3.

Fluidised bed catalytic cracking of gasoils

Catalytic cracking of gasoil for the production of gasoline is carried out at tempertures of
the order of 525C. The catalyst containing lor 2 wt % coke is regenerated with air around
580C by reducing the coke to 0.4 to 0.8 wt %. An early type of the reactor-regenerator
system is shown schematically in Figure. The oil is fed at the bottom of the reactor
through a perforated plate distributor and the gasoline and gases are taken off at the top.
The top of the fluidized bed has a more or less clearcut surface but some solids are
entrained and a certain freeboard is necessary to minimize this. In order to avoid catalyst
loss and elutria tion the exit stream flows through a two-stage cyclone. The catalyst is fed
back to the bed through pipes, which are called diplegs, and which have a seal at their
bottom for preventing leakage of bed-fluid. The catalyst is allowed to leave the reactor
through a bottom standpipe. It is first stripped with steam in order to remove adsorbed
hydrocarbons and then moves through the transfer line, under the influence of a static
head, to the re generator, where the static pressure is lower. The lower static pressure in
the riser leading to the regenerator is due to the aeration of the gas-solid mixture with air
required for burning off the coke. More air for the regenerator is injected in the
regenerator itself, through a distributor plate. The regenerator also has a two stage cyclone
in order to reduce catalyst loss. The regenerated catalyst flows into a downcomer or
standpipe and back to the reactor. The difference in static pressure required for this is
realized by injection of the oil into the riser of the reactor. The oil rapidly evaporates in the
pipe and reduces the catalyst bulk density. Slide valves in the lines permit additional
adjustment of the flow rates. The rate of circulation of the solids is dictated by the heat
balance and activity level of the catalyst: the heat produced by the regeneration is carried
to the reactor by the catalyst and there it evaporates, heats, and cracks the oil. The transfer
lines have to be designed in such way that they are not eroded by the catalyst. The catalyst
also has to withstand attrition.
Typical operating figures for fluid catalytic crackers
Medium size capacity: 15,000 barrels/day = 2390 m3 gasoil/day
Catalyst: silica-alumina zeolite catalyst or molecular sieves 20-80
Total catalyst inventory : 250 tons
Amount in regenerator: 100 tons
Catalyst bulk densities
Reactor and regenerator: 320-560 kg/m3
Stripper: 480-640
Standpipes: 560-720
Risers: 80-480
Diplegs: 240-560
Catalyst circulation rate: 24 tons/min
Catalyst flow rate to cyclones : 7 tons/min
Catalyst loss: 2 tons/day
Superficial velocity in reactor and regenerator: 0.5-1.3 m/s
Velocities in standpipes: 1.7 m/s
Risers: 7-10 m/s
Diplegs: 1.7m/s

Simulation model
The kinetics of catalystic cracking is Mobil 10 lump model which involves
Heavy fraction(h): parafins(P),napthenics(N), aromatics(Ar) & substituted aromatics(As)
Light fraction(l): parafins(P),napthenics(N), aromatics(Ar) & substituted aromatics(As)
Gasoline (G) and coke & C1-C4 fractions (C).
Catalyst deactivation due to coke deposition is also considered.
Cracking.m is the simulation program

Reactors