Catalyst circulation in a

pressure-balanced FCCU
Significant improvements have been made in FCC reactor temperature control
at Farmland’s Coffeyville refinery. Data interpretation are presented along with
advice to consider when troubleshooting a pressure-balanced FCCU operation
David Spires Farmland Industries Inc, Coffeyville, Kansas, USA
David Hunt Davison Catalysts, Houston, Texas, USA

A
fluidised catalytic cracking unit circulation was not
(FCCU) must operate at its optimal sufficient to reach and
reactor temperature with minimal maintain the desired
variability to meet yield and feed-rate reactor temperature.
objectives. Conclusions drawn from a The regenerator and
pressure survey at Farmland’s Coffeyville overflow well was the
refinery explained why the FCCU was first area of focus. Reactor
unable to maintain its desired reactor Figure 2 shows the
outlet temperature. Pressure data showed pressure data taken
that the overflow well had a low catalyst along the regenerator
level, suggesting that catalyst flow from and overflow well.
the reactor was limited. Pressure data Determining the Regenerator
taken from the catalyst stripper and spent catalyst level in the
catalyst standpipe identified the overflow well level is

h
constricted area, and debris was removed key to troubleshooting
during the next shutdown. a pressure-balanced
operation. The Outerflow
Troubleshooting pressure differential well
Farmland Industries operates a 28 000- between the dilute
barrel per day FCC at its Coffeyville phase of the Spent ca
taly
refinery. The company’s FCCU is an regenerator and the standpip st
e
Exxon Flexicracker constructed in 1979. bottom of the overflow
Feedstock consists of virgin vacuum and well was used to
coker gas oils. A generalised schematic of compute the overflow
the FCCU is shown in Figure 1. well catalyst level. Regenerated
The FCCU is a pressure-balanced Assuming a catalyst catalyst J-bend
3
operation like many Exxon FCCU density of 38lbm/ft , a
designs. Catalyst circulation control in a catalyst height of only Figure 1 General elevation sketch of the Farmland FCCU
pressure-balanced unit is very different to 5.7ft inside the
a traditional slide valve-controlled overflow well was
operation. These differences must be calculated by the equation:
considered when troubleshooting and
2
during unit optimisation. A discussion of = (30.0–28.5) lbf/in
2 2 3
pressure-balanced versus common slide 144in /ft / (38lbm/ft )
valve-controlled operations is presented = 5.7ft.
later. The catalyst level inside the overflow Regenerator
Farmland was finding it difficult to well was approximately 35ft below the
achieve and maintain the desired riser top of the overflow well. Some 30ft of
outlet temperature. The feed temperature available overflow well length was 28.5
was increased within the constraints of unused. This information suggested that
the charge heater, and the stripping catalyst flow to the regenerator from the
Overflow well
steam rate was reduced in order to reactor/stripper might be restricted.
increase regenerator and reactor Attention was then focused on the
temperatures with limited success. spent catalyst transfer system. Figure 3
Operating at low stripping steam rates shows the pressure data taken at the 5.7 ft
was undesirable and economics strongly bottom of the catalyst stripper and along 30.0
supported operating at higher riser outlet the spent catalyst standpipe. Rather than
temperatures. building a pressure head from the
Farmland and Davison personnel bottom of the stripper to the top of the
planned a single-gauge pressure survey of spent catalyst standpipe, pressure
the entire FCC catalyst circulation loop dropped from 34–30.5psig. Figure 2 Regenerator and overflow well
in an effort to determine why catalyst A large pressure drop of 11psi (pounds pressure survey

36
P T Q REVAMPS & OPERATIONS
 discovered a large coke restriction at
Spent catalyst
stripper the bottom of the catalyst stripper, as
depicted in Figure 3. A mass of coke
had become lodged in the debris cage
34.0 Coke deposits at the base of the catalyst stripper.
found during Smaller pieces of coke and refractory
shutdown
were also noted in the spent catalyst
30.5
standpipe. After the turnaround was
complete, Farmland could maintain
34.0 Debris likely present
in the upper spent the target reactor temperature.
catalyst slide valve This simple pressure survey
explained why the unit was unable to
23.0 reach the desired reactor outlet
temperature and isolated the specific
area of catalyst obstruction. Data
collection and interpretation were
conducted in a single day.
Regenerator Troubleshooting catalyst
circulation
Catalyst overflow well level and
stability are key to understanding
any catalyst circulation shortcoming
in a pressure-balanced operation.
Figure 3 Stripper and spent catalyst Level in an overflow well can
standpipe pressure survey increase to 5–10ft below the top of
the overflow well while still
per square inch) was also noted across maintaining operational flexibility and
the upper spent catalyst slide valve. This control. A low catalyst level in the
was unexpected, since the catalyst slide overflow well confirms a low catalyst
valve was operating nearly 100% open. A circulation rate and suggests catalyst flow
pressure survey along the reactor riser from the reactor may be limiting, as was
revealed an expected riser pressure drop the case at Farmland. A high catalyst level
of approximately 4psi. in the overflow well level may suggest:
It was construed from this data that — High pressure drop or obstruction
significant restrictions existed along the along the riser or regenerated catalyst
bottom of the stripper, the spent catalyst transfer lines
standpipe and perhaps in the upper slide — Poor pressure head build-up along the
valve. To increase catalyst circulation, regenerated catalyst standpipe
Davison recommended that Farmland: — High catalyst circulation rate reaching
— Reduce regenerator pressure, as this the capacity of the circulation system.
would help increase catalyst circulation In the case where the overflow well
and increase the catalyst level in the level is high, the operator may consider
overflow well the following to increase catalyst
— Conduct gamma scans along the base circulation, improve circulation stability
of the stripper and spent catalyst and/or increase charge rate to the unit:
standpipe to confirm location of the — Increase fluidisation steam or fuel gas
potential obstruction. rates along the transfer lines
Since these pressure survey results — Confirm that the correct amount of
were so convincing, plus the fact that the aeration medium is being added to the
unit would come down for turnaround regenerated catalyst standpipe and adjust
within a few months, it was decided to as necessary. Those techniques have been
forego gamma scan testing. Instead, previously published
Farmland prepared to remove coke or — Raise regenerator pressure relative to
possibly refractory from the stripper, reactor pressure. (This will slow catalyst
spent catalyst standpipe and slide valve circulation and lower the catalyst level in
during the turnaround. the overflow well.) Increase catalyst
During the turnaround, Farmland activity to maintain unit conversion.
Control differences between pressure-balanced and slide valve-controlled units
Parameter Slide valve control Pressure balance control
Reactor temperature Independent variable Dependent variable
Catalyst circulation rate Dependent variable Independent variable
Feed temperature Higher feed temperature Higher temperature feed
will decrease cat/oil at temperature will increase reactor
constant reactor temperature temperature at constant cat/oil
Table 1
37
P T Q REVAMPS & OPERATIONS
An oscillating overflow well level can
result in a fluctuating reactor pressure
and reactor temperature. This condition
might be due to the following:
— Defluidised catalyst entering the
overflow well level or catalyst
defluidising in the overflow well
— Bubbles rising from the regenerated
catalyst standpipe blocking catalyst flow
— Slip-stick flow in the regenerated
catalyst standpipe.
Resolution of this type of problem is
likely be case-specific and requires a
detailed engineering review of the FCCU.
Pressure balance vs
slide valve control
Catalyst circulation is independently
controlled in a pressure-balanced
operation as opposed to a slide-valve
operation, where it is a dependent
variable. Reactor/regenerator differential
pressure is typically used to control
circulation in a pressure-balanced
operation, where decreasing the
regenerator pressure relative to the
reactor will increase catalyst circulation
rate. Table 1 describes several control
differences between pressure-balanced
and slide valve-controlled units.
Catalyst circulation rate in an Exxon
Model IV pressure-balanced unit can also
be influenced by the control air blower
rate and transfer line fluidisation rates.
In a pressure-balanced operation, the
catalyst level in the overflow well is
variable, depending on the reactor/
regenerator pressure differential and
resulting catalyst circulation rate. A
higher catalyst circulation rate will
generally require a higher catalyst level in
the overflow well level. Reactor catalyst
level builds over time as fresh catalyst is
added to the unit, while regenerator level
is constant and equal to the top of the
overflow well level. Regenerated and
spent catalyst slide valves normally
operate near 100% open in pressure-
balanced operations and are generally
only throttled during start-up, shutdown
and upset conditions.
David A Hunt is FCC technical service
manager, Davison Catalysts, Houston
Texas. He has over ten years of FCC
experience focusing on process design,
proprietary equipment technologies,
troubleshooting and catalysts applications.
He is currently responsible for FCC technical
service activities in North America.
E-mail: david.hunt@grace.com
Nomenclature
g Acceleration constant, ft/s2
gc Conversion constant lbm/lbf ft/s2
hofw Catalyst height inside the overflow well, ft
³Pofw Pressure differential across the overflow
well, lbf/in2
pofw Catalyst density in the overflow well,
lbm/ft3