Debasis Bhattacharyya
(bhattacharyad1@indianoil.in)
Outline
Process fundamentals
Catalytic cracking Fluidization regimes Position in refinery Process flow diagram Mode of catalyst regeneration Heat balance Process variables
Technology evolution
Reactor-Regenerator configuration Hardware internals Catalysts & Additives Resid processing Requirement specific developments
Summary
Refining Processes
Crude oil separation
Refinery
Thermal
High coke
Catalytic
Hydro
Low coke
Hydro-treated VGO
Hydro-cracker bottom Coker gas oil (CGO) De-asphalted oil (DAO) Reduced crude oil (RCO)
LPG
(C3, C4)
Gas
LPG
Crude
C R U D E D I S T
Gasoline Blending
Gasoline
HDS
V A C D I S T
FCC
Schematic of FCC
Products to Fractionator Flue Gas to WHRU Minimum fluidization (0.001-0.05 m/s) Reactor Bubbling (0.05-0.30 m/s) Stripper Steam Regenerator Turbulent (0.7-1.1 m/s) Air Fast fluidization/ Pneumatic transport (5-20 m/s)
SCSV
RCSV RCSV with Riser outlet temp. SCSV with reactor level
Steam
Riser Feed
Fluidization Regimes
P L P L
Umf
Umb
Uch
.. . . . ...
Fixed bed
Particulate regime Bubbling regime Slug flow regime Turbulent regime Fast fluidization
DDSV Orifice chamber CO boiler Waste heat recovery section Flue gas stack
FCC Internals
Reactor dome quench nozzle
Cyclone separator
H Transfer
Branched Paraffins
Olefins
Naphthenes
Aromatics
Aromatics
Unsubstituted aromatics + olefins Different alkyl aromatics Polyaromatics Alkylation Dehydrogenation Condensation
Coke
Coke deposited on catalyst blocks the active site causes temporary deactivation needs burning to regenerate before circulating to riser
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Types of Coke
Coke yield = Feed coke + Catalytic coke + Strippable coke + Contaminant coke Feed coke = 1 (feed CCR); where, 1 = f1(feed vaporization/distribution)
Coke deposited on catalyst blocks the active site cause temporary deactivation of the catalysts Coke on catalyst needs to be burnt to regenerate before circulating to riser bottom Balancing coke is the most crucial in design of FCC unit
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Mode
Coke on regenerated catalyst, wt% Effective catalyst activity Regenerator temperature, oC CO in flue gas, ppm Requirement of CO Boiler Chances of Afterburning
Total Combustion
< 0.05 Higher Higher < 1000 No Lower
Partial Combustion
> 0.05 Lower Lower > 1000 Yes Higher
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Heat losses
Regeneration Air
Regenerated Catalyst
Fresh Feed
Feed Pre-heater
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Delta Coke = (Cpcat / DHcoke )*(Trg-Trc) (Trg-Trc) Coke yield = Reactor heat demand per unit total feed
Variables in FCC
Independent
Feed rate Recycle ratio Feed preheat Riser top temperature Reactor pressure Fresh catalyst activity / Selectivity
Major dependent
Regenerator temperature Catalyst circulation rate Regenerator air flow Coke on regenerated catalyst Product yields
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Post 1970s
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Flexi-cracking by ExxonMobil
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Source: www.kbr.com
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at 90% vaporization
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T-Type Disengage r
Vented Riser
Direct-Connected Cyclones
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Source: www.kbr.com
Source: www.hason-steel.com
Regenerator Cyclones
Orifice chamber
Commonly used
Pipe grid Air ring
Flat pipe grid preferred due to uniform coverage & lower discharge velocity
Zeolite: Silica-alumina Amorphous matrix: Silica, silica-alumina, alumina Filler clay: Silica-alumina Other elements: Rare earth, Sodium
1942
1 micron
1948
1955 1961 1964 1980 1986
0
0.9 20
10
1.0 5
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1.4 1
Porous spray dried micro-spherical powder Particle size distribution of 20 -120 micron & particle density ~ 1400 kg/m3 Comprising Y zeolite in many derivatives of varying properties Supplied under various grades of particle sizes & attrition resistance Continuing improvement metal tolerance, coke selectivity Zeolite based catalyst improved yields of desired products with given feed & hardware
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Use of Additives
ZSM-5 Additive
Increases yields of LPG / Light olefins Improves Gasoline RON Bottom Cracking Additive Upgrades bottom fraction of feed without proportional increase in coke make
GSR Additive
Reduces Gasoline Sulfur content by ~ 30%
CO Promoter
Enhances CO burning in regenerator dense bed
Con. Coke
High Regen temp, Low Cat/Oil High catalyst consumption to maintain activity
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Removal of heat Reduces regenerator temperature Retains catalysts activity Increases catalyst to oil ratios Better yields & enhanced profitability
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Catalyst flows over entire cross sectional area of tube bundle in dense phase Provides variable heat sink & produces steam upto 850 psig
Operating Objective
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INDMAX
Light olefins, LPG, Deep cracking of heavier feed high octane with lesser Coke & Gas gasoline formation Unit heat balance Metal deactivation of catalyst
INDALIN
Naphtha
Light olefins, LPG, Cracking of low molecular gasoline weight hydrocarbon Unit heat balance Auto-grade LPG (saturated) & high octane gasoline Cracking of low molecular weight hydrocarbon Unit heat balance Saturation of LPG without using external hydrogen
Optimization of intermediate fraction with lower yield of bottom fraction
INDALIN Plus
Naphtha
Dist-Extra
Heavy feedVGO
Successfully commissioned at Guwahati refinery in June03 - Smoothest commissioning in IOCs FCC start-up
Indmax can handle high CCR, non-hydrotreated feed with attractive LPG / light olefins yield
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Indmax-FCC Reactor-Regenerator
Direct-Coupled Cyclones Reaction Riser (Short Contact Time) Cyclone Containment Vessel (CCV) Direct-Coupled Cyclones Cyclone Containment Vessel (CCV)
MG Stripper
MG Stripper
Being worldwide licensed by Lummus Technology, USA based on Basic Process Design data/information & catalyst from IndianOil
Micro-Jet Feed Injection Nozzles 39
INDMAX
Yields of light olefins with paraffinic VGO feed (wt%):
Propylene: 27 Butylenes : 15 Ethylene : 14
IndianOils proven INDMAX technology can meet Refiners objectives of propylene maximization 40 &
Summary
FCC has been the most profitable & flexible refining process for more than seven decades because of its ability to meet changing demands FCC technology is still undergoing significant evolution
Beyond certain feed CCR, RFCC becomes too expensive due to high consumption of catalyst & inferior product yields
Increasing gap in propylene demand & supply drives orientation of FCC operation towards propylene maximization Scenario specific tailor made technology can be developed through proper understanding of fundamentals IndianOils proven INDMAX technology can meet the Refiners objectives of propylene maximization & residue upgradation in an cost effective manner
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