FLUIDIZED

CATALYTIC
CRACKING-AN
OVERVIEW
By:
Parveen Kalia
Suresh Mahalingam
Date:20th October 2007

FCC-Overview 1
 CONTENTS

► INTRODUCTION
► PROCESS CHEMISTRY
► CATALYST
► FEED
► PROCESS CONDITIONS
► MAIN PRODUCTS
► YIELD
► FCC –PROCESS FLOW DIAGRAM
► COMPARISON OF DTA AND JERP FCC

FCC-Overview 2
 INTRODUCTION

FCC- Heart of Refinery

Naphtha
Crude
Kerosene

SBM TAME MEROX Petrol

DHT Diesel
MEROX LPG
MTF/RTF
CDU/ FCC Aro
VGOHT PX

VDU
PRU PP
PP

Coker Coke
Sulfur SGU Sulfur

FCC-Overview 3
 INTRODUCTION (contd.)

THREE TYPES OF CRACKING

 THERMAL
 FLUIDIZED CATALYTIC
 HYDROCRACKING

ADVANTAGES OF FCC
 Cheapest Available Conversion Process
 Offers great flexibility of operation (can run in LPG,
Gasoline or Distillate Mode without any modification)
 Produces large quantity of Petrochemical feed stocks.
 Steam and Power Generation from waste heat.

FCC-Overview 4
 INTRODUCTION (contd.)

HISTORY OF FCCU

 INVENTED BY HOUDRY IN 1930 AS BED CRACKING AND

MODIFIED IN 1940 TO MOVING BED
 UOP : MODEL 1 AND MODEL 2
 UOP:1947 MODEL
 UOP: 1963- ZEOLITE CRACKING
 UOP : RISER CRACKER IN 1970 AND HAS
CONTINUOUSLY MADE MODIFICATIONS TO IMPROVISE

FCC-Overview 5
 INTRODUCTION (contd.)

RIL-FCC

Capacity:
Design 130 KBPSD
Current 200 KBPSD UOP,USA (licensor)

Salient features:
 Largest FCC in the world.
 Heat integration (power recovery train, heat pump in PP splitter
column)
 Produces large quantity of Petrochemical feed stock.
 Can be run in 3 modes of operation(LPG, Gasoline, Diesel Mode)

FCC-Overview 6
 INTRODUCTION (contd.)

DIFFERENT UNITS IN FCCU

 411- Reactor and Regenerator section

 412-Power Recovery Train
 413-Main Column section
 414- Unsaturated Gas concentration section

FCC-Overview 7
 PROCESS CHEMISTRY
 Formation of carbenium ion, R-CH2+,either by adding +ve charge to olefin
or by removing a hydrogen and 2 electrons from paraffin.
R-CH=CH-CH2-CH2-CH3 + H+  R-C+H- CH2-CH2-CH2-CH3
R-CH2-CH2-CH2-CH3  R-C+H-CH2-CH2-CH3

Carbenium ion undergoes three dominant reactions as follows.

 Cracking reaction:
Paraffins -----› olefins + smaller paraffins
Olefins -----› smaller olefins
Naphthenes -----› Olefins + smaller ring compounds

 Isomerization:
Olefins -----› Iso-olefin
Paraffins -----› Iso paraffins

FCC-Overview 8
 PROCESS CHEMISTRY
(contd.)
 Hydrogen transfer:
Naphthenes +Olefins -----› Aromatics + Paraffin
Olefins -----› Paraffins + Aromatics

 Other reactions are:

Transalkylation, Cyclization of olefins, Dehydrogenation,
Dealkylation and condensation.
 Order of cracking:
The order of cracking in decreasing order.
Olefins- napthenes – isoparaffins - paraffins

FCC-Overview 9
 CATALYST

 These are fine porous powder with APS of about 70-75

micron They act like fluid when fluidized and are oxides
of silica alumina.
 The primary components are zeolites , active matrix, clay
and binder. Relative percentage of these materials affect
performance.
 Zeolites are crystalline silica aluminates. The basic crystal
structure is tetrahedral with a Si or Al atom in the centre
and oxygen atom at the corner. The basic building block
combine at their oxygen atoms to form cage. The length
of the smallest repeating unit in the crystal structure called
unit cell size is the key property of zeolite. The zeolite
used in catalytic cracking is known as faujasite.

FCC-Overview 10
 CATALYST (contd.)
 In addition to zeolite, active matrix are also catalytically
active surface having pores (30 –500 A) larger than
zeolites (8-9 A). This causes reduction in bottom & thus
increasing lighter products. Active matrix is resistant to V
attack and hydrothermal deactivation in regenerator.
 Clays added to catalyst also serves as heat sink and Na
sink
 Binders provide physical integrity holding all catalyst
component together and the mechanical integrity.

FCC-Overview 11
 CATALYST (contd.)

 Fresh Catalyst: Tailor- manufactured & supplied by

manufacturer
 E Cat: Cat being used
 Flush cat: Bought out e cat
 Spent cat: From system, from reactor
 ZSM-5: Additive which preferentially cracks long straight
chain HC into LPG and high octane gasoline
 Combustion promoters: Contains Pt or metals promoting
combustion of CO to CO2

FCC-Overview 12
 CATALYST (contd.)

 SOx reduction : Used to reduce sulfur oxide in flue gases.

Adsorbs SO3, reacts with metals to form sulfates which
are carried to the reactor and reduced to H2S.
 NOx conversion
 Bottoms conversion: Catalyst particles containing active
matrix increasing yields of LCO/ gasoline.
 Metal Passivators: Liquid added to feed to reduce
-ve effects of metal deposited on the cat (Sb/Bi)

FCC-Overview 13
 CATALYST (contd.)

CATALYST INJECTION RATE

 Vendor : Engelhard
 F Cat Addition rate : ~ 30 TPD ( Inventory : 1500 TPD,
Losses: 7.5-8 TPD)
 ZSM-5 addition : ~ 3.5 TPD
 Maximum Propylene Solution-RIL-02 & MOA
 CO promoter addition : 53 kg per day

FCC-Overview 14
 CATALYST (contd.)

CATALYST POISONS

 Nitrogen-Reduces catalyst activity by blocking catalyst

acid sites for promoting cracking reactions. Nitrogen also
get converted to NH3 and cyanides causing plugging and
corrosion.
 Sulphur-Causes corrosion and increases difficulty and
cost of treating products
 Metals
o Ni
o V
o Na
o Cu

FCC-Overview 15
 FEED

Throughput: 200 Kbpsd

VGO 60.0% - 87.5%
LSWR 12.5% - 40.0 %

Feed Properties :
API : 24.55 UOP K : 12.14
Sulfur, wt%: 0.2 Nitrogen wt.ppm: 871
CCR wt.%: 0.68 Nickel wt.ppm: 0.1
Vanadium wt.ppm: 0.57 Chlorides wt.ppm: <1.0

FCC-Overview 16
 FEED (contd.)

FEED CHARACTERISATION
 PARAFFIN
 PARAFFINS STOCK EASY TO CRACK
 GASOLINE HIGH
 BUT LOW OCTANE.
 GENERALLY 50 TO 65 % PARAFFINS IN FCC FEED.

 OLEFINS
 THE PRESENCE INDICATES PREPROCESSING ELSEWHERE.
 THERMAL CRACKING OR CAT. CRACKING.
 REACTS WITH O2.
 FORMS SLURRY AND COKE.
 USUALLY CONTENT IS < 5%.

FCC-Overview 17
 FEED (contd.)

FEED CHARACTERISATION
 NAPHTHENES
 SATURATED
 DESIRABLE FEED SOCK.
 HIGH OCTANE GASOLINE.

 AROMATIC
 BENZENE IS MOST STABLE.
 AROMATIC DOES NOT CRACK EASILY.
 THE SIDE PARAFFIN CHAINS CRACK.
 POLYNUCLEAR AROMATIC IS A COKE.
 LOWER CONVERSION.
 LOWER GASOLINE YIELD.

FCC-Overview 18
 FEED (contd.)

REACTION VARIABLES
 Feed Properties
 Boiling range 260oC-540oC
 Carbon residue less than 0.5%
 UOP K factor 11.2-12.5
 Metal factor :Fe+V+10(Ni+Cu) less than 1
 Nitrogen N2:below 1000ppm

 Feed Temperature : Increase at constant reactor temperature results in

 Decrease the catalyst circulation
 Lower coke production
 Increase in delta coke (kg coke/kg catalyst)

 Reactor pressure

FCC-Overview 19
 FEED (contd.)

REACTION VARIABLES
 Reactor temperature :Increase in reactor temperature at constant cat.
Circulation
 Increase conversion
 Increase lighter products
 Increase aromatic and olefin content
 Increase octane number

 Catalyst/ Oil ratio: Increase at constant reactor temperature

 Increase conversion
 Increase lighter products
 Increase aromatic and olefin content
 Increase coke yield
 Mode of operation

FCC-Overview 20
 Process Conditions In Different Modes Of
Operations

MODE LPG GASOLINE

DISTILLATE

• FEED TEMP.C 218 260 316

• REACTOR TEMP. C 546 527 496
• REG. TEMP.C 728 693 696
• CAT/OIL RATIO 9.95 8.07 6.37
• CONV (VOL%) 81.1 81.99 61.02
• COMBINED 1.06 1 1.4
FEED RATIO

FCC-Overview 21
 MAIN PRODUCTS OF FCC
 MCB- Used as refinery fuel oil
 LCO- Used as diesel blending component
 Heavy Cracked Naphtha (180-2150C)-Used as GT fuel or Gasoline
blending component
 Heart Cut Naphtha (105-1800C)- Routed to HNUU or used as
gasoline blending component
 Light Naphtha (C6-1050C)- Routed to LNUU or used as gasoline
blending component
 C5 product –Used as feed stock for SHP
 LPG- Routed to LPG merox units
 Amine absorber Off gas- Routed to RFG system
 Sour water- Routed to WWSU.

FCC-Overview 22
 YIELD
Mode of LPG wt % Gasoline Dist. wt %
Operation wt %

H2S 0.07 0.07 0.06

FG 5.11 3.09 2.52
LPG 24.51 17.45 12.45

Total C5 9.70 9.75 6.76

LN 13.4 15.17 11.08

FCC-Overview 23
 YIELD (contd.)

Mode of LPG wt % Gasoline Dist. wt %

Operation wt %
Heart Cut N 16.29 21.05 15.85
Heavy 3.69 5.65 4.32
Cracked N
LCO 14.81 16.58 30.77
MCB 5.9 6.14 11.68
Coke 6.22 5.05 4.69

FCC-Overview 24
 FCC- PROCESS FLOW DIAGRAM
L .G .W .
F L U ID IZ E D C A T A L Y T IC C R A C K IN G U N IT -P O S T V M P P r im a r y
W a te r
A b so rb er
C o lu m n
M C ovhd vapor
2 .3 5 K g /c m 2 g
R x 1 2 1 oC
V apors Sponge
5 5 1 oC R e flu x A m in e
C W
D rum A b sorb er A b sorb er

to FG System
M a in

Treated Gas
C o lu m n R e c e iv e r

1 W ash
F lu e G a s to P R T W et G as
R e a cto r C om p ressor L ean w a ter
H P O il
R e c e iv e r ( c o o le d
10 H P L iq u id to S tr ip p e r L C O
m a in ly C 3 ,C 4 a n d C 5 - 1 8 0 w ith le s s C 1 a n d C 2
strea m )
R eg e n e r a to r
1 H eavy R ic h L ean
26 N a p h th a M C o v h d liq u id A m in e A m in e
R ic h to A T U
S tr ip p e r U n s ta b ilis e d G a s o lin e fr A T U
O il
S tr ip p e r
s tr ip p in g L ig h t 6

ste a m 1 C y c le M P S tr ip p e r N a p h th a N a p h th a
O il S te a m D e b u ta n iz e r D e p e n ta n iz e r
S p litte r -1 S p litte r -2
R e g e n e r a te d S tr ip p e r
C a ta ly st
6
Combustor

R is e r C 5 to S H P /
M P
L P G to L N U U
S te a m M erox H e a rtcu t
C 6 ,7 to L M G /
L N U U /R x R is e r to H N U U /
Spent 42 H M G
C a ta ly s t
R a w o il L C O P r o d u c t to
F uel
D ie s e l B le n d in g
G as P rocess S y ste m /L C O ta n k H ea v y cr a c k ed N a p h th a
A ir P r o d u c t (1 8 0 -2 1 5 ° C )/H e a v y
M o g a s h e a d e r /D ie se l b le n d in g /
S ta c k G T fu e l/ F O s y s te m
H P ste a m H M G
header
O r ific e F lu e G a s C o o le r 413-
C ham ber S03 B H eavy i-C 6 to L ig h t
R a w o il to r is e r
C rack ed M ogas h ead er
N a p h th a
to H M G C 6-1 0 5 N a p h .
3rd H P B FW to L N U U
stg S tea m
sep . A ir D e is o h e x a n iz e r
G u lf t r o n ic f ilt e r F u e l O il P r o d u c t
4 th M a in A ir S te a m B F W B FW to F O S y ste m
s tg . E xpander M o to r/ an d coker
B lo w e r T u r b in e G e n e r a to r
C 7-1 0 5 N a p h .
sep . R a w o il fe e d
C o ld V G O fr o m ta n k a g e to R ise r
su r g e d ru m C 6-1 0 5 N a p h . to
P r o c e ss A ir to R g H o t V G O (L V G O ,H V G O , L N U U / L ig h t
T o R e co v er e d C a t. H o p p e r H C G O e x V G O h y d r o tr e a te r )
M ogas header

FCC-Overview 25
 411-Reactor & Regenerator Section

• Process flow diagram

FCC-Overview 26
 411-Reactor & Regenerator Section
(Contd.)
 PREHEATED FEED AND REGENERATED
CATALYST IS MIXED
 FEED IS ATOMIZED IN SPECIAL NOZZLES
 REACTIONS OCCUR IN LESS THAN 2 SEC IN THE
RISER
 COKE IS DEPOSITED ON THE CATALYST &
LIGHTER, OLEFINIC PRODUCTS ARE FORMED
 MOST OF THE CATALYST AND PRODUCTS ARE
SEPARATED BY VSS AND REMAINING CATALYST
ALONGWITH HYDROCARBON VAPORS RISE
TOWARD STRIPPER & CYCLONES

FCC-Overview 27
 411-Reactor & Regenerator Section
(Contd.)

 CYCLONES SEPARATE VAPORS FROM CATALYST

 PRODUCT VAPORS ARE SENT TO MAIN
FRACTIONATOR
 CATALYST GOES TO STRIPPER BED THROUGH
DIPLEGS
 STEAM IS USED TO STRIP REMAINING
HYDROCARBON FROM CATALYST
 CATALYST IS ROUTED TO REGENERATOR BY
SLIDE VALVES

FCC-Overview 28
 411-Reactor & Regenerator Section
(Contd.)
 AIR IS USED TO BURN THE COKE
 COKE ON THE CATALYST IS BURNED TO CO AND CO2
 CATALYST IS REGENERATED IN COMBUSTOR &
REGENERATOR
 FLUE GAS (CO,CO2,N2 etc ) AND CATALYST GO TO
REGEN CYCLONES
 TWO SETS OF CYCLONES (PRIMARY AND SECONDARY)
SEPARATE FLUE GAS FROM ENTRAINED CATALYST
 FLUE GAS IS SENT TO THIRD STAGE SEPARATOR AND
THEN TO EXPANDER FOR POWER RECOVERY
 CATALYST IS RETURNED TO REGENERATOR BED
THROUGH DIP LEGS

FCC-Overview 29
 411-Reactor & Regenerator Section
(Contd.)
 Optimix device uses small
amount of steam 0.5 to 2 wt
% of fresh feed using
innovative three stage
atomization Atomization
occurring very close to tip
prevents coalescing and
pulsating flow. Tip generates
flat fan spray generated by
the use of special orifices the
orifices are designed based
on feed quality and rate,
riser dimension capacity.
Maintenance and inspection
are almost nonexistence.
Source UOP, www.uop.com FCC Process
Technology and Equipment

FCC-Overview 30
 412-Power Recovery Train

• Process flow diagram

FCC-Overview 31
 412-Power Recovery Train (Contd.)
 TO UTILIZE THE THERMAL AND PRESSURE ENERGY OF
FLUE GASES LEAVING THE REGENERATOR
 TO DRIVE THE MAIN AIR BLOWER
 HOT FLUE GAS IS EXPANDED TO RECOVER
HORSEPOWER FOR BLOWER
 STEAM TURBINE & MOTOR ARE THERE TO SUPPLY
POWER DURING START-UP
 EXCESS POWER IS EXPORTED TO GRID BY GENERATOR
 AIR BLOWER TAKES AMBIENT AIR INTO REGEN
 COMMON ROTOR FOR ENTIRE MACHINE TRAIN
(BLOWER,EXPANDER AND TURBINE)

FCC-Overview 32
 413-Main Column Section

• Process flow Diagram

FCC-Overview 33
 413-Main Column Section (Contd.)
 VAPOURS ENTERING FROM THE REACTOR ARE
DESUPERHEATED AT THE BOTTOM OF THE COLUMN
 ADDITIONAL HEAT IS REMOVED IN THE
CIRCULATING REFLUX LOOPS
 PRODUCTS ARE DRAWN FROM THE COLUMN
(SLURRY, HCN ,LCO)
 OVERHEAD VAPOURS ARE SENT TO OVERHEAD
CONDENSERS AND WET GAS COMPRESSORS
 HCN IS STEAM STRIPPED AND SENT TO HMOG / HSD
OR GT FUEL OIL
 LCO IS STEAM STRIPPED AND SENT TO DIESEL or
FUEL OIL

FCC-Overview 34
 413-Main Column Section (Contd.)

 STEAM STRIPPING IS FOR REMOVING LIGHTER ENDS

AND IMPROVING FLASH POINT OF PRODUCTS
 SEPARATES ENTRAINED CATALYST FROM SLURRY
OIL
 AFTER SEPARATION SLURRY IS CALLED CLARIFIED
OIL AND SENT TO FUEL OIL
 EACH MODULE OF GULFTRONIC SEPARATOR IS
BACKFLUSHED TO MAKE IT READY FOR NEXT CYCLE
 GULFTRONIC FILTERS WORKS ON THE PRINCIPLE OF
ELECTROPHORESIS

FCC-Overview 35
414-Unsaturated Gas Concentration Unit

• Process flow diagram-WGC

FCC-Overview 36
414-Unsaturated Gas Concentration Unit
(Contd.)

 MAIN FRACTIONATOR OVERHEAD VAPOURS ARE

COMPRESSED FROM 1.66 KG/CM2(g) AT 38oC TO 8
KG/CM2(g) AT 96oC IN 1st STAGE AND IN 2ND STAGE
FURTHER COMPRESSED TO 16.1 KG/CM2(g) AT 79oC .
 TWO STAGE COMPRESSION WITH INTERSTAGE AND
DISCHARGE COOLING

FCC-Overview 37
414-Unsaturated Gas Concentration Unit
(Contd.)

• Process flow diagram-Gas section

• Process flow diagram-Liquid section

FCC-Overview 38
414-Unsaturated Gas Concentration Unit
(Contd.)

Unit has the following components

 HP RECEIVER
 GAS Circuit
• PRIMARY ABSORBER: Recovers the C3s & C4s from the
gases.
• SPONGE ABSORBER: Recovers C5s from fuel gas.
• AMINE ABSORBER : H2S is removed from Fuel gas.
Absorption media is Methanol Di Ethyl Amine (MDEA)

FCC-Overview 39
414-Unsaturated Gas Concentration Unit
(Contd.)

 LIQUID Circuit
• STRIPPER: Strips H2S and lighter ends (C2 minus)
• DEBUTANIZER : Separates C3/ C4 from gasoline. Top Product
is sent UnSat MEROX, bottom is sent to Depentanizer. A part of
bottom is also recycled to Primary absorber.
• DEPENTANIZER : Separates C5s from gasoline. Top product is
C5s and bottom is full range gasoline.

FCC-Overview 40
 414-Unsaturated Gas Concentration Unit
(Contd.)

 LIQUID Circuit (contd.)

• NAPHTHA SPLITTER 1 : Splits full range gasoline. Products are

light gasoline, heart cut naphtha (rich in aromatics like xylenes)
and heavy gasoline.
• NAPHTHA SPLITTER 2: Splits heart cut naphtha. Products are
routed to aromatics.
• DEISOHEXANISER : Separates High Benzene stream & enables
production of <1% Benzene Gasoline.

FCC-Overview 41
 Utility Requirement :
Fluid Description Normal Kg/h Max Kg/h
HP Steam 10192 351161
MP Steam 132551 271509
LP steam 172990 424208
HP BFW 191370 266105
MP BFW NNF 18300
Cooling Water Supply 6556400 7134500
Cooling Water Return 6556400 7134500
Potable Water NNF 34000
Utility Water 20807 44807
Fuel Gas 1129 11822
Pilot Fuel Gas 40 140
Plant Air 7570 13050
Instrument Air 4992 5990
Condensate 29500 75000
Breathing Air NNF 55
Nitrogen 100 2120

FCC-Overview 42
COMPARISON OF DTA AND JERP FCC

JERP FCC Design

DTA FCC JERP FCC
• Capacity 200 KPBSD 180KPBSD
• Feed Rate 1200 T/hr 1080 T/hr

Products & Yields (%) DTA FCC JERP FCC

• Fuel Gas 4.42 3.30
• LPG 33.82 31.96
• Gasoline 38.25 39.61
• LCO 11.65 12.51
• CSO 8.09 6.39
• Coke 5.71 6.23
• Propylene 11.39 11.29

FCC-Overview 43
COMPARISON OF DTA AND JERP FCC (contd.)

FCC Product Routings in JERP and DTA

Product Routings DTA JERP

(Primary)

• Fuel Gas RFG system RFG system

• LPG MEROX (DTA) MEROX(DTA/JERP)

• C5 SHP Unit Extractive
Gasoline Merox
• Naphtha Gas.Merox SCANfiner
• LCO Diesel Blend LCO Hydrocracker
• CSO Fuel Oil System Fuel Oil system

FCC-Overview 44
COMPARISON OF DTA AND JERP FCC (contd.)

Major Modifications from DTA in JERP FCC

 RxCat mixer chamber at riser bottom to maximize propylene yield.

 Additional RxCat slide valve that provides Higher Cat/Oil Ratio and
Higher conversion
 Additional valve at Expander inlet
 New Expanders with increased capacity (32.33 MW)
 Higher capacity MABs
 No Enriched air and additional air blower
 Higher capacity Flue gas coolers

FCC-Overview 45
 COMPARISON OF DTA AND JERP FCC
(contd.)

Major Modifications from DTA in JERP FCC

 Bigger water boot in main column reflux drum

 Increased HCN circulation
 MCB steam generators with higher vapor space
 Debutanizer redesigned with 2 HCO Reboilers with enhanced capacity.
 Motor operated isolation valves for WGC
 Deisohexaniser modified with 89 ECMD trays
 Deisohexaniser with additional HCO reboiler

FCC-Overview 46
THANK YOU

FCC-Overview 47