This document provides a summary of a report on a hydrocracking unit. It begins by explaining that hydrocracking is a process that converts higher molecular weight hydrocarbons into more valuable lower molecular weight hydrocarbons using hydrogen at high temperatures and pressures in the presence of a catalyst. It then discusses why hydrocracking is used over other processes like FCC and visbreaking, noting its ability to produce cleaner, more valuable products. The document outlines the major components of the hydrocracking unit including the reactor, fractionation section, and light ends recovery section. It concludes by describing some key process variables like temperature, pressure, and feed properties that impact the hydrocracking reaction.
This document provides a summary of a report on a hydrocracking unit. It begins by explaining that hydrocracking is a process that converts higher molecular weight hydrocarbons into more valuable lower molecular weight hydrocarbons using hydrogen at high temperatures and pressures in the presence of a catalyst. It then discusses why hydrocracking is used over other processes like FCC and visbreaking, noting its ability to produce cleaner, more valuable products. The document outlines the major components of the hydrocracking unit including the reactor, fractionation section, and light ends recovery section. It concludes by describing some key process variables like temperature, pressure, and feed properties that impact the hydrocracking reaction.
This document provides a summary of a report on a hydrocracking unit. It begins by explaining that hydrocracking is a process that converts higher molecular weight hydrocarbons into more valuable lower molecular weight hydrocarbons using hydrogen at high temperatures and pressures in the presence of a catalyst. It then discusses why hydrocracking is used over other processes like FCC and visbreaking, noting its ability to produce cleaner, more valuable products. The document outlines the major components of the hydrocracking unit including the reactor, fractionation section, and light ends recovery section. It concludes by describing some key process variables like temperature, pressure, and feed properties that impact the hydrocracking reaction.
This document provides a summary of a report on a hydrocracking unit. It begins by explaining that hydrocracking is a process that converts higher molecular weight hydrocarbons into more valuable lower molecular weight hydrocarbons using hydrogen at high temperatures and pressures in the presence of a catalyst. It then discusses why hydrocracking is used over other processes like FCC and visbreaking, noting its ability to produce cleaner, more valuable products. The document outlines the major components of the hydrocracking unit including the reactor, fractionation section, and light ends recovery section. It concludes by describing some key process variables like temperature, pressure, and feed properties that impact the hydrocracking reaction.
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Vocational training report
Hydrocracker Unit IOCL
By Vismay Patel Bachelor of Chemical Engineering MSU Baroda. OUTLINE • Introduction • Why Hydrocracker required? • Feed & Products • Catalyst • Hydrocracker reaction mechanism • Hydrocrcker configuration • Major sections • Process variable What is Hydrocracking? • The process of converting higher molecular weight hydrocarbons into more valuable lower molecular weight hydrocarbons.
• In presence of Hydrogen • At high temperatures(365 – 441oC) & high pressures (170 Kg/cm2g) • In presence of catalyst Other Units • Fluid Catalytic Cracking (FCC) • Visbreaking • Delayed coking
• Poor product quality with respect to stability & sulphur content
• Have to be blended with other straight run products to be able to market them. • Product treatment would be necessary. Why Hydrocracker? • Eco friendly Products containing mostly saturated hydrocarbons & low to ultra low sulfur. So the technology is gaining greater and greater importance. • Very high flexibility in terms of feed and products generated and very high selectivity for products. • Middle distillate yield is 80% as compared to 45% in FCCU. • The products are clean, saturated & high in value. • No coke or by products. FEED: Vaccum Gas Oil(VGO) from FPU and Hydrogen.
PRODUCTS: (1) L.P.G (2) Stabilized Light Naphtha (3) Heavy Naphtha (4) Aviation Turbine Fuel(ATF)/Superior Kerosene(SK) (5) High Speed Diesel(HSD) Catalyst • Bifunctional Catalyst • Metal function (for Hydrogenation) : •Platinum •sulfided metals of Nickel , Molybdenum , Tungsten as Base Metal • Acidic function (for cracking) : •Amorphous silica‐alumina, zeolites Hydrocracking Reaction Mechanism HYDROCRACKING REACTIONS • Hydrocracking = catalytic cracking + hydrogenation • Catalytic cracking is the scission of a carbon–carbon single bond, and hydrogenation is the addition of hydrogen to a carbon–carbon double bond. Hydrocracker Configuration • Major Sections (1) Reactor section (2) Fractionation section (3) Light Ends Recovery Section
• Feed Filter (>25 micron size are retained to avoid plugging of catalyst in the reactor top bed) • VGO heated in exchangers and brought to the pressure of 185 kg/cm2 by feed booster pumps. • Mixed with recycle H2 and Pure H2 from make up gas compressors. Reactor section • Fixed Bed Reactor containing 3 bed • High Temperature for the catalyst to hydrocrack the feed. • High Temp. => increase the catalyst activity. • Cracking reaction => requires heat • Hydrogenation => generates heat • Overall Exothermic process • Quenching zone • 1st bed => not active catalyst but functions as rust/particulate arrestor and prevents early deterioration of catalyst. • Nitrogen compounds => NH3 • Sulfur compounds => H2S • Oxygen compounds => H2O • Two Stage Hydrocracking configuration Fractionation section • Overhead products = off-gases , light naphtha • Off gas are washed with amine to remove H2S and sent to fuel gas system. • Heavy naphtha (146oc) • ATF (188oc) • HSD (286oc) • Bottom Product => Vacuum Column • Bottom of Vacuum column => second stage reactor Light Ends Recovery Section • Light unstabilized naphtha form fractionator => De-ethanizer • Gases (ethane,H2S,water)(at Top) => Amine Absorber(To remove H2S) • H2S free fuel gas => Fuel Gas System • Rich Amine with dissolved H2S => Amine Regeneration Unit • Bottom of De-ethanizer => De-butanizer , for recovery of LPG (at Top) • LPG => Caustic wash (To remove H2S) Water wash (To remove caustic traces) Demister pad & coalesce pad (To remove entrained water) • Bottom of De-butanizer(stabilized Naphtha) => Hydrogen Unit for for H2 production Process variables (1)Reactor Temperature • primary means of conversion control. • 10°C increase in temperature almost doubles the reaction rate, but does not affect the conversion • necessary to raise the average temperature about 0.1 to 0.2°F per day to compensate for the loss in catalyst activity. • Catalyst has to be replaced or regenerated when avg. temperature reaches a value close to design max. (2)Reactor Pressure • The primary effect of reactor pressure is in its effects on the partial pressures of hydrogen and ammonia. • An increase in total pressure increases the partial pressures of both hydrogen and ammonia. • Conversion increases with increasing hydrogen partial pressure and decreases with increasing ammonia partial pressure. (3)Space Velocity • The volumetric space velocity is the ratio of liquid flow rate, in barrels per hour, to catalyst volume, in barrels. • The catalyst volume is constant, therefore the space velocity varies directly with feed rate. • As the feed rate increases, the time of catalyst contact for each barrel of feed is decreased and conversion is lowered. (4)Nitrogen Content • The organic nitrogen content of the feed is of great importance as the hydrocracking catalyst is deactivated by contact with organic nitrogen compounds. • An increase in organic nitrogen content of the feed causes a decrease in conversion. (5) Hydrogen sulfide Thank you
