Reactor-Regenerator Control Systems

Most of the control systems in a Fluid Catalytic Cracking unit are similar to those
used
elsewhere in the refinery.
Good control of the catalyst circulation through the reactor and regenerator is critical
for
stable operation. The catalyst circulation control scheme is shown in Figure 1. This
figure shows a side by side unit with a bubbling bed regenerator but the catalyst
circulation control between the reactor and regenerator is the same on all FCC and
RFCC units.
The circulation of hot regenerated catalyst from the regenerator to the reactor is
controlled to maintain a constant reactor temperature with the regenerated catalyst
slide
valve. The circulation of spent catalyst from the reactor to the regenerator is
controlled
to maintain a constant catalyst level in the reactor with the spent catalyst slide valve.
The controls on both the spent catalyst and regenerated catalyst slide valves also
include a low differential pressure override. If the differential pressure across either
slide
valve drops to a very low or negative value the override will close the slide valve.
This
minimizes the possibility of reverse flow in the standpipes, either air entering the
reactor
or hydrocarbon entering the regenerator, which are hazardous situations.
Figure 1 shows signals from the reactor temperature controller and level controllers
going to low level selectors (LSS). The low signal selectors also receive signals from
the
differential pressure controllers on the corresponding slide valve. If the differential
pressure across the slide valve is greater than the override setpoint, typically 2 psi
(0.14
kg/cm2) the LSS will select the process variable (level or temperature) to control the
slide valve. If the slide valve pressure drop falls below the override setpoint the LSS
will
send that output to the slide valve which will start closing. The low differential
pressure
override controllers should always be in automatic.