Residue Fluid Catalystic Cracking Unit (Rfccu)

DUNG QUAT REFINERY PROJECT
MANAGEMENT BOARD
3rd TECHNOLOGY GROUP
RESIDUE FLUID CATALYSTIC

CRACKING UNIT (RFCCU)
QUANG NGAI -2006
PRESENTATION CONTENTS
I.
II.
III.
IV.
V.
VI.
INTRODUCTION;
BASIC OF DESIGN;
PROCESS DESCRIPTION;
MATERIAL BALANCE (TYPICAL);
SPECIFICATION OF CATALYST AND CHEMICAL;
SAFETY.
I- INTRODUCTION
1.
2.
3.
4.
Licensed by IFP/AXENS;
Technology: R2R;
The role of RFCC in the Refinery;
Location of RFCC in the Refinery.
I.3 THE ROLE OF RFCC IN THE REFINERY
I.4 LOCATION OF RFCC IN THE REFINERY
II-BASIC OF DESIGN
1.
2.
3.
4.
5.
6.
Unit objectives and capacity;

Feedstock properties;
Product specifications;
Operating conditions;
Battery limit conditions;
Utility operating / Design conditions.
II.1 UNIT OBJECTIVES AND CAPACITY

a.
Objectives: Process:
Bach Ho
Mixed BH/DB
Off-gas
LPG
Off gas
HSO (5000BPSD)
LSO (5000BPSD)
b.
c.
Atmosphere
Residue
From CDU
Cracking
Lighter
more valuable
Products
From NHT
From
Refinery
Capacity: 69700 BPSD (3 256 000 tonnes per year)

Operational:
Maximum Gasoline;
Maximum Distillate.
Blending
Gasoline
DO
II.2 FEEDSTOCK PROPERTIES

a.
Atmospheric residue properties;

Crude Blend
100%BachHo
Cut range, TBP (oC)
370+
370+
Vol. % on crude
46.6
47.3
SG at 15/4oC
0.893
0.882
50
52
IBP
263
262
50%
475
480
Vol% above 550oC
32.4
32.5
Property
Pour point (oC)

ASTM distillation @ 760 mmHg (oC
II.2 FEEDSTOCK PROPERTIES (CONT.)

b.
CDU stabilizer off-gas;

100% Dubai
100% Bach Ho
339.0
291.0
Flow rate (kg/h)

Composition (mol%)
C1
0.7
C2
6.3
4.8
C3
37.0
22.7
C4
54.9
69.5
C5
0.4
0.4
Molecular weight
50.6
52.6

c.
10
NHT stripper off-gas to RFCC;

H2O
(kg mol/h)
0.13
H2S
(kg mol/h)
0.32
H2
(kg mol/h)
13.17
C1
(kg mol/h)
1.69
C2
(kg mol/h)
1.37
C3
(kg mol/h)
0.83
C4
(kg mol/h)
0.46
C5
(kg mol/h)
0.24
C6+
(kg mol/h)
0.63
Total
(kg mol/h)
18.84

d.
CDU LPG rich steam.

Crude (sour) Blend
100% Bach Ho
Flow rate (kg/h)
6206
2071
SG at 15oC
0.565
0.572
C2
1.2
0.8
C3
19.3
10.7
C4
78.2
87.1
C5+
1.3
1.4
Total
100
100
Composition (mol%)
11
II.3 PRODUCT SPECIFICATIONS

a.
LPG;
PROPETIES
MMG
BMG
MMD
BMD
0.565
0.566
0.565
0.565
Mercaptans (wt ppm)
78
7.1
78
7.1
COS (wt ppm)
5.0
5.0
5.0
5.0
Total sulphur (wt ppm)
3768
332
4260
383
Butadiene (wt ppm)
3012
1647
1358
1063
Sp. Gr 15/15
12
II.3 PRODUCT SPECIFICATIONS (CONT.)

b.
Gasoline (MG: C5-205oC; MD: C5-165oC);

PROPERTIES
MMG
BMG
MMD
BMD
Sulphur (wt ppm)
340
10
230
10
RON clear
92.1
91.8
92.0
RVP (kPa)
32
34
48
51
0.736
0.732
0.719
0.715
IP
39
39
35
34
50%
90
87
72
70
EP
197
197
159
156
Olefins (wt%)
34
35
43
45
Sp. Gr. 15/15
13
91.7

c.
LCO (MG: 205-360oC; MD: 165-390oC);
PROPERTIES
14
MMG
BMG
MMD
BMD
Sulphur (wt ppm)
0.619
0,055
0.45
0.04
Cetane number
24.4
28.1
33.9
Pour point (oC)
-12.8
-14.0
-17.3
-18.9
Flash point (oC)
76
74
67
67
Sp. Gr. 15/15
0.926
0.911
0.881
0.864
IP
188
180
189
189
50%
263
262
263
264
EP
353
353
373
374
38.4

d.
Slurry (MG: 360+oC; MD: 390+oC);
PROPERTIES
MMG
BMG
MMD
BMD
Sp. Gr. 15/15
1.092
1.043
0.994
0.960
Sulphur (wt%)
1.03
0.10
0.835
Conradson carbon (wt%)
15.7
12.7
12.5
9.5
Viscosity @ 100oC (cSt)
160
140
110
45
15-20
15-20
15-20
15-20
Pour point (oC)
15
0.07

e.
Decant Oil (after slurry separation):
f.
16
100
ppm wt max
Fuel Gas:
g.
Catalyst content:
H2S content:
50
ppm wt max
Flue Gas (after EP and DeSOx unit):
NOx:
1000
mg/Nm3 max
SOx:
500
mg/Nm3 max
Catalyst fines
50
mg/Nm3 max
CO content
300
mg/Nm3 max
II.4 OPERATING CONDITIONS

a.
Reaction/Regeneration Section;
RISER/REACTOR
MMG
BMG
MMD
BMD
Outlet temperature (oC)
520
518
511
505
Feed flow rate (ton/h)
407
407
524.1
524.1
Feed temperature (oC)
170
290
170
290
MTC
(ton/h)
76.4
MTC recycle temp. (oC)
181
170
170
170
170
79.94
80.76
62.60
61.88
HCO back flush (t/h)

HCO back flush temp. (oC)
Stand. conversion (wt%)
17
II.4 OPERATING CONDITIONS (CONT.)

a.
Reaction/Regeneration Section (Cont.);
FIRST REGENERATOR
MMG
BMG
MMD
BMD
Dilute temperature (oC)
678
646
641
631
Dense temperature (oC)
683
651
646
636
Dilute pressure(kg/cm2g)
2.28
2.28
2.28
2.28
70
70
70
70
15.2
5.5
15.2
5.5
MMG
BMG
MMD
BMD
Dilute temperature (oC)
772
734
733
720
Dense temperature (oC)
762
713
712
695
Dilute pressure (kg/cm2g)
1.3
1.3
1.3
1.3
Coke burnt (%)

Cat. dry make-up (t/d)
SECOND REGENERATOR
18

b.
Fractionation Section;
MAIN FRACTIONATOR
MMG
BMG
MMD
BMD
Top temperature (oC)
103
102
100
96
Top pressure(kg/cm2g)
0.85
0.85
0.85
0.85
Heavy naphtha
156
152
162
161
LCO
218
210
230
230
Bottom temperature (oC)
340
340
340
340
Bottom pressure (kg/cm2g)
1.15
1.15
1.15
1.15
Draw-off temperature (oC)
19

c.
20
Gas Recovery Section;
PRIMARY ABSORBER
MMG
BMG
MMD
BMD
51
49
50
48
Top pressure (kg/cm2g)
14.8
14.8
14.8
14.8
59
58
58
58
Bot. pressure(kg/cm2g)
15.1
15.1
15.1
15.1
SECOND ABSORBER
MMG
BMG
MMD
BMD
50
47
47
45
14.4
14.4
14.4
14.4
60
58
59
59
14.7
14.7
14.7
14.7

c.
Gas Recovery Section (Cont.);

STRIPPER
MMG
BMG
MMD
BMD
59
59
60
60
15.7
15.7
15.7
15.7
120
122
122
126
16
16
16
16
MMG
BMG
MMD
BMD
68
68
68
68
11.7
11.7
11.7
11.7
180
178
172
171
12.1
12.1
12.1
12.1
DEBUTANIZER
21

c.
Gas Recovery Section (Cont.);
22
Fuel Gas Absorber

o
o
o
o
LPG Amine Absorber
o
o
o
o
56
13.7
61
14
40
17.9
42
19.7
II.5 BATTERY LIMIT CONDITIONS
TEMP. (oC)
PRES.(kg/cm2g)
Atmospheric residue from CDU
115
4.5
Atmospheric residue from storage
70
4.5
46-52
20
Off gas from CDU
50
0.7
Off gas from NHT
40
0.6
Lean amine from ARU
55
22.6
Light slops from off-site
50 max
3.5
Heavy slops from off-site
70 max
3.5
STREAM
LPG rich stream from CDU
23
II.5 BATTERY LIMIT CONDITIONS (CONT.)
TEMP. (oC)
PRES.(kg/cm2g)
Unsaturated off gas
54
4.5
LPG to LTU
40
18
RFCC naphtha to NTU
40
9.5
LCO to LCO Unit/ Storage
50
6.0
DCO to blending
90
8.0
Sour water to SWS
42
3.5
Rich amine to ARU
41-50
7.0
STREAM
24
II.6 UTILITY OPERATING/DESIGN CONDITIONS

SERVICE
25
NORMAL
MAXIMUM
MINIMUM
DESIGN
NORMAL
MAXIMUM
MINIMUM
DESIGN
HHP STEAM
105.5
107.5
103.5
112.9
500
510
490
535
HP STEAM
42.3
44.3
40.3
48.3
380
400
360
450
MP STEAM
14.1
15.1
13.1
16.8
250
270
230
320
POWER STATION LP STEAM
4.1
4.6
3.6
6.3
160
180
148
230
LP STEAM
3.6
4.6
3.6
6.3
160
180
148
230
POWER STATION LP STEAM
4.1
4.6
3.6
6.3
160
180
148
230
SERVICE WATER
1.5
9.3
30
35
15
60
POTABLE WATER
2.5
0.5
4.2
30
35
15
60
DEMIN WATER
1.5
9.3
30
35
15
60
HHP BFW
130
135
110
141.8
112
131
105
160
HP BFW
60
66
58
89.2
112
131
105
160
LP BFW
22
24
20
37.5
112
131
105
160
COLD BFW
9.3
60
90
50
115
FRESH CW SUPPLY
4.5
5.5
9.2
32
34
25
70
FRESH CW RETURN
1.5
2.5
9.2
47
60
25
70
SEA CW SUPPLY
3.8
4.8
3.3
7.4
30
30
20
70
SEA CW RETURN
0.8
1.3
0.8
7.4
38
40
20
70
REFINERY FIRE WATER
15
19.3
30
35
15
60
SALT FIRE WATER
10
15
19.3
30
30
20
70
II.6 UTILITY OPERATING/DESIGN CONDITIONS
SERVICE
26
NORMAL
MAXIMUM
MINIMUM
DESIGN
NORMAL
MAXIMUM
MINIMUM
DESIGN
HP CONDENSATE
7.5
48.3
170
450
MP CONDENSATE
7.5
16.8
170
320
LP CONDENSATE
63
133
230
VACUUM CONDENSATE
2.5
4.7
50
80
50
110
INST AIR/PLANT AIR
7.5
10.6
35
40
10
65
REFINERY NITROGEN
6.5
11.7
30
40
10
65
CCR NITROGEN
8.5
11.7
30
40
10
65
FUEL GAS COLLECTION
3.8
3.5
6.7
46
53
38
75
FUEL GAS SUPPLY
3.3
3.5
6.7
46
53
38
75
REFINERY FUEL OIL
16
17.5
14
30.5
90
100
50
125
50 Be CAUSTIC
6.3
40
45
30
70
20 Be` CAUSTIC
1.5
5.5
40
45
30
70
14 Be` CAUSTIC
6.3
40
45
30
70
5 Be` CAUSTIC
1.5
4.3
40
45
30
70
III - PROCESS DESCRIPTION

1.
2.
3.
4.
27
Reactor/Regeneration (Rx/Rg) - Catalyst handling;

Flue gas treatment;
Feed fractionation;
Gas Recovery section.
III.1 RX/RG CATALYST HANDLING
28
III.1.1 RX
To flue gas
To main
fractionator
T1501
TC
Withdrawal wel
MP Steam
LC
FC
LC
PdC
Combustion air
FC
FC
1
To flue gas
FC
PC
FC
Standpipe
FC
Backflush Oil
FC
FC
LC
Riser
Combustion air
Fluidization air
Lift air
FC
FC
Plug valve
29
FC
MTC
III.1.1 RX (CONT.)
Feed MTC
Injecti Injecti
on
on
30
Riser
Outlet
ELE
V
III.1.1 RX (CONT.)
Vapor Pro.
To Frac. Section
Riser Outlet
Seperation System
Spent Cat. To
First Stage
Regenerator
Reg. Cat. From
Second Stage
Regenerator
Backflush Oil
MTC(MMG)
Feed
MP Steam
31
III.1.2 RG
Flue gas to
COB/WHB
Reg. Cat. To Riser

Combustion Air
Spent Cat
From Stripper
(Reactor)
Lift Air
32
III.2 FLUE GAS TREATMENT
33
III.3 FEED FRACTIONATION
34
III.3 FEED FRACTIONATION (CONT.)
35
III.4 GAS RECOVERY
36
IV- MATERIAL BALANCE (TYPICAL)
FEED (KG/HR)
Residue
37
PRODUCTS (KG/HR)
407000
Fuel gas
9812
CDU LPG
2071
LPG
77250
CDU off gas
291
Naphtha (RFCC)
216962
NHT off gas
243
LCO
56889
Light/Heavy slops
(NNF)
DCO
29574
Total
409605
Total:
390487(Loss 9118)
V- SPECIFICATION OF CATALYST AND CHEMICAL

1.
2.
Catalyst;
a. Used in:
Reaction/Regeneration section ;
b. Type of catalyst:
RE-USY;
c. Catalyst inventory: 600 tons;
d. Addition rate (ton/day): 15.2(Mixed)/5.5(BachHo).
Chemicals:
a. Antimony (Nickel passivator)
38
Used in:
RFCC feed section;
Type:
NALCO EC919ZA or equivalent;
Antimony content(%):
23;
Injection rate:
Ratio Sb/Ni in feed: 0.5;
Normal consumption (kg/day):109(Mixed)/0(Bach Ho);
Max consumption (kg/h): 15.
V- SPECIFICATION OF CATALYST AND CHEMICAL

a.
b.
39
Corrosion Inhibitor:
Used in:
Fractionator overhead ;
Type:
CHIMEC 1430;
Normal consumption (kg/day):
60;
Max consumption (kg/day): 120.
Amine Antifoaming Agent:
Used in:
FG/LPG amine absorbers;
Type:
CHIMEC 8045;
Normal consumption (kg/day):
10;
Max consumption (kg/day): 20.
VI - SAFETY
1.
2.
3.
40
Precaution for entering vessels;

High temperature precautions;
Chemical hazards.
VI.1-PRECAUTION FOR ENTERING VESSELS

a.
b.
The Reactor must be cooled to below 150oC before any manways or

nozzles are opened.
The following precautions should be followed to prevent the personnel
entering a vessel:
The vessels should be isolated by positive action;
An air mover should be installed at the vessels manway to sweep
away any vapors and provide a continuous supply of fresh air;
Responsible personnel must test the atmosphere in the vessel for
explosiveness, toxic fumes, oxygen content, dust, etc;
Personnel entering the vessel must be equipped with a pressure
demand respirator that is in proper working condition, and is
connected to a suitable fresh air supply;
Separate air supplies which are independent of electrical power
should be available for immediate use and transfer to personnel in
the vessel.;
41
Personnel entering the vessel should wear a safety harness

with a properly attached safety line.
VI.1-PRECAUTION FOR ENTERING VESSELS (CONT.)
42
If the work is to be performed at a high level above the bottom of

the vessel, such as cyclone inspection, scaffolding and support
flooring must be built to prevent fall;
There should be a minimum of two backup men at the vessel
manway in continuous surveillance of the personnel in the vessel.
There should be spare pressure demand respirators, complete with
their own separate air supplies, to allow backup personnel to enter
the vessel quickly in case of an emergency.
any personnel working in a vessel which has an inert or
contaminated atmosphere not be permitted to move too far away
from the entryway, or into any tight areas, such as through a
fractionator tray manway;
VI.2 HIGH TEMPERATURE PRECAUTIONS

a.
43
Anyone working around the uninsulated lines or vessels should be

warned that these will get hot. Combustible materials and trash should
be kept away from the unloading lines and equilibrium catalyst hoppers.
VI.3 CHEMICAL HAZARDS

1.
2.
44
If the hydrocarbons, catalyst, and chemicals are mishandled, or allowed to

escape into the atmosphere, some of them may be a hazard to the health of
anyone in the area;
Should be carefully for Hazardous materials present in the RCC Unit, as
follows:
a.
Catalyst:
FCC is a fine dust capable of causing eye and Lung irritation. When
unloading catalyst cars, drawing samples, etc., goggles or a face
shield, a dust mask should be worn;
When drawing hot regenerated catalyst samples, gloves and long
sleeved clothing should always be worn.
Personnel should not walk over or work around piles of spilled
catalyst.
VI.3 CHEMICAL HAZARDS (CONT.)

a.
b.
45
Iron Sulfide:
Iron sulfide has pyrophoric properties. It will ignite
spontaneously when exposed to air, which is most likely to occur in
recently opened refinery vessels.
A vessel suspected of containing iron sulfide must be thoroughly
steamed out and washed with water before air is permitted to enter.
Heavy Cracked Hydrocarbons:
Heavy cracked oils are skin irritants. In case of actual contact, the
skin should be thoroughly washed with hot soapy water, and any
oil-saturated clothing should be removed;
Should any hydrocarbon enter the eye, First Aid is to wash with a
copious amount of clean water and obtain trained medical
assistance as quickly as possible.

a.
b.
46
Light Cracked Hydrocarbon Liquids:

Those gasoline streams which contain aromatics will be particularly
dangerous. Benzene is a poison, and heavier aromatics have a
narcotic effect;
In case of exposure, no time should be lost in removing any
gasoline-soaked clothing and washing the skin with hot soapy
water. First Aid for eye injuries is the same as that discussed above
under Heavy Cracked Hydrocarbons.
Aromatic Hydrocarbons:
Benzene:
Benzene has carcinogenic effect on the bodys blood-forming
organs, an effect which is cumulative with each exposure;
If clothing, including gloves, becomes wet from benzene,
immediately remove the clothing. Wash the skin areas exposed
to benzene with soap and water. The person will inhale
benzene vapors over a long period of time with serious hazard
to health.

o
a.
47
Avoid draining benzene on the ground or into the sewers

where it can vaporize and create a health hazard. If you must
enter an area of high benzene vapor concentration resulting
from a spill, wear a pressure demand respirator.
Toluene, Xylenes, and Heavier Aromatics:
o
These aromatic compounds principal effect is skin, eye, and
respiratory irritation. Avoid breathing aromatic vapors;
o
All employees should be alerted as to the early signs and
symptoms of excessive absorption of aromatics, and all
workers should report such symptoms to the Medical
Department.
Light Hydrocarbon Vapors:
These vapors can be toxic, since they may contain aromatics, H2S,
or other lethal compounds.
A person who has breathed quantities of hydrocarbon vapors should
be removed from the area and kept warm and quiet. If necessary,
artificial respiration with or without the use of oxygen should be
administered and medical aid summoned. Professional medical
attention should be obtained at once.

a.
b.
48
Hydrogen Sulfide:
Hydrogen sulfide is one of the most poisonous gases known.
Exposure to an atmosphere containing less than 0.1% H2S may be
fatal in 30 minutes or less;
A person exposed to H2S may become excited or dizzy, may
stagger, and can ultimately lose consciousness. First Aid consists of
removal from the area and the administration of artificial respiration
with or without oxygen if breathing has stopped. The patient should
be kept warm and medical aid summoned.
Flue Gas:
Flue gas from the regenerator can cause asphyxiation if a person
enters an improperly ventilated duct or a low area where the high
density of flue gas;
Symptoms of asphyxiation may be dizziness, headache, or
shortness of breath;
49
RCC flue gas is very dangerous since it contains carbon

monoxide, which is toxic. A concentration of 0.4% can be
fatal in about one hour. One visible symptom of carbon
monoxide poisoning is a bluish-red color of the skin;
First Aid in cases of flue gas asphyxiation or poisoning
consists of keeping the victim warm and administering
artificial respiration and oxygen, if necessary, obtain
professional medical attention immediately.
50

Residue Fluid Catalystic Cracking Unit (Rfccu)

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Residue Fluid Catalystic Cracking Unit (Rfccu)

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DUNG QUAT REFINERY PROJECT

RESIDUE FLUID CATALYSTIC

QUANG NGAI -2006

I.3 THE ROLE OF RFCC IN THE REFINERY

I.4 LOCATION OF RFCC IN THE REFINERY

Unit objectives and capacity;

II.1 UNIT OBJECTIVES AND CAPACITY

Capacity: 69700 BPSD (3 256 000 tonnes per year)

II.2 FEEDSTOCK PROPERTIES

Atmospheric residue properties;

Cut range, TBP (oC)

Vol% above 550oC

Pour point (oC)

II.2 FEEDSTOCK PROPERTIES (CONT.)

CDU stabilizer off-gas;

Flow rate (kg/h)

II.2 FEEDSTOCK PROPERTIES (CONT.)

NHT stripper off-gas to RFCC;

II.2 FEEDSTOCK PROPERTIES (CONT.)

CDU LPG rich steam.

Flow rate (kg/h)

II.3 PRODUCT SPECIFICATIONS

Mercaptans (wt ppm)

COS (wt ppm)

Total sulphur (wt ppm)

Butadiene (wt ppm)

II.3 PRODUCT SPECIFICATIONS (CONT.)

Gasoline (MG: C5-205oC; MD: C5-165oC);

Sulphur (wt ppm)

Sp. Gr. 15/15

II.3 PRODUCT SPECIFICATIONS (CONT.)

LCO (MG: 205-360oC; MD: 165-390oC);

Sulphur (wt ppm)

Pour point (oC)

Flash point (oC)

Sp. Gr. 15/15

II.3 PRODUCT SPECIFICATIONS (CONT.)

Slurry (MG: 360+oC; MD: 390+oC);

Sp. Gr. 15/15

Conradson carbon (wt%)

Viscosity @ 100oC (cSt)

Pour point (oC)

II.3 PRODUCT SPECIFICATIONS (CONT.)

Decant Oil (after slurry separation):

Flue Gas (after EP and DeSOx unit):

II.4 OPERATING CONDITIONS

Outlet temperature (oC)

Feed flow rate (ton/h)

Feed temperature (oC)

MTC recycle temp. (oC)

HCO back flush (t/h)

Stand. conversion (wt%)

II.4 OPERATING CONDITIONS (CONT.)

Reaction/Regeneration Section (Cont.);

Dilute temperature (oC)

Dense temperature (oC)

Dilute temperature (oC)

Dense temperature (oC)

Dilute pressure (kg/cm2g)

Coke burnt (%)

II.4 OPERATING CONDITIONS (CONT.)

Top temperature (oC)

Bottom temperature (oC)

Bottom pressure (kg/cm2g)