23
General Letter for Domestic Samples (from within the USA)
Revised January 15, 2003
Following are the general procedures to be used when sending sample(s) to UOP for
analysis, with the exception of SPA Catalyst samples, which will continue to be handled as
before.
Information:
1. Please complete the attached Form and Fax it to UOP in Des Plaines, IL at (847) 627-
8225 when the samples are shipped. Please note that completing this form will minimize
delays in sample analysis.
Samples:
1. Label samples clearly with refinery name, location, sample description, and date
collected.
2. Ship samples to:
UOP LLC
Sample Receiving
200 E Algonquin Rd
Des Plaines, Illinois 60017-5016
Attn: Catalyst & Advanced Materials – OTS Sample Coordinator
3. We recommend that samples be shipped by Federal Express or Emery. US Mail may be

used for non-hazardous samples when expedited service is not required. Samples must be
classified for "IATA" or "DOT" regulations and MUST be accompanied by the appropriate
Material Safety Data Sheet (MSDS). The MSDS should include CAS numbers for
identification per TSCA (Toxic Substances Control Act).
4. Include a copy of the attached Form with the samples.
5. Hand carrying of samples to UOP without proper documentation is illegal. Therefore,

UOP employees and customers are to refrain from transporting any samples by this
method, from any refinery to any UOP laboratory or office.
uop 117108-6 IX-24
DOMESTIC
Analytical Requisition Form - UOP Technical Service
TO: UOP Catalysts & Advanced Materials – Sample Coordinator

Phone 847-391-2620 FAX: 847-627-8225
UOP Technical Service Contact ____ _____ Phone 847-391-___ _ Fax 847-391-2253
Customer: Refinery
Address
Address
Contact Name Phone Fax
e-mail address
Liquid & Gas Sample(s)

Check if Rush
MSDS is or
Description Analysis Required: Included Standard
Catalyst & Adsorbent Sample(s):
Process or unit: Sample Location:

Check if Rush
MSDS is or
Catalyst Type Regen or Spent Analysis Required Included Standard
Billing Information:
Address:
Attention:
Sample Shipping Information:

Shipped Via:
Phone Number of Carrier:
Airwaybill No.:
uop 117108-6 IX-25
General Letter for International Samples (from outside of the USA)
Revised August 4, 2003
SAMPLE SHIPPING PROCEDURE:

To Be Used For All Samples Except SPA Catalyst
In order to comply with U.S. regulatory laws outlined by the Environmental Protection
Agency (EPA) and United States Customs, UOP LLC must assure that all chemical
substances imported into the United States adhere to the following procedures.
IMPORTANT: The use of a freight forwarder (e.g. Burlington Air Express (BAX) or Emery
Worldwide) or commercial cargo airline is preferred. Please note that UOP, as importer,
must provide the TSCA (Toxic Substances Control Act) Certification. For samples sent by
a freight forwarder or a commercial cargo airline, UOP will provide the TSCA Certification
directly to our Customs Broker.
Overnight couriers (e.g. DHL, FedEx, UPS) may be used only if the written TSCA
certification, authorized, signed and dated by a UOP LLC employee, is obtained prior to
shipment, and physically included with the documentation shipped with the package, both
in the customs pouch and inside the package with the samples.
All samples should be routed through Chicago O’Hare International Airport, and
addressed as follows:
UOP LLC
Sample Receiving
200 East Algonquin Road
Des Plaines, IL 60017-5016
Attn: Catalysts & Advanced Materials – OTS Sample Coordinator
All imports must have the following documentation:
1. Bill of Lading (also known as a Master Airwaybill) which includes vessel/flight

information. If using BAX Global, the Bill of Lading description field must include the
words “TSCA Certified Chemical Sample.” “Customs Clearance Through BAX
Global, O'Hare International Airport, Chicago, IL Attn: Frances Willis”. If not
using BAX Global, the Bill of Lading description field must include the words “TSCA
Certified Chemical Sample.” “Customs Clearance Through Expeditors
International, 1300 Arlington Heights Rd, Itasca, IL 60143.
2. Pro forma invoice (See attachments 2a and 2b: a blank form and example) including the
following required information:
• Shipper’s name, address, contact name, phone number and fax number.
• Importer’s name, address, and contact name, (this must include the UOP
contact person within the U.S.). UOP has provided this information, except for
Contact Person.
uop 117108-6 IX-26
• Consignee/Delivery name, address, contact name, phone number and fax

number (this must include the actual delivery location). UOP has provided this
information.
• Approximate market value (for Customs purposes), for each item, in U.S.
Dollars.
• Sample descriptions in English.
• Packing details – the number and types of containers.
• Net weights and Gross weights for each item, in kilograms.
• Country of origin. This is the country where the sample was taken.
3. TSCA Certification (See attachment 3 ) including the following information:

• Sample description in English, UOP has provided this information.
• Date the sample is to be shipped, in English.
• Signature by UOP LLC employee.
4. Analytical Requisition Form (Attachment 4) including the following information:

• Shipper’s name, address, contact name, phone number, fax number, and e-mail
address.
• Sample shipping information: Carrier and flight information, phone number of the
carrier, airwaybill number.
• Fill in all pertinent sample and analytical request information as required.
5. Material Safety Data Sheet (MSDS) if the sample material is regulated as hazardous by
IATA, IMO or DOT.
All samples must be prepared according to the hazardous materials shipping regulations of
the International Air Transportation Association (IATA), if shipped by air, or International
Maritime Organization (IMO) if shipped by sea.
Prior to shipping, the UOP Technical Services Sample Coordinator must be notified of all
imports. Please fax a copy of the Pro Forma Invoice, the Bill of Lading, TSCA
Certificate Form, and the Analytical Requisition Form to the UOP Catalyst &
Advanced Materials – OTS Sample Coordinator at 847-627-8225. In addition, include a
copy of all the documents inside the package, with the samples. UOP will then ensure
proper Customs and TSCA clearance.
Failure to send samples with the proper documentation and information will result in a delay
of Customs clearance or refusal of the sample.
uop 117108-6 IX-27
Attachment 2a
Pro-Forma Invoice
INTERNATIONAL SHIPPER/EXPORTER (NAME & ADDRESS)

Invoice No:
Invoice Date:
Terms: Pro-Forma Invoice

Contact Name: Reference No:
Contact Phone No. Fax No.
DESCRIPTION AMOUNT
* * * NO CHARGE INVOICE * * *
US DOLLARS
QUANTITY: $
MARKET VALUE
--DECLARED
DESCRIPTION OF SAMPLE(S): FOR CUSTOMS
CLEARANCE
PURPOSES
ONLY
PACKED IN BOX(ES)
GROSS WEIGHT: KGS.
COUNTRY OF ORIGIN (where sample was taken) __________________________
MARKS: AS ADDRESSED
IMPORTER OF RECORD CONSIGNEE / DELIVERY ADDRESS:

UOP LLC UOP LLC
25 EAST ALGONQUIN RD. SAMPLE RECEIVING
DES PLAINES, IL 60017 200 EAST ALGONQUIN RD.
DES PLAINES, ILLINOIS 60017-5016
ATTN: ATTN: UOP Tech Service Sample Coordinator
UOP Contact Name
Refinery Representative Signature Refinery Representative Name: please print
I HEREBY CERTIFY THAT THIS INVOICE IS TRUE AND CORRECT.
ORIGINAL INVOICE
uop 117108-6 IX-28
Attachment 2b
Example
Pro-Forma Invoice
INTERNATIONAL SHIPPER/EXPORTER (NAME & ADDRESS)

Invoice No:
Mountain View Refining Invoice Date:
1000 Mountain View Dr.
Boulder City Terms: Pro-Forma Invoice
Refining Country
Contact Name: Joe R. Engineer
Reference No:
Contact Phone No. (12) 3 456 -7890 Fax No. (12) 3-098-7654
DESCRIPTION AMOUNT
* * * NO CHARGE INVOICE * * * US DOLLARS
$ 30.00
QUANTITY: Three 1 liter catalyst samples
MARKET VALUE
--DECLARED
DESCRIPTION OF SAMPLE(S): R-134 CCR Platforming Catalyst FOR CUSTOMS
CLEARANCE
Two regenerated samples and one spent sample PURPOSES
ONLY
PACKED IN 1 BOX(ES)
GROSS WEIGHT: 3.5 KGS.
COUNTRY OF ORIGIN (where sample was taken) Refining Country
MARKS: AS ADDRESSED
IMPORTER OF RECORD CONSIGNEE / DELIVERY ADDRESS:

UOP LLC UOP LLC
25 EAST ALGONQUIN RD. SAMPLE RECEIVING
DES PLAINES, IL 60017 200 EAST ALGONQUIN RD.
DES PLAINES, ILLINOIS 60017-5016
ATTN: Robert S. UOP ATTN: UOP Tech Service Sample Coordinator
UOP Contact Name
Joe R. Engineer Joseph R. Engineer

Refinery Representative Signature Refinery Representative Name: please print
I HEREBY CERTIFY THAT THIS INVOICE IS TRUE AND CORRECT.

ORIGINAL INVOICE
Attachment 3
uop 117108-6 IX-29
TSCA CERTIFICATION FORM
To: Area Director of Customs

Date:
Description of Sample:
( X ) TSCA Positive Certification

I certify that all chemical substances in this shipment comply with all
applicable rules or orders under TSCA and that I am not offering a
chemical substance for entry in violation of TSCA or any applicable
rule or order under TSCA.
Signature (Authorized UOP LLC employee)
Printed Name (Authorized UOP LLC employee)
uop 117108-6 IX-30
Attachment 4
International Analytical Requisition Form - UOP Technical Service
TO: UOP Catalysts & Advanced Materials – Sample Coordinator

Phone 847-391-2620 FAX: 847-627-8225
UOP Technical Service Contact ____ _____ Phone 847-391-___ _ Fax 847-391-2253
Customer: Refinery
Address
Address
Contact Name Phone Fax
e-mail address
Liquid & Gas Sample(s)

Check if Rush
MSDS is or
Description Analysis Required: Included Standard
Catalyst & Adsorbent Sample(s):
Process or unit: Sample Location:
Check if Rush
MSDS is or
Catalyst Type Regen or Spent Analysis Required Included Standard
Billing Information:
Address:
Attention:
Sample Shipping Information:

Shipped Via:
Phone Number of Carrier:
Airwaybill No.:
uop 117108-6 IX-31
Fixed-Bed Platforming – General Operating Manual Troubleshooting
X. TROUBLESHOOTING
For the most part, Platforming Unit operation after startup and dryout involves
monitoring performance and correcting for any upsets or emergencies that may
occur. Quick action to correct upsets or emergencies will minimize lost production
and prolong catalyst life.
A. OPERATION TROUBLESHOOTING
Normal operation of Platforming Units is steady and relatively trouble-free.

However, upsets and process and equipment problems do occur. Troubleshooting
equipment problems is beyond the scope of this manual and is not covered except
for special items. This includes such items as water washing the recycle
compressors and stabilizer column to maintain good operation which are included in
Chapter XIII “Special Procedures”.
When performance of the Platforming Unit gives indications that there is a problem,
the first step is to confirm that there is a problem and not a normal response to a
change in feed quality, low feed rate, etc. Troubleshooting must follow a logical
sequence and be accompanied by sufficient, reliable data in order to analyze the
situation, diagnose the problem and find the solution. A typical, logical approach to
troubleshooting a performance problem in a Fixed-Bed Platforming unit is
represented as a flow chart in Figure X-1. For further details of the steps of this
flow chart, see the relevant sections of this manual.
For typical Fixed-Bed Platforming operational problems, Table X-1 lists possible
causes and corrective actions required. Some discretion and judgment is required in
the use of these tables because the symptoms seen and the departure from normal
will depend on the degree of the upset or problem and the elapsed time since the
problem started. For example, in the case of high nitrogen content in the feed, the
longer the elapsed time the more chloride will be lost from the catalyst and the lower
will be the catalyst activity.
uop 117108-6 X-1
Figure X-1
Fixed-Bed Platforming Troubleshooting Guide
Apparent performance problem

Accurate mass
balance and rx
Improve data collection,
effluent processing and analysis.
Determine accurate course of events yields? No
Yes
Review operating data and conditions

Operating No
at design / Adjust operating conditions
typical
accordingly
conditions?
Yes
No
H 2O-Cl
Adjust water and/or chloride
Review water-chloride balance balance
OK? injection rates
Yes
Feedstock/ Permanent Yes Remove contaminant.

Check unit feed. upstream catalyst Evaluate economics of
processing poisons?
changed? Yes catalyst replacement
No
No
Yes
Temporary Remove contaminant. Take
catalyst
poisons?
remedial action
No
Adjust upstream unit
Yes operating conditions
Feed
composition
accordingly. If not possible,
change? adjust Platforming unit
operating conditions
No accordingly.
No
Check previous Previous
Determine step where Consider economics of
Regeneration / Re-start Regen
OK? problem occurred. early regeneration.
records and data
Yes
No
All cat
Take remedial action based
Sample catalyst results
OK? on results.
Yes
Yes
Check for CFE or Feed
bypassing?
Shut down to repair leak.
reactor bypass leak
No
Yes
Check for catalyst in
Catalyst
downstream equipment/ containment Shut down to repair leak.
vessels/ tanks lost?
No
Contact UOP
uop 117108-6 X-2
Table X-1
Troubleshooting Guide for Common Problems
Process Possible Cause Operational Response

Symptom
1. Low Reactor ∆T Charge stock less None

naphthenic
Sulfur contamination Eliminate source.
Do not increase reactor inlet
temperature (see note)
Metals contamination Eliminate source
High chloride on catalyst Reduce chloride injection
High water in unit Reduce water injection and
eliminate source of excess
water
Bad temperature indicator Repair or replace
2. High Reactor ∆T Charge stock more None

naphthenic
Nitrogen contamination Eliminate source
3. Low H2 Purity, Charge stock less None

Production naphthenic
Excessive chloride injection Reduce chloride injection
rate
Metals contamination Eliminate source
Water contamination Eliminate source
4. Low Reformate Charge stock less None

Yield naphthenic
High chloride Reduce chloride injection
High water Reduce water injection and
eliminate source of excess
water
5. High Coking Low H2/HC ratio Increase recycle rate

Charge stock highly None
paraffinic
uop 117108-6 X-3
Process Possible Cause Operational Response

Symptom
6. High Reactor ∆P Internal screens plugged Shutdown and clean

reactors
Excessive coke levels Shutdown and clean
reactors
Bad pressure indicator Repair or replace
7. Low Reactor ∆P Loss of catalyst containment Shutdown and repair

reactors
Bad pressure indicator Repair or replace
8. Loss of Chloride Pump stops or valve closed Restart or line up

Injection
Suction or discharge check Stop pump and repair
stuck ball check
Note: Suspected causes of operating problems should be confirmed by analysis or

otherwise before action is taken, except in extreme or emergency cases.
B. SCALE ACCUMULATION IN REACTORS
Flow maldistribution in reactors can be caused by scale buildup. Because of the

longer cycles possible with bimetallic catalysts, reactors are not being dumped and
the catalyst screened as frequently as in the past. In downflow and spherical
reactors, scale buildup plugs the top layers of support material and catalyst resulting
in channeling through the catalyst beds. In downflow reactors the scale buildup can
be detected by an increase in the reactor pressure drop. In radial flow reactors,
scale buildup can occur with very little, if any, increase in reactor pressure drop.
Maldistribution in this case is normally detected by observing shifts in the percent
delta temperature in a reactor during operation and a long residual burn during a
regeneration. However, there have been cases of serious distribution problems with
no apparent indication during the carbon burn. Tables X-2 and 3 present the
analysis of the catalyst and scale removed from a radial flow reactor that had shown
poor performance during the run. During the regeneration, this reactor showed
signs of residual carbon burn for several hours after the carbon burn in the next
uop 117108-6 X-4
reactor had been started. We are recommending that reactors be dumped and the
catalyst screened every two years or every third regeneration. During this time the
reactors and internals should be carefully inspected and cleaned.
Table X-2
Catalyst and Scale Removed from Platforming Unit RX. 1 Samples
Catalyst Type: Used R-22 after Carbon Burn
Composite Sample: Catalyst on Scallop:

Grey and few Black with Grey to Black with
Reddish Dust Coating Reddish Dust Coating
Carbon Deposit, wt.% 0.06 0.69

Chlorine wt.% Cl 0.97 0.70
Total Sulfur, wt.% S 0.02 -
Emission Spectrographic Analysis weight percent
Iron 0.21 0.68

Calcium 0.005 0.023
Copper 0.015 0.12
Lead 0.003 0.014
Sodium 0.020 0.37
uop 117108-6 X-5
Table X-3
Analysis of Scale from Catalyst on Scallops
The sample identified as RX. 1 catalyst on scallops after separating the obvious
catalyst spheres was analyzed for the indicated tests.
The deposit appears to consist of largely iron oxides, iron calculated as iron oxide is
approximately 93 wt.%. Some aluminum and silica was also observed. There
appears to be a low concentration of platinum 0.030 wt.%.
The estimated composition is:
Component Weight percent
Iron oxide 92.8

Water 0 to 2
Al2O3 6.3
Chloride 0.13
Sulfur 0.31
NH4+ 0.09
Platinum 0.030
Loss on ignition at 900°C 2.1
uop 117108-6 X-6
Fixed-Bed Platforming – General Operating Manual Normal Shutdown
XI. NORMAL SHUTDOWN
The following shutdown procedure covers a normal planned complete shutdown

such as would be required for a catalyst change and/or the periodic cleaning and
inspection of vessels.
The operations described in these sections must overlap to some extent. The extent
to which these operations may be conducted simultaneously will depend upon the
availability of operating personnel.
The shutdown instructions that follow are divided into sections for convenience.
Below is a list of the various sections to be discussed:
1. Notify operating foreman and other units of shutdown.

2. Reduce heater temperatures and charge rates.
3. Cut out Platforming reactor charge.
4. Shutdown the Platforming separator(s).
5. Shutdown all Platforming reactor heaters.
6. Shutdown and block in all columns.
7. Shutdown the recycle compressor(s).
8. Depressure and purge reactor system.
9. Isolate system and install necessary system blinds.
10. Remove catalyst from reactors.
The above outline is expanded into more detailed steps which cover each
operation, as follows:
1. Notify Operating Foreman and Other Units of Shutdown
a. Notify foreman and other operating units concerned as to exact time when the
shutdown operations will start. Changes in fuel gas composition, steam
requirements, etc., may affect other units.
uop 117108-6 XI-1
b. Pumpers and others who might be concerned with handling charge and
product streams should also be informed of the coming change.
2. Reduce Heater Temperatures and Charge Rates
a. Start reducing the Platforming reactor inlets to 850°F (454°C) at 25-54°F (14-
30°C) per hour.
b. At 900°F (482°C) reactor inlets begin reducing the feed rate stepwise to half
the design rate but not less than 0.75 LHSV. Strive to reach 850°F (454°C) on
the Platforming reactor inlets simultaneously with the charge reduction rate.
3. Cut Out Platforming Reactor Charge
a. At 850°F (455°C), stop charge to the unit.
b. Discontinue water and organic chloride injection.
c. Adjust Platforming heater firing to hold 850°F (455°C) and maintain maximum
recycle gas rate for at least one hour to sweep all residual hydrocarbons from
the catalyst.
d. When sweeping of the catalyst is complete, cool the Platforming reactor inlets
to 750°F (399°C).
4. Shutdown the Platforming Separator(s)
a. Gas production will cease as soon as hydrocarbon stops passing over the
Platforming catalyst. At that point the offgas lines from the separator to other
units and to fuel gas must be blocked in to maintain system pressure for
continued recycle compressor operation. Booster or net gas compressors must
be shutdown as per normal procedure.
b. When liquid has ceased flowing into the Platforming separator(s), stop any
pumps on the separator liquid outlet stream(s) and block in the level control
valve(s).
uop 117108-6 XI-2
c. Drain all hydrocarbons from the separator(s), the Platforming Unit charge line
downstream of the flow control valve, and all low points in the system.
5. Shutdown All Platforming Reactor Heaters
a. After the reactors have been swept for at least one hour at 850°F (454°C) and
then cooled to750°F (399°C), shutdown all reactor heaters. Block in fuel lines
to each burner.
b. Continue recycle gas circulation to cool the reactor bed outlets to less than
200°F (93°C) at 54°F (30°C) per hour. If the catalyst is to be handled during
the shutdown, the catalyst beds should be cooled to less than 150°F (66°C)
and preferably less than 130°F (54°C).
NOTE: If catalyst is to be regenerated or if the shutdown is only of a temporary

nature, do not cool below 750°F (400°C). Following heater shutdown, circulate
only long enough to cool the heater tubes (15 to 20 minutes) and then stop the
recycle compressor. Block in the compressor and the separator off-gas line.
This is not recommended for stacked reactors. If the “temporary” shutdown is
prolonged such that the piping can cool off while the catalyst inside the
reactors is still hot, stresses can be induced at the reactor nozzles.
Caution: Prolonged gas circulation (greater than eight hours) should be

avoided in order to preserve the catalyst properties.
6. Shutdown and Block in All Columns
a. Continue reflux and reboiler flows until the respective towers have cooled
down. Add sweet fuel gas or nitrogen, if required, to maintain a positive
pressure during cooling.
b. The overhead receivers should be emptied by pumping the liquid out the
product line or back into the column if there is no net overhead liquid product
line.
uop 117108-6 XI-3
c. The bottom levels in the towers should be pumped or pressured out of the unit.
d. The towers, receivers and reboiler heaters may be steamed out to gas free the
equipment after the towers have been emptied of oil and depressed to the
offgas and flare header. Normal refinery practice for purging and washing of
this equipment should be followed.
7. Shutdown Recycle Compressor(s)
a. When reactor outlet temperatures have cooled down to the desired level,
shutdown the recycle gas compressor(s) and take it off line.
b. To guard against the danger of getting oil or moisture into the compressor(s),
purge it out with nitrogen rather than evacuating. Any moist air that gets into
the compressor will combine with deposits to form corrosive compounds.
Recycle gas may be removed from the machine by blocking in at the suction
and discharge valves. After depressuring, purge with nitrogen through the
machine to the vent line.
c. Leave the machine blanketed with a slight positive pressure of nitrogen.
d. Same for net gas compressors.
8. Depressure and Purge the Reactor System
Depressuring, evacuation, and purging of the reactor system should be done

according to the normal refinery practices. In general, these will be similar to the
following guidelines:
a. Depressure the Platforming reactor system into the fuel gas system until the
fuel gas system pressure is reached. Do this at the product separator or piping
in the net gas recontact section.
uop 117108-6 XI-4
b. Bleed the balance of the system pressure off to flare or atmosphere, as

appropriate. Also do this from the product separator.
NOTE: During depressuring, evacuation and purging, normal flow through the
catalyst beds should be used. This reduces the danger of catalyst
displacement in the reactors.
c. Isolate the reactor section and connect the steam ejector to the product
separator.
d. Evacuate Platforming Unit to at least 20 inches (500 mm) of mercury vacuum.
e. Break with nitrogen by introduction to the discharge side of the recycle gas
compressor. Pressure the unit to 5 psig (0.35 kg/cm2).
f. Repeat evacuation and purge twice.
NOTE: Make sure all dead legs are properly purged.
g. Check for explosive gas mixtures at various points in the unit. If any readings
are higher than the upper limits set by the refiner safety department repeat
step f. Also check block valves which separator this section of the unit from
others that still contain hydrogen and/or hydrocarbon.
h. The reactor section is now ready for insertion of the necessary blinds.
9. Isolate System and Install Necessary System Blinds
a. Install blinds to isolate the Platforming reactor section from the remainder of
the unit. Exercise care while installing the blinds to ensure the catalyst is not
exposed to moisture.
b. If possible, establish a small nitrogen purge into the reactor section.
uop 117108-6 XI-5
c. Install additional blinds at the battery limits and between equipment as

necessary for safety.
10. Remove Catalyst from Reactors
NOTE: UNDER NO CIRCUMSTANCES SHOULD AIR BE PULLED THROUGH

THE PLATFORMING REACTORS SINCE SPONTANEOUS COMBUSTION IS
POSSIBLE. WOOD, CANVAS OR OTHER COMBUSTIBLE MATERIALS SHOULD
NOT BE USED IN THE CATALYST DUMPING OPERATION BECAUSE OF THE
DANGER OF FIRE. IN ADDITION, THE GENERAL AREA AROUND THE
REACTORS SHOULD BE FREE OF COMBUSTIBLE MATERIALS.
a. Do not open the reactors at the top and bottom simultaneously as this can set
up a natural chimney draft effect that will pull air through the reactors.
b. Be sure that several CO2 extinguishers are available and provide a small water
hose with a spray nozzle attachment.
c. Catalyst is removed from fixed-bed Platforming reactors through two 4-inch

withdrawal nozzles located on the bottom of the reactor stack. The blind flange
is removed from the nozzle and a dumping spout is connected. A slide valve in
the dumping spout allows the flow of catalyst to be stopped as necessary for
catalyst drum changing, etc. The catalyst support plate in the unloading nozzle
is removed through the opening in the dumping spout.
For units with stacked reactors, the unloading pipes between reactors must be
connected by installation of the transfer boxes on the appropriate external
unloading nozzles; this installation is shown on the reactor drawings and will
permit all reactors to be emptied through the unloading nozzle on the lowest
reactor in the stack.
uop 117108-6 XI-6
If unregenerated catalyst is to be unloaded, the reactors must be kept under a

nitrogen blanket so the spent catalyst does not contact air. Any personnel who
enter the reactors must be equipped with the proper safety equipment
specified for entry into a contaminated atmosphere.
d. If the catalyst becomes bridged in the unloading nozzle or is not free flowing,
break the plug with a blast of nitrogen.
e. Use only metal drums for unloading and if possible dump directly into drums. It
is best to screen the catalyst after it has had time to cool to ambient
temperature. Each drum should be either purged with N2 during unloading or a
piece of dry ice should be placed at the bottom of each drum. Do not seal the
drum air tight since this could result in sudden rupture of the drum should
combustion occur. Burning of catalyst in the drums is not serious and can be
quickly extinguished with carbon dioxide or nitrogen.
f. It is expected that some “sparking” of the pyrites will take place. All workmen in
the area must be supplied with face and eye protection. In addition, they
should wear long sleeve shirts with the collars and cuffs tightly buttoned.
g. If ignition of pyrites takes place inside a reactor, increase the N2 purge to

maximum.
h. Return spent Platforming catalyst to UOP for metals recovery. This return will
normally be made in the original empty Platforming catalyst drums.
i. After the catalyst drums have cooled, the drums should be sealed with the
proper cover and rubber gasket to keep out moisture.
j. With the catalyst removed, the reactors are now ready for cleaning and internal
inspection.
uop 117108-6 XI-7
Fixed-Bed Platforming - General Operating Manual Emergency Procedures
XII. EMERGENCY PROCEDURES
Emergencies must be recognized and acted upon immediately. The operators

should carefully study, in advance, the steps to be taken in such situations. While
some of the emergencies listed in this section may not result in a unit shutdown,
they could cause serious trouble on the unit if not handled properly. In addition,
damage to the catalyst might occur.
Hard and fast rules cannot be made to cover all situations that might arise. The
following outline lists some situations that might arise and suggested means of
handling the situation.
A. POWER FAILURE
1. If the unit is equipped with a motor-driven recycle compressor(s) and the

failure is of sufficient duration to shut it down, follow the procedure under the
appropriate heading (Section XII-B or XII-C).
Otherwise, check which pumps and air cooler motors have stopped and
restart them. If the reactor charge pump has stopped, be sure that reactor
inlet temperatures have not risen excessively before cutting oil in again.
Reduced fires and use of purging steam through the heater boxes are
methods of cooling the heaters.
2. If any emergency power supply is not available or does not work properly, all
electrical control instruments will fail. Thus, all electronic controllers must be
operated manually and temperatures must be read by means of a battery-
operated potentiometer.
3. Any motor-driven pumps that have been in service should be swung over to
steam-driven spares, where available.
uop 117108-6 XII-1
4. If the failure affects the cooling water system, action to restore normal water
circulation must be taken.
5. If a power failure of some duration is encountered, the unit should be shut

down, following the normal procedure as much as possible.
6. When power is again available, startup in the normal manner, noting the
precautions that are described in Section XII-C.
B. PARTIAL LOSS OF RECYCLE GAS FLOW
This procedure is for when more than one recycle compressor is available and one
recycle compressor shuts down.
1. Lower the heater outlet temperatures by 15-25°F (10-15°C) for all reactors.
2. Reduce the reactor charge rate to that permissible with the remaining flow of
recycle gas.
3. Load up the other recycle compressors if additional capacity is available.
4. If possible, restart the compressor, and, if the reason for the shutdown can
be determined and fixed, return to normal operations.
5. Steps 1 and 2 must be done immediately to protect the catalysts. Continued

operation on one compressor is possible, but the hydrogen-to-hydrocarbon
ratio should be checked to be sure that it is above the minimum for
operation. Temperature adjustments can be made for continued operation on
one compressor after laboratory or other tests indicate changes are required.
6. If the compressor cannot be started, or if the reason for failure remains

undetermined, the supervisor should be contacted so that proper action can
be taken. There is always the possibility that the failure may have been
caused by some factor that might stop all compressors almost immediately.
uop 117108-6 XII-2
C. TOTAL LOSS OF RECYCLE GAS FLOW
This procedure is for when one or more recycle compressor(s) is/are available and
it/all of them shut(s) down. The main concern is to cool the heaters and reactors
while preventing hydrocarbon from condensing in these areas.
1. Stop firing in all reactor heaters. Open dampers and registers and/or
maximize operation of forced draft combustion air fans to cool the heaters.
2. Stop feed. Shut down and double block in the reactor charge pump.
3. If possible, consider partially depressuring the reactor section to remove

hydrocarbon and heat from the system:
a. If a source of high pressure hydrogen or nitrogen is available to re-

pressure the unit for re-starting, proceed to depressure the reactor
section from the separator to flare. Decrease the reactor pressure to
approximately half the operating pressure. This will vaporize
condensed hydrocarbons and carry them into the separator.
b. If the unit cannot be re-pressured for re-starting, maintain reactor
pressure. Block in the separator off-gas valve so that system pressure
will be maintained.
NOTE: Steps 1, 2, and 3 should be done immediately to protect equipment and the
catalyst.
4. Follow the normal shutdown procedure in blocking in the separator and

columns.
5. Restart the compressor if possible, or find out what is wrong. Remember

that, with no flow through the furnace, the material in the heater tubes may
become excessively hot, and if it is put through the reactors, it could result in
deactivation of the catalyst. Thus, when a compressor is started after such a
shutdown, immediately check the reactor inlet temperatures. If they are 25°F
uop 117108-6 XII-3
(15°C) higher than the normal operating temperature, stop the recycle flow
and continue to allow the heater to cool until the reactor inlet temperatures,
with recycle flow, are below 925°F (496°C). Do not introduce steam into the
heater fireboxes to cool the heater tubes.
6. If the compressor cannot be re-started within 15 to 30 minutes of the

shutdown, but a source of make-up hydrogen is available, depressure further
to see if any more hydrocarbons can be condensed in the separator. When
re-pressuring the unit, do so slowly to avoid cooling the reactor inlets too
quickly. Leave the reactor circuit at normal operating pressure under
hydrogen.
7. When the compressor(s) is again in service, proceed with a normal startup.

Remember that normal operating pressure or 125 psia (8.8 kg/cm2 absolute)
minimum H2 partial pressure, whichever is lower, at the reactor products
separator is required for feed cut in.
8. If there is no hydrogen source to re-pressure for start-up, but the nitrogen

header pressure is high enough to meet the recycle gas compressor suction
minimum pressure requirements, proceed to re-pressure the Platforming unit
with nitrogen. Start-up the reactor section at low severity. Increase reactor
temperatures only as necessary to produce hydrogen. As soon as hydrogen
production begins, the nitrogen will be purged out of the net gas system.
When normal hydrogen partial pressure is achieved, reactor temperatures
can be increased to the required severity.
D. PLANNED REPAIRS WHICH REQUIRE STOPPING THE RECYCLE

COMPRESSOR(S)
1. Decrease reactor inlet temperatures to 900°F (482°C). Lower the charge rate
to one-half rate but not less than 0.75 LHSV. Decrease reactor inlet
temperatures to 850°F (454°C). Cut out charge. Maintain gas circulation for
one hour at 850°F (454°C) inlet temperatures. Cut heater fires completely.
uop 117108-6 XII-4
2. For lower pressure units, it may be advisable to increase the unit pressure
before the shutdown. The purpose of the increase in pressure is to assure
sufficient hydrogen partial pressure for startup with consideration given for
gas leakage during the shutdown period.
3. Continue to circulate recycle gas while reducing reactor inlets to 700°F

(371°C).
4. Stop the recycle compressor(s).
5. Make the required repairs. Follow normal startup procedures.
E. EXPLOSION, FIRE, LINE RUPTURE, OR SERIOUS LEAK

(DO THE FOLLOWING IF POSSIBLE)
1. Stop firing in all heaters. If the heaters or control valves are beyond reach,
use the battery limit block valve(s).
2. Stop the reactor charge pump.
3. Leave the recycle compressor(s) running if possible while other items are
attended to, since it will contribute no extract pressure to the system and the
gas circulation will cool heater tubes and sweep hydrocarbons to the
separator.
4. Depressure the plant to the flare. Use of the separator safety valve will
depressure the system more rapidly if necessary.
5. Shut down the balance of the plant as circumstances permit or require. Shut
down the recycle compressor(s) when its lower operating pressure limit is
reached.
uop 117108-6 XII-5
6. In the case of a heater tube rupture, do not close the stack damper or
attempt to put the fire out with snuffing steam. The fire is much safer in the
firebox than outside the heater.
F. WATER FAILURE
1. If a water failure is feared, prepare for shutdown by reducing reactor

temperatures and charge rate.
2. For a partial cooling water failure, it should be necessary only to reduce the
charge rate to the unit to the extent required to maintain reasonable receiver
and product temperatures.
3. For a total loss of cooling water, the unit must be shut down. Follow normal
shutdown procedures as much as possible, except to stop heater firing
immediately. The compressors should be left running as long as possible to
sweep hydrocarbons from the reactors to the separator. Maintain unit
pressure.
G. STEAM FAILURE
1. Operation may be continued on the Platforming Unit, depending upon the

extent of steam driven equipment in the unit.
2. If the failure affects the cooling water system, action to restore normal water
circulation must be taken.
3. If the unit must be shut down, block in the unit and proceed with as normal a
shutdown as is possible.
4. When an adequate steam supply is again available, start up in the normal

manner, noting the precautions that are described in Section XII-C.
uop 117108-6 XII-6
H. INSTRUMENT AIR FAILURE
1. Be familiar with the action of all control valves; memorize all actions on air
failure.
2. If the reason for failure is in the air drier system, bypass that section
responsible. This can then be repaired when possible.
3. If the instrument air cannot be obtained, the alternatives are a plant

shutdown or operation of the various controls on hand control. Action will
depend upon the desires of the supervisor.
4. Under no circumstances should nitrogen be used in place of the lost

instrument air due to the possibility of asphyxiating control room
personnel.
I. EMERGENCY SITUATIONS DURING CATALYST REGENERATION
Since the process environments during Regeneration are different from that during
normal operation, emergency situations need to be considered separately. The
catalyst is more vulnerable during regeneration so special care needs to be taken.
Outlined below are some emergency situations which could occur during the carbon
burn and oxidation steps. The steps after oxidation (reduction and sulfate removal)
are with the reactor system in a hydrogen environment so the emergency
procedures in the previous sections apply.
1. Carbon Burn
a. Chloride Injection System Failure
Organic chloride is injected during carbon burn to prevent Platinum agglomeration.

Should that injection system fail during the carbon burn step, proceed as follows:
uop 117108-6 XII-7
(1) Continue to burn, maintaining corrosion control. Try to re-start the

chloride injection system.
(2) If chloride injection cannot be established within 8 hours, stop air
injection.
(3) Drain all water from the separator and all low points in the cold section
of the reactor circuit.
(4) Reduce reactor inlet temperatures to 625°F (329˚C) or until there is no
further water accumulation in the separator.
(5) Restart carbon burn as per the normal procedure once the chloride
injection system is operational again.
b. Caustic System Failure
Caustic is injected to the circulating water during carbon burn to prevent corrosion
to the reactor circuit. Should any part of that injection or circulation system fail
during the carbon burn step, proceed as follows:
(1) Stop chloride injection.

(2) Stop air injection.
(3) Continue recycle nitrogen circulation.
(6) Restart carbon burn as per the normal procedure once the caustic
system is operational again.
c. Reactor Temperature Excursion
Carbon burning is an exothermic reaction. The maximum temperature increase per

reactor to prevent any damage to the catalyst and reactor internals is 100°F. For
this reason, the oxygen content is limited to a maximum of 0.8 vol%. If the reactor
outlet temperature starts to increase beyond this limit, this is an indication that the
uop 117108-6 XII-8
air injection rate is higher than it should be or there is a hydrocarbon pocket

somewhere in the system.
(3) Continue maximum recycle nitrogen circulation.
(4) Maintain system pressure with make-up nitrogen.
(6) Drain all water from the separator and all low points in the reactor
circuit.
(8) Carefully restart after the reactor outlet temperature has returned to
the same temperature as the inlet temperature and after verifying that
the excursion did not have any mechanical implications on the reactor
and other equipment.
2. Oxidation
a. Chloride Injection System Failure
Organic chloride is injected during Oxidation to achieve the required catalyst

chloride level. Should that injection system fail during the Oxidation step, proceed
as follows:
(1) Continue Oxidation, maintaining corrosion control. Try to re-start the
chloride injection system.
(2) If chloride injection cannot be restarted within 4 hrs, stop air injection.
(5) Once the chloride injection system is operational again, restart air,
caustic and chloride injection.
(6) When the HCl at the reactor inlet and outlet is equal, re-start the 11
hour oxidation hold (i.e. extend the oxidation step by an amount at
least equal to the time without chloride addition).
uop 117108-6 XII-9
b. Caustic System Failure
Caustic is injected to the circulating water during Oxidation to prevent corrosion to

the reactor circuit. Should any part of that injection or circulation system fail during
the carbon burn step, proceed as follows:

(3) Continue recycle nitrogen circulation. Restart air injection as required
to maintain a minimum O2 concentration of 1.0 mol%.
(6) Once the caustic system is operational again, restart Oxidation as per
the normal procedure from the point where air and chloride were cut
out. Extend the oxidation step by at least the period of time that
chloride was not being injected.
c. Reactor Temperature Excursion
All carbon burning should be completed before the Oxidation step such that there
should be no reactor temperature rise at all. Any residual coke which was not
burned during the carbon burn step or a hydrocarbon pocket somewhere in the
system which was not purged out previously will burn readily in the oxygen-rich
environment during Oxidation. This combustion will produce high temperatures that
can cause damage to the catalyst and/or reactor internals. If the reactor outlet
temperatures start to increase when no adjustment has been made to the inlet
temperatures. Proceed as follows:

(4) Maintain system pressure with make-up nitrogen.
uop 117108-6 XII-10
circuit.
(7) After the reactor outlet temperature has returned to the same
temperature as the inlet, restart the regeneration in the carbon
burn/proof burn step as per the normal procedure.
d. System Leak or Rupture
If corrosion control is not properly maintained during regeneration, there is the

possibility that piping and equipment can rapidly corrode, resulting in a leak or
rupture. One area of particular concern is the product condenser. Should a leak
occur, proceed as follows:

(3) Stop caustic injection and basic water circulation.
(5) Try to maintain system pressure with make-up nitrogen.
circuit.
(7) Proceed to shut down the reactor circuit as per the normal procedure.
(8) Isolate and repair the affected section.
uop 117108-6 XII-11
Fixed-Bed Platforming - General Operating Manual Special Procedures
XIII. SPECIAL PROCEDURES
A. CATALYST LOADING
Correct catalyst loading is one of the major factors in obtaining the expected
performance from a Platforming process unit. It is not uncommon for refiners to
experience less than expected performance because of errors in the catalyst
loading. Also, there are many instances when catalyst loading problems could not
be eliminated as a cause of poor unit performance because proper records and
measurements of the loading were not checked or maintained. With diligent care
and proper planning by staff and supervisory personnel, correct catalyst loadings
can be assured. The purpose of this section is to review the basic reactor designs
and present guidelines for the correct loading of the reactors.
Before catalyst can be loaded into a reactor it is very important the reactor and
entire reactor circuit is dry. This is especially true for new units or after a major
turnaround.
There are three types of reactors predominantly in use today in the Platforming
process. These are radial, downflow, and spherical. We have classified spherical as
a special case because of inherent problems in loading these reactors. The
following discussion will present general guidelines for catalyst loading and
handling.
1. General Guidelines for Catalyst Handling and Loading
a. An inventory of catalyst, support material, and any reactor internals

stored outside the reactors, should be made well in advance of
loading.
b. Inspection of the reactors and internals should be made as soon as

possible prior to loading.
uop 117108-6 XIII-1
c. All catalyst loading equipment should be checked for availability and

operability. This would include safety equipment, lights and ladders
when these are required.
d. Placement of catalyst and support material drums in the unit area and
stacking of empty drums should be planned in advance to prevent
confusion while reactor loading is underway.
e. When the loading procedure is scheduled as a round-the-clock

operation, adequate lighting should be provided for safe night-time
activity in the working area.
f. Sometimes, the staff and personnel doing the work involved in loading
the reactors do not understand the operation of the unit or know why
loading details have to be followed exactly as designed. They should
be properly informed as to the reasons and requirements for correct
catalyst loading through the use of pre-planned loading diagrams. In
addition, procedures for follow-up and attention to detail on the part of
the supervisors should be established.
g. Do not leave any extraneous material in the reactor bed. Aside from
the embarrassment of unloading a reactor to retrieve an object
overlooked during the loading period, serious problems during startup
or the run can and have occurred as a result of an oversight in this
matter.
h. Although the following point is made many times in all the procedures
concerning Platforming catalyst loading and unloading, it will be
repeated here. Do not allow a natural draft of air to flow up through a
reactor bed at any time. Regardless of the state of the catalyst, fresh,
spent, regenerated, hot or cold, a flow of air for a prolonged period
can possibly cause serious damage to the catalyst and reactor
internals.
uop 117108-6 XIII-2
i. Of special importance in the catalyst loading is the “topping off” stage.

It is at this point that careful measurements should be taken to insure
that the proper amount of catalyst has been loaded and that the
allowances for seal, catalyst slump, and hold-down material are
verified. Good practice is to have a unit supervisor personally verify
the measurements. Copies of the loading diagrams should be
forwarded to UOP for record purposes.
2. Radial Flow Reactors Catalyst Seal and Slump
Figure XIII-1 shows a typical radial flow Platforming reactor. All of UOP’s radial flow
reactors require a catalyst seal above the open slot and screen areas of the
scallops and the centerpipe. This is shown in more detail in Figure XIII-2. Most of
the vapors go down the outer annulus and then pass horizontally and radially
through the catalyst bed to the centerpipe. The flow path length through the catalyst
bed at the bottom of the outer shield is the length L. The height of catalyst seal that
has been used for many years is L/2. This is measured from the bottom of the outer
shield to the top of the catalyst bed.
Vapor flows up, over, and then down in the catalyst seal zone as shown by the
arrows. Some vapor flows up along the inside wall of the skirt, breaks through the
catalyst surface, passes over the top of the catalyst bed, and then flows down along
the outside wall of the centerpipe until it can enter the screen portion of the
centerpipe. The catalyst seal height of L/2 was established so that vapors flowing
along the above mentioned path would flow up through catalyst for a distance of L/2
and then down through catalyst for a distance of L/2, for a total path length of L.
This rather simple technique of making the minimum path length through the
catalyst seal zone equal to the catalyst bed depth L has worked well for many
years. It has provided sufficient seal to prevent bypassing of too much vapor
through the seal zone and yet has provided adequate flow through the seal catalyst
so it will not excessively coke and can be considered as 100% effective catalyst.
uop 117108-6 XIII-3
UOP uses a computer program to calculate required catalyst seal lengths. In some
cases, a seal height greater than L/2 may be required, but the well-established
standard of L/2 has been retained as a minimum seal height.
With scallop or outer basket internals in Platforming reactors, 1 in. of slump for
every 4 ft. of catalyst bed height is normally provided. (Note: For extruded catalyst
that are sock loaded, there should be 3 in. of slump for every 4 ft. of catalyst bed
height.) This mechanical slump, which is a decrease in catalyst bed height at
constant temperature, occurs because the particles slide over one another slightly
to pack the bed to a lower void fraction. This slight movement of catalyst particles is
due to normal reactor vibration and/or vapor flow through the bed over an extended
period of time.
Figure XIII-1 presents a sketch of a typical radial flow reactor with the normal criteria
for proper loading. Figures XIII-3, 4 and 5 present the bottom head details with
Figure VI-5 being UOP’s current design with no concrete or fire brick in the bottom
head. UOP does not currently specify firebrick or concrete in the bottom heads, but
instead recommends adding SAB (spherical alumina base) in this bottom head
area.
There are certain circumstances where the typical criteria may not apply. If unit
throughput is being increased substantially above design, or if unit pressure is being
reduced well below the normal level, the L/2 rule for seal may not apply and an
increased amount of seal catalyst may be needed. Also, the loading for the stacked
reactor designs is different. Always refer to the specific project specifications before
proceeding with a loading.
3. Radial Flow Reactor Loading Guidelines
a. The centerpipe should be wire brushed during shutdown and carefully

inspected for small holes that would allow the 1/16 in. catalyst to
migrate. Repair all such holes using inert gas welding techniques. Be
certain that the centerpipe is sealed firmly in the outlet nozzle, then
uop 117108-6 XIII-4
pack the perimeter annulus with ceramic fiber rope to prevent catalyst
dropping into this space.
b. Similarly, all cracks in reactors with concrete or fire brick at the reactor
bottom should be checked to see that catalyst cannot drop in during
loading. Fill these cracks with thin ceramic fiber rope. Migration of
catalyst into these spaces may result in severe localized
hydrocracking due to the low space velocity possible. This, in turn,
may lead to carbon formation that has been known to fracture the
concrete and lift the centerpipe.
c. The scallops should be checked for damage that would allow them to
fill with catalyst. In older units that might still be using the press-fit
screen type scallop, we recommend replacing these scallops with the
newer (and more reliable) punched plate scallop. Again, any holes in
the scallop large enough to pass catalyst should be welded with inert
gas. Check the scallops visually by measurement after each catalyst
loading to be sure that no migration of catalyst into the scallops has
occurred during loading. Any catalyst found in the scallops can be
removed by vacuuming.
d. The scallops must not be bowed or warped, and all welds should be
ground smooth so that the scallops fit flush against the reactor wall to
prevent catalyst from freely migrating to the backside where
hydrocracking and possible carbon formation can occur due to the low
space velocity. Any such pockets of carbon could cause substantial
damage to the reactor internals during regeneration as a result of the
potentially high temperature that can occur with oxygen present.
Therefore any scallops that do not fit flat against the wall should be
repaired or replaced.
e. Once the scallops are set in place the center expander ring should be
tightened until it is just snug. Making this ring too tight will prevent
uop 117108-6 XIII-5
proper growth of the scallops during startup and may result in crushed
scallops.
f. Whenever a radial reactor is short-loaded, extensions must be made

for the deflection baffle skirt along with a snug fitting shroud for the
centerpipe. It is important that the bottom edge of the skirt always be
horizontal with the first row of exposed holes in the centerpipe to
ensure even distribution and flow of vapors across the reactor.
g. Once catalyst is loaded level with the deflection baffle skirt bottom,
seal and slump catalyst is loaded inside the skirt to prevent vapors
bypassing the catalyst. Slump catalyst must also be loaded between
the skirt and the scallops. Seal and slump catalyst must not be loaded
directly above the centerpipe. If this does occur, a centerpipe sleeve
extension above the centerpipe should be made.
• Slump is equal to 1 in. per 4 ft. of spherical and dense-loaded

extrudate catalyst bed depth. For sock-loaded extrudates 3 in.
per 4 ft. of catalyst bed depth.
• Seal is equal to one half the distance between the centerpipe
OD and the baffle skirt OD, unless otherwise specified.
• A 4 in. layer of ¼ in. diameter ceramic material is loaded above
the seal catalyst, if space allows. The ceramic material may be
loaded directly above the centerpipe.
h. Ceramic material is also loaded around the annular space between

the baffle skirt (shield) and scallops to prevent eddy currents from
lifting catalyst up into the scallop tops. These two layers of ¾ in. and
¼ in. diameter ceramic material should be of equal depths of 4 in.
(minimum) to 10 in. (maximum).
i. Catalyst loading should not take place during rainy weather, and the
reactors should be kept purged with dry instrument air throughout
loading. The remainder of the unit should be sealed off to prevent
uop 117108-6 XIII-6
entry of moisture and all reactor tops must be kept covered or closed
except during loading.
j. A detailed record should be kept of the catalyst loaded into each

reactor with all dimensions and outages shown.
k. Be sure that the top baffle plate and manway are properly bolted and
sealed to ensure all incoming vapors will be directed into the scallops.
l. Check the inlet distributor to make certain that it is in good condition

and will properly act to deflect the incoming vapors.
m. Prior to final closure, a check should be made at the reactor outlet to

be certain that no catalyst leakage has occurred during loading.
NOTE: Figure V-3 (Chapter V, “Process Equipment”) is a diagram of a cold

wall, internally insulated radial reactor. This reactor is loaded in the same
manner as the previous hot-wall radial reactors. The alloy liner and
monolithic refractory insulation on internally insulated reactors must be
inspected carefully prior to loading. There have been problems with the
integrity of the liner and crumbling refractory/concrete behind the liner.
4. Downflow Reactors Loading Guidelines
Figure XIII-6 represents a sketch of a typical downflow reactor.

Figure XIII-7 is a view of the bottom head details.
a. Inspect the outlet distributor per drawing specs to ensure containment

of the ceramic material.
b. Load the bottom support material. Each layer must be carefully

leveled. One method is to mark the reactor walls for the height of fill of
each size layer of ceramic material. Each layer can then be leveled
using a flat board and large carpenter’s level.
uop 117108-6 XIII-7
c. The personnel loading the support material should stand on a large

board so that they do not disturb the thin layers of ¼ in. and 1/8 in.
material.
d. While the first 6 to 12 in. of catalyst is being loaded, the flow of

catalyst through the loading sock should be restricted so that a crater
is not produced in the 1/8 in. support material from the impact force of
falling catalyst.
e. If a man is used inside the reactor to control the loading, he should be

equipped with appropriate safety equipment. He should not step or
stand directly on the catalyst.
f. After the catalyst has been loaded, the layers of ceramic hold down
material should be carefully loaded and leveled. First, the layer of ¼
in. (6mm) ceramics are loaded on top of the catalyst bed. Then, the ¾
in. (19mm) ceramics are loaded on top of the ¼ in. ceramics. The
loading should be calculated such that the distance from the top of the
¾ in. hold down material to the bottom of the inlet distributor is not
less than that indicated in the following table:
Reactor I.D. Height of Open Space

4 ft. 0 in. – 6 ft. 0 in. 18 in. minimum
6 ft. 6 in. – 8 ft. 0 in. 15 in. minimum
8 ft. 6 in. and larger 12 in. minimum
Experience indicates that loading catalyst to a depth greater than

permitted by these dimensions has resulted in movement at the top of
the catalyst bed due to the high velocity eddy currents generated
around the perimeter of the reactor. In all cases catalyst should never
be loaded such that the level of ¾ in. hold down material will be above
the reactor tangent line.
uop 117108-6 XIII-8
5. Spherical Reactor Loading Guidelines
Figure V-1 (Chapter V, “Process Equipment”) shows a typical spherical reactor

design. Spherical reactors present a special problem because of the large
diameters of these reactors. It is very difficult to accurately level a thin layer of
support material over a large diameter. For this reason we recommend that the
thickness of the bottom layers of ¼ in. and 1/8 in. support material be increased to 6
in. for any reactor having a diameter greater than 8 ft. Also, when planning the
loading of a spherical reactor the catalyst bed should be spaced on equal distance
above and below the reactor centerline. The same concerns apply to spherical as
for downflow in regards to the distance from the top of the bed to the bottom of inlet
distributor.
6. Recommended Sock Loading Procedure
The steps involved in the actual loading of Platforming catalyst into any of the three
types of reactors are identical 1. The reactor inlet “L” and inlet distributor is removed
and placed away from the congested loading area. A catalyst loading hopper should
be constructed well before the loading is to occur. It should be built so that it will
securely sit on the exposed top flange of the reactor but take care not to damage
the flange face. The hopper should be wide enough at the top (about three ft. in
diameter) so that a drum of catalyst can be poured into the hopper without danger
of excessive catalyst spilling. The hopper should taper down in a funnel-like fashion
to a 4 in. diameter outlet nozzle, to which a canvas sock may be securely attached.
There must be enough open space left between the bottom of the hopper and the
top flange so that loading personnel (equipped with a fresh air mask) may reach into
the inlet section of the reactor to regulate the flow of catalyst (by restricting the
canvas sock) and to direct the catalyst back and forth across the bed. See Figure
XIII-8.
1
Some spherical reactors have an entrance manway for access.
uop 117108-6 XIII-9
The current UOP recommendation for most Platforming catalyst loadings is to use a
short sock, one that will extend one to two ft. below the top baffle cover. With this
short sock the catalyst loading rate should be slightly regulated and the sock should
be continuously moved across the top of the bed. There should be enough lighting
provided to allow the person who is directing the catalyst flow to observe the bed
height so that he may raise the catalyst level evenly: this is considered to be the
most important consideration in the loading step. If the bed is raised unevenly,
catalyst will have a chance to roll down the “hills” created, resulting in a varying
density across the reactor. See Figure XIII-9.
Some other important notes on catalyst loading.
a. Take care that the sock extends far enough into the reactor that there
is no possibility of accidental catalyst loading into the scallops (or
outer annulus) of a radial flow reactor. Tape the openings in the top of
the scallops closed.
b. Because some catalysts are presulfided and may emit small

quantities of H2S, because catalyst is sometimes loaded into a
nitrogen blanketed reactor, and because some dust will be generated
by the loading procedure, make sure that the person directing the
sock movement is provided with a safe air supply.
c. For downflow reactors, when first starting to load catalyst, the loading
rate should be minimized until a 12-18 in. layer of catalyst has been
loaded uniformly across the reactor bottom. The purpose of the slow
loading rate is to prevent “cratering” or upsetting the layer of 1/8 in.
catalyst support. This may be accomplished using a long sock with a
man in the reactor throttling the flow of catalyst.
d. As noted earlier, extreme care should be exercised in taking the final

outage measurements for catalyst and hold down material levels.
uop 117108-6 XIII-10
e. Remember, raise the catalyst level evenly over the cross section of
the reactor.
f. A final check of the loaded catalyst density should be made to ensure

that the proper volume of catalyst has been loaded.
Upon completion of catalyst loading, the reactor top internals should be very
carefully replaced and the reactor should be closed as soon as possible. Once the
reactors are closed, they should be blanketed with either instrument air or nitrogen.
By minimizing the contact of the catalyst with ambient air, the amount of water
adsorbed by the catalyst will be minimized and the following startup will be drier.
Wet catalyst can result in a premature deactivation and a subsequent short cycle.
7. Dense Loading
Some extruded Platforming Catalyst may be “dense” loaded by using UOP’s Dense
Loading Device. Dense loading has the primary advantage of being able to load
more catalyst into the same reactor volume. In addition, this technique gives a more
even and uniform loading that leads to better flow distribution during operation.
In general, there are only a few differences in the sock loading and dense loading
procedures. In dense loading, the dense loading machine is anchored either above
or inside the reactor. A loading sock attached to the loading hopper feeds the
loading machine with catalyst. The operator of the machine regulates its operation
so that the catalyst is loaded uniformly and so that the level rises evenly. Even
when dense loading, it will probably be necessary to level the bed after reaching the
desired catalyst height. Afterwards, an outage measurement should be taken and
recorded. See Figure XIII-10.
8. Stacked Reactor Catalyst Loading
Drums of catalyst are hoisted up to the reactor manway area where a temporary
loading hopper is situated. As catalyst is dumped into the hopper, it flows out the
bottom through piping or conduit and enters the reactor through the reactor
uop 117108-6 XIII-11
manway. At the end of the pipe or conduit is a loading sock that extends a few ft.
below the reactor coverdeck. From the other end of the sock the catalyst free falls to
the bottom of the reactor. During the loading procedure, the sock is shifted to
different areas of the catalyst bed annulus so the catalyst fills the reactor uniformly.
If the catalyst falls in only one area, it will put an uneven stress on the centerpipe,
and cause variations in the loading density. Obviously, this frequent movement of
the loading sock requires that a man be in the coverdeck area of the reactor
throughout the loading. Dust protection is required. The loading hopper can be
bolted to the manway but it is usually easier to locate it a deck (permanent or
temporary) above the manway. The layout of the piping and sock must be arranged
so the catalyst flows freely. An angle greater than 35 degrees from horizontal
should be acceptable. When everything is running smoothly, the loading crew
should be capable of moving approximately 20 drums per hour.
A small variation to this approach can increase this loading rate significantly to over
60 drums per hour. It calls for loading the catalyst into large bins at grade and then
lifting the bins up to the hopper. Typical bins used by catalyst handling companies
hold approximately 3000 lbs (1400 kg) of catalyst. A separate crew at grade would
be responsible for loading the catalyst into the bins, always staying ahead of the bin
transfers.
Regardless of whether drums or bins are used, loading should always start in the
lowest reactor and move up to the next highest when done.
(1) Step-by-Step Description
After a final reactor inspection following unit dryout or turnaround, the reactors may
be loaded by the following procedure:
(a) Confirm that the manways on all reactors except the lowest reactor in the
stack are closed to prevent a natural draft.
uop 117108-6 XIII-12
(b) Establish dry instrument air purges to the reactor stack by connecting air
hoses to the reactor outlet line pressure gauge connections or placing air
hoses in the manway of the open reactor.
(c) Remove two or three coverplate segments at equal spacing around the
coverdeck in the lowest reactor in the stack.
(d) Place covers over top of each scallop riser prior to reactor loading. This
should be done as soon as the reactor manway is opened.
(e) Located the catalyst loading hopper above the reactor manway. The deck
above, temporary scaffolding or a special structure can be used to support
the hopper. The loading hopper should be sized larger than the catalyst
drums or bins.
(f) Attach piping or flexible hose from the loading hopper outlet to the reactor
manway.
(g) Attach the loading sock to the piping or flexible hose; the sock should be
long enough to extend at least two feet below the coverdeck level at each of
the open coverplate locations.
(h) If bins will be used to lift catalyst up to the reactor catalyst loading hopper,
set up scaffolding and a catalyst addition hopper at grade to facilitate loading
of the bins.
(i) Start catalyst loading by lifting catalyst drums or bins up to the loading
hopper located above the reactor manway.
NOTE: If the reactor unloading nozzles were not filled during the final reactor
inspection with ceramic alumina balls as specified in the unit design specification,
this should be completed prior to catalyst loading.
uop 117108-6 XIII-13
(j) As catalyst is loaded to the reactor, move the loading sock to the different
open coverplate locations; this will minimize the chance of loading at
different densities at different points in the reactor bed. Raising the catalyst
level evenly over the entire cross section of the reactor will also facilitate a
constant density loading and reduce centerpipe stress.
(k) Continue sock loading until the correct catalyst level is achieved.
(l) For record purposes, measure the catalyst bed outage with respect to the
bottom of the coverplate and note the total number of drums loaded.
(m) Restore all coverplate segments.
(n) Remove any debris or catalyst spillage from the coverplate area and remove
the covers from the scallop risers.
(o) Close reactor manway.
(p) Proceed to load the other reactors in the same manner as described above,
moving from lowest to successively higher reactors in the stack.
(q) After catalyst loading is complete and the reactors are headed up, the
reactor system should be evacuated and placed under a positive nitrogen
pressure to await unit startup.
(r) At the conclusion of the catalyst loading activities, the quantity of catalyst
contained in each reactor should be determined. In addition, the loaded
density should be computed based on measured reactor volumes.
uop 117108-6 XIII-14
Figure XIII-1
Radial Flow Reactor Loading Diagram
Catalyst level
Shield
Seal and slump
catalyst
Ceramic Support
Material
Main Catalyst Bed
Ceramic fiber rope
1/4” (6 mm) CSM

F.B. Plat
117108 XIII-1
uop 117108-6 XIII-15
Figure XIII-2
uop
Radial Flow Reactor Loading
Shields
Top Section
Centerpipe
Shroud
1/4” Ceramic
Material
3/4” Ceramic
Material Seal Catalyst

1/4” Ceramic
Material Slump Catalyst
4”
Minimum of4” 4”
117108-6
L/2 (Unless otherwise
Minimum of4”
4” specified)
= 1” per 4ft of spherical

Bottom of or dense-loaded extrudate
shields / top row catalyst bed below the
of centerpipe shields or 3” for sock-
holes L loaded extrudate.
Catalyst Bed
F.B. Plat
117108 XIII-2
Special Procedures
XIII-16
Figure XIII-3
Bottom Head Brick Packing
F.B. Plat
117108 XIII-3
Figure XIII-4
Bottom Head Concrete Lining
F.B. Plat
117108 XIII-4
uop 117108-6 XIII-17
Figure XIII-5
Bottom Head Without Filler
Perforated scallop
Center pipe
Ceramic
fiber rope
F.B. Plat
117108 XIII-5
uop 117108-6 XIII-18
uop
Figure XIII-6
Typical Downflow Reactor Loading Diagram
Inlet Distributor
Catalyst Bed
3/4” (19 mm) CSM

1/4” (6 mm) CSM
117108-6
Ceramic balls (CSM)
1/8” (3 mm)
1/4” (6 mm) Unloading nozzle

and valve
3/4” (19 mm)
Elephant stool Outlet screen F.B. Plat
117108 XIII-6
Special Procedures
XIII-19
Figure XIII-7
Typical Downflow Reactor
Bottom Head Detail
1/8” Dia.
Dia. (3 mm dia.)CSM
dia.)CSM
A 1/4” Dia.
Dia. (6 mm dia.)
dia.) CSM
B 3/4” Dia.
Dia. (19 mm dia.)
dia.) CSM
A and B:
4 inch (250 mm)
minimum
thickness
Fill catalyst withdrawal
nozzle with equal layers of
catalyst support material
(1/8”, 1/4” and 3/4” CSM)
F.B. Plat
117108 XIII-7
Figure XIII-8
Typical Catalyst Loading Hopper
3” - 0” (915) I.D.
(150)
Hopper to be
6”
#10 gauge
1’ - 1”
(330)
Tackweld 5 equally
spaced eyes and wire
(200)
8”
canvas tube to pipe
Manway
Note: dimensions in parentheses are millimeters

UOP 3089e-54
uop 117108-6 XIII-20
Figure XIII-9
Loading Techniques
Short Sock
Loading Hopper
Loading Sock – Keep the sock moving

– Bring the catalyst bed
up as level as possible
– Minimize formation of
catalyst cones or ‘hills’
– Load slowly to try and
achieve a ‘raindrop’
effect
Uniform bed density
(Equal flow through
all areas)
UOP 3089e-53
Figure XIII-10
Radial Flow Reactor Dense Loading
Rotor Tape
Catalyst
Catalyst Mound
Flight
Paths
Centerpipe
Bed level
UOP 3089e-59
uop 117108-6 XIII-21
B. CATALYST UNLOADING AND RELOADING
1. Partial Catalyst Unloading and Reloading
In the case of a partial reload case (for example one reactor of a multiple reactor
system), UOP recommends the loading of oxidized catalyst. The use of oxidized
catalyst will allow for both the safe unloading of spent catalyst and the reloading of
fresh catalyst after the carbon burn step.
Sequence of Steps for Loading Oxidized Catalyst:
a. Complete the carbon burn step per UOP procedures.
b. Unload spent catalyst from reactor.
c. Reload oxidized catalyst.
d. Follow UOP procedures for proof burn, oxidation and reduction.
The loading of oxidized catalyst in a partial reload minimizes the time requirement
for maintenance, and the regeneration as a whole. It also lessens the possibility of
damage to the catalyst performance by reconditioning the catalyst immediately after
the interruption, as well as maximizing safety. Adding reduced and sulfided
catalyst before the oxidation, as was commonly done in the past, would introduce
sulfur to the reactor circuit and the catalyst performance could suffer as a result of a
sulfur-laden reduction.
2. Unloading of Unregenerated Catalyst Containing Iron Pyrites
The following precautions are recommended for use during unloading of

unregenerated Platforming catalyst. The main concern is that no oxygen be allowed
to contact the catalyst inside the reactors, since this can result in spontaneous
combustion of the iron pyrites that in turn can start the carbon catalyst burning. The
temperature generated by this combustion can be quite high, and left unchecked
uop 117108-6 XIII-22
can result in severe damage to the catalyst and reactor internals. Of secondary, but
no less importance, is protection of personnel and proper handling of catalyst during
unloading. All personnel involved with the unloading must be properly informed of
the dangers involved and proper safety measures. See Figure XIII-11 for a diagram
of the equipment to be used.
a. Follow the shutdown procedure as outlined in the Procedures section.

Be very careful to drain all residual hydrocarbons from the system low
points, the separator and the feed line down stream of the feed flow
control valve.
b. After all residual hydrocarbons have been drained from the system,
cut out the heater fires and cool the reactor beds to less than 150°F
(66ºC) – preferably to less than 130°F (54ºC). At temperatures above
this level, combustion of iron pyrites is greatly accelerated and more
difficult to control. If the catalyst is to be screened during unloading,
the catalyst beds should definitely be cooled to less than 130°F
(54ºC).
c. After cooling the beds to 150°F (66ºC), the unit should be evacuated
and purged with N2 at least twice. The unit should then be properly
isolated and a small N2 purge established at the compressor
discharge or preferably at the inlet to each reactor. Do not open the
reactors at the top until all reactors have been unloaded.
d. Connect the unloading equipment to the unloading nozzle and be sure

that a full opening but positive shutoff valve is installed. This is best
accomplished by using a ball type or slide valve.
e. Remove all combustible materials from the area.
f. Be sure that several CO2 extinguishers are available.
uop 117108-6 XIII-23
g. Use only metal drums for unloading, and dump directly into drums if
possible. It is best to screen the catalyst after it has had time to cool to
ambient temperature. Each drum should be either purged with N2
during unloading or a piece of dry ice placed at the bottom of each
drum. Should the catalyst be screened at the same time as it is being
dumped from the reactors, nitrogen should be purged through the
dumping nozzle to the top of the first screen to provide additional
protection from pyrite ignition.
Do not seal the drum air tight since this could result in sudden rupture
of the drum should combustion occur. Burning of catalyst in the drums
is not serious and can be quickly extinguished with nitrogen or CO2.
h. It is expected that some "sparking" of the pyrites will take place in any
event. Therefore, all workmen in the area must be supplied with face
and eye protection. In addition they should wear long sleeve, fire
retardant shirts with the collars and cuffs tightly buttoned.
i. Maintain a positive flow of N2 out of the unloading nozzle throughout

the unloading. If the catalyst becomes bridged in the unloading nozzle
or is not free flowing, break the plug with a blast of N2 or steam. Do
not allow air to be drawn into the reactor.
j. If ignition of pyrites takes place inside a reactor, stop unloading in that

reactor and increase the N2 purge to maximum until burning has
stopped.
3. Catalyst Screening
When screening 1/16” extrudates or spherical catalyst it is recommended to use an

oversize screen with a 2.4 – 4.0 mm opening (slotted opening preferred) and an
undersize screen with a 1.2 – 1.4 mm square opening.
uop 117108-6 XIII-24
Figure XIII-11
Unloading Used Catalyst
Reactor Slide Valve

Control Handle
0-2 Kg / cm2
Dump Spout
Gage
P Fitted Canvas Top

Grounding
Cable
54” Sweco
Screen-Shaker
12 mm Copper
Tubing Grounding
Clamp
P Barrel
Loading
12mm - 7-9 Kg / cm2 To Lid
Nitrogen Supply Placement
0-2 Kg / cm2 Gage
6mm Rubber Barrel Roller
Next Barrel
to Be Loaded
Procedure
1. Normal Cooling and Purging.

2. Install Dumping Spout and Nitrogen Purge Facilities.
3. Commission Nitrogen Purge to Reactor.
4. Open Reactor Top, Remove Baskets, Break-Up and Remove any Surface Crust.
5. Close and Blind Reactor Top
6. Set Nitrogen Purges on Dumping Spout and Barrels.
7. Dump and Screen Catalyst at 3 to 5 Minutes per Barrel to Obtain Good Separation of
Catalyst and Fines.
8. Roll Away Barrels and Install Gaskets, Lids and Clamps as Each Barrel Is Filled.
PLT-R00-
uop 117108-6 XIII-25
C. REGENERATION
The need for regeneration of Platforming catalyst is normally determined by one of

the following parameters:
a. The reactor temperature limit has been reached;

b. The economic limit of yield decline has been reached;
c. The heater firing limit has been reached.
All of these limits are primarily a result of carbon deposition on the catalyst. The
carbon deposition rate is a function of the feedstock quality and operating conditions
of the unit. A properly controlled regeneration will fully restore the catalyst
performance. The need for regeneration can also result from plant upsets such as
high feed sulfur, high feed end point, compressor failure, severe water or chloride
upsets, excessive catalyst temperatures and contamination of the feed with metals.
Only in the case of catalyst deactivation by metals or excessive temperature is the
catalyst not regenerable.
Regeneration of UOP Platforming catalyst is accomplished by combining the basic

steps of carbon burn, oxidation and reduction. For those units that have
experienced sulfur contamination, a sulfate removal step may be necessary to fully
recover fresh catalyst performance. See Chapter II, “Process Principles”, for a
detailed discussion of all aspects of regeneration. See Figure XIII-12 for an outline
of the steps of the regeneration procedure. The following sections will review the
important aspects of Platforming catalyst regeneration.
This regeneration procedure is not intended to apply to all individual units and
refinery situations. The purpose is to provide guidelines for the refiner to use when
preparing the procedures that will be used on an individual unit.
uop 117108-6 XIII-26
Fixed Bed Platforming Catalyst Regeneration Procedure Outline

Figure XIII-12
uop 117108-6 XIII-27
1. Pre-Shutdown
a. Plan all activities carefully.

b. Prepare auxiliary regeneration equipment.
c. Ensure that all necessary chemicals and materials are available.
2. Unit Shutdown
This period can be used beneficially not only to free the unit of liquid hydrocarbons
but also to properly prepare the unit and the additional equipment for regeneration.
All necessary supplies and utilities (such as nitrogen, air, reduction hydrogen,
analyzers, etc.) should be available. All meters, pressure gauges, and
thermocouples should be checked, calibrated and placed in good working order.
In order to shorten the duration of the carbon burn as much as possible, it is

important to strip and drain the maximum amount of liquid hydrocarbons from all low
points in the regeneration gas circuit. Water washing of the product condensers and
separator is recommended.
a. Notify all other areas and units which will be affected by the shutdown
(i.e., boiler house, crude unit, etc.). Follow normal refinery practice for
shutdown of the fractionation equipment.
b. Begin decreasing the reactor inlet temperatures to 850°F (454°C) at

approximately 55°F (30°C) per hour.
c. At 900°F (482°C) reactor inlet temperatures, begin reducing the feed

rate stepwise to half the design feed rate but not less than 0.75 LHSV.
Strive to reach 850°F (454°C) reactor inlet temperatures
simultaneously with the reduction in feed rate.
d. At 850°F (454°C), stop chloride injection, water injection, and feed to

the unit. Maintain maximum recycle gas circulation.
uop 117108-6 XIII-28
e. Adjust the heater firing to cool the catalyst beds to 750°F (399°C) at
approximately 55°F (30°C) per hour. Drain the products separator and
all low point drains until liquid hydrocarbon free.
f. At 750°F (399°C) reactor inlet temperatures, shut down the heater

firing. Continue recycle gas circulation for 15 to 20 minutes to cool the
heater tubes, then shut down, isolate, and purge the recycle gas
compressor(s). Follow the manufacturer’s recommended procedure
for shutdown and purging of the recycle gas compressor(s). Drain the
compressor suction and discharge snubbers and blow down all
compressor casing drains.
g. Depressure the unit to fuel gas, then evacuate the unit three times to
20-25 in. (510-635 mm) Hg, breaking each vacuum with nitrogen 3 to
5 psig (0.2 to 0.35 kg/cm2g). Isolate and blind the reactor section as
required to prevent contamination of and from other equipment and
units (feed, separator gas, separator liquid, flare, fuel gas, etc.).
NOTE: Be sure no valves or equipment are open to atmosphere such that

air will be pulled into the unit during evacuation.
h. Ensure that all of the low points in the cold section of the regeneration
circuit have functional valved drains. If valves are not functional, repair
them now. Valved drains should be added to any low points that
cannot be drained. It is prudent to check all low points before a
scheduled turnaround such that any work required would not add to
the regeneration time.
i. Isolate the recycle gas moisture analyzer. This will prevent saturating
the analyzer during the regeneration, which could produce artificially
high moisture results at startup.
uop 117108-6 XIII-29
j. While maintaining a nitrogen blanket on the reactor section, make all

connections for controlled addition of air and purge nitrogen at the
outlet of the charge heater, caustic injection (for corrosion control) at
the outlet of the combined feed/reactor effluent exchanger, and
chloride injection at the first reactor and the last reactor inlets. Provide
a means for controlling plant pressure by venting the excess
regeneration gases to atmosphere from the separator. (See the
Auxiliary Piping section later in this chapter for required connections.)
k. The first and last reactors may be burned simultaneously, in parallel,

to shorten the time required for regeneration. If this is desired, a
separate air line with independent metering and control equipment
and a continuous oxygen analyzer will be required for installation at
the inlet of the last reactor. Locate the air addition point ten to fifteen
pipe diameters upstream of the sample point to assure good mixing
prior to sampling.
l. Check the calibration of the air flow meter(s) and the recycle gas
meter. For nitrogen circulation, the recycle gas flow meter factor must
be changed.
NOTE: The connections at the charge heater outlet and compressor

discharge for purging the unit should be at least 1½ to 2 in. to allow for
maximum flow rates of nitrogen during the purge steps.
3. Carbon Burn
If channeling is evident, especially if the reactor pressure drop has been above
normal, the catalyst should be dumped and screened prior to the oxidation step.
Channeling can best be detected by an extended tail on the reactor ΔT’s and
overlapping of the reactor ΔT’s as the catalyst goes through the carbon burn. Two
possible reasons for improper gas distribution (channeling) in radial reactors are
loss of seal catalyst and plugging in the scallops or outer basket. For Cold Wall
Reactors, see “Note” at the end of this Carbon Burn step.
uop 117108-6 XIII-30
a. Throughout the regeneration, maintain a record of all operating

conditions and analytical results.
b. Pressure the unit to the highest pressure possible, usually 50-300

psig (3.5 to 21 kg/cm2g), with nitrogen consistent with the nitrogen
supply pressure, air supply pressure, plant pressure limitations and
compressor horsepower and discharge temperature limitations.
c. Establish maximum nitrogen circulation consistent with compressor

limitations. Fire the heaters to adjust each reactor inlet temperature to
725°F (385°C). The higher the pressure and the nitrogen circulation
rate, the faster the carbon burn will proceed as long as sufficient air is
available. Drain all liquid hydrocarbons from the regeneration circuit
low points prior to the next step.
d. Begin injection of once-through water or circulated water at the outlet

of the effluent side of the combined feed exchanger to flush the
reactor products condenser and products separator. Maximize cooling
of the product condenser to minimize the product separator
temperature. This temperature should be minimized throughout the
entire regeneration to prevent recycling excessive moisture back to
the reactors. This also decreases chloride and caustic consumption.
Continue water injection until the water drained at the separator is
clean and no further accumulation of hydrocarbon or scale is evident.
Since hydrocarbons will float on the water, drain the separator
completely at least three times.
e. Line out all of the reactor inlet temperatures to 725°F (385°C). Hold
these temperatures until the reactor outlet temperatures stabilize.
Record the inlet and outlet temperatures.
f. Start air injection at a low rate initially, then increase the air rate to
give between 0.6 and 0.8 mol-% oxygen at the compressor discharge
(and last reactor inlet if a parallel burn is employed). A minimum of 0.3
uop 117108-6 XIII-31
mol% oxygen is required for continuous combustion. Do not exceed a

850°F (454°C) maximum reactor outlet temperature or a 125°F (69°C)
temperature rise above the stabilized outlet temperatures measured
and recorded above. Avoid exceeding the 850°F (454°C) maximum
outlet temperature by adjusting the oxygen content of the circulating
gas within the specified range.
g. Once the burn is established and stabilized in reactor #1, a parallel

burn can be started in the last reactor. Follow the same procedure as
above except air is injected in the outlet of the last heater and the
oxygen content is controlled at the inlet of the last reactor.
h. After starting air injection, continuously inject HCl, or a light organic

chloride to the inlet of reactor #1 at a rate required to give a 20:1 mole
ratio of water to chloride (See “Calculations” Section later in this
Chapter). If the last reactor is burned in parallel, also inject chloride at
the inlet of the last reactor at a rate sufficient to give a 30:1 mole ratio
of water to chloride at that reactor inlet while it is burning.
When an organic chloride is used, the injection rate must be carefully controlled to
avoid high temperatures as the compound decomposes. The chloride should be
injected at the inlet(s) of the first reactor (and last reactor if a parallel burn is used)
to avoid any possibility of the material settling in a low spot in upstream lines, then
surging through the heaters and reactors. The water content of the circulating gas is
based on saturated conditions at the separator. Maintain this ratio throughout the
carbon burn. If the last reactor is burned in parallel, also inject chloride at the last
reactor inlet at a rate sufficient to give a 30:1 mole ratio of water to chloride at that
reactor inlet while it is burning. When organic chloride is injected, start at a low rate
initially and increase to the specified rate, watching the reactor ΔT’s closely. An
injection nozzle for the chloride injection must extend to the centerline of the pipe to
assure proper mixing and to protect against localized corrosion.
uop 117108-6 XIII-32
i. While chloride is being injected, the unit must be protected against

corrosion. Circulate or inject once-through caustic (dilute caustic or
carbonate) at the outlet of the combined feed exchanger(s). Use the
maximum flow rate possible in order to ensure adequate
neutralization of the acidic circulating gas. Circulation pumps are
usually sized for of 50-100 vol% of the unit’s design naphtha charge
rate: 50% is to be considered an absolute minimum. Control the
separator water pH at 7.5 to 8 and the total alkalinity at 1.5 to 2.0 wt-
% NaOH equivalents. (See the section on “Chloride Neutralization
During Regeneration” in Chapter II “Process Principles” for a full
discussion). If there is any brass in the unit, the pH should be
controlled below 9 to protect the copper from alkaline attack. Keep the
solids concentration of the circulating water below 6-7 wt-% to avoid
foaming problems. An iron content above 10 ppm in the circulating
water could indicate excessive corrosion. The caustic injection point
should have a nozzle such that mixing occurs at the center of the
pipe. (See the section on Auxiliary Piping later in this chapter.)
j. Particular attention should be paid to the caustic quality when the burn
wave moves from one reactor to the next. As burning starts in a new
reactor the entire catalyst bed temperature will rise. Equilibrium at a
higher temperature can cause chloride to come off the catalyst and
create an increase in the rate of caustic consumption.
k. Monitor the HCl and SO2 at the reactor outlet. The SO2 concentration
should be checked as the burn wave breaks through the reactor; the
maximum SO2 concentration will be detected at the highest reactor
temperature and when oxygen starts to become available. At all
times, the SO2 concentration should be less than 25 ppm. If not, there
is excessive sulfur on the catalyst and a sulfate removal step should
be performed. (See Chapter IX “Analytical” for the sampling
schedule.)
uop 117108-6 XIII-33
l. Monitor the burn wave: the trend of ΔT and oxygen consumption of

each reactor. These burn “profiles” will indicate how the burn is
progressing. Figures XIII-13~15 give some examples of burn profiles.
If the wave does not subside sharply at the end of burning of that
reactor (a “ΔT tail”) or there is overlapping of the reactor ΔTs as the
carbon burn progresses, this is an indication of channeling.
Channeling is a type of flow maldistribution caused by loss of catalyst
seal or plugging of the scallops (or outer basket) in a radial-flow
reactor. If ΔT tails are observed, the catalyst should be dumped and
screened (see note later in this section).
m. If the reactors are burned in parallel, carefully monitor the oxygen

concentration at the last reactor inlet as the burn is completed in the
upstream reactors. Reduce the air injection to the last reactor as
necessary to maintain 0.8 mol-% oxygen maximum or a 125°F (69°C)
temperature rise above the stabilized outlet temperatures, whichever
comes first. Air injection to the last reactor must be stopped when the
temperature rise in the preceding reactor decreases more than 17°C
(30°F). Note that carbon burning may temporarily cease in the last
reactor when air injection to that reactor is stopped.
n. The carbon burn is considered complete when all reactor ΔT’s have
been at their base levels for a period of 4 hours, with the oxygen
concentration at all reactor inlets and outlets equal at 0.6-0.8 percent.
When organic chloride is being injected, it will contribute to the first
reactor ΔT, and must be taken into account (See “Calculations”
Section later in this Chapter). Attention should also be paid to the air
consumption when the final reactor ΔT begins to decrease. The air
demand should also begin to decrease proportionally.
o. Frequently check and drain all low points in the regeneration gas
circuit as well as all dead end lines.
uop 117108-6 XIII-34
Note for Cold Wall Reactors: Since hydrocarbons remaining behind the reactor
liners could prematurely reduce the catalyst, it is recommended to pull a vacuum on
the reactor section following the completion of the carbon burn step. It is important
to proceed through the evacuation as quickly as possible, since there is a high
potential for corrosion during this period. All cold-wall reactors designed by UOP are
rated for full vacuum at 725°F (385°C). This is so that a vacuum can be pulled while
the unit is hot to ensure that no hydrocarbons condense behind the lining. The
following procedure will help remove these hydrocarbons from behind the liner
without causing any harm to the refractory or liner:
(1) Finish the Carbon Burn step through the four-hour hold period.
(2) Verify that the reactor is rated for full vacuum at 725°F (385°C). If so,
do not decrease reactor temperatures. If not, decrease reactor
temperatures to the rating of the vessel at full vacuum.
(3) Stop the chloride addition, stop the caustic circulation and start
draining the separator. Stop the recycle compressor. Continue to drain
the low points until a vacuum is pulled.
(4) Depressure and pull a vacuum on the unit. If evacuation equipment is

not available, perform repeated pressure-depressure steps with
nitrogen.
(5) Break with nitrogen.
(6) Resume Carbon Burn conditions and look for further burning of the
trapped hydrocarbon pulled from behind the liner.
NOTE: Proper scheduling of unit maintenance required at the time of regeneration

is a major factor in guarding against catalyst damage during a turnaround. Dumping
and screening of catalyst, whether done as a scheduled routine maintenance item
or as a result of observed maldistribution during a carbon burn step (ΔT tail, high
reactor ΔP), should always be performed immediately after the carbon burn step
uop 117108-6 XIII-35
and prior to the oxidation. Dumping & screening is usually performed every 2 years
or every third regeneration, whichever is sooner.
If flow distribution problems exist, there will be pockets of residual carbon that will
not be combusted during the carbon burn step. If oxidation conditions are
established, these residual pockets of carbon may begin to burn rapidly due to the
elevated temperatures and increased oxygen partial pressure. Such rapid burning
at elevated temperatures can damage both the catalyst and the reactor internals.
Therefore, the recommended procedure for dumping and screening after

completing the carbon burn step is to stop chloride injection, flush and drain the
separator, and begin cooling the catalyst in an atmosphere containing 0.8 mol-% or
less oxygen. Dump and screen the catalyst after cooling to a temperature at which
the catalyst can be safely handled and reactor internals safely inspected.
This is also the best time for performing all other maintenance which is required.
Carbon has been burned off the catalyst so it is in its safest state to unload but the
catalyst has not been oxidized so it is less sensitive to damage from the
atmosphere. Performing maintenance after the oxidation step risks damage to the
catalyst since it is in a sensitive (oxidized) state.
uop 117108-6 XIII-36
Figure XIII-13
Platforming Regeneration Burning Wave
‘Good Burn’
50
50 (90)
(90)
T, °C
Delta T,
Reactor Delta (°F)
°C (°F)
25
25 (45)
(45)
Reactor
Rx 1 Rx 2 Rx 3
00 (0)
(0)
Elapsed
Elapsed Time
Time Since O22 Introduction
Since O Introduction
Figure XIII-14
‘Low Catalyst Carbon Level’
50
50 (90)
(90)
T, °C
Delta T,
Reactor Delta (°F)
°C (°F)
25
25 (45)
(45)
Rx 1 Rx 2 Rx 3
00 (0)
(0)
Elapsed
Elapsed Time
uop 117108-6 XIII-37
Figure XIII-15
‘Excessive Tailing’
50
50 (90)
(90)
T, °C (°F)
Delta T,
Rx 1 Rx 2 Rx 3
Reactor Delta
25
25 (45)
(45)
00 (0)
(0)
Elapsed
Elapsed Time
uop 117108-6 XIII-38
4. Proof Burn
The Proof Burn Step is the transition from Carbon Burn to Oxidation. It is required in
order to insure that all carbon burning is complete before Oxidation. Any residual
carbon may begin to burn rapidly due to the elevated temperatures and increased
oxygen partial pressure of the Oxidation step. Such rapid burning at elevated
temperatures can damage both the catalyst and the reactor internals.
a. Increase the reactor inlet temperatures to 950°F (510°C) over a period

of four hours. Watch for residual carbon burning as indicated by a
decrease in the oxygen concentration of the circulating gas or by
increased carbon dioxide production. Maintain 0.6 to 0.8 mol-%
oxygen in the circulating gas.
b. With the reactor inlet temperatures at 950°F (510°C), increase the

oxygen concentration of the circulating gas to the maximum possible
over a period of at least two hours. The oxygen limit must be set low
enough to prevent an explosive mixture from forming in the recycle
gas compressor's seal oil system. The maximum is typically in the
range of 8 to 10 mole %, but this level depends on whether or not the
seal oil system is nitrogen blanketed. Contact the compressor vendor
to determine the maximum oxygen content allowed in each machine.
The minimum oxygen level for the oxidation step is 5 mole %
c. Carefully check for signs of residual carbon burning as indicated by

reactor ΔT’s and carbon dioxide production. If there is residual
burning, this could be another indication of maldistribution in the
reactor(s). Residual coke burning at 950°F (510°C) is more
detrimental to catalyst surface area and platinum dispersion than
during the carbon burn because of the elevated temperatures.
Therefore, if there is an indication of residual carbon burning, the
oxygen concentration should be constrained so that the reactor outlet
temperatures are less than 970°F (521°C). If this is not possible then
uop 117108-6 XIII-39
serious consideration should be given to dumping and screening the

reactor(s).
Note for Cold Wall Reactors: If there is a history of coke ball formation or
damage to reactor internals, maintaining a maximum of 3 mol-% oxygen
during oxidation should be considered. In rare cases (less than 5% of
regenerations), it is possible for coke to remain behind the liner after the
carbon burn and proof burn steps. Decreasing the oxygen concentration from
5 mol-% to 3 mol-% would lower the temperature by about 300°F (150°F per
1 mol-% oxygen) in the bed, thereby minimizing the degree of damage to
reactor internals if residual coke remains behind the liners.
Since all cold-wall reactors are in older units, a general rule of thumb would
be not to exceed oxygen concentrations that were successfully employed
during oxidation steps of past regenerations.
5. Oxidation
Oxidation of the catalyst is required in order to achieve the desired oxidation state of
the active metals and fully disperse the platinum. These results can only be
achieved through the proper balance of time, temperature, oxygen content, chloride
level, moisture, and the absence of contamination by sulfur. The conditions
specified for oxidation provide for proper platinum dispersion. Care, therefore, must
be exercised to prevent upsets during the oxidation, purging, and reduction steps
that might cause damage. These upsets include: hydrocarbon contamination,
excessive catalyst temperatures caused by combustion of residual carbon at
elevated oxygen concentrations, and a catalyst deficient in chloride. These items
are easily controlled, and the conditions and guidelines given in the procedure will
optimize the catalyst performance.
a. Hold the system at 950°F (510°C) reactor inlet temperatures, the

same pressure as used for carbon burn and a minimum of 5 mol-%
oxygen in the circulating gas.
uop 117108-6 XIII-40
b. Inject chloride to the inlet of the first reactor to establish the required
mole ratio of water:chloride in the circulating gas dependent on
catalyst age as per Figure XIII-16.
NOTE: The relationship represented in Figure XIII-16 is a general

guideline and should be adjusted commensurate with any data from
actual catalyst chloride analytical results or performance following
previous regenerations.
c. Maintain corrosion control. There is very little CO2 produced during

the oxidation step so there will be little conversion of the caustic to
sodium bicarbonate. Therefore, the total alkalinity during Oxidation will
be low (0.5 to 1.0 mass-% NaOH equivalents) and can be difficult to
control. The caustic strength should be maintained by controlling the
pH between 7.5 to 8.0. Keep the solids concentration of the circulating
water below 6 to 7 wt-% to avoid separator foaming problems. This
may require frequent or continuous separator draining.
d. Maintain these oxidation conditions for 11 (eleven) hours. Begin

timing these eleven hours once the reactor outlet temperatures have
stabilized.
e. During the oxidation, measure the HCl concentration at the reactor

outlets. There should be a strong detection of HCl at each reactor
outlet (greater than 50 mol-ppm, as detected by Dräger-type tubes)
and less than 5 to 10 ppm SO2. If HCl is not detected at this level at
the outlet of each of the reactors, check the chloride injection system
to ensure that the chloride is being injected as required. Also make
sure that the sample points at the reactor outlets do not include
sections of copper piping or tubing (see Chapter IX “Analytical” for
sampling schedule and further discussion of sniffer tube sampling).
uop 117108-6 XIII-41
f. The completion of Oxidation is not immediately apparent. Indications

are:
(1) HCl content is equal at each reactor inlet and outlet (within
error reading).
(2) Catalyst samples from the last reactor are creamy-white in
color.
(3) There are no suspected platinum dispersion problems.
g. If indications are that Oxidation is complete, the duration of hold can

be decreased. There is no adverse affect to continuing the Oxidation
step. If indications are that Oxidation is not complete then the hold
time is a minimum of eleven hours and can be extended by a further 5
hours.
uop 117108-6 XIII-42
Figure XIII-16
Approximate Water-Chloride Ratio Requirements with
Catalyst Age
210 1
205
Approximate Catalyst Cycles

Catalyst Surface Area, m /kg
200
2
2
195
190
3
185
4
180
5
175 6
7
170 8
165 10
10 12 14 16 18 20
Molar Water-Chloride Ratio
uop 117108-6 XIII-43
6. Separator Flushing
Following the Oxidation step, the caustic circulation system must be flushed to
remove all residue from the neutralization reactions. All water must also be removed
from the system to minimize water adsorbed by the catalyst during subsequent
cooling for the reduction step.
Since the catalyst’s capacity for adsorbing water increases as catalyst temperature
decreases, the oxidation temperatures should be maintained until all flushing and
draining is complete. Cooling during the flushing step will result in large amounts of
water adsorbed on the catalyst. This water will then be desorbed during the heatup
for the reduction step, making the reduction wetter and more corrosive. Since much
of the flushing is done after stopping chloride addition, this step should be done as
quickly as possible to minimize chloride loss from the catalyst.
a. Three hours prior to the end of oxidation, begin maximum fresh water
addition to the caustic circulation system. Drain spent caustic at an
equal or slightly greater rate. Monitor pH and continue to add fresh
caustic to maintain a pH of 7.5 to 8.0.
b. At the completion of the oxidation period, stop water addition and

drain the caustic system as rapidly as possible. Stop the circulation
pump when a level is no longer visible in the separator. Stop chloride
addition immediately after stopping water circulation. Finish draining
all liquid from the system as rapidly as possible.
c. Re-inventory the separator with clean condensate (the minimum

needed to maintain pump suction). Circulate for 10-15 minutes. Stop
pump and drain as rapidly as possible.
d. Repeat the previous step until the water drained appears to be free of
suspended solids. Two or three separate flushes should be sufficient.
uop 117108-6 XIII-44
e. Following the final flush, drain the unit thoroughly. With no caustic
and decreasing amounts of water, that water will become more acidic.
Monitor the pH of the water being drained and insure that it does not
go below 5. At this point, sufficient water should have been drained
from the system and further draining risks corrosion damage to piping
and equipment. If pH drops below 5, proceed to step f, below.
NOTE: It is especially important for R-72 to drain all low points

thoroughly before reducing heater firing. It is critical that oxidizing
conditions (temperature and oxygen concentration) be maintained
until there is a significant decrease in the rate of accumulation of
water at cold low points and in the Separator. Water is to be drained
regularly (at 15 minute intervals from the end of the last flush and
drain) and the amount drained recorded. When the amount of water
drained over two consecutive such intervals is less than or equal to
0.1 wt-%/hr (0.12 gallons per hour per thousand lb or 1 liter per hour
per metric ton) of the total catalyst loading, proceed to cool down,
continuing to drain water. If the rate of water collection is higher than
0.1 wt-%/hr of the total catalyst, continue draining water before
beginning the cooldown.
f. Only when all flushing and draining is complete, start to decrease

heater firing and begin cooling the reactors.
h. It is recommended that the areas upstream (to the first low point) and
downstream (for a distance of about six ft.) of the water injection point
should be checked for possible corrosion. The air condenser inlet and
outlet headers should also be checked. This inspection should be
performed by ultrasound to check for metal loss; the piping should not
be opened.
NOTE: Opening the regeneration circuit at this point to perform any

maintenance risks damage to the catalyst in its sensitive (oxidized)
state and must be avoided at all costs. If this is unavoidable due to
uop 117108-6 XIII-45
some emergency situation, a 4-hour oxidation must be performed

upon restart prior to reduction of the catalyst.
7. Cooldown
It is important to complete the flushing and draining of the separator and caustic
circulation loop while circulating gas at 950°F (510°C) reactor inlet temperatures. If
the flushing is continued while the catalyst is cooling, the catalyst will absorb
excessive water. This water will be desorbed during the reduction and startup, with
subsequent chloride loss and possible damage to the catalyst. Therefore, drain the
separator and all low points 2 to 3 times per hour during the cooldown.
Oxygen is required in the circulating gas throughout the cooldown to prevent an

improper reduction of the catalyst metals. A minimum of 1.0 mol-% oxygen in
nitrogen should be maintained. Using as high an oxygen concentration as possible
(consistent with compressor limitations) during oxidation will minimize the need to
add air during this step. The purpose of the cooldown is to prepare the catalyst for a
gradual low temperature reduction. Such a reduction minimizes the water level
prevailing at the reduction site and more consistently gives a properly reduced
catalyst.
a. After all flushing and draining of the caustic circulation system has
been completed, reduce heater firing.
b. Continue maximum gas circulation and cool down the reactors at

100°F (55°C) per hour (50°F or 28°C per hour for stacked reactors)
until all reactor outlet temperatures are below 400°F (204°C). Water
will still be liberated as the catalyst cools down. Do not decrease
reactor temperatures until all water is removed at that temperature.
c. Maintain system pressure by adding nitrogen. If it is necessary to add

air, dry instrument air is strongly preferred.
uop 117108-6 XIII-46
d. To minimize water absorption and possible corrosion, frequently drain

the separator and all low points. It is recommended this be 2 to 3
times per hour.
e. Continue gas circulation until all reactor outlet temperatures are below
400°F (204°C). Maintaining high unit pressure (within plant limitations)
during this cooldown step will hasten the rate of cooling.
f. When all reactor outlet temperatures are below 400°F (204°C), stop
heater firing, stop and isolate the recycle compressor and depressure
the unit.
8. Nitrogen Purge
Oxygen and carbon oxides must be removed from the unit prior to the introduction
of hydrogen for reduction. Once-through nitrogen purging is recommended over
repeated evacuation and nitrogen breaking for the following reasons:
(1) Evacuation will allow moist, ambient air to enter the unit through any
leaking valves, flanges, etc. This will result in oxygen in the unit and
added water adsorption by the catalyst.
(2) Evacuation may allow contamination of oxidized catalyst by

hydrocarbons from the colder sections and dead-end lines of the unit.
(3) For reactors with internal insulation (cold-wall reactors), hydrocarbons

and sulfur compounds could be pulled out of the insulating material
across the oxidized catalyst, later interfering with the proper reduction.
To avoid this, maintain the plant pressure existing at the time of
compressor shutdown throughout the purging and reduction steps.
The recommended method is to employ bi-directional (reverse and forward

directions) nitrogen purging as outlined below. This method was designed to purge
any sulfates from the charge heater and CFE tubes away from the catalyst bed.
uop 117108-6 XIII-47
This method is also is more effective at removing oxygen and carbon dioxide from
the regeneration circuit.
a. Depressure the unit completely to atmosphere.
b. Connect a source of nitrogen between the charge heater outlet and

reactor #1 inlet. Open the vent at the compressor discharge to start
the reverse-direction purge. Do not install any blinds. The nitrogen
should fill the whole regeneration circuit and just be vented at the
compressor discharge. See Figure XIII-17.
NOTE: For units with Packinox CFEs: During this reverse purging, ensure that the
effluent side pressure is not greater than the feed side pressure by more than the
maximum specified by Packinox.
c. Monitor the sulfur dioxide content of the purge gas between the
combined feed exchanger and the compressor discharge as close to
the combined feed exchanger as possible. Maintain the purge until the
vented purge gas contains less than 0.3 mol-% oxygen and 0.1 mol-%
carbon dioxide, and until the sulfur dioxide content of the purge gas is
less than 50 mol-ppm at the sulfur dioxide sampling point.
d. Close the vent line at the compressor discharge and open up the vent
at the compressor suction, thereby purging forward through the
reactors and interheaters. See Figure XIII-18.
e. Continue this purge until the vented purge gas contains less than 0.3
mol-% oxygen and 0.1 mol-% carbon dioxide. Measure the CO2
content by Dräger tube, using 100 strokes for greater precision.
f. During the above purges, purge all dead-end lines. Drain all low
points in the circuit.
uop 117108-6 XIII-48
g. Follow the manufacturer’s recommended procedure for purging the

recycle compressor.
h. At the completion of the purges, blinds that were installed to isolate

the reactor section can be swung, and regeneration piping can be
removed in preparation for unit startup. It is advisable to drain and
purge the chloride injection lines to prevent possible plugging.
uop 117108-6 XIII-49
Figure XIII-17
Nitrogen Purge - Reverse Direction
Nitrogen Nitrogen
Supply Vent
FRC
PI
Air
Compressor
Rx Rx Rx
1 2 3 Vent to
Atmosphere
Separator
FI PI
PLT-R01-193
Figure XIII-18
Nitrogen Purge - Forward Direction
Nitrogen Nitrogen
Supply Vent
FRC
PI
Air
Compressor
Rx Rx Rx
1 2 3 Vent to
Atmosphere
Separator
FI PI
PLT-R02-193
uop 117108-6 XIII-50
9. Reduction – Catalysts Other Than R-72
The reduction of the catalyst is achieved by establishing a hydrogen atmosphere in

the unit and then raising reactor outlet temperatures to a minimum of 800°F (427°C)
preferably 900°F (482°C). This temperature must be maintained for one hour, or
more, to ensure complete metal reduction.
The reduction is achieved gradually. Water evolution from the metal sites is slow
and the high rate of gas circulation serves to rapidly carry this water away from the
catalyst surface. In order to increase the evolution of water from the catalyst and
decrease post oil-in drydown time, UOP recommends raising reactor outlet
temperatures to 900°F (482°C) during reduction. However, circulating hydrogen at
high temperatures can strip chloride from the catalyst so the procedure should be
performed without delay. High recycle gas moisture content exacerbates this
problem. The refiner should strive to complete the procedure in 18 hours or less.
The procedure outlined below can be used for all Platforming catalysts except R-72.
a. Introduce hydrogen (refer to the Chemical Specifications section later

in this Chapter) to the unit and pressure the system to 100 psia (7.0
kg/cm2 absolute) minimum hydrogen partial pressure. Electrolytic-
grade hydrogen is the best for reduction.
b. Establish maximum recycle gas circulation consistent with the

compressor operation. If electrolytic-grade hydrogen is used, it may
require the addition of nitrogen to increase the gas density such that
the compressor can deliver the maximum possible mass flow rate.
c. Raise the reactor outlet temperatures to a minimum of 800°F (427°C),

preferably 900°F (482°C). Do this by raising the reactor inlet
temperatures no more than 75-100°F (40-55°C) per hour. For units
with stacked reactors the heat-up rate should be kept at 45-55 °F (25-
30°C) per hour. Do not, however, exceed the reactor design
temperature limitation: typically 980°F to 1010°F (527°C to 543°C)
depending on the specific unit design.
uop 117108-6 XIII-51
d. When raising reactor temperatures, frequently drain the separator and

all low point drains in the cold section of the regeneration circuit. This
will minimize the recycle gas moisture content and, in turn, reduce the
drydown time.
e. Periodically measure the H2S content of each reactor effluent stream

to provide a complete sulfur history of the regeneration. Monitor also
the composition of the recycle gas to ensure the correct gravity for
compressor operation and hydrogen purity for reduction.
f. As reactor temperatures are raised to the target reactor outlet

temperature of 900°F (482°C), reduction will be complete. As the
catalyst temperature increases above 600°F (315°C) there will be a
high rate of water released from the catalyst that needs to be drained
from the separator and low point drains.
g. Hold the reactor outlet temperatures at 900°F (482°C) until there is no

significant water accumulation in the separator or low point drains.
Since water is a product of reduction, this indicates that reduction is
complete. This should take at least one hour and more likely two to
three hours.
NOTE: Maximum time from starting to increase reactor temperatures

for reduction to feed-in should be 18 hours.
NOTE: Monitor the pH of the water being drained. Since there is no

neutralizing caustic circulation, any chlorides that are stripped off the
catalyst will dissolve in the water evolved and can cause corrosion.
h. Once the reduction is completed, reduce heater firing to lower the

reactor inlet temperatures to 700°F (371°C) in preparation for a check
for H2S, pre-sulfiding (if necessary), and feed introduction. Keep
draining low points and separator as necessary.
uop 117108-6 XIII-52
10. Reduction – R-72 Catalyst
The reduction procedure recommended for R-72 catalyst is slightly different from
that of other catalyst systems. This procedure is for a more thorough reduction
(than that outlined in the previous section) and can be adopted for all catalyst types.
A 50 mol-%/50 mol-% mixture of electrolytic hydrogen and nitrogen is used; the

pure hydrogen is best for reduction and the nitrogen to increase the gas density and
hence mass flow rate. It is most important to maintain a minimum product separator
temperature and thoroughly drain all water from the system to minimize the recycle
gas moisture content.
a. Pressure the unit with nitrogen to 90% of the absolute pressure used
in the Oxidation step. Maintain this pressure until it is increased in
step c below.
b. Commission compressor; establish maximum gas circulation rate and

maintain maximum cooling to minimize the Product Separator
temperature. Stabilize reactor inlet and outlet temperatures at 350°F
to 400°F (177°C to 204°C) and drain low points. Do not exceed
400°F (204°C) reactor inlet temperatures until hydrogen is introduced
to the unit or an impure catalyst reduction could take place.
c. Pressure the unit with electrolytic hydrogen to 1.8 times the pressure
used in the Oxidation step while maintaining recycle gas flow. This is
to achieve 45 to 55 mol-% hydrogen in nitrogen for the reduction.
This H2/N2 ratio at this pressure gives approximately the same gas density as that
during the Oxidation step. The mass flow of gas should hence be the same as that
of the Oxidation step and not be a problem for the compressor.
In the event that 1.8 times the Oxidation step absolute pressure exceeds the normal
operating pressure, both the nitrogen and electrolytic hydrogen pressuring should
uop 117108-6 XIII-53
be reduced proportionately so that the total pressure equals the normal operating
pressure of the unit.
If the unit pressure can be increased beyond 1.8 times the Oxidation step absolute
pressure, the pressure should be increased consistent with that limitation.
Increasing the mass flow rate of circulating gas improves and speeds up the
reduction. Again, both the nitrogen and electrolytic hydrogen pressuring should be
increased proportionately so that the total pressure equals the normal operating
pressure of the unit.
d. As hydrogen is introduced and as reactor temperatures are increased,

frequently drain water from the Separator and all low points. Record
times and quantities of water drained.
NOTE: Monitor the pH of the water being drained. Since there is no

neutralizing caustic circulation, any chlorides that are stripped off the
catalyst will dissolve in the water evolved and can cause corrosion.
e. Increase reactor inlet temperatures at 45-55°F (25-30°C) per hour to

750°F (399°C). Continue to drain water from the separator and all low
points in the cold section.
f. Increase reactor inlet temperatures at 75-100°F (40-55°C) per hour

(heat-up/cooldown rate remains 45-55°F or 25-30°C per hour for
stacked reactors) to reach 900°F (482°C) at the reactor outlets. For
the Pt-Re catalyst it is only necessary to raise the reactor outlet
temperature to 800°F (427°C) though it is preferable to also increase
the Pt-Re catalyst to 900°F (482°C) for reduction.
NOTE: Reduction of the Pt-Re catalyst at a higher temperature is not harmful. It

drives off more water and hence decreases drydown time.
g. Continue to drain water from the separator and all low points in the
cold section.
uop 117108-6 XIII-54
h. Make up pressure with electrolytic hydrogen. Nitrogen can be used if

necessary to maintain gas density as long as the target 45 to 55 mol-
% hydrogen concentration is maintained (0.47 to 0.56 specific gravity
relative to air).
i. Hold 900°F (482°C) reactor outlet temperatures until there is no

significant water accumulation at low points and in the Separator.
This is expected to take 2 to 3 hours. In any event, hold for at least
one hour.
j. The circulating gas H2S content and specific gravity or composition

should be monitored and recorded.
k. When reduction is complete, start displacing the nitrogen in the

reactor circuit by injecting electrolytic hydrogen at the compressor
discharge and venting at the separator. The system pressure can be
increased to normal operating pressure as nitrogen is displaced.
Separator off-gas must be vented to flare initially to avoid
contaminating the fuel gas with nitrogen, which could extinguish
burners.
l. While displacing the nitrogen, reduce heater firing and cool reactor
inlet temperatures to 700°F (371°C) in preparation for feed cut-in. As
nitrogen is displaced with hydrogen, and with the system pressure
stable, the recycle gas flow indication will decrease. Once recycle
gas flow has stabilized, nitrogen displacement can be considered
complete. Every effort should be made to displace as much nitrogen
from the circuit as possible before introducing hydrocarbons.
Continue to drain water from the Separator and system low points if
any accumulates.
NOTE: Maximum time from starting to increase reactor temperatures

for reduction to feed-in should be 18 hours.
uop 117108-6 XIII-55
11. Sulfate Removal
In some situations, the catalyst itself or the plant hardware is contaminated with
excessive amounts of sulfur. When this is the case, there is a chance to form sulfate
on the catalyst during regeneration. This sulfate will promote platinum crystallite
growth, interfere with the establishment of a normal catalyst chloride level and can
severely retard the metal activity of the catalyst. Sulfate also competes with chloride
for space on the catalyst surface. High catalyst sulfate level is invariably associated
with inability to sufficiently chloride the catalyst.
To remove the excessive sulfur from the catalyst, a “Sulfate Removal” step is
included. Sulfate removal is accomplished by reducing the sulfur to hydrogen sulfide
at high temperatures in a reducing atmosphere. Chloride addition at the reducing
conditions aids in the sulfate removal.
The decision to use a sulfate removal step can be based on:
1. A catalyst sample that shows more than 400 wt-ppm sulfur, either from a
previous regeneration or from a just completed carbon burn.
2. There was more than 25 mol-ppm SO2 detected during the carbon burn step.
3. There has been a history of sulfur in the plant and on the catalyst:
a. The unit previously operated on non-hydrotreated feed and the

upcoming regeneration is only the first or second since adding feed
hydrotreating.
b. The naphtha feed averaged more than 1 wt-ppm sulfur content during
the previous cycle.
c. There were an excessive number of high sulfur excursions during the

previous cycle and the catalyst appears to be damaged by excessive
sulfur. The sulfur damage should appear as decreased stability and
uop 117108-6 XIII-56
selectivity. The presence of high sulfur levels should have been

confirmed by feed or recycle gas analyses.
d. A history of decreasing cycle lengths.
If the above criteria indicate that sulfate removal is necessary, the regeneration will
take the Sulfate removal path as per Figure XIII-12.
The incorporation of a sulfate removal step in the regeneration will add 24 to 60

hours to the duration of the regeneration and will increase the usage of chloride,
nitrogen, and hydrogen. It should be incorporated only after a thorough examination
of the previous cycle’s history and available catalyst analyses.
Sulfate and sulfur in general can be effectively stripped from the catalyst by
circulating relatively high purity hydrogen at elevated temperatures. The addition of
chloride during the sulfate removal improves the rate of sulfur removal. Scrubbing
with dilute caustic or carbonate is required for removal of H2S from the circulating
gas. The caustic or carbonate circulation is also, of course, required to neutralize
excess chloride in the condenser and separator.
a. If a sulfate removal step is used, complete the carbon burn and

proceed to the proof burn and oxidation steps as normal. The
oxidation hold period can be shortened to four hours. Proceed through
the separator flushing, cool down and nitrogen purge steps as detailed
in the normal procedure above.
b. Proceed to establish the conditions for Reduction of catalysts other

than R-72 as detailed above. See the “Chemical Requirements and
Specifications” section for the hydrogen specification for the sulfate
removal step. Establish maximum recycle gas flow.
c. From the 800°F (427°C) or 900°F (482°C) conditions of the Reduction

step, increase the reactor outlet temperatures at 100°F (55°C) per
uop 117108-6 XIII-57
hour (heat-up/cooldown rate remains 55°F or 30°C per hour for

stacked reactors) to 950°F (510°C).
d. Start chloride injection to the first reactor inlet to maintain a 20:1 mole
ratio of H2O:chloride in the recycle gas.
e. Start corrosion control just as during the oxidation step maintain a

circulating water pH of 7.5 to 8.0 with an alkalinity of 0.5 to 1.0%
NaOH equivalents.
f. Maintain a minimum of 950°F (510°C) reactor outlet temperatures and

100 psia (7.0 kg/cm2 absolute) hydrogen partial pressure. The sulfate
is removed in a plug flow fashion so a "wave" of high H2S
concentration should be detected passing through the reactors. This
step should be continued until the "wave" has passed through all the
reactors and all of the reactor outlets contain less than 2 mol-ppm
H2S. Therefore, to properly monitor sulfate removal, an H2S peak
(maximum) value must be observed at each reactor outlet. This
usually requires between 8 and 48 hours at temperature depending on
sulfur loading.
g. When the H2S wave comes off the reactor, pay special attention to the
caustic strength. If any H2S is detected at the product separator then
the caustic solution needs more attention. Any H2S which is not
scrubbed out and hence recycled back to the reactors decreases the
effectiveness (and increases the time) of the sulfate removal step.
h. If no H2S wave is observed, the sulfate removal conditions must be

held for 24 hours.
i. Monitor the hydrogen concentration of the circulating gas. Some

hydrogen will be consumed due to reduction, reaction such as
cracking/coking of any hydrocarbons present, methane production
from the organic chloride injected or loss from leaks. The Sulfate
uop 117108-6 XIII-58
removal reactions are dependent on the partial pressure of hydrogen.

Maintain 100 psia (7.0 kg/cm2 absolute) hydrogen partial pressure by
making up with hydrogen.
j. At the end of the Sulfate Removal step, stop chloride injection and
caustic addition. Thoroughly flush and drain the separator and drain
any other low points before reducing heater firing just as in the
Separator Flushing procedure.
k. Continue gas circulation until all reactor outlet temperatures are below
750°F (399°C).
l. Shut down, isolate, and nitrogen purge the compressor. Depressure

the unit to fuel gas or flare. Evacuate and purge the unit three times,
pulling a vacuum to 20-25 in. (508-635 mm) Hg and breaking each
vacuum with nitrogen to 3 to 5 psig (0.2 to 0.35 kg/cm2g). Break the
last vacuum with nitrogen to 3 to 5 psig (3.5 to 7.0 kg/cm2g). Swing
blinds for regeneration.
m. Re-establish the conditions of the carbon burn. If no residual burning

is observed, proceed to the proof burn step. When the proof burn is
complete, continue with the procedure through the oxidation,
cooldown, nitrogen purge and reduction steps as outlined above.
12. Startup
a. Following the reduction step, decrease heater firing to lower the

reactor inlet temperatures to 700°F (371°C). Keep draining low points.
b. Check for H2S at 700°F (371°C) and pre-sulfide at 700°F (371°C), if

necessary, following the procedure given in “Pre-Sulfiding”, section C2
of chapter VII: “Normal Startup”.
c. Proceed to startup the reactor section as per “Initial Operation”,

section C of chapter VII: “Normal Startup”.
uop 117108-6 XIII-59
13. Auxiliary Regeneration Piping
Figure XIII-19 shows the general piping layout for the regeneration of a Fixed-Bed
Platforming Unit. The details of the additional piping and considerations for chloride
injection and caustic circulation will be discussed in more detail.
a. Caustic Circulation
Figure XIII-20 depicts a typical caustic injection and circulation system used during
the regeneration of Platforming catalysts.
(1) Injection Point
It must be stressed that the actual caustic injection point is vital for corrosion control
and gas scrubbing. As the Regeneration Chemistry section in Chapter II “Process
Principles” discusses, in order to lower the pH of the circulation caustic from 10+ to
~7, it must react with CO2. In addition, to properly neutralize and scrub the
regeneration gas, all of it must contact the circulating caustic. The only way to
insure this is to inject the caustic at the correct location:
1. At the bottom of a vertical run of at least 30 ft. in length. This

will force the gas to bubble through and carry the liquid up the
vertical run, thus promoting 100% contact of gas and liquid.
2. At 10 pipe diameters distance from the last elbow (before
vertical section of pipe). This will allow the vapor to establish
the proper flow regime for contacting with the caustic.
3. As close as possible to the CFE outlet. This is to minimize the
amount of unprotected piping.
Injection of the caustic in horizontal piping runs gives very poor dispersion into the
vapor. The gas and liquid separate, forming a very corrosive gas-liquid interface. It
also allows gas to pass over the caustic and reduce the effectiveness of neutralizing
and scrubbing. Even if downstream of the injection point the pipe is vertical, the
liquid tends to stay on one side of the pipe and the gas on the other.
uop 117108-6 XIII-60
Piping modifications to promote proper gas liquid contact may involve an otherwise
unnecessary vertical run. However, this type of modification has been proven
effective and is strongly recommended. If piping modifications are not possible, the
use of a more efficient injection nozzle should be investigated.
(2) Circulation Rate
Many problems with corrosion control and scrubbing are due to low caustic
circulation rates. This is especially true with multiple bundles of air-cooled
exchangers. If the circulation rate is limited due to system hydraulics, the outer
bundles of air-cooled exchangers may have very little caustic flow. This will create
localized pools of liquid, which will become very corrosive. The obvious solution is
higher circulation rates and forcing more caustic down header lines to multiple air-
cooled exchanger header boxes.
If the circulation rate cannot be increased, it may be necessary to isolate some

bundles of the air-cooled exchanger (see Figure XIII-21). If this is required, isolation
valves on the inlet and outlets, should be installed in such a way the liquid does not
pool at the valves. In other words, the valves should be at the high points. During
the regeneration, air-cooled exchanger bundles should be rotated to evenly
distribute any corrosion that may be occurring.
It may also be advantageous to turn off some of the fans of air-cooled exchangers,
if there is a water trim cooler, to prevent condensation in the air cooler. Since the
cooling requirement during regeneration is only about 30 to 50% of the design duty,
use of the trim cooler is usually satisfactory.
NOTE: These recommendations are given with the provision that a sufficiently
low separator temperature can be maintained.
(3) Filling and Draining
During flushing of the product separator, chloride is being stripped off the catalyst
and dissolving in the remaining water to form a corrosive, acid solution. For these
reasons, separator flushing needs to be as quick as possible. By UOP’s design, the
separator is capable of being be filled within 15 minutes and drained within 15
uop 117108-6 XIII-61
minutes. If this is not possible, the piping should be modified to allow these times to
be met.
b. HCl Injection System
Figure XIII-22 shows the details of the injection system used when HCl is used as
the chloriding agent during the regeneration of Platforming catalysts.
(1) Specifications for Equipment and Piping
(a) Use the cylinder regulator recommended by the gas supplier.

(b) Use drop-forged steel globe and needle valves.
(c) Use drop-forged steel fittings and standard flanged unions.
(d) The piping between the cylinder and rotameter must be
sufficiently flexible to allow accurate weighing of the cylinder as
it is gradually emptied.
(2) Data and Safety
(a) Physical Properties

HCl
Molecular Weight 36.47
Specific Gravity (3°F, 1 atm.) 1.268
Critical Temperature, °F 124.5
Critical Pressure, psia 1198.
uop 117108-6 XIII-62
(3) Handling and Storage of Hydrogen Chloride
Handling and Storage: The same basic precautions apply to

handling of HCl as for chlorine. Workers who handle the cylinders
should wear protective clothing such as rubber or plastic aprons and
rubber gloves, with suitable gas tight chemical safety goggles. Woolen
outside clothing is advisable. Never store HCl at, nor subject the
cylinder, to temperatures above 52°C (125°F). Above this temperature
the fresh cylinders may become liquid full, causing excessive pressure
buildup and rupture of the safety plug. Mark cylinders EMPTY after
using. Always keep the protective cap in place when the cylinder is not
in use.
Leak Detection: Large leaks of HCl will be evident by the formation of

dense white fumes on contact with the atmosphere. Small leaks may
be detected with aqueous ammonia, the same as for chlorine. Do not
allow even the smallest leak to go unrepaired. If a cylinder valve leak
cannot be stopped, notify the supplier immediately.
Toxicity: HCl is a highly toxic corrosive gas, having a suffocating odor

and causing severe irritation to the upper respiratory tract. It is
corrosive to the skin, eyes and mucous membranes. The acid formed
neutralizes the alkali of the tissues and can cause death as a result of
edema or spasm of the larynx. Concentrations above 0.1% are lethal.
First Aid: If a worker is overcome by HCl, call a physician

immediately. Remove the victim as quickly as possible to fresh air. If
breathing has stopped, apply artificial respiration. Oxygen may be
given but only by trained personnel. Keep the victim warm, but not hot.
Skin and eye contact should be treated by thoroughly and completely

flushing with copious quantities of fresh water for 15 to 20 minutes.
Remove all contaminated clothing.
uop 117108-6 XIII-63
Figure XIII-19
Regeneration Piping Locations
999
33 33 22
FRC
FRC
999 222 2 PI
PI
999
Air
Air
Compressor
Compressor PPC
C
Rx
Rx Rx
Rx Rx
Rx
11 22 33 111 Vent
Vent to
to
555 Atmosphere
Atmosphere
Separator
Separator
FRC
FRC 999 444
999 999 111
diam.
Air
pipe diam.
Air FI
FI PI
PI
PI
PI 888
10 pipe
11
Legend
10
1.
1. Low
Low Point
Point Drain
Drain 6. Fresh
999
2. Purge 6. Fresh Condensate
Condensate Make-Up
Make-Up 11
1
2. Purge Vent
Vent
3.
3. Chloride
Chloride Injection
Injection Point
Point
7.
7. Fresh
Fresh Caustic
Caustic Make-Up
Make-Up 777 666
8.
8. Spent
Spent Caustic
Caustic to
to Safe
Safe Disposal
Disposal
4.
4. Caustic
Caustic Injection
Injection Point
Point 9.
9. Sampling
Sampling Point
Point
5.
5. Nitrogen
Nitrogen Purge
Purge Point
Point
and
and Reduction
Reduction Hydrogen
Hydrogen F.B. Plat
Injection
Injection Point
Point 117108 XIII-19
Figure XIII-20
Caustic Circulation System for Regeneration
T
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Leeaasstt 3300''))
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Deettaaiill AA
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((L L
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K
K LLooccaattee O Oppeenniinngg aatt CCeenntteerr
MMaakkee--uupp
ooff PPrroocceessss LLiinnee PPooiinnttiinngg **PPuum mpp SSiizzeedd ffoorr5500--110000% % Diissppoossaall
ttoo SSaaffee D
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F.B. Plat
117108 XIII-20
uop 117108-6 XIII-64
Regeneration
Blind Off at
high point
for
Air Fin Condenser Isolation for Regeneration
Combined Feed Reactor Effluent Exchanger

Figure XIII-21
Reactor Effluent from
To Trim Cooler
uop 117108-6 XIII-65
Figure XIII-22
HCl Injection System for Regeneration
PI Disconnect and Blind

When Not in Use
HCI Vent
1/2” SCH 40 CS Rotometer Line
No. 1
Pressure Regulator
for HCL Service
Note:
PI PI PI Steam Trace from the
Cyclinder Pressure Regulator
to the Point of Injection during
N Low Cold Weather (Less than
Minimum Point Na2CO3 or 10°C OR 50°F).
Distance Drain NaOH
Dry Air Use Nozzle Extension for the
Neutralization
or HCl Injection Point so that
Solution Tank
Nitrogen Mixing Takes Place at the
Center of the Process Line.
HCL Cyclinder
with Weigh Scale N = Needle Valve
Figure XIII-23
HCL Vapor Pressure versus Temperature
2,00
1,00
80
60
50
40
30
20
10
0 5 10 15 20 25
Temperature, °F
UOP PLT-R00-195
uop 117108-6 XIII-66
14. Chemical Requirements and Specifications
a. Sodium Hydroxide or Sodium Carbonate

Requirement: 4-12 wt-% based upon catalyst loaded.
b. Hydrogen Sulfide or organic sulfiding compound - for catalysts

requiring pre-sulfiding
Requirement: 0.05 wt-% based upon catalyst loaded.
Spec: Purity 99.5 mol-% minimum for H2S
c. Anhydrous HCl or Organic Chloride

Requirement: 3 to 8 wt-% chloride based upon catalyst loaded.
This amount will depend on the conditions of the carbon burn,
whether or not a sulfate removal step is required, and upon
prevailing separator temperature (see Figure XIII-24).
Spec: Purity HCl 99.0 mol-% minimum

Organic chlorides - Technical grade (see Table XIII-1)
d. Reduction Hydrogen (Electrolytic or net Platforming Unit hydrogen)

Requirement: Approximately 60 catalyst volumes
Spec Electrolytic Grade Net Platforming Unit Hydrogen
Purity 99.5 mol-% minimum 75 mol-% minimum

Carbon Monoxide 10 mol-ppm maximum Nil
Carbon Dioxide 10 mol-ppm maximum Nil
Nitrogen Remainder Nil
Oxygen Nil Nil
Sulfur (H2S) Nil 5 mol-ppm maximum
Chlorine & Chlorides Nil 50 mol-ppm maximum
H2O Nil 20 mol-ppm maximum
uop 117108-6 XIII-67
e. Sulfate Removal Hydrogen (Platforming Unit Net Hydrogen)
Requirement: Approximately 60 catalyst volumes. Allowance must be made

for leakage during the sulfate removal step.
Spec: Purity 75 mol-% minimum

Carbon Oxides Nil
Nitrogen Nil
Oxygen Nil
Sulfur (H2S) 5 mol-ppm maximum
Chlorine and Chlorides 50 mol-ppm maximum
f. Nitrogen
Requirement: Approximately 120 catalyst volumes. Twice this quantity will be

needed if a sulfate removal step is required.
Spec: Purity 99.5 mol-% minimum

Oxygen + Noble Gases 0.5 mol-% maximum
CO 20 ppm maximum
CO2 20 ppm maximum
Cl2 20 ppm maximum
H2O 5 ppm maximum
uop 117108-6 XIII-68
Figure XIII-24
Estimated Chloride Consumption During Regeneration
2. Pressure
Correction
2
20 Factor Basis:
1. 100 psig Separator
Pressure
20 / 1 H2O / CL Ratio
1
15 Non Parallel Burn
0 50
5 100
10 150
15 200
20
Separator Pressure (psig)
1
10
5
60°F
0
0 10
100 20
200 30
300
Volume of Gas Circulated with Chloride Addition
(MMSCF)
UOP PLT-R00-196
uop 117108-6 XIII-69
Table XIII-1
Properties of Organic Chlorides
Compound Molecular Melting Boiling Specific Carbon Chloride Heat of Auto

Mass Point Point Gravity wt% wt% Combustion Ignition
(°C) (°C) @ 20°C (kJ/kg) temp (°C)
Propylene 112.99 -100.4 96.2 1.156 31.9 62.8 17803 557

Dichloride (1,1
Dichloropropane)
Ethylene Dichloride 98.96 -35 84 1.256 24.3 71.7 11414 413

(1,2
Dichloroethane)
Methyl Chloroform 133.41 -37 74 1.33 18.0 79.7 7346 485

(1,1,1-
Trichloroethane)
Carbon 153.82 -23 76.5 1.594 7.8 92.8 NA 1000+

Tetrachloride
Perchloroethylene 165.8 -23 120.6 1.63 14.5 85.5 4840 NA

(PERC)
uop 117108-6 XIII-70
15. Calculations
a. Chloride Injection Rates for Various H2O/Cl- Ratios
The following five plots may be used to determine the proper chloride
injection for a given H2O/Cl mole ratio during the Platforming Unit
regenerations once the product separator temperature and pressure and
recycle gas rate are known.
Example XIII-1: Calculation of TCE Injection Rate
During the carbon burn of Platforming catalyst, it is desired to maintain the

H2O/Cl ratio at 20:1 with TCE.
Product Separator Temp. = 70°F

Product Separator Press. = 80 psig = 95 psia (6.7 kg/cm2a)
Recycle gas rate = 40.0 MM SCFD
a. From Figure XIII-25, a 70°F separator will have a water vapor

pressure of 0.36 psia.
b. From Figure XIII-26, the water vapor pressure to separator
pressure ratio is 0.0038.
c. From Figure XIII-27, 20 lb. moles of H2O per hour are in the
recycle gas.
d. From Figure XIII-28, 38 lb. of Cl - per hour are required.
e. From Figure XIII-29, the necessary TCE injection rate is about

4 gal/hr.
uop 117108-6 XIII-71
b. Calculated ΔT’s vs. Organic-Chloride Injection Rate
Figures XIII-30~33 may be used to obtain an approximation of the ΔT to be

expected as the result of organic chloride injection into the regeneration gas
circulation during the carbon burn and oxidation steps of a Platforming Unit
regeneration.
The actual ΔT for each unit will also be a function of the reactor size, and
heat loss from the reactor. In general, the ΔT upon completion of the burn
step should be less than that shown. This is particularly true for the smaller
(3000 BPD) capacity units.
The curves should assist the operator in determining the completion of the
carbon burn in reactor one, as the ΔT may well remain positive. They should
also alert him to the danger of obtaining excessive, and potentially damaging,
temperatures if the organic chloride injection is not carefully monitored.
Example XIII-2
From Previous Example:

TCE injection rate: 4 GPH
Recycle Gas Rate: 40 MMSCFD = 1.7 MMSCFH
From Figure XIII-14:

Increase in reactor ΔT because of TCE injection = 5°F
c. Sample Calculation of % Carbon on Catalyst
Required Data;
Total Air Injection during Burn = 2.50 × 106 SCF
Total TCE Injection during Burn = 150 gal.
Total Loading Fresh Catalyst = 100,000 lbs.
uop 117108-6 XIII-72
Determine Moles Oxygen and TCE Injected
2.50 × 106 ft3 Air 0.2095 Mole O 2

Moles O2 = × = 1382
379 ft3 Air/Mole Mole Air
150 8.331 lb. Mole TCE

Moles TCE = × 1.330 × × = 12.5
gal. gal. 133.41 lb.
Determine Moles Oxygen Consumed by TCE and by Coke
CH3CCl3 + 2 O2 2 CO2 + 3 HCl
Moles O2 = 2 × 12.5 = 25.0 by TCE
Moles O2 = 1382-25 = 1357 by Coke
Determine Moles Carbon
(Carbon:Hydrogen for Coke is assumed to be 1.0)
4 CH + 5 O2 4 CO2 + 2 H2O (1/5 of O2 Consumed by Hydrogen)
Moles C = 1357 × 0.80 = 1085
Weight % Carbon
1085 Moles C 12.011 lb.

%C = × × 100 = 13%
100, 000 lb. Mole C
uop 117108-6 XIII-73
Figure XIII-25
Chloride Injection - Graph A
0.9
0.9
0.8
0.8 Graph
Graph A
A
psia
Pressure, psia
0.7
0.7
Vapor Pressure,
0.6
0.6
0.5
0.5
Water Vapor
0.4
0.4
0.3
0.3
Water
0.2
0.2
0.1
0.1
40
40 50
50 60
60 70
70 80
80 90
90 100
100
Temperature,°F
Temperature,°F
10
10 15
15 20
20 25
25 30
30 35
35
F.B. Plat
117108 XIII-25
Figure XIII-26
Chloride Injection - Graph B
1.0
1.0
195
195 psia
psia 145
145 115
115 95
95 75
75 55
55 40
40
Water Vapor Pressure, psia
0.8
0.8
0.6
0.6
Graph
Graph B
0.4
0.4
Parameter:
Parameter:
0.2
0.2 Product
Product Separator
Separator in
in psia
psia
0.002
0.002 0.006
0.006 0.010
0.010 0.014
0.014 0.018
0.018 0.022
0.022
Absolute
Absolute Water Vapor Pressure
Pressure
Absolute Separator Pressure
Separator Pressure
F.B. Plat
117108 XIII-26
uop 117108-6 XIII-74
Figure XIII-27
Chloride Injection - Graph C
100
100 80
160
160
Graph
Graph C
C 60
Pound Moles per Hour
Parameter:
Recycle Gas Water,
120
120
Recycle Gas Rate
in MMSCFD 40
80
80
30
20
40
40
10
0 0.002 0.006
0.006 0.010 0.014
0.014 0.018
0.018 0.022 0.022
Absolute Water Vapor Pressure
Absolute Separator Pressure
F.B. Plat
117108 XIII-27
Figure XIII-28
Chloride Injection - Graph D
180 40
40 // 11
50
50 // 11 30 / 1
160 Graph
Graph D
D
140
Pound Moles per Hour
20 / 1
Recycle Gas Water,
120 15
15 // 11
100
80
80
10
10 // 11
60
60
40
40
Parameter:
20
20 O/Cl-- Mole Ratio
H22O/Cl
0
00 40
40 80
80 120
120 160
160 200 240
240
Chloride (Cl-) Injection, Pounds per Hour F.B. Plat

117108 XIII-28
uop 117108-6 XIII-75
Figure XIII-29
Chloride Injection - Graph E
30
30
PDC
PDC
28
28 Graph E
Organic Chloride Injection,
EDC
24
24
Gallons per Hour
20
20 TCE
TCE
16
16 PERC
12
12
88 EDC
EDC -- Ethylene
Ethylene Dichloride
Dichloride at
at 68°F
68°F
PDC
PDC - Propylene Dichloride at 68°F
- Propylene Dichloride at 68°F
44 TCE
TCE -- Trichloroethane
Trichloroethane at
at 68°F
68°F
PERC
PERC -- Perchloroethylene
Perchloroethylene at
at 68°F
68°F
00
00 40
40 80
80 120
120 160
160 200 240
240
Chloride (Cl-) Injection, Pounds per Hour
F.B. Plat
117108 XIII-29
Figure XIII-30
Calculated ΔT vs. PDC Injection Rate
60
60
30
30 Parameter:
Parameter:
50
50
26 PDC
PDC Injection
Injection Rate
Rate in GPH
26
°F
T, °F
40
40
ΔT,
20
20
°C
15
T, °C
15
Reactor Δ
30
30
Reactor
ΔT,
15
15
Δ
20
20 99
10
10
55
10
10
55
11
00
00 11 22 33 44 55
Recycle
Recycle Gas
Gas Rate,
Rate, MMSCFH
MMSCFH
F.B. Plat
117108 XIII-30
uop 117108-6 XIII-76
Figure XIII-31
Calculated ΔT vs. EDC Injection Rate
60
60
30
30 Parameter:
Parameter:
50
50
26 EDC
EDC Injection
Injection Rate
Rate in
in GPH
GPH
26
°F
ΔT, °F
40
40
Reactor ΔT,
20
20
ΔT, °C
30
30
Reactor
ΔT,
15
15
15
15
20
20
10
10 99
10
10 55
55
11
00
00 11 22 33 44 55
Recycle
Recycle Gas
Gas Rate,
Rate, MMSCFH
MMSCFH F.B. Plat
117108 XIII-31
Figure XIII-32
Calculated ΔT vs. TCE Injection Rate
60
60
30
30 Parameter:
Parameter:
50
50
26 TCE
TCE Injection Rate in GPH
26
°F
ΔT, °F
40
40
Reactor ΔT,
20
20
ΔT, °C
30
30
Reactor
15
15
15
15
20
20
10
10 99
10
10 55
55
11
00
00 11 22 33 44 55
Recycle
Recycle Gas
Gas Rate,
Rate, MMSCFH
MMSCFH F.B. Plat
117108 XIII-32
uop 117108-6 XIII-77
Figure XIII-33
Calculated ΔT vs. PERC Injection Rate
60
60
30
30 Parameter:
Parameter:
50
50
PERC
PERC Injection
Injection Rate
Rate in
in GPH
GPH
26
26
°F
ΔT, °F
40
40
Reactor ΔT,
20
20
ΔT, °C
30
30
Reactor
ΔT,
15
15
15
15
20
20
10
10 99
55
10
10
5 11
0
0 11 22 44 3 55
Recycle
Recycle Gas
Gas Rate,
Rate, MMSCFH
MMSCFH
F.B. Plat
117108 XIII-33
uop 117108-6 XIII-78
16. Regeneration Report
A Platforming catalyst regeneration report should consist of:
1. A cover letter which includes:
a. refiner, location, unit, catalyst type, cycle just completed;

b. any unusual problems experienced during the previous cycle;
c. dates of regeneration;
d. UOP Personnel involved;
e. what basic procedure was followed
f. deviations from standard procedure and why they occurred;
g. the source of the hydrogen used for the reduction;
h. problems encountered during regeneration;
i. any suggestions for future regeneration.
2. Regeneration summary Tables A, B and C.
3. Regeneration data Tables D, E and F.
4. Plotted carbon burn and oxidation data in Figure A.
5. Plotted carbon burn ΔT’s in Figure B.
6. Log of Operations.
7. Catalyst loading diagram if dumping and screening is performed.
8. Other attachments that may be appropriate for a particular job.
uop 117108-6 XIII-79
IMPORTANT – FILL OUT COMPLETELY

UOP PLATFORMING CATALYST REGENERATION SUMMARY
Table A
Refinery Name
Location Unit
Catalyst Type Cycle No. DOS BPP Regen Start Date
Catalyst Distribution, wt-%: Rx #1 Rx #2 Rx #3 Rx #4
Total Catalyst, lbs(kg) Average P/N/A, lv-%: P N A
Avg RONC Avg LHSV Avg H2/HC Avg Sep Press, psi(kg/cm2)
Reason for Regeneration
Dump & Screen? (Y/N) Dual Burn? (Y/N)

Regeneration Steps (circle each completed):
Carbon Burn Proof Burn Oxidation Separator Flushing
Cooldown N2 Purge Reduction Sulfate Removal
Peak SO2 level during Carbon Burn, ppm Max. H2S level, ppm
Sulfate Removal duration, hours
Total Time Required for Regeneration (less delays), hours
Source of H2
Carbon Burn, wt-%:Rx1 Rx2 Rx3 Rx4 Total
Highest Reduction Temperature, °F(°C)
Comments:
uop 117108-6 XIII-80

Table B
Step Time Delays, Ave. Ave. Ave. O2 Chloride Ave. Maximum

Required, hours Separator Recycle conc., used, wt- H2O:Cl- Observed
hours Press* Gas Rate* mol-% % of Ratio SO2/H2S levels,
catalyst mol-ppm
R1 R2 R3 R4
Shutdown,
Sweep, flush,
purge
Carbon Burn
Proof Burn
Oxidation
Separator
Flushing
Cooldown
N2 Purge
Reduction
Sulfate
Removal
Total
* - Please indicate units of measure

** - Repeat this page for proof burn, second oxidation, cooldown, purge and final
reduction when a sulfate removal step is used.
uop 117108-6 XIII-81

Table C
Meter Factors
P
Gas flows: F = KR
TG
F = flow K (air to Rx #1)
R = FRC reading K (air to last Rx)
T = flowing temperature K (recycle gas)
P = flowing pressure
G = flowing gravity
K = meter factor
Liquid Flows: F= KR K (caustic circ.)
Note: These meter factors are needed to convert FRC readings on logsheets to
actual flow rates.
Chemical Consumption Summary:
Chloride type:
During carbon burn Gal (m3)
During oxidation Gal (m3)
During sulfate removal Gal (m3)
Total wt-% Cl- (as a % of catalyst loading)
Caustic or Carbonate used for neutralization

Total used lbs (kg)
Total used wt-% Cl- (as a % of catalyst loading)
Nitrogen used SCF (Nm3)
Source of hydrogen
Total used SCF (Nm3)
Dräger Tubes Used HCl

SO2
H2S
Carbon Burned Off Catalyst

Rx #1 lbs (kg) wt-% of catalyst
uop 117108-6 XIII-82
UOP PLATFORMING CATALYST REGENERATION DATA

Carbon Burn, Proof Burn, Oxidation, Separator Flushing and Cooldown
Refiner
Location
Unit Table D-
Date
Date/Time
Temperatures, °F (°C)
Rx #1 In
Rx #1 Out
Rx #2 In
Rx #2 Out
Rx #3 In
Rx #3 Out
Rx #4 In
Rx #4 Out
Compressor Discharge
Separator
Pressures, psig (kg/cm2g)
Comp. Discharge
Separator
Air header
Flows
Recycle gas
Air to Rx #1
Air to last Rx
Caustic circulation
Make-up water
Caustic make-up
Chloride to Rx #1
Chloride to last Rx
Total Chloride
Analyses
%O2 comp. discharge
%O2 last Rx Inlet
Circulating Caustic pH
SO2 / HCl Rx#1 Outlet
SO2/HCl Comp. Disch.
Please indicate all units of measurement
uop 117108-6 XIII-83

Sulfate Removal
Refiner
Location
Unit Table E-
Date
Date/Time
Rx #1 In
Rx #1 Out
Rx #2 In
Rx #2 Out
Rx #3 In
Rx #3 Out
Rx #4 In
Rx #4 Out
Separator
Comp. Discharge
Separator
Hydrogen Source
Flows
Recycle gas
Caustic circulation
Make-up water
Caustic make-up
Chloride to Rx #1
Analyses
Circulating Caustic pH
H2S / HCl Rx#1 Outlet
H2S /HCl Comp. Disch.
%H2 Recycle Gas
Please indicate all units of measurement
uop 117108-6 XIII-84

Reduction and Initial Operation (Drydown)
Refiner
Location
Unit Table F-
Date
Date/Time
Rx #1 In
Rx #1 Out
Rx #2 In
Rx #2 Out
Rx #3 In
Rx #3 Out
Rx #4 In
Rx #4 Out
Separator
Comp. Discharge
Separator
Flows
Recycle gas
Water Drained
Hydrocarbon feed
Analyses
H2S /HCl Comp. Disch.
%H2 Recycle Gas
H2O Recycle Gas
HCl Recycle Gas
H2S Recycle Gas
RONC
1. Indicate all units of measurement

2. Indicate methods of analyses for recycle gas H2O
HCl
H2S
3. Log GC analyses during reduction when reformer net gas is used.
uop 117108-6 XIII-85

Carbon Burn – Oxidation Plot
Figure A
Inlet Temperature
Reactor #1
ΔT
Date
Inlet Temperature
Reactor #2
ΔT
Unit
Inlet Temperature
Reactor #3
ΔT
Inlet Temperature
Location
Reactor #4
ΔT
injection
Recycle
rates
Flow
Gas
Air
Recycle
Analyzer
Calc.
Refiner
O2
uop 117108-6 XIII-86

Carbon Burn Wave Plot
Figure B
35
Date
30
25
Unit
20
Time, hours
15
Location
10
5
Refiner
Reactor #1 ΔT, ˚F Reactor #2 ΔT, ˚F Reactor #3 ΔT, ˚F Reactor #4 ΔT, ˚F

125
125
125
125
uop 117108-6 XIII-87

Initial Operation (Drydown) Plot
Figure C
Recycle gas
ppm
H2O
Date
Recycle gas
ppm
HCl
Injection
Chloride
ppm
Unit
gas H2S
Recycle
ppm
Reactor
WAIT
Location
Recycle Gas
Flowrate
Feed Rate
Refiner
Time, hours
uop 117108-6 XIII-88
UOP PLATFORMING CATALYST REGENERATION

Log of Operations
Refiner
Location
Unit
Date Time Log
uop 117108-6 XIII-89
D. COMPRESSOR WASHING
During operation, a fine gray powder-like deposit may collection on the internals of
Platforming recycle gas compressors. This material (mostly ammonium chloride
salts) is soluble in hot water. It is non-corrosive when dry, but when exposed to air it
absorbs moisture readily and become corrosive not only to iron and carbon steel but
also to all stainless chrome steels, especially if they have been hardened. For
protection of the compressor internals, steps must be taken to avoid contact with air
when this deposit is present. Several precautions will assist in this matter.
For centrifugal compressors, a thorough washing of the compressor internals is

recommended before the machine is opened. Such washing is carried out with a
2% soda ash solution to which a small amount of non-sudsing detergent has been
added. Higher carbonate concentrations are unsatisfactory because of the need to
avoid damage to any aluminum labyrinths in the compressor. After several such
washes have been carried out, the internals are flushed with clean water, dried and
treated with a corrosion inhibitor. The following details a satisfactory procedure for
carrying out this operation:
1. Shutdown; nitrogen purge and maintain a nitrogen blanket on the

compressor until ready to proceed with the following steps.
2. Provide sufficient 2% soda ash solution with 0.1-0.3% non-sudsing

detergent, such as Calgon, tripotassium phosphate, etc., for at least five
washings, estimated at 40-80 gallons (150-300 liters) for each washing, at a
temperature of 80-100ºF (25-35ºC). A pump for circulation of the washing
solution should be available. A 10-20 gpm (3-5 m3/hr) pump is a convenient
size.
3. Break the suction and discharge piping and blind off the compressor. Make
reversing connections to the inlet and outlet drains under the case so that the
solution can be pumped through from either end.
uop 117108-6 XIII-90
4. Pump the solution slowly into the suction drain connection with the seal oil
circulating system operating as per the manufacturer’s instructions, and with
the rotor turning over at approximately 60-250 rpm run by an air motor, a
small auxiliary motor, or by a rope wrapped around the coupling. In order not
to take any chance of accelerating to a high speed with liquid in the case, do
not use the main driver to turn the rotor over. Wash for approximately ten
minutes each time, observing the color and pH of the solution.
5. Drain and replace the wash solution with fresh solution; continue the
washings until there is no change in the solution. Maintain the temperature of
the solution with a steam hose, if necessary.
6. Flush out with clean hot water at 150ºF (66ºC) for ten minutes; drain and
repeat twice. Remove the drain plugs to the intermediate stages in order to
drain all water. Note: If any discoloration of the drain water occurs, proceed
with an additional soda ash treatment.
7. If the compressor does not have individual stage drains, steam it until all of
the case is up to 200ºF (93ºC ), and blow with nitrogen or dry air to remove
water from case.
8. Provide about 50 U.S. gallons (200 liters) of reformate with four liters (one
U.S. gallon) of Unicor thoroughly mixed. (For an alternate inhibitor, Gulf
Agent 178 or Kontal 77 may be used.) With the stage drains closed,
introduce Reformate through the suction drain with the rotor turning over
slowly. Wash thoroughly for at least 30 minutes and drain.
9. Remove all blinds and prepare for startup with nitrogen purges, or if an
inspection is desired, proceed to dismantle the machine and remove the rotor
in accordance with the manufacturer’s recommendations.
For non-lubricated reciprocating compressors, the procedure is somewhat different.

First, the valves should be freed of salts as soon as they are removed from the
machine. This is done easily by washing the valves in a bucket of hot water, which
uop 117108-6 XIII-91
will dissolve the corrosive powder. The valves can be tested for leakage with water
during this procedure. Do not allow prolonged soaking in water, since acidic
compounds will buildup in the water which can also damage the parts. When the
valves are removed from the hot water, they will dry very quickly and are then ready
for reinstallation. If the valves are to be stored for some time, it is advisable to apply
a coating of light oil to the valve faces to prevent possible rusting. This oil should be
removed before the valve is reinstalled.
In order to inspect the piston and rings, it is necessary to remove the outboard head
of the cylinder, remove the rod from the crosshead, and pull the piston out far
enough to view the rings. The dust should be wiped from the internal surfaces with
a lint-free cloth when possible.
If the piston is entirely removed, the exposed cylinder bore and valve seating
surfaces should be covered with a light coat of oil to avoid contact with air and thus
prevent corrosion of the honed and polished surface of the bore. All of this oil
should be removed before the piston is reinstalled. The bore can be plugged with a
pump cup or other similar plug to assist in isolating it from the atmosphere. A steam
hose can be used to remove powder and scale from the cylinder gas passages but
before doing this, the valve ports must be blocked to avoid getting steam or water
on the highly finished cylinder bore surface. Extreme care must be taken if such
cleaning is attempted.
If the rings are stuck, a small amount of additional clearance can be obtained by
removing the rings and sanding the sides of the rings lightly on a flat surface. If
carbon piston blocks are used and these are stuck together, washing with hot water
may serve to free them and permit removal from the rod. When a compressor is
assembled before the rest of the plant is ready for operation, it should be blanketed
with gas to avoid contact with air. Close the block valves and pressure the
compressor to about 5psig (0.3 kg/cm2) with nitrogen after purging out all air in the
system.
uop 117108-6 XIII-92
Platforming reciprocating compressors are normally installed in outdoor locations.

Therefore, the proper weight and quality of lubricating oil in the crankcase must be
used during the various seasons of the year and oil should be changed with the
seasons, particularly in cold climates. Use the manufacturer’s recommended type of
oil for the anticipated temperature.
E. COLUMN WASHING
Stabilizer column fouling sometimes occurs when the Platforming unit is processing
naphtha with high levels of nitrogen. This is especially true when the Platforming
unit is processing cracked naphtha or naphtha stock from inherently high nitrogen
level crudes. The nitrogen and chloride combine to form ammonium chloride salts
that deposit in the stabilizer feed/bottoms exchanger, on column trays, and in the
overhead system.
Salt build-up on column trays decreases the fractionation efficiency and can lead to
off-specification products. Typically, RVP control of reformate becomes difficult and
the top to bottom column delta P increases.
If the unit is down for a turnaround, the column and overhead system should be
cleaned and inspected for corrosion. Steaming out the system should sufficiently
clean the equipment of any ammonium chlorides salts that may be present.
However, when column performance deteriorates due to salt plugging it is not

always convenient to shut down and clean. The following procedure is prescribed
for the removal of chloride salts in debutanizer towers while remaining on line. It
has proved successful in commercial application.
1. Unit Preparation
Most refiners typically conduct the water washing when the unit is operating at less
than 100% of the design feed rate (usually around 70%) for economic (rather than
technical) reasons.
uop 117108-6 XIII-93
2. Reactor Preparation
Since the column is slightly slumped during on-line Stabilizer column water
washing, the reformate RVP can increase to the 10 ~ 12 psi range. To counteract
this, some refiners reduce the reactor inlet temperatures to minimize LPG
production during water washing.
a. The temperature reduction required depends on the feed stock quality.

If the feed is rich (high naphthenes and aromatics), 900°F reactor inlet
temperatures may be low enough to stop most LPG production.
However, if the product will be slopped anyway, we would suggest a
further reduction in reactor inlet temperatures if necessary (unless
more hydrogen is badly needed).
b. Between one and two hours after decreasing the reactor inlet
temperatures (watch the Stabilizer net overhead liquid rate), begin the
procedure by decreasing the stabilizer reboiler temperature.
3. Prepare Tower
a. Lower reboiler temperatures from the 500-550˚F (260-288˚C) range to

approximately 300˚F (149˚C).
b. Reduce tower pressure to allow for rapid water vaporization; e.g. 250
psig (21.7 kg/cm2g) should be reduced to 180 psig (12.7 kg/cm2g). It is
usually not possible to maintain the normal operating pressure of the
Stabilizer with the reduced heat input and perhaps reduced production
of light ends. It is, however, desirable to reduce the operating pressure
from normal to help the vaporization of water and removal of light
ends from the reformate.
4. Water Injection and Washing
After tower is stable at the new, "slumped" conditions, proceed as follows:
a. Turn off the overhead reflux pump.
uop 117108-6 XIII-94
b. Inject water into the tower feed at a rate of 2 to 4 lv-% for 30 minutes.
A large portion of the water will flush down the tower and be removed
with the reformate.
c. When an 80-90% hydrocarbon level has accumulated in the overhead

receiver, begin injecting water downstream of the reflux control valve
at a rate of 2 to 4 lv-% of tower feed for 30 minutes. Start reflux pump
for this 30 minute period.
d. Repeat steps a, b, and c until analysis indicates that most of the salts
have been removed. Be sure to alternate overhead reflux pumps at
each repeat.
5. Return to Normal Operation
Returning to normal operating conditions will cause large amounts of water in the
tower to pass overhead. This will complete the washing of overhead lines and
exchangers.
a. Increase reboiler temperature to normal operating level at 50˚F/hour

(28˚C/hour). Raise tower pressure to its normal operating level over a
30 minute period.
b. At the completion of the washing procedure, begin raising the reboiler

temperature and the reactor inlet temperatures at the same time.
c. Change reflux pumps every 15 minutes.
d. Drain all low points every 15 minutes.
e. Line tower out at normal design conditions.
uop 117108-6 XIII-95
6. Tankage
Each refiner should determine their acceptable water/chloride contamination level in

the reformate product tank. It may be better to run the product to slop during the
washing procedure. It is most common for refiners to run down the Stabilizer
bottoms material to sour naphtha storage or a crude tank for dilution, free water
separation, and gradual reprocessing.
If the rundown tank is a fixed roof tank there is usually no problem with high vapor
pressure. Floating roof tanks, however, have a Total Vapor Pressure limit (note that
this is not Reid Vapor Pressure since the ambient temperature may be low) of 11
psi. Below this limit, most typical floating roof tanks will not have a problem.
uop 117108-6 XIII-96
Figure XIII-34
Stabilizer Column Water Washing - Injection to Feed
REFORMATE
Figure XIII-35
Stabilizer Column Water Washing - Injection to Overhead System
uop 117108-6 XIII-97
F. ACIDIZING HEATER TUBES
Essentially, acidizing consists of seven mutually interdependent operations, not one

of which can be left out without jeopardizing the success of the entire procedure.
Since conditions, equipment, and facilities vary from refinery to refinery, it is
necessary to keep instructions such as these general in nature; however, there are
certain basic requirements that remain the same and do not change.
1. Preparation, assembling supplies, and setting up equipment tanks, a cir-

culating pump, lines, instruments, water, steam, air, soda ash, and inhibited
hydrochloric acid containing a detergent and an emulsifier are all required.
See Figure XIII-36 for a suggested equipment layout.
2. Circulation of the acidizing solution at high velocity by a large pump. The

combination of a large pump and strong acid not only removes the scale from
the tube wall but also keeps the resultant sludge in suspension until it can
settle out in the receiving sump of the acid circulating tank.
3. Large quantities of hydrogen sulfide gas generated during the acidizing

should be vented into the refinery flare or into some sort of sour gas disposal
system. Note that hydrogen sulfide (H2S) is an extremely poisonous gas, and
special precautions should be observed.
4. Measure the acid concentration and temperature at regular time intervals so

that an acid concentration curve can be plotted and control of the operation
can be maintained (see Figure XIII-37).
5. Water-wash the tubes before and after neutralizing with soda ash and
detergent to remove all traces of acid and neutralizer.
6. Dry the tubes using a low fire in the heater, blow first with steam and then
with compressed air so that no moisture is left in the tubes.
7. Remove the acidizing equipment and supplies and clean the area.
uop 117108-6 XIII-98
1. General Instructions
a. Calculate the volume of the system (heater tubes, connecting piping,

and acid circulating tank sump) and then determine the amount of
concentrated inhibited hydrochloric acid required to give a 20 wt. %
circulating solution.
b. Transfer cool clean fresh water into the acid addition tank, and slowly
add acid to makeup the desired concentration.
*Not to be used on Austenitic stainless steels.
c. Fill the system with warm (80°F / 25°C) fresh water and circulate it to
check the system for leaks and to check the operation of the valves
and the pump.
d. Drain the circulated fresh water.
e. Start to slowly circulate the 20 wt-% acid solution through the system
drawing from the acid addition tank and discharging into the acid
circulating tank. Check the operation of the ejector to be sure that the
H2S is being removed from the acid circulating tank.
f. When the gas production decreases, increase the circulation rate and
slowly raise the temperature to 160°F (70°C) or to the maximum limit
recommended by the acid or inhibitor supplier. Do not exceed this
temperature because the inhibitor will breakdown and become
ineffective.
g. When the gas production again decreases, reverse the flow through
the heater. The reversal of flow is necessary in order to clean areas
that may have been blanketed by gas, or by channeling or eddying
effects set up by a single flow pattern.
uop 117108-6 XIII-99
h. Check the acid concentration in the solution at regular time intervals

and plot the time concentration graph. Five cm3 of potassium citrate
added to a 10 cm3 sample of the dark green acid solution will
generally complex the iron ions forming a white slurry which will titrate
to a very sharp endpoint.
i. When the acid concentration curve has stabilized for one or two hours,
or when the concentration has fallen below 1 wt. %, circulation should
be stopped and the spent acid and sludge in the bottom of the acid
circulating tank sump should be drawn off.
j. Fresh 20 wt. %, acid from the acid tank should again be charged to
the system and circulation should be resumed. When mixing is
complete, as a result of circulation, the temperature should again be
brought up to 160ºF (70ºC) or the maximum temperature as
recommended.
k. Again, at regular time intervals, the acid concentration should be

determined and a curve plotted.
l. When the acid concentration curve has, after several flow reversals,
stabilized at not lower than 5-6 wt-% concentration for an hour or two,
the acidizing can be considered complete.
m. Drain the spent acid from the system and begin a vigorous water
flushing using clean fresh water and adding just enough steam at the
inlet connection to keep the water at 100-120°F (40-50°C). Reverse
the flow of the flushing stream several times.
n. After half an hour of water flushing, begin circulating a 2 wt. % soda

ash solution containing 0.1 wt. % detergent, previously prepared in the
soda ash neutralizing tank. Continue circulating, with several reversals
of flow, for half an hour to neutralize any acid that may be in the
heater tubes and to remove any of the filming inhibitor.
uop 117108-6 XIII-100
o. Close the circulating valves and once again vigorously flush the tubes
with clean fresh water.
p. After another half hour of water flushing, shut off the water and blow
out the tubes first with steam and then with compressed air.
q. When all water possible has been blown out of the heater tubes at a
low point drain, light a few of the burners and slowly begin to heat up
the tubes. Heat slowly to approximately 400-500°F (200-250°C)
firebox temperature and continue to blow compressed air through the
tubes. When no more water vapor is seen emerging from the outlet,
shutoff the fires and let the heater cool down.
r. Wash down the working area to remove all traces of spent acid, soda,
or sludge. When the acidizing operation is finished, all equipment
should be flushed with water before being dismantled for removal; all
acids should be sent to safe storage, and all sludges should be
properly discarded.
2. Notes and Precautions
It is assumed that the usual precautions of handling hydrochloric acid are known
and will be observed. However, special consideration must be paid to the disposal
of the hydrogen sulfide that is evolved in the acidizing operation so that personnel
will not be exposed to It. Therefore, make certain that proper preparations are made
to allow safe disposal of the hydrogen sulfide.
Too low an acid concentration, and inadequate circulating velocity will result in
incomplete scale removal; thus, plugging of the reactor catalyst beds may result
shortly after the plant goes into operation.
uop 117108-6 XIII-101
3. Equipment and Supplies
a. Acid
The concentrated hydrochloric acid should contain an inhibitor (it must not
contain arsenic), a detergent, and an emulsifier.
b. Pump
A high capacity pump of approximately 250 gpm (50 m3/hr) in good working
order, built or modified to handle acid solutions is required.
c. Piping
Sound pipe in good condition, not scrap or rejects, all flanges and sharp,
clean threads in all screwed connections.
d. Acid Addition Tank

A tank of approximately 500 gallons (2 cubic meters) capacity, large enough
to hold four or five carboys of concentrated acid and the necessary diluting
water. The tank must be made of sound material, not scrap.
e. Soda Ash Neutralizing Tank

A tank of approximately 500 gallons (2 cubic meters) capacity, large enough
to dissolve the soda ash and detergent, and act as a sump for the pump
during the neutralizing circulation.
f. Acid Circulating Tank

A large tank of at least 2500 gallons (10 cubic meters) containing:
(1) A vapor disengaging space behind a perforated baffle, so that

the H2S can readily release itself from the circulating acid
solution and escape through the venting system;
(2) A weir to divide the tank into a settling basin, to trap the pieces
of scale and sludge carried by the circulating acid solution, and
a sump for the pump suction. The tank must be made of sound
material, not scrap, and must be capable of withstanding a
slight vacuum.
uop 117108-6 XIII-102
Figure XIII-36
Acidizing System Piping
Figure XIII-37
Typical Acid Concentration Curves
uop 117108-6 XIII-103
G. TURNAROUND
1. Inspection
Although there are many factors that contribute to long operational runs and plant
safety, preventive maintenance is probably the most important one. A proper and
thorough plant inspection not only results in extended run lengths and maximum
safety, but also greatly reduces the probability of unscheduled shutdowns. An
unanticipated emergency shutdown can be extremely costly, particularly if
accompanied by a loss of property and prolonged interruption to continued
operations.
To avoid these emergencies, UOP recommends periodic, pre-planned inspections

of the Platforming unit, together with a periodic re-education of operating personnel
to ensure that they are kept continually aware of the potential hazards of mis-
operation.
A good, well recorded inspection enables the refiner to determine equipment

corrosion rates and, subsequently, to develop life expectancy information.
A well-planned inspection program pays off in many other ways as well:
a. It helps maintain employee morale through the knowledge that

management is giving them added protection.
b. It is a major line of defense against fires and explosions.
c. It provides a way to anticipate material requirements for maintenance

and repair, thereby enabling the refiner to keep his warehouse
inventory at a proper level.
d. It permits stocking major renewal equipment not usually stocked, and

which normally may require a long delivery time, so that they will be
on hand for prompt installation when needed.
uop 117108-6 XIII-104
e. It provides information (through inspection records) for economic

studies with respect to the use of more expensive but longer lasting
materials.
f. It permits intelligent preplanning for turnarounds, thereby reducing

downtime and turnaround costs.
Many refineries run various types of charge to their reformers, and many times the
charge is of an unknown quality in regard to content of corrosives. Many types of
chemicals used today for well treatment are retained in the crude, and where these
chemicals become corrosive, it they do, is not known until it is too late. Chemicals
used in cleaning units while on stream can also become corrosive under certain
conditions.
During a turnaround, normal planning usually does not include sufficient time for
preparation and inspection of piping systems. Normally, after all other equipment
has been opened, cleaned, and inspected, the inspector then finds time to start
checking the piping system, usually by ultrasonic instruments.
The proper inspection of all piping during a turnaround can be carried out only if a
full inspection crew and sufficient maintenance personnel are available. To
overcome the need for large manned groups during a turnaround, it is
recommended that a thorough piping inspection be made prior to the turnaround.
Some time prior to a scheduled turnaround, a thorough thickness check should be

made of all process piping in the unit (within temperature limitations). This will
require less personnel, both inspectors and maintenance people, than performing
the inspection during the shutdown. A program of making holes in insulation and
moving ladders can be done by only two men on a normal working day basis. Also,
ladders are more readily available and can be placed where required, and
scaffolding can be erected without interfering with other work that normally takes
place during a turnaround.
uop 117108-6 XIII-105
A far larger number of check-points can be made when the inspectors and main-
tenance personnel have only piping to check. During an on-stream piping
inspection, many other important conditions can be noted, and in many cases,
rectified prior to the turnaround.
a. Thin piping can be scheduled for replacement and most of the

fabrication can be completed before the shutdown.
b. Leaking flanges and valves can be identified and scheduled for

repairs.
c. Inoperative valves can be scheduled for replacement or reworking.
d. All low-points in the Regeneration circuit should be identified and the

functionality of the associated low-point drain checked. If a valved low-
point drain does not function properly or does not exist, it should be
repaired or replaced at the earliest opportunity before the next catalyst
regeneration.
e. Repair or replacement of poor insulation can be completed either

immediately or can be scheduled for the turnaround. Since scaffolding
may be required to check some piping, the scaffolding can be used to
complete repairs of the insulation at the same time.
Consideration of the advantages of an on-stream piping inspection is strongly

recommended. Even if only one important line is scheduled for replacement during
the turnaround, the time saved will more than pay for the time and expense of the
inspectors. In general, there is little corrosion on reforming units, but a number of
areas should be checked anyway.
The hot alloy piping on reforming units with hydrotreated feedstocks has been
almost corrosion-free. In a few instances, carbon steel has been installed by
mistake in place of alloy. In each case the carbon steel failed from hydrogen attack
in about twelve months, even though the carbon steel showed no metal loss.
uop 117108-6 XIII-106
The cold piping downstream of the reactor products condensers and the bottom of
the products separator is vulnerable to hydrochloric acid attack in wet plants. The
drains at the low points of these lines should be watched
The compressor suction piping should be checked for scale accumulation. In some
cases, it has been found necessary to acidize these suction lines to alleviate com-
pressor problems.
In wet units, there is generally corrosion in the stabilizer overhead area (the top of
the column and the overhead receiver) from wet acid (HCI) attack. In dry plants HCI
corrosion has not been encountered, and stabilizer section piping corrosion has
been essentially nil.
2. Heaters
There are a large number of items to be inspected in the heaters during a shut-
down. The more important points are covered below.
a. Firebox Casings: The condition of the firebox casings is very

important. Any openings between panels should be closed. This will
prevent failure of the brick or refractory that in turn would allow
moisture and air into the heater. If the panel joints are not packed
properly, moisture will enter the heater. The heater environment is
such that the moisture becomes acidic, thus causing deterioration of
the refractory and corrosion of the panels and refractory anchors.
b. Refractory: If the refractory is in good condition, it prevents

considerable heat loss. Expansion will cause hair-line cracks, and this
is expected, but where large cracks are present and loose or soft
refractory exists, the refractory should be repaired or replaced.
uop 117108-6 XIII-107
c. Burners: Burners should be removed and cleaned, and bad burner

tips must be replaced. The burner blocks and ports must be in good
condition. Burners should be kept in alignment to prevent flame
Impingement on the tubes.
d. Tubes: Experience has shown that the corrosion rate is practically nil
on reforming heater tubes processing hydrotreated feedstock;
however, thickness measurements should be taken on the tubes
during each turnaround to check the rate of metal loss. Normally, the
tubes are checked at each end and at the center on the fire-side using
an ultrasonic tester (this is a reliable method for checking heater tube
wall thickness).
The external tube surface should be checked closely to determine whether

vanadium and/or sulfur attack has occurred. If the tubes are covered with oxide or
ash, this should be removed before the tubes are examined. Fine pitting is often an
indication of a fuel oil having a high sulfur or vanadium level.
e. Miscellaneous: The following should be checked:
(1) Stack casing, refractory and damper.

(2) Tube hangers for vanadium attack.
(3) Hanger bolts for proper support of tubes.
3. Reactors
a. Vessel Shells
There are two types of reactor vessels employed in reforming service; cold-
wall and hot-wall. Although hot-wall vessels are usually preferred by our
licensees, satisfactory service may be obtained from cold-wall reactors.
uop 117108-6 XIII-108
(1) Cold-Wall Reactors: The life of the concrete lining in cold-wall

reactors is indefinite. If the concrete is properly installed, only a
failure of the alloy lining should have an effect on the
serviceability or life of the concrete. A temperature-indicating
paint is a wise investment because it indicates immediately
when something has gone wrong with the internal lining.
Prompt action and minor repairs often avoid major repairs or
replacement of the linings.
In downflow reactors having internal liners, the reactor pressure

drop should not be allowed to exceed design - usually 3-5
kglcm2 (60 psi) to prevent liner ruptures. When a liner ruptures,
an unscheduled shutdown with possible extensive repairs is
mandatory.
Type 405 alloy steel lining has been used very successfully in
reformer reactors where the charge stock is hydrotreated.
Corrosion of Type 405 alloy lining has been encountered in
units operating on non-hydrotreated feedstocks. This material
has been replaced with Type 321 or 347 and no further
corrosion has occurred to the alloy lining.
(2) Hot-Wall Reactors: There is normally no corrosion problem with

hot-wall reactors. In cases where corrosion has taken place,
Type 405 alloy strip lining was applied over the corroded area
only.
The bottom heads in the hot-wall reactors may be lined with

refractory or fire brick. This lining is installed to serve as a filler
and not as an insulator. It must be installed in a good manner to
prevent catalyst movement into the refractory and coke buildup
in it. There have been cases where poorly installed refractory
allowed coke to buildup in the refractory and force the center
pipe out of the socket joint, after which the catalyst migrated
from the reactor.
uop 117108-6 XIII-109
b. Scallops
Vacuum any debris or catalyst from the inside of the scallops. It is very
important that the bottoms of the scallops be clean so that flow can reach the
bottom head of the reactor. After vacuuming out, place covers over the top of
the scallops to prevent catalyst from accidentally being allowed inside the
scallops.
Check the outside surface of the scallops for signs of catalyst fluidization,
particularly near the top of the slot openings. Look for polished areas. Also,
make sure the scallop slots are clean. If they are dirty, clean them with wire
brushes before vacuuming them out.
Check that the scallops sit securely on the scallop support ring and that the
rest back against the Rx wall. Spaces behind the scallops should be filled
with ceramic fiber to prevent these stagnant areas from filling with catalyst.
The scallops should be secured at the top and should be fairly plum and
evenly spaced around the Rx.
The expander rings that hold the scallops against the Rx wall should not be
overly tight. You should be able to move the ring with one hand (up and
down slightly). If you can not, they are too tight. Generally, it is acceptable to
have a small gap (1-5 mm) between the scallop face and the expander ring.
This assumes the scallop is all the way back against the Rx wall.
There should be no scallops with openings larger than a pill of catalyst.
A small amount of scallop crushing (perhaps 1-2 in. of deflection) at the base
of the scallop where it rests on the scallop support ring or at the elevations of
the expander rings is acceptable. If there is more than this, the scallop
should be repaired.
uop 117108-6 XIII-110
c. Centerpipe
Check that the centerpipe is clean. If not, wire brush its surface.
The centerpipe should be plum (within 0.5-0.75 in. top to bottom). Be careful
to load catalyst evenly on all sides of the centerpipe or else the centerpipe
may be pushed over by a higher density of catalyst on one side that the
other.
Look for signs of catalyst fluidization on the face of the centerpipe (near the
top).
Do not load catalyst on top of the centerpipe. If more height is needed for
slump and seal catalyst, a centerpipe extension should be placed on top of
the centerpipe. It is acceptable to load ceramic balls on top of the centerpipe
as hold-down material.
The insertion of the centerpipe into the socket at the base of the Rx is critical
to maintaining catalyst containment. Be sure ample ceramic fiber rope is
used and that there is no gap large enough for catalyst to escape.
Look for bulging of the centerpipe screen that may indicate separation of the
screen from the inside layers of the centerpipe.
Obviously, tears in the screen or holes in the screen need to be repaired

while trying not to blankoff a section any larger than 2 in. X 2 in..
d. Inlet Distributor
Inspect the inlet distributor looking for damage to the welded areas or loose
bolting.
uop 117108-6 XIII-111
e. Shroud and Deck Sections
Check for integrity and tightness of bolting.
Make sure that overlapping sections fit-up properly so that there are no gaps
present for gas flow to bypass.
Check that any seal ventilation baskets (if present) are clean and intact.
f. Loading
Check that the unloading nozzles are properly bolted with new gaskets. The
nozzle usually has a “key” insert to hold the catalyst while the blankoff is
removed. It is a good idea to place a layer of wound ceramic rope on top of
the “key”. The unloading nozzle should them be loaded with ¼ in. ceramic
balls.
Check centerpipe base again. It is acceptable to create a catalyst dam at the

base of the centerpipe with ceramic balls. Care must be taken not to create a
low pressure drop path for the vapor to prevent bypassing of the bed.
Load Catalyst. Dense Loading may be preferred, particularly for extruded

catalyst.
Measure carefully the slump and seal catalyst outside the shroud and inside
the shroud. The UOP manual gives guidelines for the proper slump and seal
catalyst heights to use. On the outside of the shroud, after the slump catalyst
has been loaded, ceramic balls should be loaded as hold-down material. 4-6
in. layers of ¼ in. and ¾ in. balls are recommended. Do not load closer than
2 in. from the top of the scallop.
It is acceptable to load ceramic hold-down material on top of the catalyst on

the inside of the shroud, particularly if sign of fluidization were seen.
Remove scallop covers and bolt-up deck.
uop 117108-6 XIII-112
4. Reactor Section Separator(s)
No serious corrosion is normally found in these vessels. Scale and chloride deposits
accumulate in the bottom of the vessels, so they should be opened and washed out
at each shutdown before regeneration. The mesh blanket or de-mister pad should
be cleaned as well. The mesh blanket must be installed tightly to insure as dry and
as clean a recycle gas as possible.
5. Combined Feed-Reactor Effluent Exchangers
Combined feed exchangers in reforming service where the feed is hydrotreated

normally have no serious fouling problems. Scale buildup is very slow, forming on
both sides of the bundles.
One of the biggest maintenance problems on reformers is hydrostatic testing of

these exchangers each inspection. The tube bundles should be hydrostatically
tested on the basis of the operating differential pressure between shell side and
tube side. On this basis the pressure required would be around 20-30 kg/cm2 (300-
400 psi) and not 140 kg/cm2 (2000 psi) or more.
In some cases, refineries are experiencing exchanger leakage between the tube
sheet and the shell. The cause may be a combination of any of the following factors:
a. Yielding of bolts due to uneven temperature of thick tube sheets and

flanges, or unequal torquing of the bolts.
b. Temperature differential on each side of the tube sheet causing

leaking flanges.
c. Improper design of piping geometry.
uop 117108-6 XIII-113
6. Reactor Products Condensers
Air coolers are normally trouble-free on the process side. Atmospheric fouling is
sometimes experienced on the external fins. Washing with water or blowing with air
has been effective in cleaning them.
Water coolers are fabricated from mild steel if non-corrosive cooling water is used.
With brackish or salt water as a cooling medium, Admiralty brass is often used. The
process conditions on the product side are normally noncorrosive. Corrosion is
possible in wet units having stagnant traps between the tube bundle transverse
baffles. This condition is avoided when drain "V" slots are provided in the baffles.
Many refiners have had unfortunate failures due to ammonium chloride attack
(stress cracking) on Admiralty tube bundles. Cracks normally occur in the U-bends
but can occur anywhere on the tubes. Reactor products condensers constructed of
Admiralty brass tubes should be water-flushed free of chlorides prior to hydrostatic
testing with water or before opening to atmosphere. Ammonium chloride is
hygroscopic and atmospheric humidity is enough to produce a very corrosive
condition.
During regeneration, the lower than normal flow rates to air coolers sometimes
result in distribution problems. The caustic circulation used to neutralize HCl during
regeneration may not distribute evenly to all air condenser bundles, and the result is
high corrosion rates in localized areas. See the Regeneration section of this chapter
for recommendations to combat this problem.
7. Monel Trim Valves
Early reforming units were equipped with valves having 12% chrome stainless trims.
Reports from these plants indicated stress corrosion and cracking of stainless plugs
and seats in the low temperature section of the plant from the condenser through
the separator and compressors. This was attributed to moisture and chlorides,
present in the charge stock or added for process reasons.
uop 117108-6 XIII-114
At ambient temperature, the low pH solution that resulted proved to be somewhat

corrosive to low chrome or carbon steel and very destructive to the high chrome
alloys. Replacement of the valves in this zone of the plant with Monel-trimmed
valves has eliminated this trouble.
Since most of today's reforming units normally operate at much lower recycle gas
moisture levels, 12% chrome valve trims can be reconsidered and used. Even if the
reformer reactor section is considered dry, the stabilizer overhead may be wet and
corrosive if outside material is fed to this column, as has been done in some
instances to maximize LPG recovery from other unit gases If this is the case, proper
consideration should be given to the choice of metallurgy in the stabilizer overhead
system.
8. Condensate and Chloride Injection Points
Corrosion of the injection nozzle and the area of the pipe around the point of in-
jection can be expected to occur when both condensate and chloride are injected
together in the same nozzle. Corrosion has occurred on some units when these
materials were injected separately because the nozzles were too close to each
other. To eliminate this problem and a possible fire hazard if connections fail, the
chloride is injected into the combined feed at the combined feed-reactor effluent
exchanger inlet and the condensate is injected into the hot stream at the outlet of
the exchanger.
9. Recycle Gas Compressors
The recycle compressor is the most valuable piece of equipment in a reforming unit.
When the compressor is properly cleaned, inspected and maintained, it will be
trouble-Free for an extended length of time. At all shutdowns, the compressor
should be kept under a nitrogen blanket. Prior to opening the compressor and
exposing its internals to moisture, it should be washed free of acidic deposits-
Washing is carried out with a 2% soda ash solution. Higher carbonate
concentrations should not be used because of the need to avoid damage to any
aluminum labyrinths in the compressors. If cleaning procedures are not adhered to,
uop 117108-6 XIII-115
stress cracking (intergranular corrosion) can be anticipated. The procedures for

washing centrifugal and reciprocating compressors are included at the end of this
section. On centrifugal compressors, traces of chloride deposits are sometimes still
found between the impeller blades when the impellers are removed. A high
pressure jet of warm water is the best method for a final cleaning.
10. General 30-Day Platforming Unit Shutdown - Inspection Schedule
A thorough inspection can save valuable operating time and avoid costly
mechanical failures. Accumulated experience with many reforming units has
allowed UOP to develop optimum inspection intervals for the equipment.
Table XIII-2 indicates the intervals recommended between complete inspections of

the principal items of equipment in a reforming unit. Inspections at these intervals
will help ensure the well-being of the mechanical aspects of the reforming unit.
a. High-Pressure Reactor Systems
The safest procedure for protection of catalyst in the reformer and for other
high-pressure equipment in the system will be to keep these systems under a
slight nitrogen pressure. The procedure recommended following the
shutdown will be to evacuate and purge with nitrogen, then blanket with
nitrogen at about 0.7 kg/cm2(10 psig) and blind the system.
b. Towers and Vessels
It will be adequate to merely drain all hydrocarbons in various fractionators,

receivers, surge drums, etc., and apply a gas blanket to be maintained during
the entire shutdown. Where appropriate, it is recommended that the system
be allowed to float under fuel drum pressure.
uop 117108-6 XIII-116
c. Utilities
(1) Cooling Water

It will be adequate to simply shutdown the cooling water circulation system
during warm weather and start one circulating pump during freezing weather.
The cooling water in compressor cases should be drained if these systems

have not been protected against freeze-up.
(2) Steam
Minimum steam requirements must be maintained for insurance purposes
and fire protection, and also to operate turbine-driven pumps.
All steam turbines should of course be drained and all steam header dead
ends should be checked for possible freeze-ups. Make sure that all steam
traps continue to operate during this period.
(3) Fuel Gas

Fuel gas will be used to gas blanket all of the fractionators in the unit. All
process heaters will have the fuel gas blinded off at the burners or at the
main header.
(4) Power
The normal power supply may need to be maintained depending on the utility
pumps in the unit and emergency requirements. Lighting requirements, etc.,
will have to be satisfied.
(5) lnstrument Air

Having dry instrument air on all idle instruments will be of a major factor in
protecting against corrosion.
uop 117108-6 XIII-117
(6) Plant Air

There may be no need for plant air as a standby utility. If for any reason
during the shutdown, plant air is required, it can be staffed at that time. We
therefore recommend that the plant air system be shut down.
(7) Hot Oil System

This consideration is mentioned because of the freeze point of the hot oil
being used. Unless precautions are taken, it might set up in the exchangers
where it is used.
(8) Sewer Systems

In all cases as the various units are shut down, the remaining drips and
drains from the various vessels will be drained to the sewer. Careful attention
should be given to flush the sewer with fresh water and make certain all
hydrocarbons have been swept out after the units are down.
d. Pumps
No special corrosion considerations are necessary, except for small chemical

pumps, such as the chloride injection pumps. It would be better not to drain
these pumps, but take precautions that moisture does not get into them.
Block them at the discharge and keep the suctions open so that they cannot
be damaged by expansion. All other pumps should have suction and
discharge valves blocked and the drains opened. reciprocating pumps should
have the rods lightly lubricated to prevent corrosion.
Cooling water to pump glands and base coolers should be blocked in and the
water drained.
e. Turbines
No special precautions are required for the turbines, except to make certain
that all condensate has been carefully drained. Turbines and pumps can
uop 117108-6 XIII-118
remain coupled up and once every few days or so they can be turned by
hand with lubricators in service.
f. Compressors
When compressors in the reforming unit are of the non-lubricated type, they
will require special consideration if the plant is to be down for as long as thirty
days. The suction and discharge block valves should be closed to prevent
nitrogen blanketing gas from leaking out of the reactor systems, but nitrogen
must be kept in the compressor cases to avoid corrosion due to the
ammonium chloride on the compressor valves. Simply pressuring the
compressors and blocking them would not be adequate, because over a
thirty-day period the compressor cases would breathe, allowing moisture to
enter and corrosion would be the result. It is therefore recommended that a
nitrogen blanket from cylinders controlled by a small regulator be installed to
continuously bleed nitrogen through a small pipe manifold in all compressor
cases. The quantity of nitrogen should be such that just a few in. of water
pressure be maintained. Keeping the pressure at a minimum will conserve
nitrogen lost due to leakage.
A very light coat of oil should be applied to the exposed part of the com-
pressor rods, taking special care not to get oil on the carbon packing. After
this, do NOT turn the compressors over or the packing will of course wipe the
oil off.
All cooling water in the closed circulating system should be drained if it is not
protected against freezing with glycol.
When compressors are of the centrifugal type, the manufacturer's recom-

mendations should be followed. In general the lube/seal oil system should be
circulated periodically and the compressor maintained under a nitrogen
blanket.
uop 117108-6 XIII-119
g. Valves and Cocks
During the shutdown all plugged cocks should be greased while finally
closing them. No special consideration need be given to gate or globe
valves.
h. Relief System
Since the system will be full of fuel gas the flare system should remain in
service and the flare kept lit.
i. Coolers and Exchangers
As explained in the cooling water system it is best to keep the cooling water
flowing through coolers to keep the water from freezing during cold weather.
No other consideration is required. Regarding exchangers, no special
consideration is necessary except to protect hot oil exchangers from setting
up. Do NOT attempt to wash ammonium chloride from the reformer
exchangers at this time. This can only be done properly by pulling the
bundles and immediately starting the unit up after washing.
j. Heaters
The best protection for heaters against corrosion and spalling of internal
heater box insulation is to keep a very small fire going at all times, such as
with pilot lights. The stack damper should be wide open during the entire
shutdown period.
k. Tank Farm
Keep water drained wherever necessary, and if any tanks are gas blanketed,
keep the gas blanketing system in service.
uop 117108-6 XIII-120
l. Manpower Requirement
A skeleton force must be maintained for adequate plant protection. This will
require at least one man per shift, and as many maintenance personnel as
necessary to keep the unit gas blanketing systems, etc., under constant
surveillance.
uop 117108-6 XIII-121
Table XIII-2
Platforming Unit Inspection Intervals
Maximum Interval between

Inspections, months
Equipment “Wet Units” “Dry Units”
Heaters 18 30
*Reactors 24 30
Combined Feed Exchangers 18 30
Reactor Products Condensers 18 30
Reactor Products Separators 18 30
Stabilizer Column 18 30
Stabilizer Receiver 18 30
Stabilizer Exchanger and Coolers 18 30
Prefractionation Column 18 30
Prefractionation Receiver 18 30
Prefractionation Exchanger and Coolers 18 30
*- From a process standpoint, reactors should be inspected for cleanliness

every third regeneration or every two years (whichever is more frequent).
uop 117108-6 XIII-122
H. MOTHBALLING
The best approach is to nitrogen blanket the entire unit. However, this procedure
may not perfectly protect all components of the Platforming unit. Normal aging of
components during the mothballing period is fully anticipated. The following
procedures are devised to minimize the mechanical problems during start up at the
end of the storage period.
Furthermore, a refiner must realize that the storage of any component for an
extended period of time will result in extra maintenance at the start up of the unit.
For example, assuming the normal failure rate of a transmitter is one per year, then
after two years of storage, a refiner might see two transmitters fall at start up. This
means that extra maintenance at start up should be anticipated with extra spare
parts on hand in addition to the regular ones.
UOP would recommend a 2 to 5 psig nitrogen blanket be applied to the unit. Over
pressure protection should be provided. Critical components will be discussed in the
following sections: electrical, instrumentation, piping and equipment.
All equipment regardless of whether they are stored in a climate controlled

environment or installed in the unit in a nitrogen blanket at site, will all need to be
inspected, adjusted and repaired if necessary prior to startup. Access to the unit
should be restricted so that "borrowing” of equipment does not occur.
1. Electrical
a. Lighting
Lighting fixtures and circuits should remain on to provide lighting in the unit
during the idling period. This also applies to convenience, trouble and
welding receptacles.
uop 117108-6 XIII-123
b. Pump Motors
Motors for all pumps should be removed and stored in a dry and ventilated
warehouse. The electric motors must be periodically rotated (manually
without electric power) to prevent the motor bearings from flattening out.
c. Convenience Receptacles (120 vac), Welding Receptacles (480 vac)

& Trouble Lighting Outlets (24 vac)
It is recommended that these circuits remain available for maintenance

purposes during idling period. However, all breakers are to be at the off
position when not in use.
2. Instrumentation
Instruments should require no special care after the unit is nitrogen blanketed. All of
the instruments installed in the unit should be weather-proof. Bug screens should be
provided to all openings to atmosphere, if not already in place. Elastomer (rubber)
parts may not hold up well and might need to be replaced after inspection prior to
start up. The actuator piston cylinders should be coated with oil to prevent corrosion
initially and then re-coated periodically at the site. The stems should be sprayed
with anti-corrosion compound at the site and should be periodically re-sprayed. The
valves should be periodically stroked (minimum 4 times a year). In case at the
startup some valves are found to be unsuitable for use, extra valve packing in
addition to regular spares should also be purchased. Working interfaces such as
threads, bearings or gears should be lubricated on a reasonable schedule as
recommended by the manufacturers.
3. Piping & Equipment
a. Nitrogen Blanketing Piping:
The nitrogen blanketing of the entire unit piping can be accomplished by

using the nitrogen piping provided for purging during normal operation. All
uop 117108-6 XIII-124
the vessel nozzles and the majority of piping and valves are to be left open.
This should enable the majority of the piping and vessels to be blanketed by
nitrogen. In the few cases where a piping circuit is cut-off by fail close control
valves without bypasses, a “jumper” of ½ in. hose should be used at the
drain valves to bridge the control valve.
A pressure reduction valve (PCV) at the unit battery limits should be used to
provide a constant 5 psi nitrogen blanket. Also provide a pressure relief
device (PSV) set for 8 psig downstream of the PCV capable of handling an
over pressure condition in the event of PCV failure.
Note: In addition to the above recommendations, ALL manways on

equipment and vessels should be fitted with a warning tag to prevent entry by
personnel into the nitrogen atmosphere.
b. Blind Flanges at Tie-In Points:
Blind flanges should be provided at the battery limit tie-ins.
4. Insulation
Due to moisture absorbing nature of the insulation material, plastic sheets should be
securely laid over the insulation to prevent ingress of moisture during the idling
period.
5. Protective Coating
For normally un-insulated carbon steel piping and equipment, one coat of epoxy
polyamide over one coat of inorganic zinc is the usual UOP specification. This is
probably the original paint scheme. Also inspect stud bolts and nuts at site. It is
possible to replace them with new zinc-coated bolts, or they may be sprayed with
rust inhibiting compound. If rust inhibiting compound is to be applied, it should also
be applied to the gap between the flanges at each connection in order to protect the
threads of the bolts and flange faces from rusting.
uop 117108-6 XIII-125
6. Site Inspection and Maintenance Procedure During Idling Period
During idling period, the unit should be periodically inspected. For some other
equipment and components built from bulk material, it is difficult to even speculate
how often the inspection should be carried out. However, UOP recommends the
following:
a. Structural
No special requirements are needed. Periodic touch-up painting may be

required.
b. Electrical
Lighting fixtures should be inspected following a refiner’s normal inspection

procedure. All grounding connections should be checked periodically. Motors
for pumps should be inspected in accordance with the manufacturers’
recommendations. They should be rotated periodically to prevent flattening of
the bearings.
c. Instrumentation
All automatic control valves should be inspected in the interval as

recommended by the manufacturers. Bug screens should be examined for
damage. The actuator piston cylinders should be periodically coated with oil
at the interval recommended by the manufacturers. Prior to startup, some
elastomer parts should be examined as samples to determine the general
condition for all instruments.
d. Piping & Equipment
All bolts and nuts should be inspected and sprayed with rust inhibiting
chemical as required. All carbon steel and 1¼ Cr.-½ Mo. piping and
equipment should be inspected periodically. Any rusty spots should be
cleaned and painted as needed.
uop 117108-6 XIII-126
7. Special Commissioning Procedures
Special commissioning procedures may not be required as a result of the extended

idling period, however the commissioning procedures for new units found in the
General Operating Manual should be reviewed and considered. Identification and
repair of any problems will be the key to a fast start up. The following extra steps
should be carried out:
a. Insure there are enough gaskets for vessel inspection, dryout and line
blowing in the unit.
b. Insure all warehouse items are available for installation into the unit.
c. Check out the pumps including alignment check to insure they are
suitable for start up.
d. Check that all manual valves are operable and their packings are gas
tight. Replace or repack any valves as necessary.
e. Chemically clean the inlet lines to the reciprocating compressors per

original UOP specification.
f. Chemical sprayed on bolts and nuts for rust prevention should be

cleaned or neutralized to prevent potential fire hazard from happening.
g. Mineral wool insulation on piping and vessels should be inspected to

ascertain the integrity of the material. If found necessary, it should be
replaced with new material. However, the stainless steel jacket can
still be re-used.
h. The unit will need the leak test prior to start up that is conducted as
part of the normal commissioning procedure. This pressure test will be
more important than usual because of potential leaking valve packings
and gasket relaxation as a result of the long idling period.
uop 117108-6 XIII-127
Fixed-Bed Platforming – General Operating Manual Safety
XIV. SAFETY
The information and recommendations contained in this section have been

compiled from sources believed to be reliable and to represent the best opinion on
the subject as of 1994. Refer to the references in Table XIV-1 for publications that
can be used to supplement this information. However, no warranty, guarantee or
representation, expressed or implied, is made by UOP as to the correctness or
sufficiency of this information or to the results to be obtained from the use thereof.
Each refiner should determine the suitability of the following material for his
purposes before adopting them.
Since the use of UOP products by others is beyond UOP control, no guarantee,
expressed or implied, is made and no responsibility assumed for the use of this
material or the results obtained therefrom. Moreover, the recommendations
contained in this manual are not to be construed as a license to operate under, or a
requirement to infringe, any existing patents, nor should they be confused with
state, municipal or insurance requirements, or with national safety codes.
A. OSHA HAZARD COMMUNICATION STANDARD
All references to environmental, occupational safety and material transport laws are
based on U.S.A. federal, state and local laws that are applicable only within the
U.S.A. and its territories. Non-U.S. refineries should follow comparable local guide-
lines and regulations regarding safety in the unit. It cannot be assumed that all
necessary warnings and precautionary measures are contained in this manual, or
that any additional warning and or measures may not be required or desirable
because of particular exceptional conditions or circumstances, or because of
applicable federal, state or local law.
uop 117108-6 XIV-1
As of May 25, 1986, all U.S. employers covered under the Specific Industrial
Classification (SIC) Codes 20-39 must be in compliance with the Occupational
Safety and Health Standard, Subpart Z – Toxic and Hazardous Substances Hazard
Communications, Section 1910.1200 of the Federal Regulations. This standard is
commonly referred to as the “Right-to-Know Law.”
The OSHA standard is a U.S. Federal regulation requiring chemical manufacturers,

importers and distributors to evaluate the hazards of their chemical products and
convey hazard information through labels and material safety data sheets to its
employees and customers which fall within SIC Codes 20-39. The customers in turn
must pass the hazard information on to its employees and contractors that come on
the premises. In this context, UOP employees who are working in or visiting a
refinery are considered contractors to the refiner.
It is the responsibility of the U.S. refiners to inform all contractors of the hazardous
chemicals the contractor’s employees may be exposed to while performing their
work, and any suggestions for appropriate protection measures. It is then the
responsibility of UOP to provide the information to its employees about the
hazardous chemicals to which they could be exposed by means of 1) a written
hazard communications program, 2) training and information, 3) labels and other
forms of warning, and 4) material safety data sheets.
1. Written Hazard Communications Program
The OSHA standard requires that U.S. employers make available to its employees
the company’s written Hazard Communication Program. This document is intended
to describe how the company will implement the OSHA standard. The program
explains the company’s labeling system, material safety data sheets (MSDS), and
employee information and training. The latter includes a listing of hazardous
chemicals known to be present in the work place, and methods the company will
use to inform its employees and contractors of the hazardous chemicals.
uop 117108-6 XIV-2
2. Training and Information
All UOP employees receive classroom training in compliance with the OSHA
standard. This includes an overview of the standard, an explanation on how to
interpret and use the information on a MSDS, the location and availability of UOP’s
file of MSDS’s, labeling requirements and their meaning, and an introduction to
toxicology.
UOP employees working in or visiting U.S. refiners are considered contractor

employees of that refinery. The OSHA standard states that contractors performing
work in these facilities are required to train their people before they enter the
refinery. However, it is the responsibility of U.S. refiners to inform UOP of the
specific hazardous chemicals to which UOP’s employees may be exposed. UOP
complies with the OSHA standard by making available to its employees this list of
hazardous chemicals and by appraising them of the hazards they will be exposed,
relevant symptoms and appropriate emergency treatment and proper conditions
and precautions of safe use or exposure.
3. Labels and Other Forms of Warning
The OSHA standard states that all portable containers of hazardous chemicals
must have a large, readable label or tag which has on it:
a. The name and address of the manufacturer
b. The name of the chemical
c. A numerical hazard warning or other appropriate warnings supplied by

the manufacturer
For the latter, the National Fire Protection Association (NFPA) Diamond is
commonly used. An explanation of the NFPA Diamond may be found in Figure
XIV-1 and Table XIV-2 located at the end of this chapter.
uop 117108-6 XIV-3
Labels can also be color coded according to the following:
Orange Carcinogen Hazard (i.e., Benzene)

Red Chemical Burn Hazard (i.e., Acids, Bases)
Yellow Toxic Vapor Hazard (i.e., H2S)
White All Others
An example of the information that can be found on a warning label may be found in
Figure XIV-2 at the end of this chapter.
Contractor employees must label all containers of hazardous materials that they
bring into the refinery. This applies to UOP employees who are visiting or working in
refineries.
4. Material Safety Data Sheet (MSDS)
The MSDS requirement falls primarily on chemical manufacturers, importers and

distributors. The OSHA standard requires them to develop and provide a MSDS for
each hazardous chemical they produce or handle. These manufacturers, importers
and distributors are required to provide the MSDS to the purchasers of the
hazardous chemical.
Although the format of the MSDS can vary, they should all include the following
information:
• Chemical and common name

• Ingredient information
• Physical and chemical characteristics
• Physical hazards - Potential for reactivity, fire and/or explosion
• Health hazards
• Symptoms of exposure
• Primary route of likely entry into the body upon exposure
• OSHA permissible exposure levels
• Precaution for use
uop 117108-6 XIV-4
• Waste disposal
• Protective measures and equipment, including during spills and maintenance
• Emergency and first-aid procedures
• Date of MSDS preparation and last revision
• Emergency contact of manufacturer or distributor
The OSHA standard requires that the manufacturer or distributor provide quick and
easy access to all MSDS’s applicable to their work place.
5. MSDS for UOP Platforming Processes
At the end of this Safety Section UOP has included copies of the Material Safety
Data Sheets (MSDS’s) for R-86 catalyst and activated alumina 9139A. These
MSDS’s are provided for illustrative purposes only to represent the most
common products supplied by UOP. These MSDS’s may not contain exact
information relating to the materials used in each individual unit. In addition, the
MSDS’s may not be current. These MSDS’s are not a substitute for safety
information provided by the supplier. UOP assumes no responsibility for the use of
any information contained in these MSDS’s. Contact UOP for the latest MSDS
updates for the Platforming catalysts.
MSDS’s for all other chemicals (chloriding agent, oxygen scavenger, caustic, etc.)
used in the Platforming process should be obtained from the supplier of that
chemical. Refineries should have their own MSDS’s for all process streams (feed,
reformate, LPG, hydrogen, net gas, etc.) and the components therein (benzene,
toluene, etc.).
uop 117108-6 XIV-5
B. HYDROGEN SULFIDE POISONING
Hydrogen sulfide is both an irritant and an extremely poisonous gas. Breathing even
low concentrations of hydrogen sulfide (H2S) gas can cause poisoning. Many
natural and refinery gases contain more than 0.10 mol-% H2S. The current OSHA
permissible exposure limits are 20 mol-ppm ceiling concentration and 50 mol-ppm
peak concentration for a maximum 10 minute exposure.
The Platforming process recycle gas and debutanizer overhead gas can normally
contain up to 20 mol ppm H2S. During unit upsets, this value can increase to
possibly greater than 1000 mol ppm. These gases must NEVER be inhaled. One
full breath of high concentration hydrogen sulfide gas will cause unconsciousness
and could cause death, particularly if the victim falls and remains in the presence of
the H2S.
The operation of any unit processing gases containing H2S remains safe provided
ordinary precautions are taken and the poisonous nature of H2S is recognized and
understood. No work should be undertaken on the unit where there is danger of
breathing H2S, and one should never enter or remain in an area containing it
without wearing a suitable fresh air mask.
There are two general forms of H2S poisoning – acute and subacute. A list of
symptoms as they relate to the H2S concentration level and exposure time may be
found in Table XIV-3 at the end of this chapter.
1. Acute Hydrogen Sulfide Poisoning
Breathing air or gas containing more than 500 mol-ppm H2S can cause acute
poisoning and possibly be fatal.
uop 117108-6 XIV-6
a. Symptoms of Acute Poisoning
The symptoms of acute H2S poisoning are muscular spasms, irregular

breathing, lowered pulse, odor to the breath and nausea. Loss of
consciousness and suspension of respiration quickly follow.
Even after the victims recovers, there is still the risk of edema (excess
accumulation of fluid) of the lungs which may cause severe illness or
death in 8 to 48 hours.
b. First Aid Treatment of Acute Poisoning
Move the victim at once to fresh air. If breathing has not stopped,
keep the victim in fresh air and keep him quiet. If possible, put him to
bed. Secure a physician and keep the patient quiet and under close
observation for about 48 hours for possible edema of the lungs.
In cases where the victim has become unconscious and breathing has
stopped, artificial respiration must be started at once. If a Pulmotor or
other mechanical equipment is available, it may be used by a trained
person; if not, artificial respiration by mouth-to-mouth resuscitation
must be started as soon as possible. Speed in beginning the artificial
respiration is essential. Do not give up. Men have been revived after
more than four hours of artificial respiration.
If other persons are present, send one of them for a physician. Others
should rub the patient’s arms and legs and apply hot water bottles,
blankets or other sources of warmth to keep him warm.
After the patient is revived, he should be kept quiet and warm, and
remain under observation for 48 hours for the appearance of edema
of the lungs.
uop 117108-6 XIV-7
2. Sub-acute Hydrogen Sulfide Poisoning
Breathing air or gas containing H2S anywhere between 10 to 500 mol-ppm for an
hour or more may cause subacute or chronic hydrogen sulfide poisoning.
a. Symptoms of Subacute Poisoning
The symptoms of subacute H2S poisoning are headache,

inflammation of the eyes and throat, dizziness, indigestion, excessive
saliva, and weariness. These can be the result of continued exposure
to H2S in low concentrations. Edema of the lungs may also occur.
b. First Aid Treatment of Subacute Poisoning
Keep the patient in the dark to reduce eyestrain and have a physician
treat the inflamed eyes and throat. Watch for possible edema.
Where subacute poisoning has been suspected, the atmosphere

should be checked repeatedly for the presence of H2S by such
methods as testing by odor, with moist lead acetate paper, and by
Tutweiler H2S determination to make sure that the condition does not
continue.
3. Prevention of Hydrogen Sulfide Poisoning
The best method for prevention of H2S poisoning is to stay out of areas known or
suspected to contain it. The sense of smell is not an infallible guide as to the
presence of H2S, for although the compound has a distinct and unpleasant rotten
eggs odor, it will frequently paralyze the olfactory nerves to the extent that the
victim does not realize that he is breathing it. This is particularly true of higher
concentrations of the gas.
uop 117108-6 XIV-8
Fresh air masks or gas masks suitable for use with hydrogen sulfide must be used
in all work where exposure is likely to occur. Such masks must be checked
frequently to make sure that they are not exhausted. People who must work on or in
equipment containing appreciable concentrations of H2S, must wear fresh air masks
and should work in pairs so that one may effect a rescue or call for help should the
other be overcome.
As mentioned above, the atmosphere in which people work should be checked from
time to time for the presence of H2S.
REMEMBER – JUST BECAUSE YOUR NOSE SAYS IT’S NOT THERE, DOESN’T
MEAN THAT IT IS NOT.
C. PRECAUTIONS FOR ENTERING A CONTAMINATED OR INERT

ATMOSPHERE
Nitrogen is non-toxic. Seventy-nine mol-% of the air we breathe is nitrogen, 21

mol-% is oxygen. However, in vessels or areas where there is a high concentration
of nitrogen, there is also a deficiency of oxygen for breathing. Breathing an
atmosphere deficient in oxygen (i.e., an inert atmosphere) will rapidly result in
dizziness, unconsciousness, or death depending on the length of exposure. Do not
enter or even place your head into a vessel that has a high concentration of
nitrogen. Do not stand close to a valve where nitrogen is being vented from
equipment at a high rate that might temporarily cause a deficiency in oxygen close
to the valve.
UOP policy is not to allow any UOP technical advisors to perform work in a
vessel which is known to be contaminated or under an inert atmosphere. UOP
does not permit its technical advisors to perform “inert entry” work inside any
vessel.
uop 117108-6 XIV-9
Refinery personnel who do have to enter a contaminated or inert atmosphere

should follow all prescribed standard safety precautions and regulations that apply
for the refinery. OSHA regulations concerning the use of respirators (29 CFR
Subpart 1, Section 1910.134) should be read and thoroughly understood.
It is also important to emphasize that if a person has entered a vessel and becomes
unconscious, no individual should go in to help him without first putting on a fresh
air mask, confirming that the air supply is safe, donning a safety harness, and
enlisting the aid of a minimum of two other people to remain immediately outside of
the vessel to assist him. This may seem to be an obvious warning, but people do
forget this in the trauma of an emergency situation. Often the first thought is to save
the person in distress and people enter the vessel without proper protection only to
succumb to the same hazard without anyone else being present to save them.
D. SAFETY FOR VESSEL ENTRY
Whenever any personnel must enter a vessel, a meeting should be arranged

between the refinery personnel who will be involved. The meeting should include
review of the vessel entry procedures, the refiner’s safety requirements and
facilities, preparation of a vessel entry schedule, assignment of responsibility for the
preparation of a blind list, and assignment of responsibility for the vessel entry
permits.
The most common tasks that could involve a potentially hazardous vessel entry are:
Unit Checkout Prior to Startup

Turnaround Inspections
Reactor Loading
Reactor Unloading
There are many precautions common to each situation. In the remaining part of this
section, these general precautions will be summarized, followed by a discussion of
the particular hazards associated with these common tasks. The precautions apply
uop 117108-6 XIV-10
equally to entry into all forms of vessels, including those enclosed areas that might
not normally be considered vessels:
Reactors
Regenerators
Separators
Columns
Drums
Receivers
Fired Heaters
Storage Tanks
Sumps
The API publication “Guide for Inspection of Refinery Equipment” or the NIOSH
publication No. 87-113; “A Guide to Safety in Confined Spaces” can be referred to
for additional information on safety procedures for vessel entry and accident
prevention measures.
1. General Precautions
a. The vessel must be positively isolated.
b. Safe access to the vessel must be assured.
c. Ladders, or safe internal access, must be provided.
d. Personnel entering the vessel must be provided with safety

harnesses.
e. Two standby personnel must be available outside of the vessel to

assist the personnel inside.
uop 117108-6 XIV-11
f. The safety of the atmosphere inside of the vessel must be confirmed

by checks for toxic gases (e.g., H2S), oxygen content and for
explosive gases before entry.
g. A dedicated supply of fresh air must be available for the standby

people who will assist personnel in the vessel in the event that they
encounter difficulty.
h. A vessel entry permit must be obtained and registered with the

responsible persons.
2. Positive Isolation
Every line connecting to a nozzle on the vessel to be entered must be blinded. This
includes drains connecting to a closed sewer, utility connections and all process
lines. The location of each blind should be marked on a master piping and
instrumentation diagram (P&ID), each blind should be tagged with a number and a
list of all blinds and their locations should be maintained. One person should be
given responsibility for the all blinds in the unit to avoid errors.
The area around the vessel manways should also be surveyed for possible sources
of dangerous gases that might enter the vessel while personnel are inside.
Examples include acetylene cylinders for welding and process vent or drain
connections in the same or adjoining units. Any hazards found in the survey should
be isolated or removed.
3. Vessel Access
Proper access must be provided both to the exterior and interior of the vessel to be
entered. The exterior access should be a solid, permanent ladder and platform, or
scaffolding strong enough to support the people, equipment, and safety gear that
will be involved in the work to be performed.
uop 117108-6 XIV-12
Access to the interior should also be strong and solid. Scaffolding is preferred when
the vessel is large enough to permit it to be used. The scaffolding base should rest
firmly on the bottom of the vessel and be solidly anchored. If the scaffolding is tall,
the scaffolding should be supported in several places to prevent sway. The platform
boards should be sturdy and capable of supporting several people and equipment
at the same time. Rungs should be provided on the scaffolding spaced at a
comfortable distance for climbing on the structure.
If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always
preferred over a rope ladder and is essential to avoid fatigue during lengthy periods
of work inside a vessel. The bottom and top of the ladder should be solidly
anchored. If additional support is available, then the ladder should also be anchored
at intermediate locations. When possible, a solid support should pass through the
ladder under a rung, thereby providing support for the entire weight should the
bottom support fail. Only one person at a time should be allowed on the ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each
new job. All rungs should be tested for strength, whether they are made of metal or
wood. Each rope must be individually secured to an immovable support. If possible,
a solid support should pass through the ladder so that a rung can help support the
weight and the bottom of the ladder should be fastened to a support to prevent the
ladder from swinging. As with the rigid ladder, only one person should climb the
ladder at a time.
4. Safety Harness
Any person entering a vessel should wear a safety harness with an attached safety
line. The harness is not complete without the safety line. The harness should be
strong and fastened in such a manner that it can prevent a fall in the event the man
slips and so that it can be used to extricate the man from the vessel in the event he
encounters difficulty. A full-body type harness is required by OSHA since it
distributes the shock load during a fall and it prevents some falls which simple belts
do not. Another advantage of the parachute type harness over a belt type is that it
uop 117108-6 XIV-13
allows an unconscious person to be lifted from the shoulders, making it easier to

remove him from a tight place such as an internal manway.
A minimum of one harness for each person entering the vessel and at least one
spare harness for the people watching the manway should be provided at the
vessel entry.
5. Manway Watch
Before a person enters a vessel, there should be a minimum of two people

available outside of the vessel, one of who should be specifically assigned
responsibility to observe the activity of the people inside of the vessel. The other
person must remain available in close proximity to the person watching the manway
so that he can assist or go for help if necessary. He must also be alert for events
outside of the vessel, such as a nearby leak or fire, which might require the people
inside to come out. Standby people should not leave their post until the people
inside of the vessel have safely gotten out.
A communication system should be provided for the manway watch so that they
can quickly call for help in the event that the personnel inside of the vessel
encounter difficulty. A radio, telephone, or loud speaker can be used for this
purpose.
6. Fresh Air
The vessel must be purged completely free of any noxious or poisonous gases and
inventoried with fresh air before permitting anyone to enter. The responsible
department, usually the safety department, must test the atmosphere within the
vessel for toxic gases, oxygen level and explosive gases before entry. This must be
repeated every 4 hours while there are people inside the vessel. Each point of entry
and any dead areas inside of the vessel, such as receiver boots or areas behind
internal baffles, where there is little air circulation should be checked. Fresh air can
be circulated through the vessel using an air mover, a fan, or, for the cases where
moisture is a concern, the vessel can be purged using dry certified instrument air
uop 117108-6 XIV-14
from a hose or hard piped connection. When an air mover is used, make certain
that the gas driver uses plant air, not nitrogen, and direct the exhaust of the driver
out of the vessel to guarantee that the exit gas does not reenter the vessel. When
instrument air is used, responsible personnel must check the supply header to
ensure that it is properly lined up and that there are no connections where nitrogen
or a contaminated backup source can enter the system. The fresh air purge should
be continued throughout the time that people are inside the vessel.
A minimum of one fresh air mask for each person entering the vessel and at least
one spare mask for the standby should be provided at the vessel entry. These
masks should completely cover the face, including the eyes, and have a secure
seal around the mouth and nose. When use of the mask is required, it must first be
donned outside of the vessel where it is easy to render assistance in order to
confirm that the air supply is safe. Each mask must have a backup air supply that is
completely independent of the main supply. It must also be independent of
electrical power. This supply is typically a small, certified air cylinder fastened to the
safety harness and connected to the main supply line via a special regulator that
activates when the air pressure to the mask drops below normal. The auxiliary
supply should have an alarm that alerts the user that he is on backup supply and it
should be sufficiently large to give the user 5 minutes to escape from danger.
7. Vessel Entry Permit
Before entering the vessel a vessel entry permit must be obtained. A vessel entry
permit ensures that all responsible parties know that work is being conducted inside
of a vessel and establishes a safe preparation procedure to follow in order to
prevent mistakes which could result in an accident. The permit is typically issued by
the safety engineer or by the shift supervisor. The permit should be based on a
safety checklist to be completed before it is issued. The permit should also require
the signatures of the safety engineer, the shift supervisor, and the person that
performed the oxygen, toxic and explosive gas checks on the vessel atmosphere.
Copies of the approved permit should be provided to the safety engineer, the shift
supervisor, the control room, and one copy should be posted prominently near the
manway through which the personnel will enter the vessel. The permit should be
uop 117108-6 XIV-15
renewed before each shift and all copies of the permit should be returned to the
safety engineer when the work is complete. Additional requirements or procedures
may be imposed by the refiner, but the foregoing is considered the minimum
acceptable for good safety practice.
8. Checkout Prior to Startup
The risk of exposure to hydrocarbon, toxic or poisonous gases, and catalyst dust is
low during a new unit checkout; the primary danger is nitrogen. There will be
pressure testing, line flushing, hydrotesting, and possibly chemical cleaning being
conducted in the unit and nitrogen may be used during any of these activities.
Some of the equipment may have been inventoried with nitrogen to protect the
internals from corrosion. An additional hazard is posed by operations in connected
plants that may be beyond the control of the people entering the vessel. Actions
taken at a remote location could admit nitrogen, fuel gas, steam, or other
dangerous material through a connecting process line into the vessel that is being
entered. For these reasons vessel entry procedures must still be rigorously followed
during the checkout of a new unit.
Each vessel should be blinded using blinds at each vessel nozzle. However, in the
event that many vessels are to be entered in a new unit that is isolated from other
plants, the entire unit can be isolated by installing blinds at the battery limits rather
than by individually isolating every vessel nozzle.
The oxygen content of the atmosphere inside a vessel should be rechecked before
every entry.
9. Turnaround Inspections
In turnaround inspections, the possibility that vessels will contain dangerous gases
is much higher. Equipment that has been in service must be thoroughly drained and
purged before entry. The vessel should have been steamed out, unless steam
presents a hazard to the internals, and then fresh air circulated through it until all
traces of hydrocarbons are gone. If liquid hydrocarbon remains or if odors persist
afterwards, repeat the purging procedure until the vessel is clean. The service
history of the vessel must also be investigated before entry so that appropriate
uop 117108-6 XIV-16
precautions may be taken. The service may require a neutralization step or a

special cleaning step to make the vessel safe. Internal scale can trap poisonous
gases such as hydrogen sulfide that may be released when the scale is disturbed. If
this sort of danger is present, fresh air masks and protective clothing may be
required to be worn while working inside of the equipment.
In a turnaround inspection, every vessel nozzle must be blinded with absolutely no

exceptions. There will always be residual process material at the low and high
points in the lines connecting to the vessel because it is not possible to purge them
completely clean. The blinds must all be in place at the vessel nozzles before the
vessel is purged.
Another factor to be cautious of, especially if entering a vessel immediately after the
unit has been shut down, is heat. The internals of the vessels can still be very hot
from the steam-out procedure or from operations prior to the shutdown. If that is the
case, the period of time spent working inside of the hot vessel should be limited and
frequent breaks should be taken outside of the vessel.
10. Reactor Loading
Catalyst loading has perhaps the highest risk for asphyxiation or injury because
some of the safety practices could be overlooked in the rush to complete the
loading and get the unit on stream. If the reactor being loaded is new, the main
concerns are catalyst dust and nitrogen. It is also possible that pre-sulfided
catalysts can emit small amounts of H2S so fresh-air breathing apparatus is
required. If the loading is a reload, any of the dangerous conditions described for
turnaround inspections may also be present.
During reactor loading, dust will always be present. The effect of dust on the lungs
is cumulative and even small concentrations with short exposure times should not
be tolerated. Spent catalyst dust is especially hazardous because it can contain
hydrocarbon that may be flammable or other absorbed material that may be toxic,
such as arsenic. Whenever possible, fresh air should be supplied from above the
catalyst bed and exhausted from below the bed so that the downward flow of air will
uop 117108-6 XIV-17
hold the dust down and prevent hazardous material from being carried into the
working space inside of the reactor. This might not be possible when spent catalyst
is present because of residual hydrocarbon and carbon on the spent catalyst. In
either case, the fresh air should never be supplied from below the catalyst bed
because the air may carry hazardous gases into the working space of the men
inside of the reactor.
People who are exposed to the catalyst either outside or inside the reactor should
wear OSHA/NIOSH approved dust masks or fresh air respirators. Goggles are also
recommended. Exposure to catalyst dust can be minimized greatly by staying
outside of the vessel during catalyst loading and by allowing the dust to settle
before entering the vessel for inspection after loading.
Platforming units can have another danger from iron sulfide. Iron sulfide is
pyrophoric, which means that under favorable conditions it can ignite on exposure
to air. The iron sulfide can be present on the vessel and piping walls, as loose
scale, or in the catalyst bed. When this danger could be present, special
precautions have to be taken to either keep the iron sulfide moist or to prevent the
iron sulfide from being exposed to air.
11. Reactor Unloading
Reactor unloading can present extraordinary health risks, especially to personnel

working in the reactor. During the unloading, large quantities of catalyst dust may
be generated. Additional hazards may include a contaminated or inert atmosphere
in the reactor, residual hydrocarbons or toxic forms of catalyst chemical reactants.
UOP believes that the OSHA exposure limits to catalyst chemicals will not be
exceeded if proper handling procedures are followed, and the proper protective
clothing and safety devices are used. UOP recommends that the following minimum
safety procedures be established and adhered to:
a. Personnel working in reactors being unloaded should wear a fresh air

respirator with a hood or helmet operated in a pressure demand or
other positive pressure mode, or in a continuous flow mode (NIOSH
uop 117108-6 XIV-18
Respirator Code SAFE: PD, PP, CF). This respirator should have a
primary, secondary, and emergency supply of air.
b. Personnel in the reactor should be equipped with safety harnesses

and safety lines for rescue and a means for visual, voice or signal line
communication with standby personnel, who should be strategically
located with suitable rescue equipment.
c. The OSHA regulations concerning use of respirators (29 CFR,

Subpart 1, Section 1910.134) should be read and thoroughly
understood before undertaking to place personnel in reactors during
catalyst loading and unloading operations.
d. Protective clothing and all safety devices should be thoroughly

decontaminated after each use. Worn-out, broken or defective safety
equipment and clothing should be removed from service and repaired
or replaced. Good personal hygiene after handling a catalyst or being
exposed to catalyst dust is an essential part of a responsible catalyst
safety program. Do not eat, drink, or smoke in areas where the
catalyst is being handled or where exposure to catalyst dust is likely.
E. GENERAL UNIT SAFETY NOTES
a. All equipment containing hydrogen shall be evacuated and purged

with nitrogen before opening and admitting air and after closing before
admitting hydrogen.
b. This unit and all streams leaving can contain hydrogen sulfide. Care
must be exercised when opening lines and equipment.
c. Care must be exercised when venting and draining equipment to

prevent personnel exposure to toxic aromatics.
uop 117108-6 XIV-19
F. AROMATIC HYDROCARBONS
1. Benzene
Benzene will be present in the Platforming process. Benzene is extremely toxic. A

summary of health effects which can occur from exposure to benzene appear in
“Documentation of the Threshold Limit Values (Benzene), 4th edition, 1980,
ACGIH” included at the end of this chapter.
Special Instruction: If clothing (including gloves, shoes) becomes contaminated with

benzene, the clothing should be removed immediately. Wash any skin area
exposed to benzene with soap and water. Take a complete bath if the body is
wetted with benzene. Do not wear clothing that has been wet with benzene until the
garment has been decontaminated by washing or dry cleaning. Wearing clothing
that has been wet with benzene almost assures that the person will inhale benzene
vapors over a long period of time, resulting in potential health hazards.
Avoid draining benzene to the concrete or into the sewers where it can vaporize
and create a health hazard. If benzene is accidentally spilled, flush it from the
concrete and sewer catch basin with large quantities of cold water. Do not use hot
water or steam which increases the vaporization of benzene. If you must enter an
area of high benzene vapor concentration, wear appropriate respiratory protection,
such as self-contained breathing apparatus or an air mask with an external air
supply.
Though not specifically a health hazard, an environmental problem can result from
benzene entering the sewer since benzene is much more soluble in water than any
other hydrocarbon. This places an extra load on the effluent treating system.
2. Toluene, Xylenes and Heavier Aromatics
These aromatic compounds are also present in the Platforming process. These
compounds are moderately toxic and are believed to not have the destructive effect
on the blood-forming organs as does benzene. If clothing (including gloves, shoes,
etc.) becomes wet with such aromatics, remove the clothing, bathe and put on fresh
uop 117108-6 XIV-20
clothing. Avoid breathing aromatic vapors. The NIOSH Occupational Health

Guidelines for ethyl benzene, toluene and xylene are included at the end of this
chapter.
3. Toxicity Information
Toxicity and safe handling information on most of the materials used in the unit can
be found in the following references:
a. Dangerous Properties of Industrial Materials

N. Irving Sax
Van Nostrand Reinhold
b. Patty’s Industrial Hygiene Toxicology

Craley and Craley, eds., 1979
c. ASTM D-270, “Standard Method of Sampling Petroleum and

Petroleum Products.”
d. Data Sheet D-204 “Xylene and Toluene.” Published by the National

Safety Council.
e. Data Sheet D-308 “Benzene.” Published by the National Safety

Council.
4. Minimizing Exposure to Aromatics
Operating and laboratory personnel involved in obtaining samples should wear

chemical-type safety goggles or shield, protective apron or laboratory coat, solvent-
resistant gloves, and approved respiratory protective equipment where ambient
concentrations exceed allowable limits. This protective equipment is not, however, a
substitute for safe working conditions, proper ventilation, safe sampling practices,
and proper maintenance of both operating and safety equipment. In all cases, skin
contact (especially eyes) and inhalation must be minimized.
uop 117108-6 XIV-21
Sampling liquid hydrocarbons always requires some care to limit personal exposure
and release to the atmosphere. Even greater care is needed when the liquid to be
sampled contains aromatic hydrocarbons, especially benzene. UOP’s current
design calls for flow-through sampling points that utilize closed sample containers
whenever aromatics are present.
In order to minimize vaporization, hot hydrocarbon streams must be routed through

a cooler before drawing a sample. In all sampling situations, the personnel involved
should be instructed to remain at arm’s length from the sample container and to
situate themselves upwind of the container if at all possible. These simple
precautions will greatly minimize exposure to the hydrocarbon vapors.
5. Medical Attention
The US NIOSH/OSHA guidelines attached for ethyl benzene, toluene and xylene
set forth recommendations for medical monitoring of personnel working in
environments where exposure to these materials can occur. UOP recommends that
the NIOSH/OSHA guidelines for medical monitoring be considered in development
and implementation of an occupational health monitoring program for employees
who may be exposed to toluene, xylene and/or ethylbenzene.
OSHA has recommended the following medical monitoring for employees who may
be exposed to benzene:
Preplacement and quarterly examinations, including a history that

includes past work exposures to benzene or any other hematologic
toxins, a family history of hematological neoplasms, a history of blood
dyscrasias, bleeding abnormalities, abnormal function of formed blood
elements, a history of renal or liver dysfunction, a history of drugs
routinely taken, alcoholic intake and systemic infections; complete
blood count including a differential white blood cell count; and
additional tests, where, in the opinion of the examining physician,
alterations in the components of the blood are related to benzene
exposure. (42 Federal Register 22516, 1977.)
uop 117108-6 XIV-22
UOP recommends that these guidelines be considered in development and

implementation of an occupational health monitoring program for employees who
may be exposed to benzene.
All new or current employees should be alerted to the early signs and symptoms
resulting from exposure to aromatics, and any workers experiencing such
symptoms should seek professional medical attention. In addition to the above, all
employees should be advised of the hazards involved and precautions to be taken
when working with aromatics.
OSHA has established stringent maximum exposure levels for various chemicals,
some of which may be found in UOP catalysts. These exposure limits can be found
in the Code of Federal Regulations, Title 29, Chapter 17, Subpart Z, Section
1910.1000. This information is also contained in NIOSH/OSHA Pocket Guide to
Chemical Hazards, DHEW (NIOSH) Publication No. 78-210.
G. SAFETY INFORMATION FOR UOP PLATFORMING CATALYSTS
It is during periods of opening and cleaning equipment or in sampling that bodily

exposure to UOP Platforming Catalyst can occur and caution must be exercised.
Material Safety Data Sheets should be obtained from UOP at the time of
catalyst supply and should be available to the operating personnel.
1. Potentially Hazardous Substances
The major constituent of the UOP Platforming catalyst is alumina, which is not
currently listed by OSHA as a hazardous substance. These catalysts do contain
other constituents, in lesser amounts, which might present hazards to human health
and/or the environment if handled or disposed of improperly. It is the purpose of this
safety section to provide information and recommendations that will allow safe
handling and proper disposal of these catalysts.
uop 117108-6 XIV-23
All fresh catalysts which are supplied pre-sulfided contain hydrogen sulfide. See the
“UOP Platforming Catalysts” section of Chapter II, “Process Principles” for
properties of each catalyst.
Spent Platforming catalysts may also contain additional hazardous chemicals, such
as: arsenic, carbon, hydrocarbons, iron pyrites, iron sulfide, lead, and vanadium.
The toxic properties and exposure limit of the most hazardous of these chemicals
follow:
HYDROGEN SULFIDE: Hydrogen sulfide is both an irritant and an asphyxiant. The

current OSHA permissible exposure limits are 20 ppm ceiling concentration and 50
ppm peak concentration for a maximum 10-minute exposure.
ARSENIC: Arsenic is a recognized carcinogen and can cause acute and chronic
toxicity. Symptoms of acute toxicity are somewhat dependent upon the route of
contact and can include (for ingestion or inhalation): irritation of the stomach and
intestines, with nausea, vomiting and diarrhea; liver damage; kidney damage; blood
disturbances; and allergic reactions. The OSHA 8-hour time weighted average
exposure limit to inorganic arsenic compounds is 10 micrograms per cubic meter of
air.
The greatest potential for human exposure to catalyst materials comes from catalyst
dust during reactor loading, and from dust, fumes, and vapors during catalyst
unloading operations. For the unprotected worker, hazardous dust, fumes, and
vapors may be inhaled, ingested, or contaminate the eyes and skin.
OSHA has established stringent maximum exposure levels for various chemicals,
some of which may be found in UOP catalysts. These exposure limits can be found
in the Code of Federal Regulations, Title 29, Chapter 17, Subpart Z, Section
1910.1000. This information is also contained in NIOSH/OSHA Pocket Guide to
Chemical Hazards, DHEW (NIOSH) Publication No. 78-210.
uop 117108-6 XIV-24
2. Handling Catalyst Spills and Deposited Catalyst Dust
Always wear a NlOSH-approved self-contained breathing apparatus or the

combination of toxic dust respirator-rubber frame eye goggles, protective clothing,
and gloves. Avoid cleaning methods that raise dust. Dispose of all catalyst wastes
properly in containers, which should then be labeled as to the contents and
hazards.
Do not dispose of catalyst wastes in a public water system or in the normal solid
waste. Return material to supplier for metal recovery.
3. Handling UOP Catalysts Safely
UOP believes that the OSHA exposure limits to catalyst chemicals will not be
exceeded if proper handling procedures and worker protective clothing/safety
devices are used. UOP recommends that the following minimum safety procedures
be established and adhered to:
• Handle catalysts only in a well ventilated area.
• In areas where natural ventilation is insufficient, use local mechanical

exhaust ventilation.
• Wear a NlOSH-approved toxic dust respirator with full face-piece, protective

clothing, and gloves for normal catalyst handling operations.
• Reactor loading and unloading operations present extraordinary health risks,

especially to personnel working in the reactor. During loading operations,
large quantities of catalyst dust may be generated. During unloading, the
hazards may include insert (nitrogen) atmosphere, toxic feedstock, product,
or purge materials present with the catalyst, or toxic forms of catalyst
chemicals. Personnel working in reactors should wear a supplied air
respirator with a hood or helmet, operated in a pressure-demand or other
positive-pressure mode, or in a continuous flow mode (NIOSH Respirator
uop 117108-6 XIV-25
Code SAFE: PD, PP, CF). This respirator should have a primary, secondary,
and emergency supply of air. In addition, personnel in the reactor should be
equipped with safety harnesses and safety lines for rescue and a means for
visual, voice or signal line communication with standby personnel, who
should be strategically located with suitable rescue equipment. The OSHA
regulations concerning use of respirators (29 CFR, Subpart 1, Section
1910.134) should be read and thoroughly understood before undertaking to
place personnel in reactors during catalyst loading and unloading operations.
Protective clothing and all safety devices should be thoroughly

decontaminated after each use. Worn-out, broken or defective safety
equipment and clothing should be removed from service and repaired or
replaced. Good personal hygiene after handling a catalyst or being exposed
to catalyst dust is an essential part of a responsible catalyst safety program.
Do not eat, drink, or smoke in areas where the catalyst is being handled or
where exposure to catalyst dust is likely.
uop 117108-6 XIV-26
TABLE XIV-1
Safety Topic References
OSHA, Specific Industrial Classification Codes 20-39; Subpart Z; Toxic and

Hazardous Substances Communication Act, Section 1910.1200.; 1983.
OSHA, 29 CFR Subpart 1, Section 1910.134.
Guide for Inspection of Refinery Equipment; API.
A Guide to Safety in Confined Spaces; DHHS (NIOSH) Publication No. 87-113; July
1987.
Documentation of the Threshold Limit Values; ACGIH; 4th edition; 1980.
Occupational Health Guidelines for Chemical Hazards; NIOSH/OSHA; Sept. 1978.
42 Federal Register 22516; 1977.
Sax, N. Irving; Dangerous Properties of Industrial Materials; Van Nostrand

Reinhold; 6th ed.
ASTM D-270, Standard Method of Sampling Petroleum and Petroleum Products.
Chemical Data Sheets; National Safety Council; 1984.
Code of Federal Regulations, Title 29; Chapter 17, Subpart Z; Section 1910.1000.
uop 117108-6 XIV-27
Figure XIV-1
NFPA 704 Diamond
PLT-R00-99
uop 117108-6 XIV-28
TABLE XIV-2
National Fire Protection Association

Identification of Color Coding
Color Blue: Type of Possible Injury
Signal 4: Materials which on very short exposure could cause death or

major residual injury even though prompt medical treatment was
given.
Signal 3: Materials which on short exposure could cause serious

temporary or residual injury even though prompt medical
treatment was given.
Signal 2: Materials, which on intense or continued exposure could cause

temporary incapacitation or possible residual injury unless
prompt medical treatment is given.
Signal 1: Materials which on exposure would cause irritation but only

minor residual injury even if no treatment is given.
Signal 0: Materials which on exposure under fire conditions would offer no

hazard beyond those of ordinary combustible materials.
Color Red: Susceptibility of Materials Burning
Signal 4: Materials which will rapidly or completely vaporize at

atmospheric pressure and normal ambient temperature, or
which are readily dispersed in air and which will burn readily.
Signal 3: Liquid and solids that can be ignited under almost all ambient
temperature conditions.
Signal 2: Materials that must be moderately heated or exposed to

relatively high ambient temperatures before ignition can occur.
Signal 1: Materials that must be preheated before ignition can occur.
Signal 0: Materials that will not burn.
uop 117108-6 XIV-29
TABLE XIV-2 (cont’d)
National Fire Protection Association

Identification of Color Coding
Color Yellow: Susceptibility of Release of Energy
Signal 4: Materials, which in themselves are readily capable of

detonation or of explosive decomposition or reaction at normal
temperature and pressure.
Signal 3: Materials which in themselves are capable of detonation or

explosive reaction but require a strong initiating source or which
must be heated under confinement before initiation or which
react explosively with water.
Signal 2: Materials, which in themselves are normally unstable and

readily undergo violent chemical change but do not detonate.
Also materials, which may react violently with, water or which
may form potentially explosive mixtures with water.
Signal 1: Materials which in themselves are normally stable, but which

can become unstable at elevated temperatures and pressures
or which may react with water with some release of energy but
not violently.
Signal 0: Materials, which in themselves are normally, stable, even under

fire exposure conditions and which are not reactive with water.
uop 117108-6 XIV-30
Figure XIV-2
uop 117108-6 XIV-31
Figure XIV-3
H2S Poisoning
Toxicity of Hydrogen Sulfide to Humans
uop 117108-6 XIV-32
Fixed-Bed Platforming – General Operating Manual Equipment Evaluation
XV. EQUIPMENT EVALUATION
While the majority of UOP unit performance tests are conducted in order to satisfy
contractual agreements between UOP and the customer, the potential significance
of a mechanical evaluation is much greater. From the information generated and
collected during an evaluation test, the refiner has the means to assess the
potential of the unit, to plan for future de-bottlenecking and to optimize refinery
operations.
The following description includes data necessary for contractual tests plus
information required for evaluating hydraulic systems, heater, exchangers, pumps,
compressors, etc. A large amount of the information would be gathered in any case
(flows, temperatures, pressures, samples, etc.), and much of the rest can be
obtained on a one-time basis.
However, the test information may not be of much value unless the following criteria
are met:
1. The unit must weight balance. The weight balance must be consistently
between 98 and 102 wt.%, and preferably between 99 and 101 wt.%.
2. All operations must be steady, including quality of charge stock, product

specifications, exchanger outlet temperatures, etc.
3. Sufficient sample containers and laboratory analytical time must be available,

including containers for sample shipment to UOP (optional).
4. Sufficient technical manpower must be available to gather data and take

samples, in addition to those normally available for operating the unit.
5. The instrument technicians will be required before and during the

performance test in order to calibrate the instrumentation daily during the
test.
uop 117108-6 XV-1
The following list indicates the amount and type of information required:
1. Flows: All process flows into and out of the unit, and also intermediate
streams such as recycle gas and reflux, utility flows such as steam, BFW,
instrument and plant air, cooling water, fuel oil and gas, power consumption.
2. Temperatures: All process temperatures, including those not usually

measured, but provided for by thermowells, heater and exchanger
temperatures, storage tank temperatures.
3. Pressures: All process pressures, including single gauge hydraulic surveys

on reactor systems and columns, pump and compressor suction and
discharge pressures.
4. Levels: Particularly storage tank levels for feed and products, chemical
consumption (chloride, alcohol, Unicor, BFW chemicals, etc.), process levels
in columns, drums, receivers, compressor seal oil and/or cylinder oil losses,
etc.
5. Samples: Samples of feed and products, intermediate streams such as

reflux, recycle gas, fuel gas and oil, flue gas, sour water, catalyst.
Why is all this data required? There are many reasons, but those used most
frequently are to establish a unit base line performance, to predict the unit’s
maximum capacity, and to identify where the unit bottlenecks are. Another reason is
for UOP’s Engineering Department to evaluate actual unit and equipment
performance compared to design. It is suggested that the data is accumulated at
one time (during the performance run for contract demonstration), and that
evaluation of the equipment is made later. It is important, however, to have all the
necessary information available. To this end, the following lists and data sheets are
given to use as guides in collecting data.
uop 117108-6 XV-2
General
Ambient air conditions: temperature

relative humidity
barometric pressure
wind velocity and direction
(shown on rough plot plan)
General description of unit – includes process flow diagram.
Unit system used (e.g. USA, Imperial, Metric) and definition of any
uncommon units (e.g. kPa) and Standard Conditions (0°C, 760 mm; 60°F,
14.7 psia, etc.)
Guarantee
Data as required for Guarantee Agreement.
Complete weight balance, including meter correction factors.
Exchangers
Flow through exchangers on both sides (gas and liquid), composition and
mass flow.
Temperature in and out on both sides, also between shells, bundles.
Pressures in and out on both sides, if possible.
If air coolers; air temperature out, air velocity out, motor amps, note any belt
slippage, variable pitch positions, louver positions, etc.
In preparing data, submit overall heat transfer coefficient, specifics on
exchangers.
uop 117108-6 XV-3
Heaters
Process flows (volume and mass, avg. mol wt., composition, etc.)
Process pressures in and out
Process temperatures in and out
Flue gas composition
Fuel gas composition
Fuel gas rate, pressure, temperature
Fuel oil composition (Specific Gravity, distillation, viscosity, metals, sulfur)
Fuel oil rate, temperature
Steam pressure for oil atomization
Temperatures at bridgewall, any intermediate convection points, stack, tube

skins, firebox skins, fuel oil, preheat air
Temperature of BFW coils in and out, superheated steam pressure and

temperature
Steam generation rate, pressure, temperature
BFW pressure, rate, temperature
Draft, each cell

Basic data on process coils (size, number, material, layout sketch, etc.)
Basic data on convection coils (size, number, material, layout sketch, etc.)
uop 117108-6 XV-4
Burner data (rating, design release, etc.)
Need sufficient data to calculate heat flux from process side, heat flux from
fire side, calculate steam balance, calculate total heat release, calculate
heater efficiency.
Chemical Consumption
PDC or other organic chloride
H2O or alcohol
BFW chemicals
Unicor
Other
Hydraulic Survey and Process Separations
Single gauge pressure survey of every point available on reactor circuit
All control valve positions (including fuel, BFW, etc.)
Pump and compressor motor amps
Pump suction, discharge pressure, flow rates, composition, temperatures,

with manufacturer’s curve data for comparison
Compressor suction, discharge pressures, flow rates, composition,

temperatures, with manufacturer’s curve data for comparison
Single gauge pressure survey of fractionation systems, with sufficient data to

calculate internal reflux, number of theoretical trays, etc.
uop 117108-6 XV-5
Samples of separator liquid and vapor and recontactor liquids and vapors for
phase separation data
Utility consumption/production data:
Steam (all pressures)

Air (Plant and Inst.)
N2
Cooling water
BFW
Utility water
Steam condensate
Process condensate
Samples (typical)
Unit charge
Separator liquid
Separator gas
First stage recontactor gas
First stage recontactor liquid
Second stage recontactor gas
Second stage recontactor liquid
DC4 ovhd gas (repeat for other columns as required)
DC4 ovhd liquid (even if only reflux) (repeat for other columns as required)
DC4 bottoms (repeat for other columns as required)
Catalyst – fresh on-stream catalyst sample(s) if possible
Catalyst – spent on-stream catalyst sample(s) if possible
Flue gas for each cell, if divided
Fuel gas
Fuel oil
uop 117108-6 XV-6
Comments:
It is not necessary to obtain all the data at one time. It is acceptable to run various
segments of the survey at different times, and one possible period would be during
the line-out period prior to the guarantee test period. Data collections for heater and
air-fin exchangers, in particular, are lengthy processes, and may be done at any
time when the unit is stable, provided all the required process data is available.
If the data are collected, it obviously is necessary to have a good weight balance
(100 + 2%) for the information to be meaningful. For most pieces of information, if
the unit is lined out, spot data will be sufficient, rather than long-term averaged
data. It might be possible, taking into consideration, to obtain the spot data in
sections spread out during the guarantee test (one exception is column
performance).
In presenting the data, some order should be kept. UOP suggests keeping sections
by type of information, i.e., one section on the guarantee test results, one on
heaters, one on exchangers, one on hydraulics, etc. Attached are some typical
summary sheets for his purpose.
uop 117108-6 XV-7
COLUMN SUMMARY page_______________________________

date_______________________________
Item No.: ____________________________ by_______________________________
Service: _________________________________________________________________
Type of Operation: _________________________________________________________
No. of Trays: ________________ Reflux Ratio: ________________________________
Type of Trays: ____________________________________________________________
Net
Off Ovhd.
Feed Reflux Gas Btms. Liquid Other
Mass Flow,________ _______ _______ ________ _______ _______ _______

Temperature, ° _____ _______ _______ ________ _______ _______ _______
Pressure, _________ _______ _______ ________ _______ _______ _______
Composition, ______ % _______ _______ ________ _______ _______ _______
H2 _______ _______ ________ _______ _______ _______
N2 _______ _______ ________ _______ _______ _______
H2S _______ _______ ________ _______ _______ _______
H2O _______ _______ ________ _______ _______ _______
C1 _______ _______ ________ _______ _______ _______
C2 _______ _______ ________ _______ _______ _______
C3 _______ _______ ________ _______ _______ _______
iC4 _______ _______ ________ _______ _______ _______
nC4 _______ _______ ________ _______ _______ _______
iC5 _______ _______ ________ _______ _______ _______
nC5 _______ _______ ________ _______ _______ _______
C6+ _______ _______ ________ _______ _______ _______
Avg. Mol. Wt. _______ _______ ________ _______ _______ _______
Gravity _______ _______ ________ _______ _______ _______
Distillation, ° _______ _______ _______ ________ _______ _______ _______
IBP _______ _______ ________ _______ _______ _______
5% _______ _______ ________ _______ _______ _______
10% _______ _______ ________ _______ _______ _______
20% _______ _______ ________ _______ _______ _______
30% _______ _______ ________ _______ _______ _______
40% _______ _______ ________ _______ _______ _______
50% _______ _______ ________ _______ _______ _______
60% _______ _______ ________ _______ _______ _______
70% _______ _______ ________ _______ _______ _______
80% _______ _______ ________ _______ _______ _______
90% _______ _______ ________ _______ _______ _______
95% _______ _______ ________ _______ _______ _______
EP _______ _______ ________ _______ _______ _______
(Sketch system showing flows, P, T, Q on separate page) __________________________

Weight balance ______________________ Heat balance ________________________
Deviations from UOP Specifications: ___________________________________________
uop 117108-6 XV-8
CENTRIFUGAL COMPRESSOR DATA

page _______________________________
date _______________________________
Item No.: _____________________________ by _______________________________
Service: __________________________________________________________________
Manufacturer: _____________________________________________________________
Type, Model: ______________________________________________________________
No. of Stages: _____________________________________________________________
OPERATING CONDITIONS/PERFORMANCE
Flow Rate: ____________ Suction Temperature: ________ °F
Suction Pressure: ____________ psig Discharge Temperature: ________ °F
Discharge Pressure: ____________ psig Power: ________ hp
Differential Head: ____________ MW: ________
Polytropic η: ____________
Operating Speed: ____________ rpm
Type of Seal: _________________________________________

Lube/Seal Oil System: ________________________________________
Buffer Gas: (yes/no) Buffer Gas Rate: ______________ SCFH
Automatic Surge Control: (yes/no)
DRIVER
Motor Manufacturer: _________________________________________
Rating: ____________________ Service Factor: ______________
Insulation Class: ____________________ Voltage/phase/cycle:
Turbine Manufacturer:_________________________________________
Speed: ______________ Steam Supply: _______ psig ______ °F
Steam Rate: ______________ Steam Exhaust: _______ psig ______ °F
Gear Manufacturer: _________________________________________

Rating: ____________________ Service Factor: _____________
Type: ____________________ Power Loss: _____________
Deviations from UOP Specification: ____________________________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
uop 117108-6 XV-9
RECIPROCATING COMPRESSOR DATA

page ___________________________
date ___________________________
Item No.: ______________________________ by ___________________________
Service: _______________________________
Manufacturer:___________________________ Cylinder Lubrication: ____________
Type, Model: ___________________________ Clearance Pockets: (yes/no)
No. of Stages, No. of Cylinders: ___________ Sparing Description: ____________
OPERATING CONDITIONS/PERFORMANCE
Flow Rate: ____________ Suction Temperature: _________ °F
Suction Pressure: ____________ psig Discharge Temperature: _________ °F
Discharge Pressure: ____________ psig HP/stage: _________ hp
MW: ____________
Operating Speed: ____________ rpm Cylinder Diameters: _________

Piston Speed: ____________ ft/s # of Suction/Discharge Valves: _________
Actual Rod Loadings, T/C: ________________________________________ lbf
Max Allowable Rod Loadings, T/C: ________________________________________ lbf
DRIVER
Motor Manufacturer: ________________________________________
Insulation Class: ____________________ Voltage/phase/cycle:
Turbine Manufacturer: ________________________________________

Speed: _______________ Steam Supply: _______ psig ______ °F
Steam Rate: _______________ Steam Exhaust: _______ psig ______ °F
Gear Manufacturer: ________________________________________

Type: ____________________ Power Loss: _____________
Deviations from UOP Specification: ___________________________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
uop 117108-6 XV-10
CONTROL VALVE SUMMARY

page ___________________________
date ___________________________
Item No.: ______________________________ by ___________________________
Service: __________________________________________________________________
Description of Valve: _____________________ Design CV: ______________________
Mfgr. and Catalog No.: ______________________________________________________
Positioner? _______________________________________________________________
Actual Design
Percent open (valve position) ____________
Flow rate: ______________________ ____________ __________
Upstream pressure: ______________________ ____________ __________
Downstream pressure: ______________________ ____________ __________
Flowing temperature: ______________________ ____________ __________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
uop 117108-6 XV-11
AIR FIN COOLER SURVEY

page_______________________________
date_______________________________
Item No.: ____________________________ by_______________________________
Service: _________________________________________________________________
Manufacturer:_____________________________________________________________
Type, Model: _____________________________________________________________
No. of Bundles: _______________________ No. of Passes: _____________________
No. of Tubes per Pass: _________________ Fans/bundle: ______________________
Tube Size_______________ ID x_______________ Gauge x _____________ Length
Piping Geometry: ______________________ Type*:____________________________
Overall Heat Transfer Coefficient: _____________________________________________
Pressure Temperature
Inlet ______________ _____________
Outlet ______________ _____________
Air In ______________ _____________

Out ______________ _____________
No. fans on__________________________ Pitch control ________________________
Louver position_______________________
Air Process
Mass flow ______________ _____________
Q (calc.) ______________ _____________
Composition, ____ %
H2 _____________
N2 _____________
H2S _____________
H2O _____________
C1 _____________
C2 _____________
C3 _____________
iC4 _____________
nC4 _____________
iC5 _____________
nC5 _____________
C6+ _____________
Avg. Mol. Wt. _____________
Relative Humidity ______________
uop 117108-6 XV-12
Gravity
Distillation, ° ______
IBP _____________
10% _____________
30% _____________
50% _____________
70% _____________
90% _____________
EP _____________

________________________________________________________________________
________________________________________________________________________
*Include sketch of piping geometry if different from UOP standard practice types.
uop 117108-6 XV-13
Figure XV-1
Manifold Piping Requirements for Air Cooled Items
uop 117108-6 XV-14
FLOW METER SUMMARY

page ___________________________
date ___________________________
Item No.: ______________________________ by ___________________________
Service: __________________________________________________________________
Type of Fluid: __________________________ Normal Units of Flow:_______________
_____________________________________
Type of Meter:_____________________________________________________________
Meter Reading: ____________________________________________________________

Pressure _________________
Temperature _________________
Sp. Gr.** _________________
Meter Factor _________________
Corrected Flow Rate _________________
Mass Flow Rate _________________
Avg. mol. wt. _________________
Molar Flow Rate _________________
**Sketch piping layout, showing distances in nominal pipe IDs.
uop 117108-6 XV-15
HEAT EXCHANGER SURVEY

page_______________________________
date_______________________________
Item No.: ____________________________ by_______________________________
Service: _________________________________________________________________
Manufacturer:_____________________________________________________________
Type, Model: _____________________________________________________________
No. of Bundles: ___________________________________________________________
No. of Passes/Bundle: __________________ Tubes per Pass: ____________________
Tube Size_______________ ID x_______________ Gauge x _____________ Length
Heat Exchange Surface Area/Bundle: __________________________________________
Piping Geometry (sketch if necessary): _________________________________________
Length of Service: _________________________________________________________
Design Heat Transfer Coefficient: _____________________________________________
Stream Pressure Temperature

Shell Side Inlet A ______________ _____________
Outlet ______________ _____________
Tube Side Inlet B ______________ _____________

Outlet ______________ _____________
Q (calc.) Shell side ______________

Q (calc.) Tube side ______________
Composition, _____ % A B
H2 ______________ ______________
N2 ______________ ______________
H2S ______________ ______________
H2O ______________ ______________
C1 ______________ ______________
C2 ______________ ______________
C3 ______________ ______________
iC4 ______________ ______________
nC4 ______________ ______________
iC5 ______________ ______________
nC5 ______________ ______________
C6+ ______________ ______________
Mass Flow ______________ ______________
Avg. Mol. Wt. ______________ ______________
uop 117108-6 XV-16
Gravity
Distillation, ° ______
IBP ______________ ______________
10% ______________ ______________
30% ______________ ______________
50% ______________ ______________
70% ______________ ______________
90% ______________ ______________
EP ______________ ______________

________________________________________________________________________
________________________________________________________________________
uop 117108-6 XV-17
PLATFORMING UNIT HEATER AND COMBINED FEED EXCHANGER DATA
Please send PODS data plus the following:
Flow Rates
Fresh Feed (BPD) _______________________________
Recycle Gas (MMSCFD) _______________________________
RON Clear _______________________________
Compositions
Fresh Feed Recycle Gas
SpGr or API ____________________ Molecular Wt ____________________
D-86 Dist, (°F) Chromatograph, (Mol%)
IBP ____________________ H2 _____________________
10% ____________________ C1 _____________________
30% ____________________ C2 _____________________
50% ____________________ C3 _____________________
70% ____________________ C4 _____________________
90% ____________________ C5 _____________________
EP ____________________ C 6+ _____________________
Pressures (psig)
Separator/Compressor Suction ___________________
Compressor Discharge ___________________
Last Reactor Outlet ___________________
Temperatures (°F)
BWT (Flue Gas from
Heaters Inlet Outlet Radiant Section)
Charge Heater _______________ ______________ _____________

Int Heater No. 1 _______________ ______________ _____________
Int Heater No. 2 _______________ ______________ _____________
Int Heater No. 3 _______________ ______________ _____________
Last Reactor _______________ ______________ _____________
uop 117108-6 XV-18
Combined Feed Exch Exch Total

Exchangers "A" "B"
Hot Side
Rx Effluent In ______________ ______________ _____________
Rx Effluent Out ______________ ______________ _____________
Cold Side
Liquid In ______________ ______________ _____________
Recycle Gas In ______________ ______________ _____________
Comb Feed In ______________ ______________ _____________
Comb Feed Out ______________ ______________ _____________
Exchanger Type (S&T or Packinox) ______________________________________

Number of Exchangers ______________ Manufacturer _________________
Tube Length, ft ______________ Number of Tubes _________________
Shell Diameter, in. ______________ Tube OD, in. _________________
Oxygen Fuel Gas

Readings Flow
Heaters Mole % SCFH
Charge Heater ______________ ______________

Int Heater No. 1 ______________ ______________
Int Heater No. 2 ______________ ______________
Int Heater No. 3 ______________ ______________
Fuel Composition, Mole %
H2 ______________
N2 ______________
H2S ______________
H2O ______________
C1 ______________
C2 ______________
C3 ______________
iC4 ______________
nC4 ______________
iC5 ______________
nC5 ______________
C6+ ______________
uop 117108-6 XV-19
HEATER SURVEY
page_______________________________
date_______________________________
Item No.: ____________________________ by_______________________________
Service: _________________________________________________________________
Manufacturer:_____________________________________________________________
Type, Model: _____________________________________________________________
No. of Passes: ________________________ Tubes per Pass: ____________________
Tube Size_______________ ID x_______________ Wall x _______________ Length
Geometry (Process): _______________________________________________________
Geometry (Flue Gas): ______________________________________________________
Stream Pressure Temperature

Radiant Inlet A ______________ _____________
Outlet ______________ _____________
Convection I Inlet B ______________ _____________

Outlet ______________ _____________
Convection II Inlet C ______________ _____________

Outlet ______________ _____________
Convection III Inlet D ______________ _____________

Outlet ______________ _____________
Fuel Gas E ______________ _____________
Fuel Oil F ______________ _____________
Flue Gas Under Convection I G ______________ _____________
Flue Gas Under Convection II H ______________ _____________
Flue Gas Under Convection III I ______________ _____________
Flue Gas Under Stack Damper J ______________ _____________
Flue Gas Above Floor K ______________ _____________
uop 117108-6 XV-20
HEATER SURVEY
page _______________________________
date _______________________________
by _______________________________
G,H,
Stream A B C D E F I,J,K
Mass Flow, _______ ____ ______ _____ ____ _____ _____
Composition, _____ % ____ ______ _____ ____ _____ _____ ______
H2 ____ ______ _____ ____ _____ _____ ______
N2 ____ ______ _____ ____ _____ _____ ______
O2 ____ ______ _____ ____ _____ _____ ______
CO ____ ______ _____ ____ _____ _____ ______
CO2 ____ ______ _____ ____ _____ _____ ______
H2S ____ ______ _____ ____ _____ _____ ______
SO2 ____ ______ _____ ____ _____ _____ ______
C1 ____ ______ _____ ____ _____ _____ ______
C2 ____ ______ _____ ____ _____ _____ ______
C3 ____ ______ _____ ____ _____ _____ ______
iC4 ____ ______ _____ ____ _____ _____ ______
nC4 ____ ______ _____ ____ _____ _____ ______
iC5 ____ ______ _____ ____ _____ _____ ______
nC5 ____ ______ _____ ____ _____ _____ ______
C6-205°C (400°F) ____ ______ _____ ____ _____ _____ ______
205°C (400°F)+ ____ ______ _____ ____ _____ _____ ______
Avg. Mol. Wt. ____ ______ _____ ____ _____ _____ ______
Gravity ____ ______ _____ ____ _____ _____ ______
Viscosity ____ ______ _____ ____ _____ _____ ______
Total Sulfur,_______ ____ ______ _____ ____ _____ _____ ______
Metals, __________ ____ ______ _____ ____ _____ _____ ______
Q (calc.) Absorbed ____ ______ _____ ____ ______
Q (calc.) Released _____ _____
Heater Gross Efficiency ______
Excess Air, % ______
Tube Skin Temps:,° _____
Burner Pressure ______________________ % of Rating _____________________
Provide sketch showing piping and controls for process piping.

________________________________________________________________________
________________________________________________________________________
uop 117108-6 XV-21
CENTRIFUGAL PUMP SURVEY

page_______________________________
date_______________________________
Item No.: ____________________________ by_______________________________
Service: _________________________________________________________________
Manufacturer:_____________________________________________________________
Type, Model: _____________________________________________________________
No., Size and Style (Mfgrs. Designation) ________________________________________
________________________________________________________________________
Suction ______________ _____________
Discharge ______________
Other Information
Rated Flow (STP) _____________ Seal Type? Single, Tandem, Double, Bellow
Sp. Gr. _____________ Spillback? Yes/No
Viscosity _____________ NPSHR? _________________________
Static Suction Head _____________ Suction Specific Speed: ________________
Speed _____________
Differential Head (flowing condition) ________________________________________
Driver Type: ___________________________________________________________

Manufacturer: ___________________________________________________________
No., Size, Rating and Style (Mfgrs. designation): _________________________________
Rating: __________________ Insulation Class: _________________
Service Factor: __________________ Voltage/Phase/Cycle: _________________
Motor:
Power consumption ______________
Speed ______________
Turbine:
Steam consumption ______________ Pressure Temperature
Steam supply ______________ ______________
Steam exhaust ______________ ______________
Speed ______________
Supply copy of Mfgrs. pump curve and plot operating point.

Deviations from UOP Specification: ___________________________________________
________________________________________________________________________
________________________________________________________________________
uop 117108-6 XV-22
REACTOR SECTION PRESSURE SURVEY

(delete unused equipment)
page _______________________________
date _______________________________
by _______________________________
Feed pump discharge ______________ _____________
Feed CV Inlet ______________ _____________
Outlet ______________ _____________
Recycle Gas Dryer Inlet ______________ _____________

Outlet ______________ _____________
Combined Feed Exchanger Inlet ______________ _____________

Intershell A ______________ _____________
B ______________ _____________
C ______________ _____________
D ______________ _____________
E ______________ _____________
F ______________ _____________
Outlet ______________ _____________
Water Injection Pump Discharge ______________ _____________

Chemical Injection Pump Discharge ______________ _____________
Charge Heater Inlet ______________ _____________

Outlet ______________ _____________
No. 1 RX Inlet ______________ _____________

Outlet ______________ _____________
No. 1 Interheater Inlet ______________ _____________

Outlet ______________ _____________
No. 2 RX Inlet ______________ _____________

Outlet ______________ _____________
uop 117108-6 XV-23
page_______________________________
date_______________________________
by_______________________________
Outlet ______________ _____________
No. 3 RX Inlet ______________ _____________

Outlet ______________ _____________

Outlet ______________ _____________
No. 4 RX Inlet ______________ _____________

Outlet ______________ _____________

Outlet ______________ _____________
No. 5 RX Inlet ______________ _____________

Outlet ______________ _____________
Combined Feed Exchanger Inlet ______________

IntershellG ______________
H ______________ _____________
I ______________ _____________
J ______________ _____________
K ______________ _____________
L ______________ _____________
Outlet ______________ _____________
Fractionator Feed/Reactor
Effluent Exchanger Inlet ______________
Intershell A ______________ _____________
B ______________ _____________
C ______________ _____________
Outlet ______________ _____________
uop 117108-6 XV-24
page _______________________________
date _______________________________
by _______________________________
Reactor Effluent Finfan Inlet ______________ _____________
Outlet ______________ _____________
Reactor Effluent Condenser Inlet ______________ _____________

Intershell A ______________ _____________
B ______________ _____________
C ______________ _____________
D ______________ _____________
E ______________ _____________
F ______________ _____________
Outlet ______________ _____________
Reactor Effluent Trim Cooler Inlet ______________ _____________

Intershell A ______________ _____________
B ______________ _____________
Outlet ______________ _____________
Separator ______________ _____________
Separator Pump Suction ______________ _____________

Discharge ______________ _____________
Separator Liquid CV Inlet ______________ _____________

Discharge ______________ _____________
SeparatorOffgas CV Inlet ______________ _____________

Discharge ______________ _____________
SeparatorGas to Booster Compressor ______________ _____________
Recycle Compressor A Suction ______________ _____________

Discharge ______________ _____________
Recycle Compressor B Suction ______________ _____________

Discharge ______________ _____________
Recycle Gas to CFE ______________ _____________
uop 117108-6 XV-25
page_______________________________
date_______________________________
by_______________________________
FOR CCR PLATFORMING UNITS
First Stage Booster Gas Compressor Suction ______________ _____________
Discharge ______________ _____________
First Stage Cooler Inlet ______________ _____________

Outlet ______________ _____________
First Stage Recontact Drum ______________ _____________
First Stage Spillback to CV ______________ _____________

from CV ______________ _____________
First Stage Pump Suction ______________ _____________

Discharge ______________ _____________
Second Stage
Booster Gas Compressor Suction ______________ _____________
Discharge ______________ _____________
Second Stage Cooler Inlet ______________ _____________

Outlet ______________ _____________
Second Stage Recontact Drum ______________ _____________
Second Stage Spillback to CV ______________ _____________

from CV ______________ _____________
Net Gas Chloride Treater Inlet ______________ _____________

Outlet ______________ _____________
Net Gas to CV ______________ _____________

from CV ______________ _____________
uop 117108-6 XV-26
page _______________________________
date _______________________________
by _______________________________
FOR FIXED-BED PLATFORMING UNITS
HPS Cooler Inlet ______________ _____________
Interstage A ______________ _____________
B ______________ _____________
C ______________ _____________
D ______________ _____________
Outlet ______________ _____________
High Pressure Separator ______________ _____________
HPS Pump Suction ______________ _____________

Discharge ______________
HPS Liquid CV Inlet ______________ _____________

Discharge ______________ _____________
HPS Offgas CV Inlet ______________ _____________

Discharge ______________ _____________
HPS Gas to Booster Compressor ______________ _____________
Booster Compressor Suction ______________ _____________

Discharge ______________ _____________
Spillback to CV ______________ _____________
from CV ______________ _____________
uop 117108-6 XV-27

Fixed-Bed Platforming General Operating Manual Rev 6 PDF

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uop

II. PROCESS PRINCIPLES

III. PROCESS VARIABLES

uop 117108-6 Page 1

IV. PROCESS FLOW AND CONTROL

uop 117108-6 Page 2

B. Cleaning and Servicing of Utility Systems

VII. NORMAL STARTUP

uop 117108-6 Page 3

VIII. NORMAL OPERATIONS

uop 117108-6 Page 4

XI. NORMAL SHUTDOWN

XII. EMERGENCY PROCEDURES

XIII. SPECIAL PROCEDURES

uop 117108-6 Page 5

16. Regeneration Report

uop 117108-6 Page 6

B. Hydrogen Sulfide Poisoning

XV. EQUIPMENT EVALUATION

uop 117108-6 Page 7

A. THE PLATFORMING PROCESS

uop 117108-6 I-1

Due to the increased sensitivity of these catalysts to feedstock contaminants and

Non-CCR Platforming units were then called “Fixed-Bed” Platforming units to

B. THE GENERAL OPERATING MANUAL

It is important to remember that UOP-issued procedures are general in nature. It is

uop 117108-6 I-2

1. Chemical Abbreviations and Symbols

C1 1 carbon number hydrocarbon (methane)

Cl, Cl- chlorine, chloride

uop 117108-6 I-3

uop 117108-6 I-4

R saturated 5-carbon-number ring compound (a cyclopentane)

—R a radical or side chain (for example - CH2CH3 an ethyl radical)

uop 117108-6 I-5

2. General Platforming Unit Terms

Å — angstrom, 10-10 meter

BPD — barrels per day

caustic — sodium hydroxide

EOR — end of run

F-1 octane — Research octane (ASTM D-2699)

uop 117108-6 I-6

H2/HC ratio — hydrogen/hydrocarbon ratio (moles of recycle hydrogen

IBP — initial boiling point

lean naphtha — a naphtha high in paraffin content, low in naphthene

m or M — prefix for thousand

PONA — paraffin, olefin, naphthene, aromatic breakdown of a

Rich naphtha — a naphtha high in naphthene content, low in paraffin

uop 117108-6 I-7

scallop — part of radial reactor internals

WABT — weighted average bed temperature (the sum of the

uop 117108-6 I-8

UOP P&I DIAGRAM ABBREVIATIONS

First Letter Subsequent Letters

uop 117108-6 I-9

FIF FLOW INDICATOR FLOAT TYPE

LG-B GAUGE GLASS TUBULAR TYPE – VISIBLE LENGTH SHOWN

LG-R GAUGE GLASS REFLEX TYPE – VISIBLE LENGTH SHOWN

LG-T GAUGE GLASS THROUGH VIEW TYPE – VISIBLE LENGTH SHOWN

OGV OMIT GAUGE VALVES

RTD RESISTANCE TEMPERATURE DETECTOR

WHEN INSTRUMENTS ARE DESIGNATED WITH AN ALARM

uop 117108-6 I-10