FCC FUNDAMENTALS : OPERATIONS & TROUBLESHOOTING

PRESENTED BY : S PALIT (DMPN)

CONCERNS IN FCC
CATALYST LOSS COKING / FOULING FLOW REVERSAL CATALYST CIRCULATION HIGH REGEN TEMPERATURE AFTER BURNING AMOUNT & QUALITY OF PRODUCTS.

MAJOR PROBLEM AREAS

CATALYST LOSS

CATALYST LOSS SYMPTOMS

CAUSES OF CATALYST LOSS

MECHANICAL CONDITION

CHANGES IN OPERATING CONDITION

CATALYST PROPERTIES

MECHANICAL CAUSES

TRICKLE VALVES ARE STUCK CLOSE OR OPEN

DEFORMATION OF TRICKLE VALVE FLAPPER OR TRICKLE VALVES DISENGAGED

TRICKLE VALVE & SPLASH PLATE

MECHANICAL CAUSES (CONTD)

SPALLED COKE OR REFRACTORY IN DIP LEG CAUSING RESTRICTION

HOLES ON CYCLONES CRACKS ON PLENUM CHAMBER DETACHED DIPLEG

A TYPICAL CYCLONE

MECHANICAL CAUSES (CONTD)

IMPROPER STEAM / AIR RESTRICTION ORIFICES ON PURGES CAN LEAD TO CATALYST ATTRITION, THEREBY GENERATING FINES

CATALYST LOSS DUE TO OPERATIONS

INCREASE IN CATALYST CIRCULATION INCREASE IN STEAM TO REACTOR

INCREASE OF CATALYST LOADING TO CYCLONES

AIR TO REGENERATOR

LOWERING OF OPERATING

PRESSURE

CATALYST LOSS DUT TO CATALYST

TROUBLESHOOTING

TROUBLESHOOTING
VERIFY THE CATALYST LEVELS IN REACTOR AND REGENERATOR CHECK THE CYCLONE VELOCITIES AND COMPARE WITH THE DESIGN OPERATIONAL

REDUCE CAT -OIL RATIO

CHECK PURGE POINT ROV

COKING / FOULING PROBLEM

POOR HEAT TRANSFER IN MCB PUMPAROUND CIRCUIT

FREQUENT CAVITATION AND LOSS OF SUCTION OF BOTTOM PUMP

HIGH PRESSURE DROP ACROSS Rx VAPOUR LINE

INCREASED PRESSURE DROP IN MCB EXCHANGERS

REASONS FOR COKING / FOULING

CATALYST PROPERTIES RESPONSIBLE FOR COKING

OPERATIONAL CONDITIONS RESPONSIBLE FOR COKING

LONG RESIDENCE TIME

LOW ROT

LOW WASH LIQUID FLOW LONG RESIDENCE TIME IN VAPOUR LINE

HIGH MCB LEVEL

FEED PROPERTIES LEADING TO COKING

ASPHALTENES AND RESID IF NOT CONVERTED IN RISER, LEADS TO COKING

MECHANICAL CONDITIONS LEADING TO COKING

TROUBLE SHOOTING

TROUBLESHOOTING
IMPROVE FEED ATOMISATION

INTRODUCE FEED WHEN REACTOR IS ADEQAUTELY HEATED DURING UNIT START UP

KEEP THE VELOCITY IN MCB EXCHANGER > 2.1 m/s

TROUBLESHOOTING
MAINTAIN MCB TEMP < 360 deg C

MAINTAIN 1ST TRAY IN THE BOTTOM TEMP < 420C BY PROVIDE ADEQUATE WASHING LIQUID TO MCB

MAINTAIN HIGH REACTOR TEMPERATURE IF POSSIBLE

FLOW REVERSAL
NORMAL CATALYST FLOW PATH

REGENERATOR

REACTOR

REGENERATOR

FLOW REVERSAL

PROPER PRESSURE BALANCE ACROSS REACTOR AND REGENERATOR AIDS CATALYST MOVEMENT

PHENOMENON OF FLOW REVERSAL

OIL SOAKED CATALYST TO FLOW REVERSE FROM RISER TO REGENERATOR IN CASE THE DIFFERENTIAL PRESSURE ACROSS REGENERATED CATALYST SLIDE VALVE BECOMES NEGATIVE

THE HOT FLUE GAS FLOW TO REACTOR AND TO COLUMN IF THE PRESSURE DIFFERENTIAL ACROSS SPENT CATALYST SLIDE VALVE BECOMES NEGATIVE

CAUSES OF FLOW REVERSALS

MAB TRIPPING PRESENCE OF WATER IN FEED HIGH OPENING OF SLIDE VALVES SUDDEN LOSS OF REACTOR / REGENERATOR LEVELS FAILURE OF REACTOR TEMP / LEVEL CONTROL

PROTECTION FROM FLOW REVERSAL

INDEPENDENT LOW DIFFERNTIAL PRESSURE OVERRIDE CONTROL FOR SLIDE VALVES CHECKING OF FEED TANK HEATING COIL OUTLET AND REGULAR DRAINING OF FEED SURGE DRUM EMERGENCY SHUT DOWN

HIGH REGENERATOR TEMPERATUR

HIGH REGENERATOR TEMPERATURE

HIGH REGENERATOR TEMPERATURE

HIGH REGENERATOR TEMPERATURE

HIGH REGENERATOR TEMPERATURE

HIGH REGENERATOR TEMPERATURE

RAISE CAT / OIL RATIO

IMPROVE FEED ATOMISATION

REMEDIES
IMPROVE STRIPPING IN REACTOR USE METAL PASSIVATOR

AFTER BURNING

CAUSES OF AFTER BURN

POOR AIR / CATALYST DISTRIBUTION

LIFT LINE WITH AIR RING AIR DISTRIBUTION PROBLEM

CAUSES OF AFTER BURN

LIFT LINE WITH AIR RING CAT DISTRIBUTION PROBLEM

CHANNELING OF CATALYST IN CURVED LIFT LINE

CAUSES OF AFTER BURN

REGEN INTERNALS CREATE TWO STAGE REGENERATION

CATALYST ENTERS ONE SIDE OF REGENERATOR

CAUSES OF AFTER BURN

EFFECT OF HIGH DENSITY CATALYST ON AIR DISTRIBUTION

REASONS OF AFTERBURNS OPERATING CAUSES MECHANICAL CAUSES

DAMAGED AIR RING

EXCESS AIR

LOW CATALYST RESIDENCE TIME

DAMAGED CATALYST DISTRIBUTOR

AFTER BURN REMEDIES

INCREASE STRIPPING STEAM RATE.

INCREASE THE CATALYST RESIDENCE TIME : RAISE THE REGENERATOR CATALYST BED LEVEL.

REDUCE FEED CCR

INCREASE CAT / OIL BY QUENCHING

CATALYST CIRCULATION

THE LIMITATION IN CATALYST CIRCULATION WILL LIMIT THE TPUT OF THE UNIT.

EXTREME HIGH CAT CIRCULATION PROBLEM WILL LEAD TO UNIT SHUTDOWN

CATALYST CIRCULATION PROBLEM

SYMPTOM: SLIDE VALVE FAR TOO OPEN EVIDNECE:
SLIDE VALVE OPENING INDICATIONS

CAUSES:
GATE OR ORIFICE TOO SMALL FOR FLOW SOLUTIONS: REPLACE WITH APPROPRIATE SIZE VALVE INCREASE REGEN PRESSURE / BED LEVEL

CATALYST CIRCULATION PROBLEM

LOW DELTA P ACROSS SLIDE VALVE

SYMPTOM:

REASONS:

HIGH PRESSURE D/S OF SLIDE VALVE

LOW PRESSURE U/S OF SLIDE VALVE

WHEN HIGH PRESSURE D/S

REASONS

HIGH DP ACROSS RISER

HIGH DP ACROSS VAP LINE

HIGH CAT CIRCULATION

LESS RISER GAS AT RISER BASE

VAP LINE COKING

HIGH RXR VAP LOAD

CAUSES

WHEN HIGH PRESSURE D/S

REASONS

HIGH DP ACROSS MF

HIGH DP ACROSS MF O/H CIRCUIT

HIGH VAP / LIQ RATES

PLUGGED TRAYS

CONDENSER FOULING

HIGHER RATES OF LIGHTER HC

CAUSES

WHEN HIGH PRESSURE D/S

HIGH DP ACROSS RISER

PROBLEMS

HIGH DP ACROSS VAP LINE

REPLACE RISER BEND

INCREASE RISER STEAM

COKING REDUCTION

VAP LINE CLEANING DURING S/D

SOLUTIONS

WHEN HIGH PRESSURE D/S

PROBLEMS HIGH DP ACROSS MF HIGH DP ACROSS MF O/H CIRCUIT

ADJUST PUMP AROUND RATES

ADD TOP OR SIDE PUMP AROUNDS

CONDENSER CLEANING

INCREASE WATER WASH TO CONDENSERS

SOLUTIONS

WHEN LOW PRESSURE U/S

REASONS
INSUFFICIENT PRESSURE BUILD UP IN STAND PIPE LOW CATALYST DENSITY IN STAND PIPE

DEFLUIDIZATION IN STAND PIPE

DE-AERATION IN STAND PIPE

IMPROPER PLACEMENT OF AERATION TAPS

PLUGGED RO

CAUSES

WHEN LOW PRESSURE U/S

PROBLEMS
IMPROPER PLACEMENT OF AERATION TAPS

DEFLUIDIZATION IN STAND PIPE

DE-AERATION IN STAND PIPE

PLUGGED RO

CHECK CATALYST PROPERTIES

INCREASE AERATION GAS FLOW TO MAXIMIZE PRESSURE BUILD UP

FLUSH RO

SOLUTIONS

LOSS IN PRODUCTS

PROBLEM INDICATORS

CONVERSION DRY GAS YIELD GASOLINE YIELD

PROBLEM AREAS

FEED QUALITY CATALYST QUALITY OPERATING CONDITION MECHANICAL DEFECT

LOW CONVERSION
FEED QUALITY
INCREASE IN METALS CONTENTS

CATALYST PROPERTIES
LOW CATALYST ACTIVITY

HIGH FBP FEED

LOW SURFACE AREA

INCREASE IN FEED AROMATICITY / NAPHTHENECITY

HIGH CRC

LOW CONVERSION
OPERATING CONDITIONS
LOW CAT / OIL RATIO

MECHANICAL CONDITIONS
PROBLEM IN FEED NOZZLE

LOW ROT

PROBLEMS IN REGEN INTERNALS

LOWER RATE OF FEED ATOMIZING STEAM

LOW F-CAT ADDITION RATE

TROUBLESHOOTING

CHECK FEED STOCK PROPERTIES

K-FACTORS, ANILINE POINT, SP. GR

CHECK E-CAT PROPERTIES VERIFY ACCURACY OF INSTRUMENT INDICATIONS OF RR SECTION CARRY OUT PRESSURE SURVEY OF FEED NOZZLES, AIR RINGS, ETC

HIGH DRY GAS YIELD

FEED QUALITY
INCREASE IN METALS CONTENTS

CATALYST PROPERTIES
LOW CATALYST ACTIVITY

INCREASE IN FEED AROMATICITY / NAPHTHENECITY

LOW SURFACE AREA

HIGH CRC

HIGH DRY GAS YIELD

OPERATING CONDITIONS MECHANICAL CONDITIONS
PROBLEM IN FEED NOZZLE

HIGH ROT

LOWER RATE OF FEED ATOMIZING STEAM

PROBLEMS IN REGEN INTERNALS

INCREASE IN RECYCLES

DECREASE IN GASOLINE YIELD

FEED QUALITY
HIGH FBP FEED

CATALYST PROPERTIES
LOW RARE EARTH CONTENT

INCREASE IN FEED AROMATICITY / NAPHTHENECITY

LOW ZEOLITE CONTENT

LOW UNIT CELL SIZE

DECREASE IN GASOLINE YIELD

OPERATING CONDITIONS
LOW / HIGH ROT DECREASE CAT / OIL RATIO HIGH DOSING OF ZSM -5

MECHANICAL CONDITIONS
PROBLEM IN FEED NOZZLE PROBLEMS IN REGEN INTERNALS