03EPOXGeneralSU---CML-517

NOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBEEPOXIDATIONAREAGENERALSTARTUPNOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBEEpoxidationSystemGeneralStartupPURPOSETheEpoxidationReactorSystemisdesignedtoreactTBHP(tertiary-butylhydroperoxide)withpropyleneusingepoxidationADMcatalystsolutiontoproducepropyleneoxide.Thereactionprocesstakesplaceintwostagesofreaction.Theeffluentstreamofeachreactionstageflowstoindependentseparationsectionsinwhichthecomponentsconsistingofpropyleneoxide,unreactedpropylene,TBA,unreactedTBHP,andADMcatalystsolutionisseparated.Unreactedpropyleneispressuredtothepropylenerecoverysystemtobeseparatedandrecycledbacktotheepoxidationsystemtobereused.ThecrudepropyleneoxideproductiscompressedandcondensedthensenttopropylenerecyclesystemforpreliminarycleanupbeforebeingpurifiedinthePOpurificationsystem.NOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBEThestart-upoftheEpoxidationsectionoftheplantmusttobecloselycoordinatedwiththestart-upofPeroxidationandPeroxidationseparation.EpoxidationwillbeinventoriedforstartupwithTBAfromtheHighPressureTBAFlushsystem,PropyleneOxidefromCrudePOstorage,andpropylenefrompropylenestorage.EnsurethatEpoxidationcatalyst(EG-ADMcatalystcomplex)isavailableandcatalystpumpsarecheckedoutandreadyforservice.•Warmisothermalreactorsand1stand2ndStageAdiabaticreactorintercoolers(shellside)withS1steamtowarmupthesystemandpreventTBAfromfreezinginequipment.•Whentheequipmentiswarm,lineupTBAintoFeedpreheaterandbeginfillingisothermalreactors,1stStageAdiabaticreactorsand1stStagePreflashColumn.Fill1stStagePreflashColumntonormaloperatinglevel.•TemporarilyconnectN7nitrogentorefluxlineonthe1stand2ndPreflashColumns,nitrogenpressurewillbeusedtopushTBAintothePrimaryFractionators.Nitrogenshouldbeuseduntilpropyleneisintroduced,thenpropylenewillprovidecolumnpressureandnitrogencanbedisconnected.EpoxidationSystemGeneralStartupNOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBE•Whenlevelreachesnormalrangein1stStagePreflashColumn,lineupbottomandbeginfillingthe1stStagePrimaryFractionatortonormallevel.•Using1stStagePrimaryFractionatorbottomspump,movematerialfromthe1stStagePrimaryFractionatortothe2ndStageAdiabaticReactors.•AdjustHPTBAflushflowtobalancelevelinthe1stStagePreflashColumn.•Fill2ndStageAdiabaticreactorsandestablishlevelinthe2ndStagePreflashColumn.Usingnitrogenandpushmaterialtoandestablishlevelinthe2ndStagePrimaryFractionator.•ReduceHPTBAflushflowasnecessarytocontrollevelinthe2ndStagePreflashColumn.•Whennormallevelestablishedin2ndStagePrimaryFractionator,usethe2ndStagePrimaryFractionatorbottompumptosendTBAtotheTBARemovalColumn.•VerifybottompurgecontrolvalveontheTBARemovalColumnisblockedintopreventsendingTBAtoPLF.EpoxidationSystemGeneralStartupNOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBE•MonitorlevelinTBARemovalColumnwhenlevelreachesapproximately50%,slowlystartsteamtotheTBARemovalColumnreboilersandstarttheTBARemovalColumnVacuumPackagetoestablishrefluxflow.•OperateTBARemovalColumninnormalconditionswithTBAroutedtotheDryTBATanktoestablishTBAcirculationthroughEpoxidation.•OnceTBAcirculationisestablished,stopsteamtotheIsothermalreactorsandadiabaticintercoolers.Inventoryboilerfeedwaterlevelsinisothermalreactorsandadiabaticintercoolers.•LineupsteamtoEpoxidationpreheaterandbeginheatingTBAinsystem.•Fillrefluxdrumonthe1stStagePrimaryFractionatorwithCrudePOtonormaloperatinglevel.•Lineupsteamto1stStagePrimaryFractionatorreboilersandestablishrefluxflow.•EnsurethePropyleneRecoveryandPropyleneRecycleColumnsareinventoriedandwarminpreparationforstartup.EpoxidationSystemGeneralStartupNOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBE•StartthePrimaryFractionatorVaporCompressorwhenpressurerisesinPrimaryFractionatorOverheadCompressorKODrum01D0235.•Adjustcolumnsteamflowandcoolingwaterflowtocondenserasnecessarytocontrolcolumnpressure,refluxflow,andlevels.•Fillrefluxdrumonthe2ndStagePrimaryFractionatorwithCrudePOtonormaloperatinglevel.•Lineupsteamto2ndStagePrimaryFractionatorreboilerandestablishtotalreflux.•EnsurePropyleneRefrigerationCompressorisinserviceandoperational.Inventorythe2ndStagePreflashColumnCondenserswithpropylene.•IncreaseTBACirculationtemperaturebyadjustingsteamcontrollerachievestartuppermissivetemperature.•Lineuppropylenetoisothermalsystemusing1ststagehighpressurepropylenepump.Useonlyonepumpatthistimetoinventorysystemwithpropylene.Commonspareneedstobeused,establishflowthroughbothjets.EpoxidationSystemGeneralStartupNOTE:ThisisforTrainingonly,andisnotintendedtobeusedasastepbystepprocedure.PO/MTBE•Aspressureon1stStagePreflashColumnincreases,blockinanddisconnectnitrogen,thenestablishrefluxflow.•Whenpressureonthe1stStagePreflashColumnincreasesclosetosetpointputtheoverheadonpressurecontrolandlineuptheoverheadtothePropyleneRecoveryColumnfeed.•Start2ndStagePropylenePumpandslowlyfeedpropyleneto2ndStage.•Whenpressureonthe2ndStag