refinery

							                     Xytel India - An Insight


The quest for bringing in “World Class Technologies” to the Indian
Subcontinent & Asian Region has been a guiding force in
establishing Xytel India.



The company was
incorporated in the
year 1992 and has its
office and
manufacturing facility
in Pune.




Xytel India is the pioneer in bringing the Revolutionary Pilot Plant
Technology to the chemical Research and Development Industry.
                        Xytel India - An Insight


Xytel India, a joint venture between Xytel Corporation, USA, the world
leader in supply of pilot plants & Aker Solutions (earlier Kvaerner/Davy
Powergas, Mumbai), a premier project/process engineering organisation is
engaged in supply of skid-mounted/modular, fully automated Pilot/Mini Plants
on turnkey basis.
                          Why Xytel India ?

Expertise in designing and building cost effective pilot and mini plants in
record time, providing modularity, portability and computerised control

Customer Satisfaction

Customized pilot/mini plants for specific requirements.

Skilled and Experienced work force

Specialized overseas/ Indian vendors

Real time consultations with Xytel Inc. US for product upgradation &
sharing their data bank and immense global experience

State-of-the-art manufacturing facility

Availability of Design software like ChemCAD, APV, PromisE, AutoCAD

In-House Software Development Capability

Prompt, Reliable & Efficient Service
                 Xytel India Methodology of Project Execution

                          Customer           Client
                         Requirement

           Literature Survey, Preliminary Engineering,     Client
                       Finalize specification

                          Firm Order
                          from Client


             Basic Engg. Package, Process Design,                   Client
Detailed Engineering, Mechanical Design & Control System Config.


              Procurement, Fabrication & Assembly


                     Factory Acceptance Test          Client
                      & Site Acceptance Test

                            Warranty
                            Support
                         Fluid Catalytic Cracking (FCC) Pilot Plant

Client: Reliance Petroleum Limited
Purpose:
• For conducting simulated testing of commercial
  units, for correctly estimating the yield changes
Project Details:
• Operating Temperature :
     Reactor : 500 – 600oC
     Stripper : 500 – 600oC
     Regenerator : 650 – 720oC
• Operating Pressure : 2 – 5 kg/cm2 g
• Feed Rate : 2 To 12 kg/hr.
• Feed Type : Naphtha, VGO/Resid of CCR < 1
  (wt%)
• Catalyst circulation rate : 40-100 kg/hr
• Stripping Medium : Steam/Nitrogen
• Adiabatic operation of the riser
• PC-PLC based control system
• Year of completion: 2009
                           Dual Hydrotreater / Hydrocracker Pilot Plant

Client: Takreer, Abu Dhabi
Purpose:
For conducting catalyst and process evaluation
studies
Project Details:
•     Feed Rate : 50-500 ml/hr
•     Operating temperature: 500oC max.
•     Operating pressure: 180kg/cm2g max.
•     Catalyst capacity: 150cc max.
•     Unit included, 5 reactor systems having
      up/down flow arrangement with series &
      parallel arrangement.
•     High Pressure Scrubber system
•     Atmospheric column for Top & Bottom
      separation.
•     PC-PLC based control system
•     Year of completion: 2009
                   Multiple Microreactor Distillate & Residues Catalyst Testing Units
                                                                           (Unit A&B)

Client: Kuwait Institute of Scientific Research
Purpose:
•     Two units meant for light and heavy feeds.

Project Details:
•     Operating Temperature: 450oC
•     Operating Pressure: 150 bar.g
•     Catalyst capacity: 250 ml
•     6 Tubular Fixed Bed Reactors
•     All 6 reactors can be operated in Series or 3
      & 2 reactors can be operated in series
      independently
•     Separator Section With 2 Phase Separator
•     On-Line GC analysis
•     PC-PLC based control System
•     Year of completion : 2009
               FULLY AUTOMATIC MICRO -REACTOR SYSTEM
                    CONSISTING OF EIGHT REACTORS
                   Client: Indian Oil Corporation Limited
Purpose:
• For rapid evaluation of hydro-processing
  catalysts.

Project Details:
• Operating Temperature:450oC max.
• Operating Pressure: 200 bar g max.
• Catalyst Capacity: 1-5 ml
• Unit     included:  total   8    reactors
  (MOC:Inconel) installed in three zone
  furnace and having separate feed, product
  & separation module for each reactor with
  high precision syringe feed pump for
  liquid feed.
• PC-PLC based control system
• Year of completion: 2009
                        TOLUENE DISPROPORTIONATION UNIT (HT&OT)


Client: Shanghai Research Institute of Chemical Technology (SRIPT), China

  Purpose:
  • To study catalyst & operating conditions in 10 Independent reactor
    system.

 Plant Details:
 • Operating temperature: 400oC
 • Operating pressure: 40 bar g
 • Catalyst capacity: 25-50 cc
 • Reactor type: Fixed Bed Reactor
 • Reactor MOC: SS316
 • Liquid feed: Toluene & Cg,C10
   Aromatic (feed rate: 5-200 gm/hr)
 • Gas feed: Hydrogen (feed rate:
   100SLPH)
 • DCS based control system.
 • Year of completion : 2008
                MULTIPLE FIXED BED HIGH THROUGHPUT
                CATALYST SCREENING REACTOR SYSTEM
Client: Sabic Research & Technology Pvt Ltd
Purpose:
•   Aromatic Alkylation, Alkane cracking, gas
    phase dehydrogenation
Project Details:
• Operating Temp.: 800oC at atm
  pressure and 600oC at 60bar.g
  pressure.
• Reactor of catalyst volume: 2ml
• Reactor MOC: Inconel 625 (Qty. : 8
  Nos.)
• Gas Feed: H2, N2, Air, Hydrocarbon
  gases (Methane/Propane)
• Liquid feed: Hydrocarbon such as
  Benzene etc.
• PC-PLC Based Control System
• Unit included 8 Port Stream Selection Valve arrangement and Multiport
  Sampling Valve with 16 Nos. of 2ml sampling loops
• Year of completion: 2006
                              DIRECT UPGRADING PILOT PLANT


Client: Kuwait Institute of Scientific Research

Purpose:
• Hydrotreating Of      VGO     For Catalyst
  Evaluation.

Project Details:
• Operating Temperature: 450oC
• Operating Pressure: 200 bar.g
• Catalyst capacity: 250 ml
• 5 Tubular Fixed Bed Reactors
• All 5 reactors can be operated in Series
  or 3 & 2 reactors can be operated in
  series independently
• Separator   Section    With     2   Phase
  Separator
• On-Line GC analysis
• PC-PLC based control System
                                SYN-GAS MICROREACTOR UNIT


Client: Indian Oil Corporation Limited

• Purpose:
• Reforming of Natural Gas, Methane,
  Naphtha Steam.
• To carry pre-reforming, primary reforming,
  HTS and MTS/LTS reactions

Project Details:
• Operating Temperature: 900oC & 550oC
  Operating Pressure: 50 bar.g
• Unit included: feed pre heater & steam
  super heater, total 5 Tubular Fixed Bed
  Reactors of 50cc catalyst capacity each
  operated independently or in series.
• Hydro de-sulfurisation, Sulfur Guard
• On-line GC Analysis
• PC-PLC based control System
• Year of completion: 2004
                                       COLD STAND UNIT

Client: Indian Oil Corporation Limited

Purpose:
• For Hydrodynamic and column internal studies in the Trickle Bed Reactor

Project Details:
• Unit included two fixed beds of 600 mm
  dia and 1000 mm height of each bed
• Unit had different types of distributors
  such as bubble cap tray, sieve tray and
  chimney tray
• Arrangement to check efficiency of
  quench box
• Specially designed liquid collector with
  60 equal compartments and separate
  measuring tube for each collector
• Column in Acrylic and internals in SS
• PC-PLC based control system
• Year of completion: 2005
                         HYDROCRACKER PILOT PLANT UNIT (FIXED BED


Client: Indian Oil Corporation Limited

Purpose:
• Hydrocracking of     VGO for catalyst
  evaluation

Project Details:
• Operating Temperature: 450oC
• Operating Pressure: 200 bar.g
• VGO feed with recycle feed module
 • Unit included: total 2 tubular fixed bed
   reactors (MOC:RA330) of 400 ml
   catalyst capacity, such that the
   reactors operate in series, parallel or
   independently.
• Unit also included separator section with 2 phase separator, Caustic
   scrubber & recycle gas compressor, liquid stripping with stripper, packed
   heated atmospheric & vacuum column, cast in Bronze block furnace and
   LPG recovery system.
• PC-PLC based control System
• Year of completion: 2005
                                 CYCLIC DEACTIVATION UNIT

Client: Chennai Petroleum Corporation Limited (Formerly MRL)
Purpose:
• For conducting simulation of
  catalyst    deactivation      for
  evaluation of fresh catalyst.

Plant Details:
•   Operating temperature: 900oC
•   Operating pressure: atm.
•   Catalyst capacity: 100 gm.
•   Reactor type: Fluidized Bed
    Reactor
•   Reactor MOC: Incolly 800
•   Liquid feed: VGO (feed rate: 5-
    25gm/min; preheat temp.: 350oC)
•   Gas feed: Air/ Nitrogen (feed
    rate: 500SCCM; preheat temp.:
    350oC)
•   PC-PLC based control system.
                  LAB-SCALE ADSORPTION UNIT FOR
                 GASOLINE DESULPHURISATION PLANT
Client: Indian Institute of Petroleum

Purpose:
•   For adsorption of Sulfur in
    packed/fluidized bed of adsorbent.
•   In-situ activation & regeneration of
    adsorbent.


Plant Details:
•   Adsorber MOC: RA-330
•   Operating temperature: 550oC,
•   Operating pressure: 30 bar.g
•   PC-PLC based control System
•   Year of completion: 2004
              MULTIPLE MICROREACTOR DISTILLATE AND
             RESIDUES CATALYST TESTING UNIT-A & UNIT-B

Client: Kuwait Institute of Scientific Research
Purpose:
• Two units meant for light and heavy
  feeds.


Project Details:
• Operating Temperature: 450oC

• Operating Pressure: 150 bar.g

• Catalyst capacity: 5 - 10 cc

• Multiple reactors in single furnace

• PC-PLC based control System

• Year of completion: 2005
                               HYDROGEN GENERATION UNIT

Client: Indian Oil Corporation Limited
Purpose:
• Reforming of Natural Gas, Methane,
  Naphtha Steam.
• To carry     pre-reforming, primary
  reforming,    HTS     and   MTS/LTS
  reactions

Project Details:
• Operating Temperature: 900oC &
  550oC Operating Pressure: 50 bar.g
• Unit included: total 5 tubular fixed
  bed reactors of 100cc catalyst
  capacity each operated independently
  or in series, steam super heater,
  online GC analyzer.
• Hydro de-sulfurisation, Sulfur Guard
• PC-PLC based control System
• Year of completion: 2004
                         REFORMING MICRO REACTOR PILOT PLANT


Client: Bharat Petroleum Corporation Limited

Purpose:
•   For studies of isomerisation       &
    reforming processes of Naphtha


Project Details:
•   Operating Temperature: 550oC
•   Operating Pressure: 50 bar.g
•   Reactor catalyst capacity: 20cc
•   Fixed bed reactor system, with
    up/down flow arrangement.
•   Plant included Hydrogen recycle
    system
•   Unit   included    on-line   CO/CO2
    analyzer
•   PC-PLC based control System
•   Year of project completion: 2003
                               STEAM DEACTIVATION UNIT

Client: Bharat Petroleum Corporation Limited

Purpose:
• Designed to decrease the activity
  of fresh FCC Zeolite catalysts by
  processing it for a period of time
  in presence of steam at 750 –
  800oC.
• To simulate fully equilibrated FCC
  catalyst      conditions       after
  deactivating the catalyst.

Plant Details:
• Operating temperature: 400oC
• Operating pressure: atm.
• Catalyst capacity: 50-100 gm/min
• Liquid feed rate: 5-25 gm/min
  (VGO/Resid)
• Gas feed rate: 200 SCCM (Air/
  Nitrogen)
• PC-PLC based control system
                               GAS CRACKER PILOT PLANT

Client: Gas Authority India Limited

Purpose:
• Cracking of Ethane
• To study the effect of anticoking
  agent on coking in the tubular
  reactor
Project Details:
•   Operating Temp.: 830oC (max.)
•   Operating Pressure: 2.5 bar.g
•   Capacity - 5 kg/hr Ethane Gas
•   Process design was done by IICT,
    Hyderabad.
• The reactor was incorporated with
  gas fired furnace using metal
  fibre (Acotech, Belgium) and
  water cooled gas burners
• PC-PLC based control system.
• Year of completion: 2001
                      DEHYDROGENATION CATALYST TESTING UNIT


Client: Indian Petrochemical Corporation Limited
Purpose:
• For catalytic    screening/kinetic
  studies    for   dehydrogenation
  reactions.

Plant Details:
• Operating temperature: 500oC
• Operating pressure: 50 bar.g.
• Catalyst capacity: 2-5 ml.
• Liquid feed rate: 3-90ml/hr.
• Hydrogen recycle capability using
  compressor.
• System included, fixed bed tubular reactor in downflow arrangement, HP
  make 6890 series Gas Chromatograph & HPLC type syringe pump for
  water addition.
• PC-PLC based control system.
• Year of completion: 2000
                                   RESID FCC PILOT PLANT

Client: Indian Oil Corporation Limited

Purpose:
• For cracking of heavier feeds with CCR to 12
  wt% max.
• For studying FCC catalyst properties, dual
  solid process and integral regenerator/reactor
  system
• For feedstock and catalyst evaluation.
Project Details:
•   Design pressure: 2 bar.g
•   Feed rate: 4 - 10 kg/hr
•   Two stage regeneration operation at 700-750oC
•   Adiabatic operation for reactor & regenerators
•   Debutaniser @ -20oc
•   Online CO/CO2/O2 analysis of flue gas
•   Steam generation facility for feed injection & Hydrocarbon Stripping
•   Internal/external cyclones in regenerator.
•   Online product and flue gas flow rate measurements.
•   Proprietary feed nozzle design by Xytel India
•   PC-PLC based control System
•   Year of project completion: 2001
                                MICRO ACTIVITY TEST UNIT

Client: Chennai Petroleum Corporation Limited (Formerly MRL)

Purpose:
• Determination of characteristics of
  a particular Fluid Cracking Catalyst.

Plant Details:
•   Reaction Temp. : 550oC
•   Regeneration Temp. : 750oC
•   Liquid Product Collection : Icebath
•   Feed Injection Rate : 0.5 to 60 ml/min
•   Feed Syringe Temp. : 100oC
•   Reactor Capacity :4-5 gm of catalyst
•   Nitrogen Flow Rate : 100 cc/min max.
•   PC-PLC based control system.
•   Year of Completion : 1996
                               FLUID CATALYTIC CRACKING PILOT PLANT



Client: Kochi Refineries Limited
Purpose:
• To   study     effect        of   reaction/
  regeneration temp.
• To study catalyst circulation rate.
• Feedstock on FCC process.
• Catalyst/feed stock comparison

Project Details:
• Operating Temperature: 600-750oC
• Operating Pressure: 2.7 bar.g
• 7.5 kg/hr catalyst circulation rate
• 2.5 kg/hr liquid feed rate
• PC-PLC based control System
• Year of completion: 1996
                                  RECYCLE FCC PILOT PLANT

Client: Indian Oil Corporation Limited

Project Details:
• Operating Temperature :
     Reactor : 45 – 510oC
     Stripper : 500 – 550oC
     Regenerator : 650 – 750oC
• Operating Pressure : 0.3 - 1.5 bar.g
• Feed Rate : 0.8 To 3.5 kg/hr.
• Feed Type : VGO, VGO + Resid of
  CCR < 1 (wt%)
• Catalyst circulation rate : 6-10 kg/hr
• Recycle Ratio < 10%
• Stripping Medium : Steam/Nitrogen
• Adiabatic operation of the riser
• Unit included: CLO column, HGO column & debutaniser at the down
  stream of reactor and online CO/CO2/O2 analyzers for flue gas
• PC-PLC based control system
PILOT PLANT & MICRO REACTOR FOR MIDDLE DISTILLATE DEWAXING
Client: Indian Oil Corporation Limited
Purpose:
• For selective Hydrogenation, Hydro de-
  sulfurization, Hydro dewaxing & Hydro
  cracking
• For catalyst screening, their performance
  evaluation & comparison and to extract
  the kinetic data

Project Details:
• Design temperature: 550oC
• Design pressure: 200 bar.g
• Reactor catalyst capacity: 150cc and
  20cc for MCR.
• Plant included Hydrogen Recycle Facility
• Unit included: two reactor system with up/down flow mode with series and
  parallel arrangement with on-line GC for product gas analysis
• PC-PLC based control system
• Year of project completion: 2002
                                  ISOMERISATION PILOT PLANT

Client: Kuwait Institute of Scientific Research

Purpose:
• Isomerisation and hydrotreating of
  hydrocarbon or naphtha gas oil
  cuts


Project Details:
• Operating Temperature: 450oC
• Operating Pressure: 100 bar.g
• Cast In Bronze Block Furnace
• On-Line GC analysis
• PC-PLC based control System
• MOC : SS316
                               HYDROTREATING PILOT PLANT

Client: Chennai Petrochemical Corporation Ltd

Purpose:
• For    selective    hydrogeneration,
  hydro-     desulferisation,    hydro-
  dewaxing,       hydro-finishing     &
  hydrocracking        for     catalytic
  screening, performance comparison
  & kinetic data.

Plant Details:
• Operating temperature: 550oC
• Operating pressure: 250 bar.g.
• Catalyst capacity: 500cc
• Unit included, 2 reactor system
  having up/down flow arrangement
  with series & parallel arrangement.
• PC-PLC based control system
• Year of completion: 1998
                                  Adsorption Micro Reactor Unit

Client: Indian Oil Corporation Limited, Faridabad

Purpose:
• For carrying out research activities in the
  area of catalytic/non-catalytic adsorption
  processes (for sulfur adsorption)
• For evaluation of different adsorbent
  systems, feed stocks and for optimization of
  process parameters

Project Details:
• Reactor MOC: Inconel 800
• Operating temperature: 600°C
• Operating pressure: 50 bar. g
• Catalyst Qty : 40 cc
• Liquid Feed Rate :100 ml/hr; Hydrogen Feed Rate :150 SCCM; Air Feed Rate :150 SCCM
• Unit included: two reactor system with down flow mode with parallel arrangement and
  sequence operation philosophy with on-line liquid and gas analysers, on-line Antek
  make sulfur analyser, on-line gas analyser (CO, CO2, SO2, O2)
• PC-PLC based control System
• Year of completion: 2010
                           Demetallation Reactor Unit

Client: Indian Oil Corporation Limited, Faridabad

Purpose:
• For development of Demetallation
  process for the removal of heavy
  metals (Ni, V, Fe etc.) from heavy
  hydrocarbon oils


Project Details:
• Operating temperature: 260 °C
• Operating Pressure: 85 bar.g
• Operating pressure: 50 bar. g
• Unit included: High Pressure CSTR Reactor of 1 litre capacity with electrodes
  (SS/Copper/Aluminium) insertion arrangement and current control facility
• Reactor MOC : C-276 Hastealloy
• Micro PLC based Control System
• Year of completion: 2010
                       Xytel India Services

Feasibility & Engineering Studies
Apart from the main activity, we also undertake, as a pre-requisite for
turnkey supply, a study to prepare pre-engineering document to convert
bench / lab-scale data to into pilot / mini plant design when very little
information about the process is available. This exercise is also useful
for estimating the project cost enabling the client to arrive at an
investment decision.

Revamping Existing Units
Xytel India offers specialized services to help clients revamp their
existing pilot plant resources.

AMC Services
Xytel India also undertake Annual Maintenance Contracts for Pilot/ Mini
Plants . Each AMC has a designated service engineer in lead role and
services will include visits at a mutually decided frequency, normal &
preventive maintenance operations, guidance & training for proper
operation & maintenance of pilot plants.
Automation of Pilot Plants
Xytel India offers solution to PC/PLC based system to replace existing,
stand alone control systems, PC based control systems.
Clients
                    Contact Us


             Xytel India Pvt. Ltd.
 Office & Works: EL-31/14, „J‟ Block, MIDC, Bhosari,
         Pune – 411026. Maharashtra (INDIA)
      Tel: +91 20 30417700 Fax: +91 20 30417799
Email: xytel@vsnl.com Website: www.xytelindia.com