Fluid Catalytic Cracking

Secondary Processing Unit

HCU FCC DCU
Feed, CCR, wt% 0.5 0.7-10 24
Product Yield, wt%
Gas 5.2 3.5 3.5
LPG 2.4 20 2.8
Gasoline 45
Naphtha 13.2 6.5
Kerosene 24
Diesel/LCO/LCGO 48.8 20 29
UCO 3
Coke 5 29
Product Quality
Diesel stream cetane 56 30 46
Diesel Stream’S’, ppm <10 12000 29600
Kero Smoke Pt 24
Gasoline/Naphtha RON 67 91
Gasoline/Naphtha ‘S’,ppm <10 300
A Typical FCC/RFCC Unit
FCC Rx – Rg SECTION
FCC Rx – Rg SECTION
 FCC Flow Diagram

FLUE GAS COL OVHD

RECEIVER
M
A
R I HN
E N FG
S Regene A
T rator C
A C LCO
O
C T
L
K O U
R M HCO
ORIFICE LPG
N Recycl
CHAMBER WGC GAS CON
e UNIT

FCCG

MAB
CLO
AIR
SLURRY
FEED SETTLER
CO BOILER
Furnace
FURNACE

Slurry Recycle
FCC Rx – Rg SECTION
FCC Pressure Balance
FCC Pressure Balance
 FCC Pressure Balance

- A clear understanding of pressure balance is extremely

important for
− Improving catalyst circulation rate

− Adjustment of pressure diff. between Reactor-Regenerator

− Optimizing load sharing of MAB/WGC

− Fine tuning of RCSV/SCSV operation

− Knowing true constraints of unit and possible debottlenecking measure

− Trouble-shooting of Rx vapor line & Main column choking/coking

Catalyst circulation in FCCU is like blood circulation in human body

 FCC Pressure Balance

Parameter affecting Pressure Balance

- Standpipe Operation

- Catalyst physical Properties (PSD, fines, ABD)

- Operating Condition
 FCC Subsystems

Stand Pipes

– Regenerated catalyst stand pipe (Rg to Rx)

– Spent catalyst stand pipe (Rx to Rg)
– Vertical or sloped (max 450 )
– Handle fluidised catalyst, supplemental aeration
– Provide necessary hydrostatic head for smooth cat circ.
– Designed to handle wide range of cat circulation
– Cat velocity 2 – 6 ft/sec, density 40 – 45 lb/ft3
– Refractory lined (cold or hot)
– Hopper, slide valve, expansion bellow
 FCC

To MF

AIR

Steam

Steam
Steam

AIR Back flush

Steam

AIR HCO
Steam
FF
AIR Steam

AIR
Compression of Catalysts in a Stand Pipe

Bed Level

Aeration counteracts the

compression of catalyst
within the stand pipe.

Slide Valve
Pressure Profiles in Stand Pipes

Normal Pressure Profile

Bed Level

Increasing Depth

Slide Valve
Increasing Pressure
Pressure Profiles in Stand Pipes

Circulation Problem
Bed Level

Increasing Depth

Slide Valve
Increasing Pressure
Pressure Profiles in Stand Pipes

Severe Circulation Problem

Bed Level

Increasing Depth

Slide Valve
Increasing Pressure
FCC Heat Balance
 FCC Heat Balance
− Heat generated by burning coke
− Heat consumed in Rx
− Cat Cracker adjusts itself to stay in heat balance
− Independent Variables
− Rx Temperature
− Feed Preheat Temp
− Recycle rate / CFR
− Fresh cat activity / selectivity
− Dependent Variable
− Regenerator Temp
− Cat circulation rate
− Conversion
− Air requirement
FCC Heat Balance
Reactor Product 510oC

Steam
350oC Regenerated Cat. 700oC

Reactor Heat of Reaction

Feed Losses
230oC

Spent Cat.
500oC
 FCC Heat Balance

Spent Cat. Regenerated

500oC Cat. 700oC

Heat of Regenerator Losses

Combustion

Flue Gas
Air at 250oC
 FCC Heat Balance

– Catalyst circulation rate can be calculated by heat

balance and directly influences Rg temp.
» Cat/Oil = Cat circulation rate (T/hr)/Feed Rate (T/hr)
» Del coke = (CSC – CRC) = Coke yield / C/O
 FCC Heat Balance

Delta Coke is decreased by

– Increased Cat / Oil ratio
» By increasing Rx temp
» By reducing combined feed temperature
– Improved feed nozzle dispersion
– Better stripping
– Improved feed quality
» Higher API, K factor
» Lower CCR, boiling range
FCC Catalyst
 FCC Catalyst

– Fine Porous Powder

– Oxides of Silica & Alumina
– Acts like fluid when aerated (fluidized)
– Types of Catalyst
» Fresh Catalyst
» Equilibrium Catalyst
» Spent Catalyst
 FCC Catalyst

FCC CATALYSTS

− Zeolite

− Active Matrix

− Clay

− Binder
 FCC Catalyst

Zeolite

− Primary source of catalytic activity

– Mineral crystalline material

– Affects activity, selectivity, product quality

 FCC Catalyst

Active Matrix
− Catalytically active surface other than zeolite

− Has larger pores

− Decreased bottom yields

 FCC Catalyst

Clay
− Fulfills remaining catalyst particle performance requirement

– Serves as heat sink

– Serves as sink for Na

 FCC Catalyst

Binder
− ‘Glue’ holding all catalyst components together

– Provides physical integrity

 CATALYST POISONS

– Nickel promotes dehydrogenation reactions which are

unwanted

– Dehydrogenation reactions result in increased hydrogen

make gas make

– Vanadium gets converted to V2O5 and then to vanadic acid

under regenerator conditions

– Vanadic acid washes away zeolite sites on catalyst

2 Stage Regeneration for Minimum Catalyst
Deactivation
FCC Nomenclature
 FCC Nomenclature
Activity
The effectiveness of the Catalyst to promote cracking. A measure
of the conversion obtained with a Standard feedstock.
Attrition
The wearing away of catalyst particles due to the particles
rubbing together and with the walls / internals of vessels and other
equipment.

After Burning
The burning of CO to CO2 in the upper part of the regenerator
giving rise to very high temperature around the regenerator
cyclones, flue gas ducts and in the stack.
 FCC Nomenclature

Dip Legs
The return pipes from the reactor and regenerator cyclones to the
catalyst beds in each vessel.

Emergency Sprays
Internal water sprays provided at the top of the regenerator to
control high temperature in case of severe after burning.

Fines
Catalyst particles of less than 20 micron diameter. Typically this
material can not be retained by the cyclones and is rapidly lost
from the plant.
 FCC Nomenclature
Carbon Balance
The balance between carbon produced in the reactor and the carbon
burnt off the catalyst in the regenerator. The catalyst circulation rate
can be estimated by means of a carbon balance.
Carbon on Regenerated Catalyst
The % by weight of carbon on the regenerated catalyst as
determined by standard Laboratory equipment.
Carbon on Spent Catalyst
The % by weight of carbon on the spent catalyst from reactor as
determined by standard Laboratory Equipment.
 FCC Nomenclature

Catalyst / Oil ratio

It is the ratio of Catalyst circulation rate (T/min) to Fresh feed rate
(T/min.)

Coke
A mixture of carbon, hydrogen, sulphur and heavy oil deposited on
the catalyst in the cracking process.

Coke burning rate

Tons of coke burned per ton of catalyst in the regenerator per hour.
Thank You