9th Workshop on “FCC for Refinery Engineers”

Indian Oil Corporation Ltd, R&D Centre, Nov 25-28, 2013

FCC Fundamentals
November 25, 2013

Debasis Bhattacharyya
(bhattacharyyad1@indianoil in)
([email protected])
 This presentation is only for the attendees of 9th “FCC Workshop for Refinery
Engineers” held at R&D Centre
Engineers Centre, Indian Oil Corporation Ltd
Ltd., Faridabad during
November 25-28, 2013. Neither the whole nor any part of this may be reproduced
or distributed in any form or by any means without the prior written consent of
Indian Oil Corporation Limited, R&D Centre, Faridabad.

2
 Outline

Introduction
Process schematic
Reactor-Regenerator configuration
Reactor-Regenerator internals
Catalyst & Additives
Catalyst regeneration
Unit heat balance
Effect of variables
 Crude Oil
• Hydrocarbons type  alkanes, cycloalkanes, aromatics
 Other organic compounds containing nitrogen,
nitrogen oxygen,
oxygen sulfur and
trace amounts of metals such as iron, nickel, copper & vanadium
 Molecular composition varies widely from formation to formation
 Typical composition:

Wt%
Carbon 83-87
H d
Hydrogen 10 14
10-14
Nitrogen 0.1-2
Oxygen 0 05 1 5
0.05-1.5
Sulfur 0.05-6
Metals < 0.1

4
 Processes in Refinery
Classification

Crude oil
separation

Contaminant
C t i t Molecular
removal /
product quality Refinery rearrangement &
combination
improvement

Molecular
cracking:
g large
g
to small
 Refining Processes
Primary processes
• Atmospheric distillation
• Vacuum distillation
Secondary processes – conversion
• Visbreakingg
• Delayed coking
• Fluid catalytic cracking (FCC)
• Hydrocracking (HC)

Separation processes (LOBS production)

 Solvent extraction
 Solvent deasphalting
 Solvent dewaxing Catalytic dewaxing

Product upgradation / treatment

 Hydro-treating (DHDS / DHDT), Merox, etc.
 C t l ti reforming
Catalytic f i (SR / CCR)
 Isomerization,
6
 Cracking of Heavy Hydrocarbon Stream
Cracking : Breaking large molecules  by application of heat  with or
without catalyst  with or without hydrogen

Thermal Catalytic Hydro

High coke Low coke
 Fluid Catalytic Cracking (FCC)
First up-flow circulating fluidized system started in May 1942
- attained 1700 BPD capacity by July 1942

Dry gas
Vacuum
acuu gas oil
o (VGO)
( GO) (H2, C1, C2)

Hydro-treated VGO LPG

(C3, C4)
H d
Hydro-cracker
k bottom
b tt
Light cracked naphtha (LCN)
Coker gas oil (CGO) (C5-150oC)

H
Heavy cracked
k d naphtha
hth (HCN)
De-asphalted oil (DAO)
(150 - 220oC)
Reduced crude oil (RCO)
Light cycle oil (LCO)
Vacuum residue (VR) (220 - 370oC)

Clarified oil (CLO) or

Decant oil (DO)

Conversion wt% = (Feed- LCO- CLO)*100/Feed

……. being continued till today8
 Schematic of FCC
Products to
Fractionator

Flue Gas Reactor

to WHRU
Minimum fluidization Bubbling
(0.001-0.05 m/s) (0.05-0.30 m/s)

Stripper
Steam
Regenerator SCSV

Turbulent (0.7-1.1 m/s)

Fast fluidization/
Pneumatic transport
Air (5-20 m/s)
Riser
RCSV
CS
RCSV  with Riser outlet temp.  Feed
SCSV with reactor level 

Steam
9
 Fluidization Regimes

P P
L Umb L
Umf Uch

.... .
.. . .
.. .
. .
. .. .
. . .
.
.. .. ....
.

Fixed Particulate Bubbling Slug flow Turbulent Fast Pneumatic

bed regime regime regime regime fluidization conveying

Increasing Gas Velocity 10

 Fluidization Regimes in FCC

Name FCC Section Gas Velocity

y Bed Density,
y
m/sec kg/m3
Packed Bed -- < 0.05 700 - 850
Min Fluidization Standpipe 0.001 - .05 700 - 800
Bubbling bed Stripper 0.05 - 0.30 600 - 750
Dense Bed Regenerator 0.30 -0.70 400 - 600
Turbulent Bed -- 0.70
0 70 - 1.1
11 300 - 500
Fast Fluid Bed Combustor 1.1 - 3.0 100 - 300
Pneumatic Flow Riser 2 - 20 30 - 100

11
 Fluid Catalytic Cracking

Wet gas compressor

Feed surge
drum & pump

 DDSV
 Orifice chamber

* 

CO boiler
Waste heat recovery
 Flue gas stack
Reactor-Regenerator
Reactor Regenerator
Configuration

13
 History of Fluidized Beds
1940s Fluid Catalytic Cracking Process for Gasoline

Period FCC p
process development
p
1936-1941 Fixed bed
1941-1960 Moving bed
1942 t d
1942-today Fl id b
Fluid bed
d

1942 1st commercial FCCU was on

stream at Baton Rouge Refinery of
Standard Oil of New Jercy

End of 1945 33 FCCU were in operation

1955-today Short contact Riser reactor -

became popular from 1970s

Dense bed cracking Riser cracking

Cat RT, s 30-120 5-15

Vap RT, s 10-60 2-5
T, oC 480-500 480-650
Evolution of FCC Hardware Design

15
Exxon’s Model-IV FCC Unit

Flexi-cracking by ExxonMobil
16
 Evolution of FCC Hardware Design

Kellogg Orthoflow FCC Converter Orthoflow Resid FCC Converter 17

 Resid FCC Units

Two‐stage 
regenerator

Fast fluidized 
regenerator
g

UOP high efficiency

Regenerator RFCCU UOP RFCC Unit 18
 Two Stage Regeneration

RFCC unit by SWEC R2R unit by Axens

Evolution of FCC Hardware Design

Source: KBR Website

20
 Angled Standpipes

Burp tube to
vent out the
bubbles

Regenerator Withdrawal
Bed Well

Sparger

Standpipe
Withdrawal Well
 Challenges in Design & Oprn of FCC
∆P in Riser / Conveying line
1 Gas acceleration
1.
2. Particle acceleration
3 Gas-to-pipe
3. G t i ffrictioni ti
4. Solid-to-pipe friction
5 Static
5. St ti head
h d off solids
lid
6. Static head of gas

"Choking velocity"- the gas velocity, when lowered from a conveying velocity,
whereby the pipeline gets choked & pneumatic conveying stops

"Saltation velocity"- the minimum velocity required to maintain solids in the

dilute-phase mode in a horizontal conveying line

Saltation velocity is typically 3-6 times the "Choking velocity".

Reactor-Regenerator
Internals

23
 Reactor-Regenerator Internals

Reactor dome Cyclone separator

quench nozzle Riser termination
device

Regenerator dome
quench nozzle
Stripper internals
Cyclone separator
Stripping steam
distributor

Spent catalyst
Regenerator air distributor
distributor

Feed injectors

24
 Feed Injection System
 Rapid feed vaporization and
g with catalyst
uniform mixing y
 Reduce non-selective cracking &
thermal reaction

 Better feed nozzle design

using dispersion steam
 Enhance vaporization
 Avoid backmixing of hydrocarbons
 Avoid thermal cracking
 Reduce hydrocarbon partial pressure
Feed coke = 1 (feed CCR)  Reduce coke make & improve yields
where, 1 = f1(feed
p )
vaporization/distribution)

Dispersion steam: 2 to 5 wt % of feed depending on feed quality 25

Feed Injection System
 Effect of Feed Atomization
Parameter Case-1 Case-2 Case-3
size 
Oil droplet size, 500 100 30
Relative no. of droplets 1 125 4630
Oil droplets/catalyst particle 0.001 0.11 4
Vaporization time, milisec
at 50% vorization 220 11 4
at 90% vaporization 400 20 8

27
 Riser Terminating Devices
T-Type Disengager Down Turned Arm Vented Riser

28
Riser Terminating Devices

Direct-Connected
Cyclones

29
 Reactor Riser Disengaging Devices

Source: www kbr com

Source: www.kbr.com

Ramshorn type or Linear Closed Cyclone Riser

Disengaging Device (LD2) Termination

Vortex Separation System

30
 Regenerator Cyclone System & Orifice Chamber

Source: www.hason-steel.com

Regenerator Cyclones
Orifice chamber
 Cyclone Placement

Dilute bed

TDH
Transition

Dense Bed

Density of solids

Air 32
 Dipleg Termination
Seal between discharging cat & upflowing vapors
Splash plate
 Circumferential area available for flow > 250% of
CSA of dipleg for free solids flow – decrease the
effect of pile

Trickle valve
 Angled less than 3 deg – creates dipleg dumping
 Operates satisfactorily when submerged in bed

Counter-weight valve
 Particles becomes lodged in clearances (pivot pin)
– Freezes the operation
 Operates satisfactorily when not submerged in bed

33
 Regenerator Air Distributor
Air distributor
• Minimizing gas bypassing or channeling
• M
Mass transfer
t f diffusion
diff i resistance
i t
• Erosion
• Thermal expansion – mechanical reliability
• Mechanical integrity of supports

Commonly used
• Pipe grid
• Air ring

Pipe grid preferred due to uniform coverage & lower discharge velocity

Efficient air grid

• Total combustion regenerators  least excess oxygen in flue gas
• Partial combustion regenerators  minimum afterburning
34
Catalyst & Additives

35
 FCC Catalyst
Catalysts  Heart of FCC process undergone evolutionary changes

Colloidal binder
 Zeolite: Silica-alumina
 Amorphous matrix: Silica, silica-alumina, alumina
Zeolite pores  Filler clay: Silica-alumina
Silica alumina
6.5-13. 5A  Other elements: Rare earth, Sodium
Interparticle void
clay
Matrix pores
10-200A

1942 Natural clay, Synthetic low alumina catalyst

1 micron 1948 Micro spheroidal catalyst (low alumina)
Micro-spheroidal
1955 High alumina synthetic catalyst
1961 D5 zeolite TCC bead catalyst
y
1964 Spray dried fluid Y zeolites
1980 Coke selective Re-HY catalysts
1986 Improvement in Y-zeolites (USY) – low coke selectivity,
Higher octane (low non-framework alumina)
 FCC Catalyst
Cracking catalysts undergone many evolutionary changes
Impro ements in FCC catalysts
Improvements catal sts

Year  1950 1970 1990

Zeolite content, wt% 0 10 Up to 40
Particle density, g/cc 0.9 1.0 1.4
Relative Attrition Index 20 5 1

Today’s
y FCC catalysts
y
Porous spray dried micro-spherical powder
Particle size distribution of 20 -120 micron & p
particle density
y ~ 1400 kg/m3
g
Comprising Y zeolite in many derivatives of varying properties
Supplied
pp under various g
grades of p
particle sizes & attrition resistance
Continuing improvement  metal tolerance, coke selectivity
37
 Reactor Configuration

Dense bed Riser cracking

cracking
Catalyst
• Activity Low High
• Stability
St bilit L
Low I
Improved
d
• Coke selectivity Poor Improved
• Attrition Index Poor Very good
• Accessibility Poor Better
Catalyst residence time, s 30-120 5-15
Vapour residence time, s 10-60 2-5
Reactor temp., / Riser outlet temp., oC 480-500 500-590
Feed CCR, wt% (max) ~ 0.6 ~6

38
 Use of Additives
ZSM-5 Bottom Cracking
GSR Additive
Additive Additive
• Increases yields • Upgrades • Reduces
g
of LPG / Light bottom fraction Gasoline Sulfur
olefins of feed without content by ~
• Improves proportional 30%
Gasoline RON increase in coke
make

SOX Control Ni passivator

CO Promoter
Additive & V- Trap
• Enhances CO • Reduces SOx in • Reduces
burning in regenerator flue detrimental
regenerator gas effects of metals
dense bed on catalyst health
& product yields
39
Catalytic Reactions
&
Modes of Operation

40
 Reactions in FCC
Thermal cracking reactions
 Formation of free radical:
A free radical is an uncharged molecule with an unpaired electron
H H H H
‫׀‬ ‫׀‬ ‫׀‬ ‫׀‬
. .
R1 – C – C – R2 R1- C + C – R2
‫׀‬ ‫׀‬ ‫׀‬ ‫׀‬
H H H H
 F
Free radicals
di l are extremely
t l reactive
ti & short-lived
h t li d  can undergo
d β
scission, polymerization
 β scission p
produces an olefin ((ethylene)
y ) and a p
primary
y free radical
. .
R-CH2-CH2- C-HR’ R- C-H2 + H2C=CHR

 High
Hi h percentage
t off olefins
l fi fformed
ddduring
i iintermediate
t di t reactions
ti
polymerize & directly form coke
41
 Catalytic Cracking Reactions
Two broad categories
 Primary cracking of feed molecules

 Secondary rearrangement & re-cracking of cracked products

 The reaction mechanism proceeds through formation of Carbenium Ion

CH3
‫׀‬
CH3 – CH – CH2 – CH2 – CH2 – CH3

Stability:
y Tertiaryy > Secondary
y > Primaryy carbon

Hundreds
H d d off reactions
ti between
b t thousands
th d off components,
t
intermediates and products in catalytic cracking
42
 Carbenium Ion Intermediates
Initiation Step
Protonation
+ –
R1 – CH = CH – R2 + HZ R1 – CH2 – CH - R2 + Z
H: abstraction
+ +
R1 – CH2 – CH2 – R2 + L R1 – CH2 – CH - R2 + HL

Propagation Step (hydride transfer):

R1 – CH2 – CH+ - R2 + R3 – CH2 – CH2 – R4
H: transfer
R1- CH2 – CH2 – R2 + R3 – CH2 – CH+ - R4

Cracking Step (β scission):

β
R3 – CH2 – CH+ - R4 R3+ + CH2 = CH – R4

Stability of carbocations decreases in the following order

Tertiary > Secondary > Primary

43
 Secondary Reactions

Isomerization reaction CH3

R – CH2 – CH2 – CH+ - CH3 R – CH2 – C+ - CH3
(Secondary carbeniumion) (Tertiary carbenium ion)

Cyclization reaction CH3

C+ CH3
CH3 – CH+ - (CH2)3 – CH = CH – CH3 H2C CH
H2C CH2
C
H2
3CnH2n + CmH2m 3CnH2n+2 + CmH2m-6 C
C C
C
C C C
C2H2n-6, CmH2m-2 H loss
Alkylation, Condensation, , C
C C
Polymerization C
C C
C
 Reactions: Summary
Paraffins Cracking Paraffins + Olefins

Cracking LPG Olefins

Cyclization Naphthenes
Isomerization Branched Olefins H Transfer Branched Paraffins
Olefins H Transfer Paraffins
y
Cyclization Coke
Condensation Coke
Dehydrogenation Coke

Cracking Olefins
Naphthenes Dehydrogenation Cyclo-olefins Dehydrogenation Aromatics
Isomerization Naphthenes with different rings

Side chain cracking Unsubstituted aromatics + olefins

y
Trans alkylation Different alkyl
y aromatics
Aromatics
Dehydrogenation Polyaromatics Alkylation Coke
Condensation Dehydrogenation
Condensation

Hydrogen transfer  Naphthene + Olefin  Aromatic + Paraffin

45
 Hydrocarbon Distribution
Lighter oils Heavier oils & Residua
I
Increasing
i Hetero-atom
H t t (N O S & Metals)
(N,O,S M t l ) content
t t
100
Polynuclear Aromatics

Mononuclear
Aromatics

50 Monocycloparaffins
Polycycloparaffins
(Naphthenes)

Normal and Branched

Paraffins

0
0 100 200 300 400 500
OC
 Product Yields vs. Conversion
50
Diesel mode Gasoline mode LPG mode
45

40
CLO
35

30
Yield,  wt%

TCO
25

20
Y

15
Gasoline LPG
10
Coke
5 Dry gas

0
15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

216 C Conversion, wt%

 Over-cracking of desired product to be restricted - Controlling reaction severity

 Recycle of unconverted bottom
 Improve LCO / HCO separation in main column to minimize recycle of LCO range material
 Modes of Operation
Mode LPG Gasoline Distillate
Typical product yields
yields, wt%
Dry gas 6.5 4 2
LPG 40 18 10
Gasoline (C5-150oC) 25 45 30
TCO (150
(150-370
370oC) 10 22 44
CLO ( 370oC+ ) 4 6 10
Coke 6.5 5 4
-216oC conversion 90 81 50

Coke deposited
p on catalyst
y – blocks active sites – causes temporary
p y
deactivation  needs regeneration before circulating to riser
48
C t l tR
Catalyst Regeneration
ti

49
 Types of Coke
Coke make = Feed coke + Catalytic coke + Strippable coke +
Contaminant coke
Feed coke = 1 (feed CCR)
where, 1 = f1(feed vaporization/distribution)
Catalytic
y coke = f2 ((ROT, Pre-heat temp,
p Catalyst
y type,
yp Feed q
quality,
y
Residence time in riser, Cat/Oil ratio, Hydrocarbon partial pressure in riser)
Strippable coke = f3 (Stripper design / operation, ROT, Catalyst type,
F d quality)
Feed li )
Contaminant coke = f4 (Feed contaminants-Ni, V, Na.., Catalyst make
up rate,
rate Catalyst type,
type Use of additive/passivator
additive/passivator, Operation severity)

50
 Catalyst Regeneration
Coke deposited on catalyst – blocks the active site – causes
p
temporaryy deactivation  needs burningg to regenerate
g
before circulating to riser
Regeneration efficiency
 Regenerator temperature
 Catalyst residence time in Regenerator
 Fluidization regime
 Distribution of spent catalyst & air
 Regenerability of catalyst
 Catalyst PSD & APS
Regeneration mode
 Partial
P ti l
 Complete / Full 51
 Mode of Catalyst Regeneration
Coke burning reactions
C + 1/2O2  CO (∆H = - 2200 kcal/kg)

CO + 1/2O2  CO2 (∆H = - 5600 kcal/kg)

H2 + 1/2O2  H2O (∆H = - 28900 kcal/kg)

Mode Total Partial

Combustion Combustion
Coke on regenerated catalyst, wt% < 0.05 > 0.05
Effective catalyst activity Higher Lower
Regenerator temperature, oC Higher Lower
CO in flue gas,
gas ppm < 1000 > 1000
Requirement of CO Boiler No Yes
g
Chances of ‘Afterburning’ Lower Higher
g

52
 Regenerator Afterburning

When part of the CO escapes dense bed & gets burnt in

dil t b
dilute bed
d
∆T between dilute and dense increases – this phenomena is
called afterburning
 Lower regenerator temperature
 Lower regenerator residence time
 Non-uniform distribution of spent catalyst & air
 Poor
P regenerability
bilit off FCC catalyst
t l t
 Higher APS of E-cat

CO Combustion Promoter enhances burning of CO in

dense bed  reduces afterburning
53
 Regenerator Oprn. in Diff. Regimes
Parameter Bubbling Turbulent bed Fast fluidized
bed bed
Mass transfer Better because Lower than Good due to
rate of continuous bubbling bed due presence of
b bbl
bubbles t mixing
to i i & continuous
ti gas
absence of phase
bubbles

Heat Transfer Good due to Excellent due to Relatively better total

rate less agitation, rapid agitation & heat transfer / unit
fluctuating temp uniform mixing & bed volume (<TB)
gradient temp

Pressure
P Fluctuating
Fl t ti St d
Steady Poor sealing
P li off
fluctuations pressure standpipes
 Challenges in Design & Oprn of FCC
Item Challenge

Riser Achieve fast mixing

mixing, vaporization & minimize catalyst slip for
better riser performance
Riser Achieve a fast & clean separation that minimizes the degradation
termination of the hydrocarbon products by minimizing post riser cracking.

Stripper Maximize the contacting efficiency in order to recover the most

hydrocarbons by proper design of stripper internals and steam
injection systems

Regenerator
g Maximize catalyst regeneration by proper distribution of spent
catalyst & air

Cyclones Design of cyclone system based on accurate estimation of

catalyst
t l t loading
l di & operation
ti with
ith proper pressure balance
b l

Standpipes maximize pressure buildup & flow stability in standpipes by

proper design of the standpipe inlet and aeration
Reactor-Regenerator Heat
Balance

56
 FCC Heat Balance
Regenerator Reactor
Flue gas Spent Catalyst

Products

H tL
Heat Losses
Heat of Coke
Heat losses Combustion

Heat of
Reaction
Recycle

Regenerated Fresh Feed

Catalyst
Regeneration
Air Feed Pre-heater
57
 FCC Heat Balance
Coke yield = Wcoke / Wfeed
= Wcat
Wcat*(CSC-CRC)
(CSC CRC) / Wfeed
= (Cat/Oil)*(Delta Coke)
D lt C
Delta Coke (Cpcatt / Hcoke
k = (C H k )*(T T )  (Trg-Trc)
)*(Trg-Trc) (T T )

Reactor heat demand per unit total feed

Coke yield =
Heat of Combustion per unit Coke

= (Cat/Oil)*(Delta Coke)

Delta Coke  (Trg-Trc)

For a given ROT, more the Delta coke, higher will be the regenerator
dense bed temperature

58
 Implication of Heat Balance
• If reactor heat demand not changed, coke yield remains
constant
• Heavy
H F
Feedd S
Same Coke
C k Yi
Yield
ld but
b High
Hi h D
with High CCR Coke, High regen temp.
Low Cat / Oil Ratio

• Coke Yield a [Heat of Combustion Per Unit Coke]-1

• High H/C of Coke Low Coke Yield
High CO2/CO in Flue Gas

 Regenerator temp.  Delta coke

(150C) (0.1)

 Riser temp. drop  Heat of reaction

(200C) (
(~100 Kcal/Kg)
/ ) Diesel Mode
(500C) (~250 Kcal/Kg) LPG Mode 59
 Factors Affecting Delta Coke
Parameters Relationship

1. Feedstock
CCR Delta Coke  CCR

2. Catalyst
Activity Delta Coke  Activity
Coke Selectivity Delta Coke  Coke Selectivity
Metal levels Delta Coke  Activity

3. Operating Parameter
Cat/oil Delta coke  1/cat/oil
Reactor Temp. Delta coke  1/Trex temp
Feed Temp. Delta coke  feed temp.
 Variables in FCC
Independent
 Feed rate
 Recycle ratio
 Feed preheat
 Riser top temperature
 Reactor pressure
 Fresh catalyst activity / Selectivity

Major dependent
 Regenerator temperature
 Catalyst circulation rate
 Regenerator air flow
 Coke on regenerated catalyst
 Product y
yields

61
 Impact of Heavy Feed
Feed Light Heavy
Density, gm/cc 0.89 0.92
CCR wt%
CCR, t% 0 15
0.15 07
0.7 Higher delta
Nitrogen, ppm 150 450 coke  Higher
Product yields, wt% regen
g temp. p &
DG 2.79 3.02 Lower cat/oil
LPG 12.47 7.24 ratio
LCN 25 27
25.27 19 13
19.13
HCN 11.15 9.65
LCO 33.59 33.55
CLO 9.46 22.41
Coke 5.27 5.0
Reg Temp,
Reg, Temp oC 650 674
Cat. Circulation rate, T/hr 1053 878
CRC, wt% 0.32 0.51
CSC, wt% 1.12 1.44
Air rate, Nm3/hr 63736 62440 62
 Effect of Feed Preheat Temp.
Base Actual
Feed rate, m3/hr 128 130
Riser Top Temp, oC 503.3 501
Feed preheat Temp, oC 404 341
Cat circulation
circulation, 6.2 8.7
MT/min.
Regen Temp, oC 715 683 Coke yield
T h oil
Torch il injection
i j ti
increased due
Yes No
to reduction of
Product Yield, wt% feed preheat
Dry Gas 22
2.2 19
1.9 temperature
LPG 10 12.9
Gasoline(C
( 5-204 oC)) 37.6 40.2
LCGO(204-370o C) 24.6 22.8
Resid( 370o C + ) 22.9 18.9
Coke 2.7 3.3
63
 Effect of CO Promoter on Coke Yield

Base With CO
promoter Coke yield
Product yields, reduced due to
wt% incremental heat
Dry gas 2.6 2.6 generation from
LPG 11.2 11.2 enhanced
Gasoline 23.5 26.5 conversion of CO
HCN 11.5 11.5 to CO2
LCO 30.2 30.7
CLO 16 0
16.0 13 0
13.0
Coke 4.3 3.8
RX temperature, °C 493 494
Feed preheat, °C 355 350
Regen temp, °C 630 648
CRC wt%
CRC, 0 45
0.45 0 32
0.32

64
 Major FCC Constraints
Regenerator dense bed temperature
Regenerator cyclone temperature
Regenerator cyclone inlet velocity
Regenerator superficial velocity – incremental
solid loading to cyclone
Reactor cyclone inlet velocity
CCR (∆P across slide valve)
MAB capacity
WGC capacity
it

Optimum operation  one or more constraints

Optimum
Debottlenecking / Revamp  Removal / Expanding constraints
65
 Shifting in objective of FCC operation
ctive

Petrochemical
feed stock
Operating Objec

Alkylation&
Isomerization feed

•Product
quality

•Resid

•Gasoline

1942 1970 1990 1995 2010 66

 Summary
FCC has been the most profitable & flexible refining process
for its ability to meet changing demands
Even after 6 decades of existence, FCC technology is
undergoing significant evolution
Optimum operation needs
Judicious selection / use of catalyst / additive
Intelligent feed management
Careful selection of parameters - understanding of complex
interaction among competing variables & fundamentals
F
Focus on long
l tterm benefits
b fit than
th short
h t term
t gain
i

67
Th k You
Thank Y
68