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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
Requirement

Client

Literature Survey, Preliminary Engineering,


Finalize specification

Client

Firm Order
from Client
Basic Engg. Package, Process Design,
Detailed Engineering, Mechanical Design & Control System Config.
Procurement, Fabrication & Assembly
Factory Acceptance Test
& Site Acceptance Test
Warranty
Support

Client

Client

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

Multireactor Fluid Bed Auto Steaming Unit


Client: Indian Oil Corporation, Faridabad
Purpose:
For deactivating zeolite based fresh FCC/RFCC
catalysts & additives without or with metals

Project Details:

Reactor MOC: Incolnel 800H


Operating temperature: 850o C
Operating pressure: Atm.
Catalyst Qty: 75 cc
Water Feed Rate: 3.6 - 25 cc/hr
Unit included: 4 reactors installed in a sand
bath, 4 feed pumps, rotameter for nitrogen
and air service, Mass Flow Controller for
Hydrogen
PC-PLC based control system
Year of completion - 2012

High Pressure Fixed Bed Pilot Plant Flow Reactor System


Client: Indian Institute of Petroleum
Purpose:
For aviation fuel production from vegetable oil.

Project Details:

Reactor MOC: SS316


Operating temperature: 500o C
Operating pressure: 150 bar.g
Catalyst Qty: 4 litres
Liquid Feed Rate: 3-10 ltrs/hr
Gas Feed Rate : 600-6000 SLPH
Mode of Operation: Once Thru & Recycle
Micro Processor Controller based system
with feature of controlling from PC
PC-PLC based control system
Year of completion - 2012

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
Purpose:

Client: Indian Oil Corporation Limited

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
Evaluation.

VGO

For Catalyst

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
evaluation

VGO for catalyst

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: 525gm/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
studies
for
reactions.

screening/kinetic
dehydrogenation

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
regeneration temp.

of

reaction/

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 desulfurization, 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,
hydrodesulferisation,
hydrodewaxing,
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: 600C
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

Claus Catalyst Test Rig


Client: Porocel Adsorbents, Catalysts & Services
Purpose:
Catalyst
Activity
(Catalyst
developed
for
production)

Testing
Sulphur

Project Details:
Operating temperature: 380C at
Atm Pressure
Reactor of catalyst volume: 100 ml
Reactor MOC : Quartz
Gas feed H2S, SO2, Nitrogen, Air, CO2
Liquid feed CS2 and Water

Reactor, Condenser Coil, Seal Pot


MOC: Glass, Installed in oven
PC-PLC based computer systems
Year of completion: 2010

Compact Steam Methane Reformer Pilot Plant


Client: Indian Oil Corporation Limited, Faridabad
Purpose:
For producing HCNG mixture for auto
fuel purpose (80% methane. 20%
Hydrogen)
Producing and storing HCNG

Project Details:

Reactor MOC: SS 321


Operating temperature: 500C
Operating pressure: 10 bar. g
Steam Feed Rate: 2.5 kg/hr; CNG Feed Rate: 2 NM 3/Hr
Unit included: Sulphur Guard reactor to remove H2S from CNG, Steam
Generator & Steam super heater, CO2 Scrubber, HCNG Gas Compressor
with Discharge Pressure 250 kg/cm2, HCNG Storage consisting of 7
cylinders of 75 litre capacity each, online analysers for methane,
hydrogen and CO2
PC-PLC based control systems
Year of completion: 2011

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

Xytel India Pvt. Ltd.


Office & Works: EL-31/14, J Block, MIDC, Bhosari,
Pune 411026. Maharashtra (INDIA)
Tel : +91 20 40737700 Fax : +91 20 40737777
Email: xytel@vsnl.com Website: www.xytelindia.com