FCC CATALYST

FLUIDIZATION

Theory & Practice

Aruba Seminar
May, 2008
 REQUIREMENTS FOR FLUIDIZING
CATALYST IN THE FCC

„ Maintain Regenerator Bed Conditions Required to

Burn Carbon from Catalyst
„ Transfer Solids from a Region of Low Pressure to a
Region of Higher Pressure
„ Maintain Fluid Conditions to Develop Pressure via
Hydrostatic Head
„ Smooth & Stable Operation to Ensure Tight Control
Over Riser Outlet Temp (ROT) and Yields.
 TYPICAL PARTICLE FLUIDIZATION
CURVE

1000
Apparent Density, dP/L

Umb
kg/m3

Umf

Standp
Ideal

Packed Bed ipe Bubbling Bed

Regime Regime
100
0.01 0.1 1 10 100
Velocity, cm/s (cold air)

Umf= Min Fluidization Vel

Umb=Min Bubbling Vel
 FLUIDIZATION STATES IN FCCU’S

FCC Catalyst Undergoes Changes in Fluidization

State, Depending on Location

ƒ Bubbling Bed: In Stripper, Regenerator

ƒ Fluidized Bed: In Standpipes, Diplegs
ƒ Dilute Phase: In Riser, Reactor Disengager,
Regenerator (Above Bed)
ƒ Transition Between States Can Lead to Unstable Flow
 FLUIDIZATION: DESIRABLE
CATALYST PROPERTIES

The Desired Catalyst Properties Differ in Each

Fluidization State

ƒ Bubbling Bed: High Density, High APS

ƒ Fluidized Bed: Low APS and High Fines
ƒ Low Density Increases tcoll
ƒ High Density Better for ΔP
ƒ Optimum Properties are a Trade-Off
 DESIGN AND OPERATION FACTORS
AFFECTING FLUIDIZATION IN PIPES

ƒ Aeration
ƒ Rate
ƒ Type (Steam, Air, Etc.)
ƒ Frequency

ƒ Catalyst Flow per Unit Area

ƒ Slope or Curvature of Pipe
 CATALYST FACTORS AFFECTING
FLUIDIZATION

ƒ Particle Size Distribution (Dp and F45)

ƒ Particle Density (ρp)
ƒ Particle Shape
ƒ Umb (Minimum Bubbling Velocity)
ƒ Umf (Minimum Fluidization Velocity)
ƒ tcoll (Collapse Time)
ƒ The Last 3 Can be Measured or Calculated, but
Calc. Values Often Differ from Measured
 THEORETICAL FLUIDIZATION
EQUATION

Umb/Umf Ratio is Key Performance Indicator

ƒ Higher Values are Desirable; Fluidized Catalyst is More

Stable
ƒ Can Be Estimated From Eq. Catalyst Properties:

2300ρg0.126μ0.523exp(0.716F45)

Umb/Umf = ------------------------------------
Dp0.8 [(ρp-ρg)g]0.934
 INDEPENDENT LABORATORY
FCC CATALYST FLUIDISATION STUDY

ƒ Measurements by University of Bradford, England

ƒ 11 FCCU Equilibrium Catalysts
ƒ Measured Umb , Umf , Collapse Time
ƒ Results Compared Results to Calculations:
ƒ Good Correlation Using ρp and Dp
ƒ Poor Correlation Using ABD and APS
 “ENGELHARD” UMB/UMF CORRELATION

ƒ Theoretical Equations Have Limited Value If

Necessary Cat. Props. Not Readily Available
ƒ Particle Geometry Difficult to Model
ƒ Engelhard Developed Correlations Using Typical Eq.
Cat. Report Data
6.9
Umb/Umf = -----------------------------
(80μ-40μ)0.2[(APS+0.5x80μ)/100]3.6
 CONCLUSIONS: FLUIDIZATION
CALCULATIONS

ƒ Use Only ρp and Dp in Standard Equations

ƒ Reliability is Poor with ABD and APS
ƒ Use Eq. Catalyst Skeletal Density and Total Pore Volume
to Calculate Particle Density:

1/ρp = 1/ρs + TPV

ƒ Simpler Option - Use Previous Correlation with

ABD and APS
 CATALYST PROPERTIES AFFECT FCC
OPERATION IN PRACTICE

ƒ Catalyst Properties ƒ Unit Effects

ƒ Density ƒ Fluidization
ƒ Particle Size Distrib. ƒ Catalyst Circulation
ƒ Attrition Resistance ƒ Catalyst Losses
ƒ Sphericity ƒ Erosion
ƒ Roughness
 STANDPIPE ENTRY CONDITIONS:
CRITICAL TO GOOD FLOW

• Proper Entry in a FLUID State is Vital

• Let Large Bubbles Escape:
Catalyst Velocity < Bubble Rise Velocity

• Degas to Stable, High Density:

Fluid Flow

• Most Standpipe Problems are Due to Poor Entry

Conditions Which Aeration Can Not Overcome
 CATALYST CONSTANTLY DEAERATES
& LOW FINES ACCELERATES THE
COLLAPSE
Standard Collapse Time v Fines
50

40
Collapse Time, s/m

30

20

10

0
0 2 4 6 8 10 12 14
% Fines: <40 m

[Ref. 9,11,13]
A trend, not an absolute correlation.
 STRIPPER EXIT SHOULD REMOVE
LARGE BUBBLES, BUT NOT
COLLAPSE INTO NON-FLUID STATE

• Excessive Degassing Zone

Below Steam Distributor

• Catalyst Deaeration Occurs

• Slumped, Non-Fluid Entry

Residence Time to Standpipe
-Collapse Time
• Aeration Cannot Overcome -
Leads to Instability, low
Head Gain
 STANDPIPE FLOW REGIMES
Bubbling Standpipe Transition Dense Phase
Low Velocity Stagnant Bubbles High Flux

UNSTABLE Aeration

Aeration

Approx
<250 250- 500 >500
kg/s/m2
VS <Ububble VS = Ub VS>Ub
 STANDPIPE OPERATION & AERATION

ƒ Pressure Increases Down Standpipe Due to Static

Head Gain ( ρh )
ƒ Gas Volume Compresses, Solids Move Closer
Together, Voidage Reduces
ƒ Approach Minimum Fluidization Conditions & Loss
of Fluidizationn
ƒ Aeration Gas Replaces Gas Volume to Maintain
Fluidizationn
DENSITY & VOLUME OF GAS
CHANGES ALONG THE STANDPIPE
~ ~ P1 = 2.0 bara

17 m Gas Density Change

ρ1(3.0/2.0) 100 = 150%

P2 = 3.0 bara

~ ~
 STANDPIPE AERATION

The Purpose of Standpipe Aeration is to

Maintain the Standpipe Solids in a Stable, Non-
Bubbling, Fluidized State
„ Gives Highest Standpipe Density
„ Shortest Standpipe Length
„ Stable Catalyst Flow for Reactor Temperature Control

Add Aeration Every 2m of Standpipe in

Staggered Arrangement to Encourage
Distribution
 PARAMETERS AFFECTING FLUID
STANDPIPE FLOW

ƒ Stable, Non-Bubbling Flow: Umf to Umb

ƒ Desire Umb>>Umf or Umb/Umf >>1
ƒ Increased Fines ( < 40μm )
• Reduces deaeration rate, fluidn prolonged
• Increases Umb-Umf gap
• Reduces need for aeration
ƒ Low Pressure & Gas Visc. Reduce Stability
(Vdeaer. Increases)
 AERATION CAN NOT REFLUIDIZE
‘DEAD’ CATALYST; GAS DISPERSION IS
DIFFICULT
Improper SP Entry -
Deaerated Catalyst
100

Response
100
10
5
m/s
6.5m
1
( 750 kg/s/m2 )

10 0 3 6 9 12 15

Ar-41

1 a time
0 3 6 9 12 15
Low vel, aligned aeration taps
 FLUIDIZATION CONCLUSIONS

ƒ Different Fluidization States Utilized in FCC

ƒ Operation and Catalyst Properties Can Affect
Fluidization
ƒ Catalyst Must be in a Fluid State Before Entering a
Standpipe (SP)
ƒ Aeration is Generally Required
ƒ Catalyst Will Deaerate and Cause Flow Instabilities if
Given Half a Chance.