Technical Specification: Isomerization Unit

1. Introduction:

The following technical specification outlines the requirements for an Isomerization Unit (ISOM) used
in petroleum refining operations. The purpose of the ISOM unit is to convert straight-chain
hydrocarbons, primarily n-pentane and n-hexane, into their corresponding branched-chain isomers.
The isomerization process improves the octane rating of gasoline and enhances the blending
properties of the final product.

2. Capacity:

The ISOM unit shall have a processing capacity of [insert desired capacity] barrels per day (BPD). The
capacity can be adjusted based on the specific refining needs and feedstock availability.

3. Feedstock:

The primary feedstock for the ISOM unit is typically a C5/C6 cut, comprising n-pentane and n-hexane.
The feedstock should have a minimum purity of [insert minimum purity] weight percent n-pentane
and n-hexane.

4. Isomerization Reaction:

The isomerization process involves the conversion of straight-chain hydrocarbons into branched
isomers, typically utilizing a catalyst and operating under specific process conditions. The general
isomerization reaction equations are as follows:

a. Isomerization of n-pentane:

n-C5H12 -> iso-C5H12

b. Isomerization of n-hexane:

n-C6H14 -> iso-C6H14

The catalyst used in the isomerization process is typically a noble metal, such as platinum or
palladium, supported on a suitable substrate.

5. Process Conditions:

The ISOM unit shall operate under the following process conditions:
 a. Operating pressure: [insert operating pressure] bar (gauge)

b. Operating temperature range: [insert operating temperature range]°C

c. Catalyst bed temperature: [insert catalyst bed temperature]°C

d. Hydrogen-to-hydrocarbon ratio: [insert hydrogen-to-hydrocarbon ratio]

e. Contact time: [insert contact time] seconds

6. Equipment:

The ISOM unit shall consist of the following key equipment:

a. Reactor: Designed to house the catalyst and facilitate the isomerization reactions.

b. Feedstock and product storage tanks: To store the feedstock and the resulting isomerized
product.

c. Heat exchangers: For heat recovery purposes within the unit.

d. Compressors: For hydrogen circulation and pressure control.

e. Pumps: For product handling and circulation within the unit.

7. Safety Considerations:

The ISOM unit shall comply with all applicable safety standards and regulations. It should include
safety features such as pressure relief valves, emergency shutdown systems, fire detection and
suppression systems, and appropriate material selection for hazardous areas.

8. Control System:

The ISOM unit shall have a robust control system that includes process control instrumentation,
distributed control systems (DCS), and advanced process control strategies to ensure safe and
efficient operation of the unit. The control system should provide real-time monitoring, alarms, and
interlocks for process variables.

9. Environmental Considerations:

The ISOM unit shall include measures to minimize environmental impacts, such as the installation of
suitable emissions control systems, vapor recovery units, and wastewater treatment facilities. It
should comply with applicable environmental regulations and standards.

10. Documentation and Training:

The supplier shall provide comprehensive documentation, including process flow diagrams,
equipment datasheets, piping and instrumentation diagrams (P&IDs), and operation and
maintenance manuals. Additionally, the supplier shall provide training to the operating personnel on
the ISOM unit's operation, maintenance, and safety procedures.

11. Project Timeline:

The supplier shall provide an estimated timeline for the design, procurement, construction, and
commissioning of the ISOM the timeline should consider factors such as equipment fabrication, site
preparation, civil works, and other project-specific considerations.

Operating Manual: Isomerization Unit

1. Introduction:

This operating manual provides guidelines for the safe and efficient operation of the Isomerization
Unit (ISOM). It outlines the key operational procedures, safety considerations, and maintenance
requirements. It is essential to read and understand this manual before operating the ISOM unit.

2. Safety Precautions:

a. Follow all safety procedures and guidelines as outlined in the site's general safety manual.

b. Ensure proper personal protective equipment (PPE) is worn at all times.

c. Familiarize yourself with the location and operation of emergency shutdown systems, fire
suppression systems, and first aid equipment.

d. Do not operate the unit beyond the specified process conditions and operating limits.

e. Regularly inspect and maintain safety equipment, including pressure relief valves and emergency
shutdown devices.

3. Start-up Procedure:

a. Ensure all valves and equipment are in the correct position as per the P&ID and operating manual.

b. Conduct a pre-startup safety check, including a visual inspection of the unit for leaks, loose
connections, or abnormal conditions.

c. Start the necessary pumps, compressors, and other auxiliary equipment as per the startup
sequence provided in the operating manual.

d. Gradually introduce the feedstock into the system and adjust the operating parameters as per the
specified process conditions.

4. Normal Operation:

a. Monitor the process variables such as temperature, pressure, flow rates, and hydrogen-to-
hydrocarbon ratio continuously using the distributed control system (DCS).
b. Regularly inspect the catalyst bed and ensure proper catalyst activity and stability.

c. Maintain hydrogen purity and circulation within the specified range.

d. Monitor the product quality and adjust the operating parameters as required to meet the desired
isomerization targets.

e. Follow the operating guidelines and procedures for catalyst regeneration or replacement, as
recommended by the equipment manufacturer.

5. Shutdown Procedure:

a. Follow the shutdown sequence provided in the operating manual.

b. Safely depressurize the system and isolate the feedstock supply.

c. Perform necessary purging and flushing procedures to remove any residual hydrocarbons and
hydrogen.

d. Conduct a post-shutdown inspection to ensure all equipment is properly secured, isolated, and in
a safe condition.

6. Maintenance and Troubleshooting:

a. Perform regular maintenance tasks as outlined in the maintenance schedule provided by the
equipment manufacturer.

b. Keep accurate records of maintenance activities, including inspections, repairs, and replacement
of components.

c. Follow the troubleshooting procedures provided in the operating manual to diagnose and rectify
any operational issues.

d. Ensure proper storage and handling of catalyst materials and adhere to the recommended catalyst
regeneration or replacement schedule.

7. Emergency Situations:

a. In the event of an emergency, activate the emergency shutdown systems immediately.

b. Follow the site's emergency response plan and evacuate if necessary.

c. Report any incidents or abnormal conditions to the designated personnel and follow their
instructions.

8. Documentation and Recordkeeping:

a. Maintain detailed operating logs, including process parameters, maintenance activities, and any
deviations or abnormalities observed during operation.
b. Keep records of product quality, yields, and consumption of utilities.

c. Retain all operating, maintenance, and safety-related documentation as per the site's
recordkeeping requirements.

Note: This operating manual provides a general overview of the operational procedures for an
Isomerization Unit. It is crucial to consult the specific equipment manufacturer's manuals, site-
specific guidelines, and applicable regulations for detailed instructions and safety considerations
related to your specific ISOM unit.