Process Of Fluid Catalytic Cracking Information

This new and improved edition focuses on providing practical information and tools that engineers can use to maximize the profitability and reliability of their fluid catalytic cracking operations. The updated chapters and new content deliver expertise and know-how to an industry that faces significant cost cutting in capital expenditure and R&D, along with the retirement of technical specialists who are taking existing knowledge out of the industry with them. This FCC Handbook provides a valuable easy-to-understand resource for both experienced and inexperienced engineers and anyone else associated with the FCC process. This book gives those who need a quick reference, and gives those who are developing their skills and knowledge trusted information that will help them succeed with their projects.

Key features include;

• Common examples that will enable engineers to achieve increased unit savings
• 
  
• Updated with the latest process technologies for handling residue and 'deep' hydrotreated feedstock
• 
  
• New chapter discussing refractory lining, providing an introduction to the different refractories employed in FCC units, examples of various refractory linings and associated anchors, installation techniques as well as some guidelines for proper drying and curing refractory lining.
• 
  
• New troubleshooting chapter, increasing the practical application of the book, along with new visual references to operation optimization
• 
  

About the author;

Reza Sadeghbeigi is President of RMS Engineering, Inc. a Houston, Texas based engineering firm providing high‐level technical expertise in the area of fluid catalytic cracking (FCC) and related processes.

Fluid catalytic cracking (FCC) has been a major refinery conversion process for more than seven decades. The technology is mature, but it continues to evolve.

Reza has 35 years of hands-on FCC experience in the refining industry, focusing on technical services, troubleshooting, process design, and project management, including major FCC revamps. A licensed Professional Engineer (P.E.) in Texas and Louisiana, Reza has published technical papers and produced industry seminars on refining and catalytic cracking operations and conducted numerous client customized FCC training courses and public seminars.

Moon Il, in, 2012 IntroductionFluid catalytic cracking (FCC) process is an important oil refinery process, since this process converts heavy petroleum fractions into lighter hydrocarbon products inside a reactor. In an attempt to maximize production and improve operating efficiency, a comprehensive analysis of a FCC unit regenerator has increased. Optimizing the burning efficiency of a regenerator is a key issue in expanding the ability of the heavy oil process. The effects of gas-particle flow and the control of a chemical dynamics factor combine to influence the burning process in a regenerator.For its important status, there has been extensive research in regenerators have been established in the past few years. A population balance model in fluidized bed regenerator was developed by Werther 1.

Steady state multiplicity analysis for FCC unit was investigated by Fernandes 2. With the development of computational technology, more and more attention is paid to the computational fluid dynamics (CFD) method for the research of fluid dynamics and reaction in gas-particle fluidized beds.

Cao 3 developed a numerical simulation model for gas-solid two phase model. Elmedia video player pro mac elmedia player pro for mac. In this article, the multiphase-particle-in-cell (MP-PIC) method based computational particle fluid dynamics (CPFD) model was established for a FCC regenerator. The fluid dynamic phenomena in regenerator was simulated the gas-particle flow behavior in the demo-type regenerator. Den Hollander. Moulijn, in, 2001 1 INTRODUCTIONFluid catalytic cracking (FCC) is an important refinery process that employs an entrained flow, or riser, reactor for the catalytic conversion of heavy oil fractions to lighter products.

1−4 The riser reactor is fed with the so-called ‘equilibrium catalyst’ coming from the regenerator. In the riser reactor coke is deposited on the catalyst, thereby lowering the activity. At the end of the riser reactor, the coked catalyst is separated from the hydrocarbon products, stripped, and sent to a fluidized bed regenerator to burn the coke and reactivate the catalyst. Generally, the coked catalyst is called 'spent catalyst' implying that the catalyst is completely deactivated. In this paper it will be shown that this is clearly not the case.

The activity of the spent catalyst is lower than that of the regenerated catalyst, but the residual activity of this spent catalyst is still significant. Moreover, in previous work it was shown that the deposition of coke takes place mainly at the first feedstock/catalyst contact in a time frame of less than 50 ms and that afterwards the conversion of the feed to the other products continued without formation of extensive amounts of coke. 5−7 To avoid confusion, we prefer to use the nomenclature of 'coked' instead of 'spent' catalyst.In industrial operation the heat balance of an FCC unit is a very important parameter.

The heat that is needed for heating and evaporation of the feedstock and for the endothermic cracking reactions is generated in the regenerator by burning of the coke from the coked catalyst. 4,8,9 The catalyst is the heat-transporting medium.

It transports physical heat (high temperature) from the regenerator to the reactor and potential heat (coke deposits, i.e., 'fuel' for the regenerator) from the reactor to the regenerator. Therefore, the amount of coke burned in the regenerator determines the heat available for conversion in the reactor. Typically, independent variables are feedstock temperature, feed rate of the oil to the riser, and combustion air rate to the regenerator. Dependent variables are the amount of coke produced, regenerator temperature (although some control of regenerator temperature is possible by using catalyst coolers like in resid-processing units), and the heat released per unit of coke (depending on the use of partial- or complete combustion). To maintain the heat balance the amount of coke produced, i.e., burned per unit time, is adjusted through changes in catalyst circulation rate. 9In this paper, experimental results from microriser experiments and a kinetic evaluation will be used to evaluate the residual activity of a coked FCC equilibrium catalyst and the performance of mixtures of this coked catalyst with a completely regenerated catalyst.

O’Connor, in, 2001 1 INTRODUCTIONFluid catalytic cracking has evolved into a process in which hot, virtually carbon-free catalyst is intimately mixed with a petroleum-derived feedstock, then transported through a turbulent reaction zone with a reactant residence time of 1-4 seconds. The vapor products from the cracking reaction are efficiently separated from the catalyst utilizing a variety of ingenious devices, then cooled and fractionated in a distillation column. The catalyst, partially deactivated by coke formed during the cracking reaction, is first steam-stripped to remove occluded hydrocarbons on its surface and then regenerated by combustion in a separate reactor.This relatively fast, efficient contacting of feed and catalyst contrasts with early reaction systems which featured poor feed/catalyst contacting, long reaction times, and poor catalyst/product separation. The benefits of modern reaction systems are improved selectivity for desirable products. However, because of the reduced reaction time and the elimination of non-selective conversion, an increase in reaction severity is required to maintain adequate conversion. This is achieved by increasing reaction temperature, catalyst-to-oil ratio, or catalyst activity. Typically, higher catalyst activity is achieved by increasing the content of active ingredients in the catalyst.In general, it has been assumed that reaction at the catalytic sites has been the controlling step in the overall reaction system.

However, the trends in reactor and catalyst design described above suggest a reexamination of this assumption. Diffusion of the larger reactant molecules through the porous structure of the catalyst particle to the reaction sites could now be a more important factor in the determination of the overall reaction rate. In addition, there must be sufficient time for the reaction products to diffuse out of the catalyst particle. The diffusion must be as efficient as possible to prevent overcracking to undesirable light products. The term accessibility 1 has been used to describe these phenomena.If diffusion to and from the catalytic sites is important in determining the overall reaction rate, then the nature of the porous structure of the catalyst particle should be examined closely. The materials and method of manufacture of the catalyst can dramatically affect the porous structure.

In addition to the distribution of pore sizes in the catalyst, the shape of the pores can also be important 1,2. For the reactants to reach the interior of the catalyst particle, they must pass through the surface, so it is very important that diffusional restrictions be minimized there.In addition to diffusional restrictions created at the surface and interior of the as-manufactured catalyst, additional accessibility problems may develop as a result of contaminants deposited on the catalyst by the feed.

These may naturally occur in the petroleum or be introduced during its recovery or refinery processing prior to the FCC. Common contaminants that have been studied extensively are Ni, V, and Na. In general, the focus of these studies has been on their effect on zeolite activity or undesirable reactions such as dehydrogenation catalyzed by the contaminant itself. There has been some discussion regarding the possible effects of V on accessibility.

There has been significant study of how these contaminants distribute throughout a catalyst particle and their mobility in the reaction system.There are a wide variety of contaminants that are less widely recognized and studied regarding their effects on the FCC process. Fe and Ca probably have little inherent catalytic activity, but have been associated with surface deposits that clearly could have a significant impact on the access to the interior of a FCC catalyst particle 3. Pereira, in, 2000 1 INTRODUCTIONThe fluid catalytic cracking unit (FCCU) is used for vacuum distillates and residues into olefinic gases. The great demand in processing heavy feedstocks and the high amounts of metals in Brazilian oils, forced to develop novel catalysts that are more resistant to metal contamination.Since the FCCU is a cyclic process, the catalyst passes through reduction and oxidation conditions.

Indeed, the reductive atmosphere and coke observed in the riser favor the deactivation and reduce the life time of the catalysts. The burn off in the regenerator releases steam, CO, NO x, SO x, and other compounds.

The catalyst is recycled in the reaction-regeneration (reduction-oxidation) between 0 times and, therefore, the change in the metal environment is very complex, affecting the metal oxidation state, which is an important parameter. Although the reaction conditions are well known in the literature, there are few reports concerning the environment of reduced vanadium species. Vanadium is the most important deactivation compound in FCC catalysts.

In steam atmosphere, the zeolite framework is completely destroyed, and therefore the rate of make-up catalyst in the unit is very high 1,2. The low melting point of V 2O 5 (690 °C) and the possibility of formation of acid species, as reported in the literature, are responsible for this deleterious effect 3,4. The control of vanadium migration and oxidation state are important to preserve the FCC catalyst. Rare earth elements have been used as metal traps, but there are still fundamental questions concerning the rare earth zeolite interactions and vanadium oxidation states.The objective is to study the effect of cerium introduced in USY zeolite and the resistance of these modified catalysts to vanadium in steam. Riascos, in, 2015 AbstractIn the Fluid Catalytic Cracking Units (FCCU) large hydrocarbon molecules are cracked into smaller molecules, generating high value products such as diesel, gasoline and useful petrochemical olefins. The control of these units is fundamental to maintain a satisfactory operation.

Hence, the Real Time Optimization has proved an interesting strategy. A dynamic simulation of a FCCU was developed using a phenomenological industrial validated model. A Dynamic Neural Network (DNN) was trained with data from the FCCU model and gross and systematic errors were added to employ this system as a virtual plant. Data from this virtual plant were used to study strategies of online data processing, considering steady state identification (SSI) and gross error detection (GED), in order to eliminate measurement noise, as the initial steps into an RTO implementation. Fallick, in, 2001 1 INTRODUCTIONCoke formation in fluid catalytic cracking (FCC) can markedly affect a unit’s performance and for over fifty years, it has been the subject of much investigation.

Coke can arise from a number of sources, namely acid catalysed, metals mediated and pure thermal reactions. Therefore, means of quantifying the respective contributions of the three main coke-forming pathways will be of significant benefit.The behaviour of small alkenes and aromatics, where carbonisation can be initiated within the zeolite framework to form catalytic coke is expected to be different to that for heavy species 4, where, intuitively, the formation of metals mediated and thermal coke from the feed is expected to occur in extra-framework mesopores. In this study, 13C labelled benzene and toluene have been doped into high and low sulfur vacuum gas oils to aid in the understanding of how catalytic reaction pathways contribute to coke formation.

The distributions of the labels have been monitored using gas chromatography isotope-ratio mass spectrometry (GC-IRMS) for the liquid products and conventional sealed-tube combustion for the cokes.Compound specific isotope analysis using GC-IRMS is now a well established technique in the petroleum industry, coal science, environmental and biomedical research 5–10. More specifically to FCC, Filley et al recently reported the isotopic composition of selected carbonisation products obtained from a FCC decant oil doped with 13C-enriched 4-methyldibenzothiophene 11. However, only selected compounds were identified and no overall mass balance to account for label distribution was attempted. This investigation represents the first attempt to obtain a quantitative audit into the fate of individual constituents within FCC product streams, particularly with respect to the reaction pathways leading to catalytic coke. A preliminary account of this investigation has been presented in the proceedings of the 2 nd International Conference on Refinery Processing hosted by American Institute of Chemical Engineers 12. Huiping Tian. Zhongbi Fan, in, 2001 1 IntroductionRFCC (resid fluid catalytic cracking) is one of the processes for the conversion of heavy oils in modem refineries.

The problem with vacuum residue as FCC feedstock is quick deactivation of catalysts by the coking of asphaltene fractions and the deposition of metals involved in metallorganic polycyclic compounds. Therefore, developing novel zeolites to achieve metal tolerance has long been a goal of catalyst researchers 1, 2, 3.Ca is mainly from synthesized additives used in petroleum exploring and exploitation.

4 has reported hydration and dealumination phenomenon by Ca in zeolites. Ni catalyzes both dehydrogenation reactions in FCC riser reactors, leading to high coke and dry gas yields, and oxidation reactions in FCC regenerators, resulting in high CO 2/CO ratio. There were two types of Ni species in catalysts, i.e., nickel oxides and nickel aluminates or silicates 5.

Nickel aluminates had lower activity than nickel oxides. Shen 6 studied Ni migration from zeolite to matrices in hydrothermal conditions. FeY dealuminated faster than NH 4Y did under same hydrothermal conditions, finally forming mesopores with Fe-Al complex oxides 7. V in crude oil was in the + 3 and + 4 valence state in porphrin compounds and remained in residue after distillation. After decomposition in riser reactors, low valence V deposited on the catalyst. The high melting points of low valence V oxides made them less harmful to the catalysts. In the regenerator, these V oxides were oxidized to + 5 valence V oxides, which had low melting point and were able to destroy the structure of zeolites and catalysts.

High valence V oxides such as V 2O 5 and its hydrate H 3VO 4 could easily migrate in catalysts, block pore apertures and cover active sites, causing catalysts permanent deactivation 8, 9, l0In this paper, a novel ultrta-stable Y zeolite (EAH-USY) are reported. The state of metal contaminants (Ca, Fe, Ni, V) and their influence on this novel USY zeolite are investigated.