PRESENTATION ON FCCU

OPERATION

Bhupesh Mishra
 FCC process
• FCC is catalytic cracking process.

• Cracking is a process for conversion of bigger

Hydrocarbon molecules to smaller hydrocarbon
molecules by raising temperature and pressure.

• Catalytic cracking gives more stable products.

• For corresponding yield and quality of gasoline,

catalytic cracking unit operates under less severe
conditions.
 FCC process
• Catalytic cracking is a process for conversion of vacuum
distillates to more valuable lighter products. – FCC.

• Catalytic cracking is a process for conversion of Mixture

of vacuum distillates, RCO and VR to more valuable
lighter products. – RFCC.

• This is accomplished by cracking the vaporized feed

over a solid catalyst (Silica alumina) at a temperature of
470 0C to 550 0C and a pressure between 0.5 to 1.5
Kg/cm2 (g).

• The catalyst promotes reactions which lead to a better

product selectivity as compared with that of the thermal
cracking process.
 FCC process flow description
The process flow of the entire unit can be divided in to 3
sections.
• Feed pre-heat section: Surge drum, feed pump, feed
preheat exchangers and feed furnace.

• Catalyst section : Riser, Reactor cyclone, Reactor

stripper, Regenerator, Regenerator cyclone, orifice
chamber. Main air blower, catalyst storage system.

• Fractionation section : Fractionator column, side cut

strippers (HN & LCO), Circulating system / P.A (HN,
LCO,HCO and Bottom), Overhead surge drum, Bottom
circulation system & draw system.
 FCC Feedstocks & Products
Feedstocks
 Vacuum gas oil (VGO)
 Coker gas oil (CGO)
 Hydro-cracker bottom
 Hydro-treated VGO
 Reduced crude oil (RCO)
 Vacuum residue (VR)
Typical products
 Dry gas (H2, C1, C2)
 LPG (C3, C4) Propylene, Iso-butylene
 Gasoline (C5 – 150 0C)  Gasoline
 Heavy cracked naphtha (LCN) (150 – 220 0C)  Gasoline / Diesel /
Cutter stock
 Light cycle oil (LCO) (220 – 370 0C)  Diesel / Cutter stock
 Clarified oil (CLO) or Decant oil (DO)  Fuel Oil
 PROCESS VARIABLES
• Feed Characteristics
– API / ‘K’ Factor
• Change may be due to boiling range and/or crude type
• UOP ‘K’ = (VABP)^1/3 / Specific gravity
• Higher API/Low Specific gravity
Feed cracks more readily for same Rx temp, higher
conversion
At constant conversion, higher gasoline yield with
lower octane
• Higher UOP ‘K’
– More paraffinic feed
– Easier to crack
 Main Catalytic Cracking
Reactions
• Cracking of paraffins, naphthenes & side chain of
aromatics.

• Isomerization of olefins

• Dehydrogenation of naphthenes and olefins

• Hydrogen transfer
Naphthene + Olefin  Aromatic + Paraffin

• Cyclization & condensation of olefins

• Alkylation & dealkylation

REACTIONS IN CAT CRACKING
REACTIONS IN CAT CRACKING
REACTIONS IN REGENERATOR

Heat effects of coke burning

 Reaction-regeneration integration in
FCC.

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 Fluidization Regime in FCCU

TC

LC

Stripper V = 0.05-0.30
 = 600-700

Air
V = 0.3-0.7
 = 400-600 V = 2-20
V=  = 30-100
0.01 Riser
= - 0. 0
700 5
-80
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0
 CYCLONE
Products Cyclone
DDSV
Flue Gas Reactor

Stripper
Regenerator
Steam
SCSV

Air Riser

RCSV
Feed

Steam
 CATALYST CIRCULATION AND
SEPARATION
• FCCU is the only refinery process where hydrocarbon and air
are handled in bulk side by side at high temperature.
• RX-RG systems operates in pressure balance mode where
catalyst circulation from low pressure reactor to high pressure
re-generator is induced by creating catalyst head in the
reactor.
• Catalyst circulation : One of the key factors to design,
engineering and operation of unit
• Upset in pressure balance can lead to a disastrous situation
of uncontrollable temperature and explosion.
 VSS outlet pipe entry window Planum chamber window

FC7343
Dome steam

78’’

FC7341

Rx fluffing steam
abrasion resistant lining

Stripper entry window Pre stripping steam

FC7342

FC7325
Upper stripping steam FC7326
Lower stripping steam

Stripper fluffing steam

FC7327
 FCC Reactor

• FCC reactor in
which catalyst
& feed
separates in
stripper &
cyclone. FCC
catalyst goes
to regenerator
& hydrocarbon
goes to main
column
 R-R Section : Inst. & Control
• Reactor
– Pressure floats with main fractionator
– WGC suction pressure controlled by speed / spillback
– Rx vapor line, fractionator, OH system pressure drop
affect reactor pressure
– Temperature controlled by RCSV
– Temperature affected by preheat, RCSV opening, DP
across Slide valves and Rg temperature
– Smooth cat circulation important for steady reactor
temperature
– Level control by SCSV
 R-R Section : Inst. & Control
• Regenerator
– Pressure
• Maintained higher than Rx
• Controlled by DDSV
• Pressure (level) measurement
– Temperature
• Depends on delta coke and heat removal
• Cat circulation dependent
• Significance of dense & dilute temperatures
– In partial combustion unit
– In complete combustion unit
– Level
• No direct level control
 FCCU CONTROL LOGIC

RX-RG DP ROT

DDSV

RX

STRIPPER

SCSV RI
S
RG E
TO TPSV R

SLURRY

FEED
RCSV
MAB TO MF
Lift steam
 HEAT BALANCE
• Heat generated by burning coke
• Heat consumed in Rx and …..
• Cat Cracker adjusts itself to stay in heat balance
• Links Dependent and Independent variables
– Independent Variables
• Rx Temperature
• Feed Preheat Temp
• Recycle rate/Combined Feed Ratio
• Fresh Cat activity/selectivity
– Dependent Variables
• Regenerator Temperature
• Catalyst Circulation Rate
• Conversion
• Air requirement
 HEAT BALANCE
REGENERATOR AND REACTOR HEAT BALANCE

SPENT CATALYST AT R X T FLUE GAS

REGENERATOR CATALYST AT BED T

COMBUSTION OF COKE AT REGENERATOR T

REGENERATOR
RADIATION & MISC. LOSSES

COMBUSTION OF AIR AT BLOWER DISC. T DESORPTION OF COKE

(A) REGENERATOR HEAT BALANCE

COKE ADSORPTION SYN CRUDE VAPOUR AT R X T

HEAT OF REACTION
REGENERATOR CATALYST AT REGENERATOR BED T
REACTOR

SPENT CATALYST AT R X T

FRESH FEED & RECYCLE AT COMBINED FEED T

RECYCLE VAPOUR AT R X T

STRIPPING & INJECTION STEAM AT SUPPLY T RADIATION & MISC. LOSSES

(b) REACTOR HEAT BALANCE

 FCC PROCESS

• Reactor
– Reactor vessel provides disengaging space
for catalyst
– Houses Riser Termination Device
– Houses cyclones
– Usually cold walled with internal refractory
lining
– Reactor stripper at the bottom of reactor
vessel
 FCC PROCESS
• Reactor Stripper
– Surrounds the upper portion of the riser
– Fitted with internals / baffles to enable stripping of the
catalyst using superheated steam.
– Stripping steam rate 2 – 5 lb per 1000 lb of catalyst
– Catalyst residence time 1 – 2 minutes
– Pre stripping rings at dip leg bottoms
– Performance can be assessed by Hydrogen on coke
 FCC PROCESS
• Slide Valves
– To regulate flow of catalyst (flue gas for DDSV)
– Hydraulically operated
– RCSV and SCSV isolate reactor from regenerator
– Carbon steel body with vibrocast lining
– Sloped bonnet / guides for self draining of catalyst
– Steam / air purge for older design.
– No purge in normal operation
– Differential pressure across slide valves
 Slide Valve Control
• RCSV with ROT

• SCSV with reactor level

• DDSV with differential pressure between

Rg and Rx

• TPSV for diversion of CO

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 FCC slide valve

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 FCC PROCESS
• Regenerator
– Largest fluid bed combustor in commercial use
– Provides heat for endothermic cracking reactions
– Air & catalyst distribution are critical
– Carbon, Hydrogen & Sulphur are combusted
– Partial and complete combustion modes of operation
– Combustion air supplied by Main Air Blower through
specially designed air grids
– Refractory lined
– Cyclone separators to retain catalyst
 FCC PROCESS
GAS OUT

CATALYST
MOVEMENT

TRANSPOORT
DISENGRAGING
HEIGHT

FREEBOARD

DENSE BED GAS BUBBLE

AIR INLET
 FCC PROCESS
• Air Grid
– For even distribution of air in spent catalyst
– Proper air distribution
• Lowers CRC (carbon on regenerated cat)
• Minimises after burn
• Reduces local hot spots / catalyst sintering
– Mechanically robust to withstand wide range of
operations / upsets
– Erosion, thermal expansion, mechanical integrity of
supports
– Pressure drop across air grid
 PROCESS VARIABLES
• Partial combustion
– Requirement of CO boiler, higher steam production
– Operation at lower regen temperature
• Less hydrothermal deactivation
• Less substantial metallurgy
• Higher coke on regenerated catalyst

• Complete combustion
– Reduced coke yield
– Higher liquid yield
– More stable operation
 FCC CATALYSTS & ADDITIVES
• FCC Catalyst
– Fine Porous Powder (APS : 70-75 u)
– Acts like fluid when aerated (fluidised)
– Oxides of Silica & Alumina

Primary Components
– Zeolites
– Active Alumina
– Binder Referred as
Catalyst Matrix
– Filler
WHAT IS CATALYSIS?

CATALYST
Agent/Power for change (In western philosophy)

Scientific definition defines catalysts as

Material which changes the rate of attainment of chemical
equilibrium without themselves being changed or consumed

Increases both forward and backward reactions

Does not change the final equilibrium conversion for a given

process/operating conditions

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 FCC CATALYSTS & ADDITIVES
– Relative percentages of each of these components affect
Catalyst Performance

ZEOLITE
– Zeolites are crystalline silica aluminates
– Basic crystal structure is tetrahedral with a silicon or
aluminium atom in the centre and oxygen atoms at the
corner
 FCC CATALYSTS & ADDITIVES

– This basic building block combine at their oxygen atoms to

form cage structure that has well defined pores of specific
diameter

– Key property of zeolite is unit cell size. The length of the

smallest repeating unit in the crystal structure
 FCC CATALYSTS & ADDITIVES
• Zeolite
– Primary source of catalytic activity

– Mineral crystalline material

– Affects activity, selectivity, product quality

– Rare Earth Exchange

• Na is exchanged with RE
• Increases zeolite activity
• Active Matrix
– Catalytically active surface other than zeolite
– Has larger pores (30 – 500 A) than zeolite (8 – 9 A)
– Decreased bottom yields
– Relatively steam stable and resistant to ‘V’ attack
– Ni & V can interact to form active dehydrogenation
catalysts initiating high H2 & coke yields
– Portion of high matrix surface area associated with
small pores may not strip well and can increase
regenerator coke loading
• Clay
– Fulfills remaining catalyst particle performance
requirement
– Serves as heat sink
– Serves as sink for Na
• Binder
– ‘Glue’ holding all catalyst components together
– Provides physical integrity
– Some binders aid bottoms cracking
 CLAY
FCC CATALYST

Re-EARTHS ZEOLITE

MATRIX

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 FCC CATALYST
• Fresh Catalyst
– As manufactured and supplied by manufacturer
– Tailor made for specific requirement
• Equilibrium Catalyst (E Cat)
– Catalyst used (being used) in the unit
– Lower activity, poor selectivity, physical changes than fresh
catalyst
• Spent Catalyst
– From system
– From Reactor, Regenerated catalyst
• Catalyst Additives

ZSM – 5

– Shape selective zeolite developed by Mobil.

– Preferentially cracks long, straight chain hydrocarbons into
LPG and higher Octane Gasoline molecules

Combustion Promoter/COP

– Contains Pt / or other metals that promote combustion of CO

to CO2
– Used in units practicing complete CO combustion.
– Helps in confining combustion in dense bed and prevent
high temp. increases in regenerator dilute phase or cyclones
– Control after burn in units operating in partial CO combustion
• Catalyst Additives

SOx Reduction

– Used to reduce Sulfur oxides in flue gases

– Adsorbs SO3 and reacts with metal oxide to form metal sulfates.
– Metal sulfate is carried with the catalyst to reactor where it is reduced to
H2 S

Bottoms Conversion Additives

– Catalyst particles that contain active matrix components, but no zeolite

– Increased yield of LCO / Gasoline at the expense of Main Fractionator
bottoms
• Catalyst Additives

Metal Passivators
– Not exactly catalyst additives. Liquids added to feed to
reduce negative effects of metals deposited on the catalyst
(Antimony / Bismuth)
– Reduces the dehydrogenation activity of Nickel

• Vanadium Traps
– Intended to collect vanadium in feed and prevent it from
reacting and destroying the zeolite in the catalyst
Thank You