Reactor Effluent Separators Overview

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Questions and Answers

What is the primary purpose of the D-310A/B separators?

To separate the cooled reactor effluent into a liquid product stream and a recycle ethylene vapor stream.

How does the T-330 scrubber help prevent issues in downstream equipment?

It removes aluminum alkyls that could cause plugging due to ethylene polymerization.

What does the E-330A/B coolers do with the ethylene vapor stream?

They cool the ethylene vapor stream using cooling water on the shell side.

What is the role of the D-330 H.P. Recycle K.O. Pot's internal demister pad?

To knock out any entrained liquid from the ethylene vapor. Signup and view all the answers

What action is taken if the T-330 scrubber experiences fouling?

It can be bypassed and shut down for cleaning. Signup and view all the answers

Where do the liquid product stream and recycle ethylene vapor stream exit in the D-310A/B separators?

The liquid product exits from the bottom, and the recycle ethylene vapor exits from the top. Signup and view all the answers

What materials are the inlet, outlet, and bypass valves of the T-330 scrubber impregnated with, and why?

They are Teflon impregnated to minimize fouling of the valve gates and seats. Signup and view all the answers

What is the purpose of the D-345 Continuous Skim Drum?

To remove the rag layer from the D-340 Caustic Settling Drum. Signup and view all the answers

How does the T-344 Degassing Tower manage the spent caustic?

It degasses the caustic and routes the vapors to the Purge Gas Header. Signup and view all the answers

What is the function of the P-344 Spent Caustic Transfer Pump?

To route the spent caustic from the D-344 Spent Caustic Settling Drum to Unit 1971 TK-60. Signup and view all the answers

Why is the D-350 Water Wash Settler important in the process?

It separates the two liquid phases into a recycled water stream and a skimmed hydrocarbon stream. Signup and view all the answers

What happens if the rag layer is allowed to accumulate in the D-350 Water Wash Settler?

It interferes with the hydrocarbon/caustic separation and increases caustic entrainment in the hydrocarbon phase. Signup and view all the answers

What is the primary function of the hairpin heat exchanger E-320?

To heat the product stream consisting of NAO and residual catalyst using 60 psig steam. Signup and view all the answers

Describe the design of the static mixer M-320.

M-320 is a 28-inch long and 6-inch diameter schedule 80 pipe with four internal elements. Signup and view all the answers

What type of heat exchanger is E-321 and what does it do?

E-321 is a double-pipe heat exchanger that cools the converted product stream with cooling water. Signup and view all the answers

What function does the D-321 Catalyst Blend Drum serve?

It dilutes the 2% nickel catalyst with C14 to a dilution of 0.2% and provides storage and supply. Signup and view all the answers

What is the purpose of the P-321A/B pumps?

To route the 0.2% nickel catalyst from the Catalyst Blend Drum to the Static Mixer. Signup and view all the answers

How does M-340 contribute to the caustic wash process?

M-340 mixes heated circulating caustic into the process for effective cleaning. Signup and view all the answers

What does T-340 do in the caustic wash system?

T-340 separates vapor from the two liquid phases in the caustic wash process. Signup and view all the answers

What role does D-340 play in the caustic wash system?

D-340 separates the two liquid phases into a caustic stream and a hydrocarbon stream. Signup and view all the answers

What is the function of the E-340 heater?

E-340 heats circulating caustic on the shell side with 100 psig steam. Signup and view all the answers

What is the significance of the skim system in the D-340 Settler?

The skim system removes any rag layer to ensure efficient hydrocarbon/caustic separation. Signup and view all the answers

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Study Notes

Reactor Effluent Separators (D-310A/B)

Dimensions: 8' diameter x 28' 8 5/16" length.
Function: Separate cooled reactor effluent into liquid product and recycle ethylene vapor streams.
Configuration: Liquid exits from the bottom; vapor exits from the top.
Operation: Only one separator in service, the standby separator remains under nitrogen pressure to prevent air ingress.

TEA Scrubber (T-330)

Dimensions: 3' diameter x 23' 6" length.
Purpose: Remove aluminum alkyls to prevent downstream plugging due to ethylene polymerization.
Cleaning: Periodic cleaning necessary due to fouling; equipped with Teflon-impregnated valves for minimized fouling.
Inlet configuration: Recycle ethylene vapor stream enters from the side bottom, C10-12 stream enters from the side top.

Ethylene Recycle Coolers (E-330A/B)

Type: Multi-tube U-type heat exchangers.
Function: Cool ethylene vapor using cooling water; both coolers typically in service.
Maintenance: Fouling indicated by rising effluent temperatures, necessitating cleaning of the affected exchanger.

H.P. Recycle K.O. Pot (D-330)

Dimensions: 3' 6" diameter x 7' 9" length.
Feature: Internal demister pad to remove entrained liquid from cooled ethylene.
Flow: Ethylene enters from the side; liquid exits from the bottom, vapor from the top.

Catalyzed Product Heater (E-320)

Design: Hairpin heat exchanger with a unique U-shaped pipe design.
Function: Heats product stream with 60 psig steam; suitable for limited space and high thermal shock risk.

Static Mixer (M-320)

Dimensions: 28" long and 6" diameter.
Use: Mixes 0.2% nickel catalyst into the process without moving parts.
Spare available featuring an internal baffle design.

Catalyzed Mixing Vessel (D-320)

Dimensions: 5' diameter x 24' length.
Purpose: Provides residence time for the nickel-based catalytic reaction; mixed product exits from the top.

Catalyzed Product Cooler (E-321)

Type: Double-pipe heat exchanger.
Function: Cools converted product stream using cooling water for heat exchange.

Catalyst Blend Drum (D-321)

Dimensions: 5' diameter x 6' length.
Purpose: Dilutes 2% nickel catalyst with C14 to achieve a 0.2% dilution for storage.

Catalyst Solution Injection Pumps (P-321A/B)

Type: Positive displacement pumps driven by 0.25 HP electric motors.
Function: Route 0.2% nickel catalyst from blend drum to mixer.

Caustic Wash System

Consists of static mixers, scrubbers, separators, and circulation pumps to facilitate caustic wash processes.

Spent Caustic System

Treats spent caustic, separating phases and routing vapors safely to flare systems or sewer lines.

Water Wash System

Provides a wash process with circulation pumps and heaters to treat hydrocarbon streams and recycle water efficiently.

Maintenance and Safety

Systems include periodic checks for fouling, operational redundancy, and precautions for vapor control to prevent atmospheric release.
Skim systems included to manage rag layer accumulation and maintain separation clarity.

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