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A Honeyweli Cottpany

FCC PROCESS
TECHNOLOGY STANDARD

Section 11 - FCC Optimization

Learner Guide

Documen

FCC Process Technology


A l{oneywell Company

Learner Guide

Section l l:FCC Optilnization

Rev 0

TABLE OF CONTENTS
l.O

FCC OPTIM:ZAT:ON....

"

1.l

Scction Outlinc. ..

5
1.2 Enabling ObieCt Cs. 5

2.0

0PTIMiZAT10N OF FCC UN:TS.

.....

2.l Feed Dispersion Stcam Optinlization.

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2.2 Accclcration Zonc Optimization. .

6
2.3 Stripper(Dptinlization.
7

2.4 Combustor Optinlization. ..

3.O

SUMMARY OF FCC OPTIMIZAT10N...

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Section ll:FCC OptilnizatiOn

1.O

1.1

Ilocumen

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FCC OPTI IIZAT10N

Section Outline

l. FCC Introduction
2. FCC Process Flow and Control
3. FCC Ftuidization
4. FCC Equipment
5. FCC lnspection and Maintenance
6. FCC Corrosion and Fouling
1. FCC Catalyst and Catalyst Management
8.
9.

FCC Process Variables


FCC Procedures

0. FCC Troubleshooting

11. FCC Optimization


1.2

Enabling Ob.iectives
Upon completion of section, the student will be able to:

Describe the method of optimization for the following:

o
o
o
o

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Feed Dispersion Steam

AccelerationZone
Stripper

Combustor

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A 4o evwe oO: pany

2.1

OPTI IIzAT10N OF FCC uNITS

Feed Dispersion Steam Optimization

o
o

Typical feed dispersion steam rate is -l wt.Vo FF


Determine yield structure at base conditions

o
o
o

'
o
o
o

Increase/decrease feed dispersion steam by 0.2 wt.Vo, equilibrate

determine new yield structure

for l}hours,

zurd

Based on results, increase or decrease feed steam to further optimize sysl-em


Note: General rule of thumb is that decreased CFT or increased feed viscosity will
require an increase in dispersion steam

optimum dispersion steam will result in uniform droplet size, flux, and
penetration of the raw feed

Purpose:
Taols:
2.2

Material balance (weight recovery conection)


Distillations (cut point correction)
GC compositions (C5+ gasoline correction)

Maximize yielcl structure


Feed dispersion steam

Acceleration Zone Optimization


Determine acceleration zot)e velocity at current conditio,s
Equation l1 - 1 Accelcration Zonc Optimization

Velocity =
Purpose:
Tools:

volume of inerts + lift

cross-sectional

Maximize the yield structure


Lift media (stearn or lift gas)

Determine yield structure at base conditions


o MAterial balance (weight recovery correction)
o Distillations (cut point correction)
o GC compositions (C5+ gasoline correction)

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FCC Optimization

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lift media input (steam and/or lift gas) to cover the range from 10-l
ftlsec in the acceleration zone (recommended levels at 10, 14, & 1g-ft/sec)
Change riser

At each velocity, allow 12 hour line out time and determine yields
Determine optimum range from abdve data and repeat experimentb to further
optimize system

Note: Low acceleration zone velocities result in higher catalyst densities at feed
injection.

Higher catalyst densities can result in poor feed penetration into the catalyst
stream.

Note: Low acceleration zone velocities contribute to backmixing, long


catalyst/feed contacl. times, over-cracking, and non-sqlectiv",reactions.

2.3

High velocities require high lift gas or steam flows using up wet gas compressor
or overhead condenser.capacity.

Stripper Optimization

Normal steam input is approximately 1.5 to 2.0lb per 1000 lb of caralyst


circulation

At steady opcrating conditions,incrcase stcam input 573 and inonitor rogeneratOr


dense phase temperatnre for any decrease

Purpose:
Tools:

Minirnize steam consumption ancl maximizc yields


Stripping steam

If regenerator temperature

decreases, continue to increase steam until no dense


phase temperar.ute change results, then increase steam another 5vo

If temperature

does.

ngt change, note 'lbase,, regenerator dense phase temperature

Decrease steam to stripper


of eqi-rilibrarion ti me

in 5voincrements

allowing severul hours

Monitor regenerator dense phase temperature for any increase


First increase in temperature, return to previous steam input setting and add
extra 5-1OVo steam

optimization can be determined by monitoring "Hydrogen iir coke,, values


l-he Flue Gas analysis timing.is usually difficulr to cooqJinate

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Se9tiOn ll:FCC OptimizatiOn


2.4

Combustor Optimization

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Open the recirculation slide valve to decrease tl-re afterburn


in the upper
regenerator

'

If recirculation slide valve is loovo open, increase the pressure in regenerar,or,


il.
possible

Purpose:
Tools:
'
o

Control temperature profiile in regenerator (limit afterburning)


Recirculation slide valve and proioter

If regenerator pressure is maximum allowable and recirculation slide valve


is
lOUVo open, use promoter to control afterbirrn
Note: A small afterburn is desirable as long as the coke is burned off of
the
catalyst; monitor the carbon on regenerated catalyst.

3.0

ST]MMARY OF FCC OPTIMIZATION


You, the participant, should have met these learning objectives for
this section:

Describe the method of optimi zatton for the folrowing:


o Feed Dispersion Steam

o
o
o

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AccelerationZone
Stripper
Combustor

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