Requesting a start-up plan for hydrotreating 1 million tons of wax oil

The information consulted is for reference only. Section 1 Preparation for the Start of Construction 1. Necessary Conditions for the Start of Construction 1. All equipment maintenance projects have been completed and accepted.； 2. Put the start-up plan and network diagram on the wall and organize the operators of each shift to learn * , master the start-up plan and be familiar with the modification project ； 3. Contact the general dispatcher to prepare medium-pressure nitrogen and high-pressure nitrogen ； 4. Contact the general blending and storage and transportation department to prepare the raw oil for start-up, and have complete laboratory analysis data ； 5. The supply of instrument air, industrial air, electricity, steam, deoxygenated water, fuel gas, etc. is normal ； 6. The torch has been lit when starting work ； 7. The test operation of the machine, pump and air cooling is normal, and the spare lubricating oil is complete. ； 8. Instruments and instruments have been adjusted; 9. Safety measures are in place, each safety valve has qualified pressure, and the upstream and downstream stop valves are opened. 2. Inspection before starting work 1. All pipelines that have been repaired or modified must be carefully inspected to see if there are any missing or wrong items. The installation of pipelines, valves, flanges and gaskets, whether welding and materials meet the process requirements, whether all bolts and nuts are tightened, and whether the one-way direction is correct. 2. Containers and reactors: Check whether the internal components are fully installed and meet the requirements ； Are manholes and head covers secure and tightened? ； Do the materials of bolts and nuts meet the requirements? ； Are pressure gauges, thermometers, thermocouples, liquid level gauges, and safety valves fully installed and functional? 3. Heating furnace: Check whether the burners, plugs, flue baffles, manholes, explosion-proof doors, fire holes, dampers, thermoelectrics, and pressure gauges are installed intact, and whether there are any debris in the furnace. If the furnace is put into use after overhaul, it must be dried first. 4. Heat exchanger, cooler, air cooler: Check whether the inlet and outlet pipelines are installed correctly, whether the thermometer, pressure gauge, vent valve, and anchor screws are installed as required, and whether the air cooling belt is easy to use. 5. Compressors and pumps: Check whether the plate is flexible, whether the cooling system and lubrication system are smooth and normal, and whether the protective cover grounding wire, ammeter, power switch, pressure gauge, temperature gauge, unloader, etc. are complete and functional. 6. Whether all instrument control systems have been calibrated and qualified. 7. Whether all blind panels of the device have been disassembled and assembled according to the requirements for starting work. 8. Whether fire-fighting equipment is fully prepared for fire-fighting. 9. Check whether the hygienic condition of the device meets the starting conditions. Section 2 Purge Test 1. Preparation 1. Prepare equipment for the seal test such as ear cleaning balls, small buckets, soapy water, brushes, chalk, etc. ； 2. Prepare 0~1.0MPa (four pieces), 0~4.0MPa (two pieces), and 0~10.0MPa (two pieces) grade 1.5 pressure gauges that have passed the inspection. ； 3. Contact the metering and ammonia nitrogen pressure station to prepare nitrogen for testing. ； 2. Purge principles and precautions 1. Before purging and sealing test, check the equipment, process flow, pressure gauges, etc., close the pressure induction valve of each primary meter, and close the inlet and outlet valves of each meter. ； 2. When the cold exchange equipment is purged with steam in one pass, the other pass must be vented to prevent pressure buildup. ； 3. Be careful when introducing steam and discharge condensation section by section to prevent water shock. ； 4. When steam purging, the steam supply should be slow and the equipment should be used as the center to purge outwards. Buried pipelines and non-heat compensation pipelines should not be purged with steam. ； 5. The steam blowing regulating valve should first go across the line and then the main body, and should not pass through the pump, regulating valve, etc. for a long time. ； The purge temperature measuring range must be removed ； 6. The reactor must be isolated when purging the reaction system and connected during the seal test. ； 7. Purge is qualified if the gas at each condensation and venting point does not contain impurities. ； 8. The sealing test system must be well isolated and install pressure gauges with appropriate accuracy and range in different parts to keep abreast of the pressure situation and prevent overpressure and pressure leakage. ； 9. The sealing test pressure standard is 1.0 times the maximum operating pressure. The sealing test is carried out after purging. ； 10. The high-pressure system should release pressure slowly, with a pressure relief speed of ≯0.05MPa/min. Nitrogen, air, etc. must not be discharged into the flare ； 11. When the reaction system uses nitrogen for the third stage of sealing test, it is necessary to start K-3102 and point furnace F-3101 to raise the temperature. After the layer temperature reaches 135°C, the pressure can be raised to above 3.4MPa. If necessary, start K-3101 to boost pressure. 3. Purge density test medium 1. Steam purge density test: Distribution system, gas system, BD system ； 2. Nitrogen purge test: Raw oil system, hydrogen system (reaction system and new hydrogen system), water injection system. 4. Purge process 1. Reaction system (1) Gas supply point: K-3101/1 export (2) process: →P3102 outlet → PV3102 → E3207 shell, E3101 shell E3101 shell → F3201 → R3201 → E3201 pipe → E3101 pipe → V3104 → K3101 export line → → TV3104 (3) Main emission point: K-3101, PV-3201, LV-3201 condensate discharge, boundary area 2, raw oil system (1) air supply point: P3102 Export (2) Process: →P3102/1 entrance and exit crossover line→→V3101/2→→P3203 line→main discharge point of raw oil filtration system: Boundary area, HV-3102 4. Separation system (1) partial steam feed point of debutanizer tower: T3201 superheated steam process: →3126 line → E3201 → V3201 steam → F3201 → 3517 line → T3201 → V3107 → V3108 → 3206 line → E3103 → E3205 shell → T3202 (2) T3202 feed line steam supply point: T3201 bottom steam sweeping line (line 3515) process: Steam→P-3201→E3205 shell→F-3201→T-3202 (3) Steam supply point at the top of the distillation tower: T-3202 superheated steam process: Steam goes to F3201 to T3202 to A3201 to E3202 to V3202 (4) Steam supply point of bottom oil line of distillation tower: Steam sweep line steam at the bottom of the tower → P-3201 → E3205 pipe, E3207 pipe, → A3203 → 5. Steam supply point of fuel gas system: Service point steam → fuel gas line → F-3101 burner, steady light, high point vent steam → fuel gas line → F-3201 burner, steady light, high point vent 6. Deoxygenated water in water injection line → P3103 → water injection point 5. Tightness test (the airtightness test is performed after the purge is completed) 1. Reaction system flow: →P3102 outlet→PV3102→E3207 shell→K3101 outlet→P2241 line→E3101 shell→E3201 shell→F3201→R3201→E3201 tube→E3205 tube→V3104 Tightness test step (1) First use nitrogen to increase the pressure to 1.0MPa, check the tightness, and after passing the test, continue to increase the pressure to 3.0MPa and maintain the pressure for 4 hours, allowing the pressure to drop no more than 0.03MPa per hour. (2) After the 3.0MPa nitrogen pressure maintenance is qualified, start the cycle machine K3102 and heat the heating furnace F3201 according to the regulations. When the R3201 bed temperature is > 135°C, the reaction system will be pressurized to 7 by the new hydrogen machine. .5MPa (heating rate is not greater than 0.05MPa/min). Check the tightness. After there are no leaks, stop the new hydrogen machine and circulation machine, and keep the system pressure for 2 hours. The average pressure drop per hour is allowed to be no more than 0.08MPa. Remark: (1) After the reaction system pressure rises to 3.0MPa and during the pressure maintaining process, record the temperature and pressure everywhere every half hour. When performing the third stage nitrogen seal test, always keep the reactor bed temperature between 135°C and 150°C. (2) During the boost operation of the new hydrogen compressor, be careful not to exceed the current ； (3) During the pressure holding process, the pressure drop caused by the temperature at the beginning and end of the system must be deducted when calculating the average pressure drop. 3.3 After the system seal test is completed, release the pressure at the following locations:: a.V3106 is short at the bottom ； b. Vent the top outlet of V3105. 2. New hydrogen system process: V3105 nitrogen V3103 K3101 pressure relief point: V3103 Bottom Drainage 3, Low Score Part Process: Nitrogen V-3104 After the tightness test of the reaction system is completed, slowly introduce nitrogen gas from V-3104 to V-3108, and slowly introduce nitrogen gas from V3105 to V-3107 to increase the pressure to 1.0MPa, and check the tightness. After the seal test is completed, vent the pressure at the bottom of V-3107. 4. Debutanizer process: →2→E3201→E3201→V3201 steam→F3201→T3201→ →V3107 →P2130 line→ →V3108 →E3103 →E3205 shell, →F3101→T3202 steam supply point: F3201 superheated steam ； After the system seal test is completed, vent the pressure at the bottom of V-3201. 5. Distillation tower process: →F3201→LS2202 line→T3202→A3201→E3202→V3202→ After the sealing test of the system in the boundary area of ​​the diesel outlet device is completed, vent the pressure at the bottom of V-3202. 6. Feed line process of sub-distillation tower: T3202 tower bottom line → E3205 shell → F3201 → T3202 feed valve front 7. Oil line flow at the bottom of the distillation tower: Steam → P3206 cross-line → E3205 pipe → E3207 pipe → E3207 pipe → A3203 → 3125 line → Pressure relief point: Boundary area discharge point 8. Fuel gas system process steam service point steam → 3415 line → steam service point steam → GF2201 line → E3201 → pressure relief point: Drainage point 9. Raw oil system flow: The raw oil from the self-irrigation area first enters the raw oil buffer tank, and then is sent to the interruption reflux heat exchanger through the boost pump. After heat exchange by the wax/raw oil heat exchanger, it enters the filtration system. From the filtration system, it enters the filtered raw oil buffer tank, and is then pumped out through the reaction feed pump. pressure relief point: After the sealing test is completed, the condensation is discharged from the lower part of the raw oil buffer tank V3101/1.2. 10. Air tightness inspection method (1) Nitrogen, air: After the air pressure reaches the test pressure, comprehensively inspect the flanges, welds, interfaces, etc. of the equipment pipeline. If there is no bubbling with soapy water, no deformation by visual inspection, and the pressure drop does not exceed the standard, it is considered qualified. (See Table 1) (2) Steam: After charging to the test pressure, comprehensively inspect the flanges, welds, interfaces, etc. of the equipment pipeline to ensure that there is no steam or deformation by visual inspection. Table 1. Reaction part of standard parts for sealing test (two stages) New hydrogen feed oil debutanizer ② Fractionation tower ② Other parts of fractionation system ③ Low fraction fuel gas One, two, three media Nitrogen or medium pressure air Nitrogen Nitrogen steam Nitrogen steam steam Nitrogen steam gas supply point K3102 outlet V3103 V3103 F3201 F3201 Fractionation tower bottom V3105 Service point pressure MPa 1.0 3.0 7.5 1.6 1.2 0.5 0.05 1.0 1.0 0.6 Position V3105 Top V3103 Top V3101 V3201 V3202 Top boundary area V3107 Top P226 P320 Time h 4 2 4 Voltage drop 0.03 0.08 0.02 Note: ①When there is an unregenerated catalyst in the reactor, only nitrogen can be used for tightness testing. After the reactor catalyst is regenerated, a pressure air tightness test can also be used. ② The debutanizer tower density test includes V3201, and the separation tower sealing test includes V3202. ③ Other pipelines in the separation system refer to other separation systems other than ②. Section 3 Start-up Procedures 1. Start-up of fractionation system: 1. Establish cold oil circulation: (1) Hot oil process: Diesel (raw material tank area) → 3102 line → T3201 → P3201 → E3205 shell → T3202 cycle process: →P3201→E3205 shell→F3101→T3202→P3206→E3205 tube, A3203→3125 line→T3201 steps: ①Contact the general dispatching, storage and transportation to send straight-run diesel to the device through the raw oil line to P3201 to T3201. When the liquid level of T3201 exceeds 60%, turn on P3201 to send oil to T3202. ； ②When the liquid level of T3202 exceeds 60%, start P3206 to establish the cold oil circulation of the fractionation system. When the liquid level of both towers is at 60%, notify the relevant units to stop oil collection. ③Drainage should be strengthened at each low point during circulation. 2. Hot oil circulation (1) Hot oil circulation process E3201→E3201→V3201 A3201→E3202→V3202 T3201→P3201→E3205 shell→F3101→T3202→P3206→E3205 pipe→A3203 crossover→T3201 (2) Hot oil circulation steps: (1) After the cold oil circulation is normal, F3101 ignites and heats up according to the regulations, activates the relevant cooling equipment, and controls the temperature rise rate at 15~20℃/h. (2) During the hot oil circulation process, pay attention to the liquid level balance in the two towers. If the liquid level drops, oil can be collected and replenished. (3) During the hot oil circulation process, contact storage and transportation to collect gasoline from V3202 until the liquid level in each container reaches 40%. (4) The F3101 outlet temperature reaches 230°C, and the system continues to dehydrate at constant temperature. T3202 bottom sampling analysis is water-free. When the system is dehydrated at constant temperature, dehydration is strengthened everywhere. (5) When the F3101 outlet temperature reaches 250°C, notify the transportation personnel that the system starts to heat up. After the heat tightening ends, the system starts to heat up again. (6) When the bottom temperature of T3202 exceeds 200°C, start blowing superheated steam into T3202, and the amount of superheated steam is 1.1t/h. (7) T3201 is pressurized to 0.55MPa with nitrogen gas, and T3202 is pressurized to 0.05MPa with fuel gas. As F3101 heats up, the tower top pressure of T3202 continues to rise, and the split-range control valve is gradually put into use. Start P208 to initiate full reflux. If the liquid level of V3202 is high, the gasoline can be properly discharged to the tank area. (8) After the hot oil circulation is established in the fractionation system, the bottom temperature of T3202 is required to be controlled at 203°C. However, it should be noted that there is medium flowing through E3205, E3207, and E3207 to avoid being heated in one pass. The liquid level of each tower is controlled at 60%, and the liquid level of V3202 is controlled at 40% to 60%. (3) Precautions for hot oil circulation: ①When heating up the hot oil circulation, air cooling should be enabled first. ②During the heating process, if the pump is found to be emptying, the heating should be stopped immediately. ③The preheating wire of the hot oil pump is put into use when the cold oil is circulating, and the operating pump must be switched. ④When priming the oil to heat the oil and establishing oil circulation, it is necessary to prevent accidents such as running, bubbling, dripping, and leaking. 2. Raw material oil system circulation 1. Raw oil tank circulation: After the hot oil circulation has been established in the fractionation system, contact the general dispatching, storage and transportation to introduce the straight-run oil into the device boundary and return HIC203. 2. Open-circuit cycle leads the raw material oil to V-3101/1. When the liquid level of V-3101/1 reaches 70%, start P-3102 to establish a cycle with a storage tank and return from the pump outlet 2177. HIC-203 gradually turns down until it is closed, waiting for oil to be fed into the reaction system. 3. Hydrogen replacement in the reaction system 1. Contact III hydrogenation, introduce PSA hydrogen into the II device, and discharge it from Capacity-206 or PRC-108/1. After 15 minutes, analyze that the oxygen content is <0.5%, and then change it to the inlet of the new hydrogen compressor. 2. After the reaction system is vented to normal pressure, new hydrogen is added into the reaction system until the hydrogen concentration is >60% and the pressure remains constant. Pay attention to the pressure of -206. The reaction system discharges BD through PRC0201 displacement and force. process: Oxygen → 2201 line → V3103 → K-3101 → K3101 cross-line → E3101 shell → F3201 → R3101, E3205 tube, E3101 tube → V3104 → V3102 → V3106 → K3102 → hydrogen mixing point PV3201 → BD 3. When the reaction system replacement is qualified, start K-3101 to increase the pressure, and the pressure increase speed is ≯0.05MPa/min. The reaction inlet is heated, and when the reaction bed temperature is lower than 135°C, the reaction pressure shall not be higher than 3.4MPa. 4. After the reaction pressure reaches the operating pressure and is stable, use an explosion meter to further verify the tightness of the system. 5. When the reactor starts to heat up, the thermal high-fraction air cooler can be gradually put into use. When starting a new hydrogen machine, E219 must be put into use. 4. Oil feeding into the reactor 1. When the reaction inlet temperature reaches 200°C, stop the circulation of the raw material system, improve the raw material diesel oil into the reactor, and control the feeding amount at 60t/h as required. TRT3202 fully opens the hot path, and at the same time increases the temperature of the burner outlet to prevent the temperature from dropping significantly after oil is introduced. The bed temperature must be guaranteed to be ≮135℃ ； Pay close attention to the temperature change of the reaction bed. When the temperature of the reactor bed rises, it means that the feed oil has reacted. ； 2. When the temperature of the reactor bed rises, start P3103 to inject water into the reaction system, and the water injection amount is controlled at 3.0t/h. ； 3. After the reaction system is filled with oil, the reactor inlet temperature continues to rise to 260 at a rate of 25-30℃t/h.℃ ； 4. Start A-201 and control the V3105 inlet temperature to 45±5℃ ； 5. Pay close attention to the V3105 liquid level and interface. When the V3102 liquid level and interface reach the specified value of 50% 0.9MPa, turn LRCA-201/1 and LRCA-202/1 into automatic. If the V3104 liquid level reaches 50%, turn LIC22 into automatic. 6. Pay attention to the V-3107 liquid level and pressure. When the V-3107 liquid level and pressure reach 50% of the specified value respectively When 0.9MPa, LRCA-203 and PV3116 are put into automatic operation. If the liquid level of V3108 reaches 50%, LIC222 is put into automatic operation, and the hot and cold low-separation oil is sent to the separation system T3201 to open up the whole process and establish a long cycle of the device. When the system oil enters the debutanizer tower, the superheated steam of the debutanizer tower is added, and the steam volume is 0.8MPa. 7. Swap in 25% of VGO: Lead the VGO wax oil to the boundary area. After confirming that the oil inlet conditions are met after a long cycle of 4 hours, open the raw material wax oil inlet valve and introduce the raw material tank into the raw material tank at a rate of 15t/h, keeping the total feed volume of the reactor at 60t/h. At the same time, the reactor inlet temperature was increased at a rate of 8 to 10°C/h. When changing the oil, the circulation volume of the distillation tower bottom oil for tank flushing will be reduced to 45t/h depending on the liquid level. The excess bottom oil will be drained out of the wax oil raw material tank or heavy dirty oil tank, keeping the total feed volume of the reactor at 60t/h. At the same time, increase the reactor inlet temperature to 280°C at a rate of 8~10°C/h. 8. Swap in 50% of VGO: After introducing 25% VGO raw material for 2 hours and the bed temperature rise stabilizes, gradually increase the amount of VGO introduced to 30t/h, and reduce the amount of circulating oil from the bottom of the distillation tower to the raw material buffer tank to 30t/h. At the same time, increase the reactor inlet temperature to 300°C at a rate of 8 to 10°C/h. Depending on the sulfur content of the bottom oil in the distillation tower, the refined wax oil combined oil line can be diverted to the outlet device. 9. Swap in 75% of VGO: After maintaining the introduction amount of VGO raw material at 30t/h for about 2 hours, the introduction amount is increased to 45t/h, and the bottom oil circulation amount is reduced to 15t/h. Increase the reactor inlet temperature to 320°C at a rate of 8 to 10°C/h. 10. Swap in 100% VGO: After maintaining the introduction amount of VGO raw material at 45t/h for about 2 hours, the introduction amount was increased to 60t/h, and all the bottom oil was discharged from the device. Increase the reactor inlet temperature to 350°C at a rate of 8 to 10°C/h. 11. When the reactor inlet temperature rises to 350°C, hold the temperature constant for 2 hours, and after the bed temperature rise stabilizes, adjust the reaction temperature until the desulfurization rate meets the requirements based on the sulfur content of the bottom oil in the separation tower. 12. Gradually increase the reaction pressure by 0.5MPa/min to the operating pressure. 13. After the device operates stably, the processing load is increased to 100%, and the raw wax oil can be introduced into the device according to the designed proportion. 14. When the reaction system starts switching wax oil, adjust the operations of T3201 and T3202 so that the operating parameters of the two towers meet the requirements of the process card indicators. Depending on the operating conditions of T3202, start P3207 to extract the T3202 diesel oil out of the unqualified oil line and out of the device, and then enter the product tank after passing the product analysis. If the V3202 liquid level is high, the gasoline can be sent to the tank area. 15. Start the corrosion inhibitor injection pump P3208 to inject corrosion inhibitor into the raw oil. 16. Analyze the quality of diesel and gasoline. After the products are qualified, they will be transferred to the corresponding oil tanks according to the general adjustment requirements. 5. Things to note when starting work: 1. New catalysts or regenerated catalysts need to be pre-sulfurized. At this time, part of the start-up process will be carried out according to the pre-sulfurization plan. ； (See "Hydrorefining Catalyst") 2. The start of construction after temporary suspension depends on the specific situation. ； 3. When starting work, the three-level inspection system of operators, squad leaders, and technicians must be adhered to when changing the process to ensure that the process is smooth and clear. ； 4. After the reactor is filled with oil, the pressure and temperature of each container and pipeline must be checked frequently. V-3101/1.2, capacity-206, and capacity must be strengthened to discharge condensate and cut water. ； 5. After the device production returns to normal, each tail gas emission shall be carried out in accordance with the dispatching requirements, and flaring shall be reduced. Appendix 1: Device startup and shutdown blind plate table Blind plate number Pipeline number Installation location Start-up status Stop status 201 2101-Dg150 Boundary area blind 202 2101-Dg150 Raw wax oil boundary area blind 203 2102-Dg150 Boundary area blind 204 2110-Dg250 Furnace entrance clear/205 2161-Dg25 E-208 shell blind pass 206 2161-Dg25 E-208 tube blind pass 207 2161-Dg25 E-206 shell blind pass 208 2161-Dg25 E-206 tube blind pass 209 2110- Dg25 (active tube) P201 inlet exhaust condensation blind pass 210 GW-2202-150 F3201 blind outlet 211 2111- Dg250 F3201 blind outlet 212 2111- Dg250 (supervisor) R3101 inlet blind 213 2111- Dg25 (active pipe) R3201 inlet exhaust condensation blind 214 2112- Dg250 R3101 outlet blind 215 3814 line R3101 export line 216 2117/1- Dg50 line 217 2125- Dg150 Refined oil line line 218 2125/2- Dg150 Heavy dirty oil line line 219 2130- Dg40 crude gasoline line 220 P2233 line 80 Diesel outlet line line 221 2134- Dg150 K-3102/1 inlet is open and blind 222 2134/1- Dg150 K-3102/2 inlet is open and blind 223 2135- Dg150 K-3102/2 outlet is open and blind 224 2140- Dg25 V3103 bottom row condensation is open 225 2154- Dg25 E-201 pipe inlet blind pass 226 2154- Dg25 E-201-shell inlet blind pass 227 2155- Dg25 E3205/1.2 pipe pass blind pass 228 2157- Dg25 A-201 exit blind pass 229 2159- Dg25 V3105 bottom exit blind pass 230 P2263 line 200 Go to F3101, blind pass 231 GW2201-150 Go to D220, blind pass 232 GW2204-150 Go to F3101, blind pass 233 2174- Dg80, blind pass 234 2175- Dg100 to draw 201, blind pass 235 2177- Dg100, heavy oil boundary clear pass 236 1201/1- Dg100 K-3102/2 entrance blind 237 1203/1- Dg80 K-3101/2 exit blind 238 2201- Dg150 blind 239 2202- Dg150 K-3101/1 entrance blind 240 2202/1- Dg150 K-3101/1 entrance cross-line blind communication 241 2203- Dg150 K-3101/2 entrance blind communication 242 2203/1- Dg150 blind communication 243 3505/3- Dg80 blind communication 244 3516- Dg50 blind communication 245 3616- Dg25 P-3202/1 blind communication 246 3716- Dg50 to V3103 Access 247 3751- Dg40 to K-3101/1 Access 248 3751- Dg40 to K-3101/1 Access 249 3752- Dg40 K-3102/2 Exit access 250 3752- Dg40 to K-3102/2 Tong blind 251 3758- Dg25 to K-3101/1 Tong blind hydrogenation start-up network diagram 24 hours C Raise temperature to bed temperature 135°C Switch raw materials to new hydrogen system Purge and seal test 4 hours Increase pressure to 3.5MPa Close inspection 5 hours Adjustment operation A 24 hours B 48 hours DFHIK Comprehensive inspection of the device, reaction system, purge, decomposition section reaction and new hydrogen system. 9 hours. Diesel temperature rises to 32 hours. Conduct gas-tight system hydrogen replacement. Check inlet temperature. Raw oil and gas system. 9 hours. 4 hours. EGJ fractionation system. Trial density split system. Hot and cold diesel cycle. Raw diesel fuel tank cycle.

Is there any information on hydrogen production?