Fluid Catalytic Cracking Unit
FCC OPERATIONS & SALIENT DESIGN ASPECTS
17TH MARCH 2011
V.SRIKANTH SENIOR MANAGER(NHT/ISOM)
CONTENTS
GENERAL FCCU SCENARIO CRACKING REACTIONS FLUIDISATION CATALYST PROCESS DESCRIPTION PROCESS VARIABLES CRACKER EQUIPMENT
GENERAL
GENERAL
PRODUCTS OF PETROLEUM CRUDE OIL
Gas (Methane & Ethane) LPG (Propane & Butane) Naphtha Kerosene / ATF Diesel Industrial fuel Household fuel Industrial feed / Motor Spirit (MS) Household fuel / Aviation Fuel Automobile fuel
Vacuum Gas Oil
No direct end use
Lube oil Lubricating oil Paraffin Wax Candle, Matches, Water proof coating Vacuum residue (Bottom) Industrial fuel, Asphalt
GENERAL
Price $/ton
H WW BS PP
Yield vs Price
Base Case GRM = 4.75 $/bbl
800 700 600 500 400
MW C3 LUB ATF MS Loc HSD KERO LPG Exp HSD Loc Naph Exp Naph
CRU Feed FCC Feed HCU Feed
Average Crude Price = 377 $/t 300 200 100
SULP LO Byp Loc FO BIT Stocks Exp FO F&L
VBU Feed PDU Feed
0 0% 10% 20% 30% 40% 50% Cum yield %wt 60% 70% 80% 90% 100%
GENERAL
PRIMARY PROCESSING UNIT SECONDARY PROCESSING UNIT Secondary units are installed to:
Upgrade lower grade products Increase value added products Maximise production of products in demand Production of specialty products Minimise production of undesired products To meet Product / Environmental specifications
GENERAL
MEANS OF VALUE ADDITION
Thermal Cracking Catalytic Cracking Hydro Cracking Extraction / Filtration Iso-Dewaxing High value light products - do - do Lube base oil / Wax Lube base oil
GENERAL
CATALYTIC CRACKING
Cracking VGO into low molecular weight products of high value, by application of heat and in the presence of catalyst Good selectivity for producing desired products Good quality products (Mainly mono-olefins) Specialty products (Propylene, Butylenes) High initial investment Low fuel and loss
WHY FCCU?
Benefits of FCCU:
Converts heavy ends into desired lighter products Reaction involves regrouping of molecules to provide the quality product Flexibility in product pattern Production of lower molecular weight special products like Propylene, Butylenes Reduces the Sulphur content in liquid streams by converting into H2S Minimise production of undesired products
FLEXIBILITY IN FCC
Easy Catalyst / Additive Loading & Withdrawal No Hot Spot Automatic Balancing of Heat / Pressure Feed Quality Variations Low pressure , Moderate temp.
FCC is Flexible and Thus Growing
Flexibility of Operating FCC Unit
Operating Conditions Reactor Temp. C Residence Time Catalyst/ Oil Ratio Recycle, CFR Middle Dist. Mode 449 510 < Base < Base 1.4 (HCO) Gasoline Mode 527 538 Base Base Optional (HDT LCO) Light Olefin Mode 538 560 > Base > Base Optional (Heavy Naphtha)
Flexibility of Operating FCC Unit
Product Yield H2S, wt.% C2, wt.% C3, LV% C4, LV% C5+ gasoline, LV % LCO, LV% HCO, LV% Middle Dist. Mode 0.7 2.6 6.9 9.8 43.4 37.5 9.2 Gasoline Mode 1.0 3.2 10.7 15.4 60.0 13.9 7.2 Light Olefin Mode 1.0 4.7 16.1 20.5 55.2 10.1 7.0
FCC BALANCES
Mass Balance Heat Balance
Coke Balance
Pressure Balance FCC is floating on balances
FCCU SCENARIO
FLUIDISED CATALYTIC CRAKING
400 FCC Units in World Major Secondary Process since 1942 Major source of high value lighter hydrocarbon Complex, Interlinked but Flexible Flexible operation modes: LPG, MS & Diesel Continuous developments in Design Development of Catalyst & Additives
FCC is Workhorse of Refinery
FCC/RFCC UNITS IN INDIA
S. NO 1 2 3 4 5 6 7 8 9 10 11 12 13 REFINERY HPCL(BOMBAY) BPCL( BOMBAY) HPCL(VISAKH) IOCL(GUJARAT) IOCL(MATHURA) CPCL (MADRAS) BPCL(BOMBAY) KRL(COCHIN) HPCL(VISAKH) IOCL(PANIPAT) Reliance (Jamnagar) IOCL(HR) RFCC IOCL(BR) RFCC CAPACITY MMTPA 0.40 1.20(0.60) 0.95(0.40) 1.4 1.00 0.78(0.60) 0.85 1.75(1.00) 0.60 0.70 8.0 1.0 1.4 LICENSOR ESSO SHELL(MODEL IV) EXXON(ESSO) UOP UOP UOP SWEC(UOP) UOP UOP S&W UOP S&W S&W YEAR OF COMMISSIONING 1954 1995(1955) 2000(1957) 1982 1983 2004(1985) 2002(1985) 2005(1985) 1985 1997 1998 2001 2002
BLOCK FLOW DIAGRAM OF MODERN REFINERY
CRACKING REACTIONS
Principal Reaction Paths
Thermal Cracking Catalytic Cracking
Primary Reactions Secondary Reactions
Process Variables
19
Primary Reactions
Paraffin Alkyl naphthene Alkyl aromatic Multi-ring naphthene
Smaller paraffin + olefin Naphthene + olefin Aromatic + olefin Alkylated naphthene with fewer rings
Process Variables 20
Secondary Reactions
Olefin + paraffin Olefin + naphthene Olefin + olefin Olefin + olefin
Paraffin + olefin Paraffin + aromatic Paraffin + diolefin (or coke) Paraffin + aromatic
Process Variables
21
FLUIDISATION
FLUIDIZATION REGIMES IN FCC
Name Packed Bed Min Fluidization Bubbling bed Dense Bed Turbulent Bed Fast Fluid Bed Pneumatic Flow FCC Section -Standpipe Stripper Regenerator -Combustor Riser Gas Velocity M/Sec < 0.05 .01 - .05 .05 - .30 .30 - .70 .70 - 1.1 1.1 - 3.0 2.0 - 20.0 Bed Density, KG/M3 700 - 850 700 - 800 600 - 750 400 - 600 300 - 500 100 - 300 30 - 100
FLUIDIZATION REGIME IN FCCU
TC
LC
V=0.05-0.30
Stripper
=700-800
Air
V=0.3-0.7 = 400-600
V=2-20 = 30-100
V=0 = 7.01-0.0 00-8 5 00
Riser
CATALYST
FCC CATALYST
CLAY
Re-EARTHS
ZEOLITE
MATRIX
PERFORMANCE FEATURES OF FCC CATALSYTS
Zeolite type and level of rare earth Particle size Distribution, density Activity and stability Fluidization Selectivity
Zeolite type matrix type and amount
Unit retention
Metal tolerance
Density, Attrition resistance
Zeolite type, matrix type, traps
FCC CATALYST ADDITIVES
Olefin maximisation additives Octane enhancement additives Bottom Cracking Additives (BCA) DeSOx additives Metal traps Gasolene Sulphur Reduction (GSR) additives
PROCESS DESCRIPTION
Products to Main Column
UOP Side by Side Fluid Catalytic Cracking Unit
Reactor Flue Gas
Flue Gas Slide Valve
Stripping Steam Regenerator
Spent Catalyst Slide Valve
Air
Regenerated Catalyst Slide Valve
Raw Oil
Regenerated Catalyst Slide Valve Control
Reactor TIC High Temperature Closes Slide Valve
Low Signal Selector < Low Differential Pressure Signal Closes Slide Valve PDIC PDI
(readable from slide valve)
PDT PI PI Regenerated Catalyst from Upper Regenerator
Regenerated Slide Valve
FC
DA Handwheel Actuator
ZI
DG
Selector Switch
Process Flow and Control
32
Reactor
Spent Catalyst Slide Valve Control
Low Level Signal Closes Slide Valve
LIC LIC
DG (LAHL) LT DG
LT
Low Differential Pressure Signal Closes Slide Valve
DG DI DG DG DG DT
Low Signal Selector > PI LI
PDIC PDT PI
PDI
ZI DG FC
Readable from Slide Valve Actuator
Actuator Selector Switch
DA
Process Flow and Control
Spent Catalyst to Regenerator
33
Conventional FCC Flue Gas System
(without Power Recovery)
HSS >
PIC
PDIC
Signal from Reactor Pressure Tap
Flue Gas Slide Valves
Flue Gas
Orifice Chamber Steam
CO Boiler Air Air Water
Electrostatic Precipitator
FCC-PC002
Process Flow and Control
34
Main Column Bottoms Circulation
Reactor Product Vapor
FIC
FIC
LIC
HCN Stripper Reboiler
Debutanizer Reboiler
Torch Oil Pump Flushing Oil
MCB Quench
FIC
Disc and Donut Minimum Flow
Steam
FIC FI
LIC
Raw Oil
FIC
BFW
FIC FIC
MCB Product
CW
Raw Oil
FCC-PC401
Process Flow and Control
35
PROCESS VARIABLES
Process Variable Effects
Regenerator Temp Cyclone Efficiency Aromatic Content Reqd Stripping Steam Rate 37 LCO Aromatic Content Olefin Content
Affected Variable
Conversion LPG Yield Gas Yield
Gasoline
Adjusted Variable
Increased Combined Feed Temperature Increased Recycle Rate Increased Reactor Temperature Increased Reactor Pressure Increased Regenerator Pressure Increased Catalyst Circulation Rate at Constant Reactor Temperature (Increased Cat Cooler Duty)
Change in Affected Variable:
increases;
decreases
Process Variables
Catalyst Entrainment
Catalyst/Oil
Coke Yield
Octane
CRACKER EQUIPMENT
HARDWARE SUBSYSTEMS FOR FCC Feed distributor Riser termination device Stripper with efficient internals Catalyst & air distributors in regenerator Catalyst cooler Cyclones Flue gas scrubber
HARDWARES PLAY MAJOR ROLE IN FCC
Feed Distributor Historical Development
Bayonet Showerhead Premix Lift Gas Optimix
Equipment
40
Reactor Riser Feed Distributor
Jet Nozzle Type
Abrasion Resistant Lining
Abrasion Resistant Lining
FCC/DS-R00-98
Drain and Vacuum Connection
Equipment 41
Elevated Optimix Feed Distributor
Equipment
42
Optimix Feed Distributor
Work Point High Density Refractory Lining
Abrasion Resistant Lining
Welding Neck Flange Steam Connection
Ceramic Fiber Blanket Insulation Reactor Riser Feed Distributor
Equipment
Feed Connection
43
Reactor Riser Disengager Designs
Down-Turned Arms Vented Riser Direct-Connected Cyclones Suspended Catalyst Separation Vortex Disengager System and Vortex Separation System
Equipment 44
Reactor Riser Disengaging Devices
T-Type Disengager
Down Turned Arm
Equipment
Vented Riser
Direct-Connected Cyclones
45
Modern Reactor Riser Disengaging Devices
Vortex Disengager Stripper
Equipment
Vortex Separation System
46
Reactor WYE Section
Hot Wall vs. Cold Wall Cold Wall Advantages
Less Thermal Expansion No High Temperature Metallurgy Metal Temperature Out of Creep Range No Stress Relief Increased Operating Life
Equipment
47
Hot Wall WYE
Regenerated Catalyst Riser 304H SS 3/4 Abrasion Resistant Lining External Insulation
Blast Steam
Charge
Equipment 48
Cold Wall WYE
Regenerated Catalyst Riser Carbon Steel 5 Refractory Cement Lining
Blast Steam
Charge
Equipment 49
Catalyst Stripper
Insulation Riser Stripper Shell
Stripping Steam Abrasion Resistant Lining
Stripping Steam
Fluffing Steam
FCC-E005
Equipment
50
Bubbling Bed Regenerator
THERMOCOUPLES (1each cyclone) CYCLONE SUPPORTS REGENERATOR PLENUM
REFRACTORY LINING
MANWAYS
LEVEL AND PRESSURE TAPS TIs FIRST STAGE CYCLONES REFRACTORY LINING
SECOND STAGE CYCLONES
SPENT CATALYST DEFLECTOR
EXTERNAL LINING TRICKLE VALVES TORCH OIL MANWAY OPEN PRIMARY CYCLONE DIPLEG TERMINATIONS
SPENT CATALYST STANDPIPE LEVEL AND DENSITY PRESSURE TAPS
AIR DISTRIBUTOR REGENERATED CATALYST STANDPIPE
CATALYST WITHDRAWAL
FCC-E003
Pipe Air Grid
Equipment
52
Plan of Air Grid
PLAN (Total Number of Arm Jets Required: 1024) = Open Jets: 850 = Plugged Jets: 174
Equipment
53
Jet Detail
FCC/DS-R00-65
Equipment
54
Cyclone-Catalyst Fines Collector
Gas Out Catalyst-Free Gas Outlet
Catalyst-Laden Gas Inlet Catalyst-Laden Gas Inlet
Disengaging Hopper Catalyst Outlet Dip Pipe
Equipment
Stream Pattern-Lower Portion Stream Pattern-Upper Portion (Principally Finer Particles)
55
Regenerator Cyclones
First Stage
Inlet Velocity Shall Not Exceed 65 ft/sec (19.8 m/sec) Outlet Velocity Shall Not Exceed 80 ft/sec (24.4 m/sec) Ratio of Barrel Area to Inlet Area Shall be 3.7 Minimum
Equipment
56
Regenerator Cyclones (continued)
Second Stage
Inlet Velocity Shall Not Exceed 75 ft/sec (22.9 m/sec) Outlet Velocity Shall Not Exceed 120 ft/sec (39.6 m/sec) Ratio of Barrel Area to Inlet Area Shall be 4.3 Minimum Minimum Barrel Diameter is Equal to First Stage Barrel Diameter
Equipment
57
Regenerator Cyclones (continued)
Both Stages
Ratio of Cyclone Length to Barrel Diameter Shall be 5.0 Minimum Projected Apex of Main Cone Shall be a Minimum Distance of 0.3 Times Barrel Diameter Above the Outlet of the Dust Hopper
Equipment
58
Cyclone Dipleg Termination
Trickle Valve Counterweighted Flapper Valve Submerged
Equipment
59
Trickle Valve
Hinge
Flapper Plate Stop
3-5 From Vertical
Equipment
60
Weighted Flapper Valve
Equipment
61
UOP Plenum Chamber Designs
External Plenum
Internal Plenum
External Manifold
Equipment
62 FCC/DS-R00-104
Orifice Chamber
Flow Internal Manways
304H Internals Hexmesh
Carbon Steel Shell Refractory
Equipment
63
Orifice Chamber
Used When Regenerator Pressure is Controlled by Flue Gas Slide Valve Reduces Pressure Drop Across the Slide Valve Grid Hole Erosion
Equipment
64
Grid Section of Orifice Chamber
Grid Holes Rings
Plan of Grid C Grid L 1 Ring #1 Ring #2 Ring #3 Ring #4
C Grid L
3/4 Abrasion Resistant Lining
Grid Section
Equipment
65
Orifice Chamber Grids
First Grid: Last Grid:
Equipment
66
Electrostatic Precipitator
Equipment
67
ESP Fines Collection Equipment
Equipment
68
