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© 2000 AEA Technology - Hyprotech. All rights reserved.

HYSYS, HYSYS.Plant, HYSYS.Process, HYSYS.Refinery, HYSYS.Concept, HYSYS.OTS,

HYSYS.RTO and HYSIM are registered trademarks of AEA Technology Engineering Software -
Hyprotech Ltd.

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This product uses WinWrap® Basic, Copyright 1993-1998, Polar Engineering and Consulting.

Documentation Credits
Authors of the current release, listed in order of historical start on project:
Lisa Hugo, BSc, BA; Conrad Gierer, BSc; Chris Strashok BSc; Peter deJonge, BSc; Adeel Jamil,
BSc; Muhammad Sachedina, BASc; Allan Chau, BSc; Nana Nguyen, BSc; Yannick Sternon,
BIng; Kevin Hanson, PEng; Chris Lowe, PEng
Since software is always a work in progress, any version, while representing a milestone, is
nevertheless but a point in a continuum. Those individuals whose contributions created the
foundation upon which this work is built have not been forgotten. The current authors would
like to thank the previous contributors.
A special thanks is also extended by the authors to everyone who contributed through
countless hours of proof-reading and testing.

Contacting AEA Technology - Hyprotech

AEA Technology - Hyprotech can be conveniently accessed via the following:
Website: www.software.aeat.com
Technical Support: support@software.aeat.com
Information and Sales: Info@software.aeat.com

Detailed information on accessing Hyprotech Technical Support can be found in the

Technical Support section in the preface to this manual.
 FCCU Reactor 1-1

1 FCCU Reactor
BETA DOCUMENTS - March 31, 2000

1.1 Introduction .................................................................................................. 3

1.2 FCCSIM Model .............................................................................................. 6

1.2.1 FCCSIM Calibration (Hosted in Excel)..................................................... 6
1.2.2 FCCSIM Model Overview......................................................................... 7
1.2.3 Design Tab ............................................................................................. 15
1.2.4 Operating Data Tab ................................................................................ 19
1.2.5 Catalyst Tab ........................................................................................... 24
1.2.6 Unit Factors Tab ..................................................................................... 24
1.2.7 Misc Data Tab ........................................................................................ 25
1.2.8 Worksheet Tab ....................................................................................... 27
1.2.9 Results Tab ............................................................................................ 28

1.3 Catop Model................................................................................................ 29

1.3.1 Catop Calibration (Hosted in Excel) ....................................................... 29
1.3.2 Catop Model Overview........................................................................... 30
1.3.3 Design Tab ............................................................................................. 31
1.3.4 Operating Data Tab ................................................................................ 35
1.3.5 Catalyst Tab ........................................................................................... 39
1.3.6 Unit Factors Tab ..................................................................................... 41
1.3.7 Misc Data Tab ........................................................................................ 41
1.3.8 Worksheet Tab ....................................................................................... 45
1.3.9 Results Tab ............................................................................................ 46

1-1
1-2

1-2

The Steady State Modelling
guide outlines all non-refinery
related operations in detail.
All other HYSYS reactor unit
operations are detailed in
Chapter 9 - Reactors in the
Steady State Modelling guide.
Refinery Ops button
FCCU button
FCCU Reactor 1-3
1.1 Introduction
The FCCU (fluid catalytic cracking unit) operation simulates a riser or
fixed bed fluid catalytic cracking unit. The operation allows you to
simulate a reactor equipped with either one or two regenerators in
series. Full heat and mass balances are calculated for the reactor and
the regenerator(s).
The FCCU reactor product forms the feed to a fractionator which is
typically modeled in HYSYS as a Column. HCO and slurry recycles from
the fractionator can then be returned to the FCCU as recycle streams
and automatically mixed with fresh feed to form the feed stream to the
FCCU. For details regarding the operation of the fractionator, refer to
Chapter 7 - Column in the Steady State Modelling manual.
The FCCU operation is an integration of KBC’s prediction technology
models based both the KBC Petrofine FCCU model (Catop) and the
KBC Profimatics FCCSIM model. You can choose which model to
incorporate into your FCC operation by selecting an algorithm (either
FCCSIM or Catop).
The choice of algorithm (Catop or FCCSIM) defines the functionality
and property views of the operation. Each algorithm holds unique
calculation methods and parameter details and thus each will be
discussed in separate sections.
The FCCU operation is added to a simulation in the Main Simulation
Environment. You can add an FCCU operation by selecting Flowsheet-
Add Operation from the menu bar (or press F12) and then selecting
FCCU. Alternatively, click Refinery Ops button located on the Object
Palette then click the FCCU button.
1-3
1-4 Introduction
For more information about
the Assay Matrix in HYSYS,
refer to Chapter 4 - Refinery
Oil Manager and the Refinery
Physical Properties manual
in the User’s Guide.
1-4
Refinery Oil Model
The feed streams to an FCCU operation require the use of a Refinery
Assay matrix generated using the Refinery Oil Manager. A Refinery
Assay consists of an Assay matrix which is a collection of information
about a hydrocarbon-based material that holds the basic data needed
to drive the Refinery Physical Property system. Using the Refinery Oil
Manager, the oil model calculates values for several hundred physical,
transport and thermodynamic properties for a given oil. The assay
matrix is organized as a series of property contribution values defined
as Hypothetical components in HYSYS.
Note that the FCCU reactor/regenerator operation will work
only with refinery streams (i.e. based on a Refinery Assay
matrix). These streams can be created using the Refinery Feed
logical operation or by loading a Refinery Assay matrix from the
Refinery Oil Manager into a standard feed stream.
Calibration
The FCCU reactor unit operation is a delta model that predicts changes
from a calibrated base point. The calibration is represented by a set of
Unit Factors that adjust the underlying technology predictions to
match observed data. Calibration is the process of calculating these
Unit Factors.
In order to calibrate the FCCU reactor unit operation, two separate
calibration applications are available; one for each algorithm. An
FCCSIM Excel application exists for FCCSIM model calibration and a
Catop Excel application exists for Catop model calibration. Each is
discussed further in their associated sections. Some of the key features
of these applications are summarized below:
• Hosted within Microsoft Excel 97 and upwards.
• Linked through OLE to HYSYS and vice versa.
• Can be used stand-alone with directly supplied configuration
information.
• Allows one or more sets of process data (i.e. feedstock flows
and qualities, operating conditions, flue gas specifications,
product yields and qualities) to be defined.
• Calculates values for calibration factors that apply to each set
of process data.
• Allows user to combine calibration factor sets to pick average
for use in predictions.
 FCCU Reactor 1-5

• Final calibration set can be directly exported back to HYSYS

through OLE.

For most cases, the most efficient way to set up an FCCU reactor
operation is first to build a calibration case using the appropriate Excel
application (FCCSIM or Catop). This involves entering (or importing)
your reactor design and test data into the Excel application, running
the calibration routines from Excel, selecting the optimum calibration
data set and exporting the calibration (Unit) factors to HYSYS. Using
the export feature, HYSYS will automatically build and attempt to solve
the reactor based on the parameters obtained from Excel.

The following figure shows a schematic representation of the data flow

for the Catop model FCCU.

Figure 1.1

Catop Model Data Flow

Reactor Test Data

Catop Excel App Run Calibration routine

Export calibration data

to HYSYS
Export design data
to back to Excel

HYSYS.Refinery

Simulation in HYSYS

As shown in the above figure, the Catop model allows export of design
data from a HYSYS case into the Catop Excel calibration application.
Using the design mode feature in the Catop Excel application you can
access a pre-built case in HYSYS. This enables HYSYS to open
automatically where you are allowed to choose the FCCU reactor
(assuming one or more exists) you wish to calibrate. All the necessary
design specifications are then imported into Excel, however you must
still enter all the necessary reactor test data. You may then calibrate and
export back to HYSYS in the same manner previously described.

1-5
1-6 FCCSIM Model

Regardless of the approach, FCC Reactor Calibration is more of an art

than an exact science. To set up a Calibration case properly, the user
must have good quality reactor data. Running the Calibration routines
in effect forces the model theory to match real data through the use of
various Unit Factors.

1.2 FCCSIM Model

When the FCCSIM algorithm is chosen, the FCCU reactor property
view consists of seven tabs each containing several pages. The FCCSIM
algorithm implements the prediction methods from KBC’s Profimatics
FCCSIM model. The FCCSIM model is designed to allow users to
evaluate the economics of existing Fluid Catalytic Cracking operations
for different feeds, operations conditions and constraints.

The FCCSIM model is based on well-known physical and chemical

principles and published theory which provide the theoretical
framework for the FCCU simulation.

Some of the key reactor features of the FCCSIM model include:

• Fundamental kinetics
• Five lump coke model
• Heat balanced
• Multiple reaction zones
• Robust convergence
• Partial or complete regenerator combustion
• Configurable reactor and regenerator configurations
• Catalyst database

1.2.1 FCCSIM Calibration (Hosted

in Excel)
In order to properly utilize the FCCSIM FCC reactor model, a set of Unit
Factors must be generated using the external FCCSIM calibration
application hosted in Microsoft Excel 97 (or greater). The Unit Factors
essentially force the theoretical model to match your test data and are
used to account for non-measured and non-modeled areas in the
simulation, such as the oil and catalyst mixing zone.

Using the separate FCCSIM Excel calibration application, process data

can be input into the worksheets. Any number of data sets may be
inputted and the best data can be chosen to be used in the calibration.

1-6
 FCCU Reactor 1-7

Once the calibration is run, the application will predict all the required
Unit Factors which are displayed in the worksheet. These factors, along
with all other necessary process and design data can then be exported
back to an existing HYSYS case.

Note that exporting Unit Factors from Excel to HYSYS requires a

HYSYS case (containing at least one FCCU reactor based on the
FCCSIM algorithm) to already exist. The export feature works
by opening a pre-built HYSYS case and selecting a reactor from
the case to export the Unit Factors to.

For details relating to the use and operation of the FCCSIM Excel
calibration application, refer to the separate FCCSIM Excel Calibration
Manual included with your HYSYS.Refinery software package.

1.2.2 FCCSIM Model Overview

The FCCSIM model simulates the reactor/regenerator system of a
typical FCCU operation, providing heat and material balanced
operating conditions. The following sub-sections provide a brief
overview of some of the key model features of the FCCSIM model.

Riser/Reactor Configurations
In the Riser and Reactor, feed is converted to lighter products (light gas
oil, naphtha, gas) and coke. Conversion is computed based on a
standard naphtha cutpoint which is adjusted for the actual naphtha
cutpoint. The reactor simulation includes expressions for coke make
and conversion which are applied to the riser and reactor. These
expressions are severity models which include terms for temperature,
catalyst activity, residence time or space velocity, feed properties, and
pressure.

Up to three feed streams can be added for either the single or dual riser
configurations. Light cycle oil, heavy cycle oil, and slurry may also be
added as recycle streams to any of the defined feed entry locations.

Three riser configurations are simulated using the FCCSIM model.

• Single Riser (see Figure 1.2)

• Two Risers - common feed composition (see Figure 1.3)
• Two Risers - segregated feeds (see Figure 1.4)

1-7
1-8 FCCSIM Model

Three reaction zones are available for conversion of the feed.

• Riser
• Reactor Dense Bed
• Reactor Dilute Phase

In the riser, oil and catalyst flow in parallel in a plug flow reaction
model. In the reactor zones, back mix or well-stirred reaction models
are used where oil flows through a well-mixed catalyst bed. The reactor
dense bed is an optional reaction zone. Feeds may be entered at an
intermediate feed location on the riser to the reactor bed itself.

1-8
 FCCU Reactor 1-9

Single Riser
In the single-riser configuration, fresh feed and recycle streams are
blended prior to riser entry. Figure 1.2 depicts a Single Riser Reaction
configuration.

Figure 1.2

Reactor
Product

Dilute
Phase

Feed Dense Bed

(If Present)

Riser
Feed
Catalyst
Stripper

Feed

1-9
1-10 FCCSIM Model

Two-Risers - Common Feed Composition

In the two-riser configuration with common feed composition, fresh
feed and recycle are mixed externally to riser entry. This type of
configuration provides parallel single-riser reaction zones. Through the
definition of riser characteristics and operation (i.e., diameter, length,
heat loss, outlet temperature and charge rate), cracking severity may be
varied. Optional bed contact with products from risers is provided
when a dense phase is present. Figure 1.3 depicts a Two-Riser Reactor
configuration with common feed composition.

Figure 1.3

Reactor
Product

Dilute
Phase

Feed Dense Bed

(If Present)

Risers
Feed

Catalyst Stripper

Recycle
Catalyst

Feed

1-10
 FCCU Reactor 1-11

Two-Risers - Segregated Feeds

In the two-riser configuration with segregated feeds, feeds of different

composition are charged to separate risers. Parallel riser reaction zones
are provided in addition to optional contact of the bed (if present) with
products from the risers. This configuration provides the ability to
couple feed selectivity with cracking severity. Figure 1.4 depicts a Two-
Riser Reactor configuration with segregated feeds.

Figure 1.4
Reactor
Product

Dilute
Phase

Feed Dense Bed

(If Present)

Riser 2
Riser 1

Feed

Catalyst Stripper

Catalyst

Feed 2 Feed 1

Regenerator
The regenerator bed kinetic reactions include conversion of coke to CO,
CO2, SO2, SO3 and H2O and the conversion of CO to CO2. The dilute
phase and plenum calculations include the removal of heat by the

1-11
1-12 FCCSIM Model

introduction of steam and/or condensate, and the addition of heat

resulting from the afterburning of CO to CO2. Furthermore, the bed and
dilute phase heat balances include the effect of dilute phase catalyst
circulation. This circulation is catalyst entrained by the flue gas and
returned to the bed via the cyclones. The model also has the capability
of handling partial or full combustion regeneration operations.

Other regenerator features include the following:

• Bed and dilute phase heat removal via steam coils, catalyst
coolers etc.
• Oxygen injection for enriched air operation
• Torch oil injection
• Flue gas energy recovery via steam coils
• CO boiler and/or flue gas expander

Single-stage regenerators are modeled as a series of combustion and

quench zones, as shown in Figure 1.5.

Figure 1.5

Flue Gas

S
C

S
Quench
Plenum

S
Quench Zone
C

Dilute Phase C
Spent
Catalyst

C
Dense Phase
Torch Oil

Air

S = Steam
Regenerated
Catalyst
C = Condensate

1-12
 FCCU Reactor 1-13

Two-stage regenerators are modeled with two flue gas routings

available, as shown in Figure 1.6 and Figure 1.7. Each stage in the two
stage model has the same features as the single-stage regenerator
model.

Figure 1.6

Two-Stage Regenerator Flue Gas Circuit - Sequence Option

Flue Gas

Stage 1 Spent
Catalyst

Flue Gas

Stage 2
Air

In this configuration the flue gas from the

2nd stage regenerator is routed back to
Regenerated
Air the 1st stage as makeup air (in sequence).
Catalyst

Figure 1.7

Two-Stage Regenerator Flue Gas Circuit - Separate Option

Flue Gas

Spent
Stage 1
Catalyst

Flue Gas

Stage 2
Air

In this configuration the flue gas from the

2nd stage regenerator is is kept separate
Regenerated
Air from the first.
Catalyst

1-13
1-14 FCCSIM Model

Product Yields and Qualities

The FCCSIM FCCU reactor model predicts yields for a number of
different products. Reactor products consist of both Pure and Hypo
components.

Reactor Products - Pure Components

H2S Methane Ethane
Ethane Ethylene Propane
Propylene n-Butane Isobutane
1-Butene trans-2-Butene Isobutene
1,3-Butadiene n-Pentane Isopentane
Isoamylenes (normal) amylenes Benzene

Reactor Products - Hypo Components

Naphtha (as 1,2 or 3 cuts) Light cycle oil (as 1 or 2 cuts) Heavy cycle oil
Clarified oil Coke and SOx

Hydrogen through C5 yields are based mainly on conversion, feed

properties, reactor temperature, catalyst type, and equilibrium metals.
The hydrogen sulfide yield is calculated by a sulfur material balance.

For more information about
the Refinery Assay matrix in
HYSYS, refer to Chapter 4 -
Refinery Oil Manager in the
User’s Guide.
Liquid yields are calculated as functions of conversion, feedstock
properties and selected operating conditions. The model predicts
values for naphtha, crude oil and slurry cuts and synthesis techniques
to build the full reactor product Refinery Assay matrix.

The major Refinery Assay properties computed include the following:

• Naphthas -gravity, distillation, sulfur, PONA, research and

motor octanes (clear and leaded), benzene and RVP
• Light Cycle Oils - gravity, distillation, sulfur, basic nitrogen,
Conradson carbon, viscosity, aniline point, diesel index, Cetane
number, flash point, cloud point, pour point, and carbon-atom
type distribution
• Heavy Cycle Oils - gravity, distillation, sulfur, basic nitrogen,
Conradson carbon, viscosity, aniline point, diesel index, and
carbon-atom type distribution
• Clarified Slurry (Decant) Cycle Oil - gravity, distillation, sulfur,
basic nitrogen, Conradson carbon, viscosity and carbon-atom
type distribution.

For further details relating to Refinery Assay properties, refer to the

Refinery Physical Properties manual.

1-14
 FCCU Reactor 1-15

1.2.3 Design Tab

The Design tab allows access to all relevant stream connections and
design parameters. Through this tab, you can define stream
connections, specify the number of risers and regenerators, and define
geometry and heat loss parameters for your FCCU. The Connections
page of the Design tab is displayed in the following figure.

Figure 1.8

The Algorithm
defines the FCCU
model being used
(FCCSIM or
Catop)

Add up to 2
Risers

Attach up to
4 Recycle
streams
Attach up to 3
Feed streams

Select from various injection point locations to

insert your Feed and Recycle streams

The air to the regenerator and
fluegas from the regenerator
are not declared as streams in
the model, so the coke burned
in the regenerator is
considered to be a product
from the reactor and the inert
combustion products from the
regenerator that are carried to
the reactor in the catalyst
interstices are considered as a
reactor feed stream.
Connections Page
The Connections page displays a schematic of the FCCU reactor along
with the following objects:
Objects Input Required
Allows algorithm selection between FCCSIM and
Algorithm Catop models. Note that the property views will differ
depending upon which algorithm is chosen.
Allows for the connection of an inert gas stream. The
inerts stream is only used for mass balance
purposes and should not connect to any other
Inerts Stream
operation. This stream represents the N2, CO and
CO2 from the regenerator air out with the catalyst to
the reactor product.

1-15
1-16 FCCSIM Model
For the Two Risers - common
feed composition configuration,
route all feeds to the second riser
and use the transfer parameter
in the second risers’ operating
data (see Riser data page of the
Operating Data tab) to define
the split of feed to each riser.
1-16
Objects Input Required
Allows for the connection of the reactor product
Product Stream stream. This stream is usually fed to the Column unit
operation.
Allows for the connection of a coke stream. This
stream is used only for mass balance purposes and
Coke Stream should not be connected to any other operation. It
represents the coke yield for the reaction process
and will be burnt in the regenerator section.
Up to two (2) regenerators may be defined for each
# Regens
FCCU.
Up to two (2) risers may be defined for each FCCU.
A single riser defines a single-stage regenerator
# Risers (max of 2)
configuration and two risers define a two-stage
regenerator configuration.
Allows for the connection of a maximum of three (3)
Feed streams for the reactor. These streams are
considered to be fresh feed streams to the FCCU
Feeds (max of 3)
and can be any refinery stream available from
flowsheet. Various injection points are available for
selection.
Allows for the connection of a maximum of four (4)
Recycle streams. Recycles streams can be any
refinery stream available from flowsheet but usually
Recycles (max of 4)
represent withdrawal streams from an attached
Column. Various injection points are available for
selection.
Contains the name of the reactor. You may edit the
Name at any time by simply selecting the field
Name
(double click the cursor inside the field) and inputting
a new name.
The Connection page also allows for specification of various Feed and
Recycle injection points. Three riser configurations can be simulated in
this model.
• Single Riser (see Figure 1.2, page 9)
• Two Risers - common feed composition (see Figure 1.3, page 10)
• Two Risers - segregated feeds (see Figure 1.4, page 11)
The regenerator can be modeled as either a single-stage regenerator
with a series or combustion and quench zones (see Figure 1.5, page 12)
or as a two-stage regenerator configuration (# Regens = 2). In the two-
stage system, two flue gas routings are available. Each stage in the two-
stage configuration has the same features as the single-stage
regenerator model.
The various reactor, riser and regenerator configuration are discussed
in detail in Section 1.2.2 - FCCSIM Model Overview .

Subsidiary Page
The Subsidiary page displays connection streams not listed on the
Connection page along with various other design options.
In Model IV, the model’s riser
outlet temperature control may
not correspond with the actual
unit’s temperature control due
to the presence of reactor bed
and dilute phases. However, the
model reports the reactor outlet
temperature associated with the
manipulated riser outlet
temperature.
Note that it is mandatory to
attach Injection Steam, Regen
Steam and Reactor plus
Stripping Steam streams for
the FCCSIM FCCU model but
stream flowrate and
composition specifications are
not required as they will be
automatically back-
calculated by the model.
FCCU Reactor 1-17
Objects Input Required
Allows algorithm selection between Catop and
Algorithm FCCSIM models. Note that the property views will
differ depending upon which algorithm is chosen.
Allows for the connection of an regenerator steam
Regen Steam
stream.
The Model IV FCC Options define a set of pressure
balance designs which use pressure balance to
control catalyst circulation. These options are not
available for two riser unit or for regenerator options
that vary regenerator heat removal.
Model IV FCC
Options
When the Model IV Options checkbox is checked,
the options available are as follows:
1. fixed riser temperature (click Fixed Riser T radio button)
2. fixed feed preheat temperature (click Fixed feed prefeat
radio button).
Leave checkbox unchecked to disable the Model IV options.
The Flue Gas circuit group is only available when a
two (2) regenerator configuration is defined. Select
either Sequence of Separate to define the flue gas
flow in the regenerators.
Flue Gas circuit
These options control whether the flue gas from the
2nd stage regenerator is routed back to the 1st stage
as makeup air (in sequence) or is kept separate (see
Figure 1.6 and Figure 1.7 for schematics of both
flue gas circuits).
Allows for the connection of an injection steam
Injection Steam
stream.
Reactor plus Allows for the connection of steam fed to the reactor
Stripping Steam and catalyst stripper.
Lift Gas Stream Allows for the connection of a lift gas stream.
1-17
1-18 FCCSIM Model

Geometry Page
The Geometry page holds all riser, regenerator and reactor geometry
and dimension specifications. Most of these details are required to be
input directly by the user based on your current FCCU geometry.

For Riser Geometry, specify Figure 1.9

either diameter or cross-
sectional area.

Heat Loss Page

The Heat Loss page displays the static reactor and regenerator heat loss
values. These terms model the convective and radiative heat losses
from the equipment to the environment.

Heat loss values are displayed in units based on the current unit set
defined (see the Variables option from Tools-Preferences menu item).
The default values are zero but can be modified by the user.

User Variables Page

The User Variables page allows you to create and implement variables
in the HYSYS simulation case. For more information on implementing
the User Variables option, see Chapter 5 - User Variables of the
Customization Guide.

Notes Page
The Notes page provides a text editor where you can record any
comments or information regarding the FCCU or pertaining to the
simulation in general.

1-18
 FCCU Reactor 1-19

1.2.4 Operating Data Tab

The Operating Data tab allows access to all relevant operating
parameters relating steam generation, risers, regenerators and reactors.
Reactor pressure and Feed parameters may also be specified.

Figure 1.10

The various operating parameters available are outlined in the

Note that, unlike the Catop following table. Refer to Figure 1.2 and Figure 1.4 for a schematic
model, the FCCSIM model representation of reactor in single and two- riser configurations,
does not include a feed
respectively. These figures may assist in visualizing many of the
preheat operation. Feed
temperature should be parameters listed on the Operating Data tab.
altered using an external
Heater/Cooler unit
operation. Page Parameters Available
Outlet T
Steam rate
Steam T
Steam P
Riser data
Condensate rate
Condensate T
Mid-riser 1 steam rate
Riser2 as R1
Regen data see description in following section

1-19
1-20 FCCSIM Model

Page Parameters Available

Cyclones condensate rate
Cyclones condensate T
Cyclones steam rate
Cyclones steam T
Cyclones steam P
Dense phase condensate rate
Dense phase condensate T
Dilute phase condensate rate
Dilute phase condensate T
Regen data : Steam Dilute phase steam rate
data Dilute phase steam T
Dilute phase steam P
Dome steam rate
Dome steam T
Dome steam P
Plenum condensate rate
Plenum condensate T
Plenum steam rate
Plenum steam T
Plenum steam P
Fluegas co (vol%)
Fluegas co2 (vol%)
Regen data : Fluegas o2 (vol%)
Fluegas data Fluegas sox (vol%)
Fluegas T
Co_co2 ratio (vo%)
Air humidity
Air T
Enriched air o2 (vol%)
Blower discharge T
Regen data : Blower efficiency
Conditions Torch oil rate
Torch oil T
Bed T with heat removal
Dilute phase T
Dilute phase heat recovery
Reactor data see description in following section

1-20
 FCCU Reactor 1-21

Page Parameters Available

Pressures see description in following section
Flue gas foe
Wet gas flash T
Naphtha option
HCGO option
Clarified oil (slurry) product rate
HCGO product rate
Total Naphtha D86 90%
Light Naphtha D86 90%
Total Naphtha D86 90%
Target data
LCGO D86 90%
Clarified Oil D86 10%
HCGO D86 90%
Mid-naphtha D86 90%
Heavy Naphtha D86 90%
HLCGO D86 90%
Regen flue gas conc
Coke heat of adsorption
Tower Pressure Drop

Regen Data Page

The Regen Data page allows selection of various primary (and
secondary) regenerator combustion targets. Select from the drop-down
list the specification which best matches your FCCU operating
conditions.

• CRC : Remove Q : Partial

• Bed Exit O2 : Remove Q : Complete
• Air Rate : Remove Q : Complete
• Flue Gas O2 : Remove Q : Complete
• Bed Temp : Remove Q : Partial
• CO/CO2 Ratio : Remove Q : Partial
• Flue Gas CO : Remove Q : Partial
• Bed Exit O2 : Bed Temp : Complete
• Air Rate : Bed Temp : Complete
• Flue Gas O2 : Bed Temp : Complete

1-21
1-22 FCCSIM Model

Single-Stage Regenerator Configuration

When only a single regenerator is used in the model, the Regen data
page appears as shown in Figure 1.11. Based on the Regen 1
Combustion Target specification selected, your current target
parameters are displayed below it. If the Target checkbox is selected for
a certain parameter, its value must be specified.

Figure 1.11

Two-Stage Regenerator Configuration

When two (2) regenerators are used in the model, the Regen data page
allows selection of combustion targets for both regenerators
individually. The page appears as shown in Figure 1.11. Regenerator
specifications for each regenerator appear in separate columns.

Figure 1.12

Reactor Data Page

The Reactor Data page displays various Catalyst Stripper
Specifications. Based on the stripper specification selected from one of

1-22
 FCCU Reactor 1-23

the three radio buttons, your current target parameters are displayed to
the right of the view. If the Target checkbox is selected for a certain
parameter, its value must be specified.

Figure 1.13

Pressures Page
The Pressures page displays various reactor and regenerator pressure
specifications. Based on the pressure specification selected from one of
the three radio buttons, your current target parameters are displayed to
the right of the view. If the Target checkbox is selected for a certain
parameter, its value must be specified.

Figure 1.14

1-23
1-24 FCCSIM Model
It is best not to modify the Unit
Factors generated by the external
FCCSIM Excel calibration
application, as they have
already been calculated to best
fit your operating conditions.
1-24
1.2.5 Catalyst Tab
The Catalyst tab allows access to all relevant catalyst parameters based
information results from the reactor calibration run.
Figure 1.15
Select a
Catalyst Activity
Target here.
Calibration runs are performed using the external FCCSIM Excel
calibration application. In the external calibration application, an FCC
catalyst must be selected from the Catalyst Database (CDB) for
FCCSIM. The CDB contains a wide range of commercial fluid catalytic
cracking catalysts along with appropriate factors. The CDB catalyst
factors modify the FCCSIM riser/reactor expressions that predict yield
and product properties.
For details relating to the FCCSIM Catalyst Database and the use and
operation of the FCCSIM Excel calibration application, refer to the
separate FCCSIM Excel Calibration Manual included with your
HYSYS.Refinery software package.
1.2.6 Unit Factors Tab
The Unit Factors tab lists the various Unit Factors (or calibration
factors) used to model the FCCU. Unit Factors are organized by kinetic
factors and update factors listed in their appropriate pages. HYSYS uses
these Unit Factors to adjust calculations to fit actual reactor operating
conditions.
 FCCU Reactor 1-25

Figure 1.16

The Update and Kinetic factors are generated using the external
FCCSIM Excel calibration application supplied with your
HYSYS.Refinery software package. The FCCU reactor unit operation is a
delta model that predicts changes from a calibrated base point. The
calibration is represented by a set of Unit Factors that adjust the
underlying technology predictions to match observed data. Calibration
is the process of calculating these Unit Factors.

For details relating to the use and operation of the FCCSIM Excel
calibration application, refer to the separate FCCSIM Excel Calibration
Manual included with your HYSYS.Refinery software package.

1.2.7 Misc Data Tab

The Misc Data tab, as the name suggests, displays various
miscellaneous parameters not listed on the previous tabs. The tab
contains a Synthesis Parameters page and a Controls page which
provide some limited control of various parameters used to synthesize
the FCCU product.

1-25
1-26 FCCSIM Model

Brief descriptions of the various Synthesis parameters are listed in the

following table.

Synthesis
Description
Parameters
This value specifies the temperature where the pour
Pour point T
point curve peaks. The default is 560°C.
This value specifies the temperature tolerance
Pour point tolerance required for convergence on given pour point values
in the synthesis. The default is 1°C
This check box option specifies whether the model is
to include pour point data for streams with defined
Pour point viscosity viscosity in the synthesis. Leaving the box
unchecked excludes pour points of streams with
viscosities greater than ???? cSt at 50.0°C.
This value specifies the temperature tolerance
Cloud point
required for convergence on given cloud point values
tolerance
in the synthesis. The default is a tolerance of 1.0°C.
This value specifies the ABP of a stream. For a
stream with an ABP below the specified value, the
Cold props T program converts the predicted cloud point to pour
point in the cold property synthesis. The default is
500.0°C.
This value specifies the octane tolerance required for
Octane tolerance convergence on given octane numbers. The default
is a tolerance of 0.02.
This value specifies a fixed cloud point at 176.7°C in
Fixed cloud point the cloud point synthesis. The default cloud point is
-40.0°C.
This check box specifies whether the model is to add
an extra, calculated cloud point at 600.0°C in the
Fixed end cloud
cloud point synthesis. Leaving the value checked,
point allows the extra cloud point to be added to the
model.

The Controls page lists various tuning parameters used with unit
factors (see Unit Factors tab) for calibration.

1-26
 FCCU Reactor 1-27

You are unable to change 1.2.8 Worksheet Tab

stream values calculated by
HYSYS. The default colour for
specified stream values is blue
and black for those calculated
by HYSYS.
The Worksheet tab displays various solved stream values along with
specified values. The views include pages for Conditions, Properties,
Composition and PF Specs.

Figure 1.17

1-27
1-28 FCCSIM Model

1.2.9 Results Tab

The Results tab displays a wide variety of various FCCU reactor output
parameters.

Figure 1.18

Each page holds results information relating to cut and yield properties
along with operating condition data for the riser and regenerator. Brief
descriptions of each are provided below.

• Standard Cuts - shows key properties calculated for four

standard cuts of the reactor product, assuming perfect
fractionation. The cuts are C4 Minus, 3.7°C-221°C Naptha,
221°C-343°C Heating Oil and 343+°C Fuel Oil. You can
change the cut points used in the Misc Data tab
• Reactor yields - reports yields of light ends and of the
standard cuts on a wt%, lv% or fresh basis
• Riser results - reports the main operating condition for each
riser
• Regen results - reports the main operating condition for each
regenerator
• Overall results - provides details of many other operating
conditions and calculated values.

1-28
 FCCU Reactor 1-29

1.3 Catop Model

When the Catop algorithm is chosen, the FCCU reactor property view
consists of seven tab each containing several pages. The Catop
algorithm implements the prediction methods from the KBC’s
Petrofine FCCU model. The Catop model is designed to allow users to
evaluate the economics of existing Fluid Catalytic Cracking operations
for different feeds, operations, conditions and constraints.

The feed streams to the FCCU operation require the use of a Refinery
Assay matrix generated using the Refinery Oil Manager. Using the
Refinery Oil Manager, various synthesis techniques calculate values for
several hundred physical, transport and thermodynamic properties for
a given oil. The assay matrix is organized as a series of property
contribution values defined as Hypothetical components in HYSYS.

1.3.1 Catop Calibration (Hosted in

Excel)
In order to properly utilize the Catop FCC reactor model, a set of Unit
Factors must be generated using the external Catop calibration
application hosted in Microsoft Excel 97 (or greater). The Unit Factors
essentially force the theoretical model to match your test data and are
used to account for non-measured and non-modeled areas in the
simulation, such as the oil and catalyst mixing zone.

Using the separate Catop Excel calibration application, process data

can be input into the worksheets. Any number of data sets may be
inputted and the best data can be chosen to be used in the calibration.
Combining data sets from various calibration runs also allows you to
take average values from a number of data sets.

Once the calibration is run, the application will predict all the required
Unit Factors which are displayed in the worksheet. These factors, along
with all other necessary process and design data can then be exported
back to an existing HYSYS case.

Note that exporting Unit Factors from Excel to HYSYS requires a

HYSYS case (containing at least one FCCU reactor based on the
Catop algorithm) to already exist. The export feature works by
opening a pre-built HYSYS case and selecting a reactor from
the case to export the Unit Factors to.

1-29
1-30 Catop Model
Unlike the FCCSIM model, the
Catop model only allows for
single riser configurations.
1-30
For details relating to the use and operation of the FCCSIM Excel
application, refer to the separate Catop Excel Calibration Manual
included with your HYSYS.Refinery software package.
1.3.2 Catop Model Overview
The Catop design model simulates the reactor/regenerator system of a
typical FCCU operation, providing heat and material balanced
operating conditions. The following sub-sections provide a brief
overview of some of the key model features of the Catop model.
Two-Stage Regenerator Configuration
The following diagram shown in Figure 1.19 shows a schematic of a
two-stage regenerator configuration for the Catop FCCU model.
Figure 1.19
Primary Regenerator
In a two-stage regenerator configuration, the primary regenerator
usually simulates partial combustion of coke on the catalyst, to
produce a flue gas containing minimal oxygen and significant amounts
of carbon monoxide and carbon dioxide.
These gases are usually passed through primary and secondary
cyclones to remove any entrained catalyst. The cyclones can be
 FCCU Reactor 1-31

simulated in the model, for each of the regenerators. The catalyst is

then fed to the secondary regenerator through a catalyst cooler.

Secondary Regenerator
In the secondary regenerator, total combustion normally takes place to
produce a flue gas containing carbon dioxide, excess oxygen, and
minimal carbon monoxide. Flue gas is passed through the primary and
secondary cyclones, which are simulated in the model.

The hot catalyst is then fed back to the riser, and from there on the
model behaves in same way as a single regenerator unit. In the two-
stage regenerator configuration, air is fed to both regenerators, and you
can specify these flowrates independently.

1.3.3 Design Tab

The Design tab allows access to all relevant stream connections and
design parameters. Through this tab, you can define stream
connections, specify the number of risers and regenerators, and define
geometry and heat loss parameters for your FCCU.

Figure 1.20

The Algorithm
defines the
FCCU model
being used
(Catop or
FCCSIM)

Attach up to Attach up to 4
Recycle streams
3 Feed
streams

1-31
1-32 Catop Model

Connections Page
The Connections page displays a schematic of the FCCU reactor along
with the following objects:

Objects Input Required

The air to the regenerator and
fluegas from the regenerator
are not declared as streams in
the model, so the coke burned
in the regenerator is
considered to be a product
from the reactor and the inert
combustion products from the
regenerator that are carried to
the reactor in the catalyst
interstices are considered as a
reactor feed stream.
Fresh feed streams should not
be connected to the Recycles
object but rather should be
connected to the Feed object.
Separate correlations exist for
treating both cracked Recycle
streams and fresh Feed
streams.
Allows algorithm selection between Catop and
FCCSIM. Note that the property views and input
Algorithm
requirements will differ depending upon which
algorithm is chosen.
Allows for the connection of an inert gas stream. The
inerts stream is only used for mass balance
Inerts Stream
purposes and should not connect to any other
operation.
Allows for the connection of the reactor product
Product Stream stream. This stream is usually fed to the Column unit
operation.
Allows for the connection of a coke stream, This
Coke Stream stream is used only for mass balance purposes and
should not be connected to any other operation.
Up to two (2) regenerators may be defined for each
# Regens
FCCU.
Allows for the connection of a maximum of three (3)
Feed streams for the reactor. These streams are
considered to be fresh feed streams to the FCCU
Feeds (max of 3)
and can be any refinery stream available from
flowsheet. The Catop model automatically mixes the
feed streams with the recycles.
Allows for the connection of a maximum of four (4)
Recycle streams. Recycles streams can be any
Recycles (max of 4)
refinery stream available from flowsheet but usually
represent withdrawal streams from the fractionator.
Contains the name of the reactor. You may edit the
Name at any time by simply selecting the field
Name
(double click the cursor inside the field) and inputting
a new name.

Subsidiary Page
The Subsidiary page displays connection streams not listed on the
Connection page along with various other design options.

Objects Input Required

Allows algorithm selection between Catop and
Algorithm FCCSIM models. Note that the property views will
differ depending upon which algorithm is chosen.
Allows for the connection of an regenerator steam
Regen Steam
stream.

1-32

Note that it is mandatory to
attach Regen Steam, Injection
Steam, and Stripping Steam
streams for the Catop FCCU
model but stream flowrate
and composition
specifications are not required
as they will be automatically
back-calculated by the model.
FCCU Reactor 1-33
Objects Input Required
A Reactor Quench stream may be added to the
reactor/disengaging section of the FCCU. This is to
quench the reactor effluent, preventing further
secondary after -cracking in the dilute phase.
Reactor Quench
A quench stream may be added at the riser top,
quenching both the catalyst and the reactor products
or added after the riser top (just before the cyclones)
so that only the reactor effluent is quenched and the
catalyst is returned to the regenerator at the reactor
temperature.
If Mixed In Effluent is not selected, an Exit Quench
stream is created which is the same as the Quench
stream, only its stream temperature and pressure
are set to that of the reactor.
Allows for the connection of a steam stream that is
injected into the reactor feed. The pressure and
Injection Steam temperature of the injected steam are assumed to be
the same as those of the stripping steam (see next
item).
Allows for the connection of a steam stream injected
into the catalyst stripper, to strip the product from the
Stripping Steam
catalyst before the latter is returned to the
regenerator.
Allows for the connection of a hydrocarbon lift-gas
stream which can be fed to the FCCU model. The
Lift stream is injected into the riser, affecting the
WHSV and the temperature in the riser, and
influencing the model’s predictions. The Lift stream
composition must be defined and the gas is
assumed inert (does not convert).
Lift Gas
If Mixed In Effluent is selected, the lift-gas stream is
mixed into the FCCU reactor product stream.
If Mixed In Effluent is not selected, an Exit Lift Gas
stream is created which is the same as the Lift
stream fed to the model, only its stream temperature
and pressure are set to that of the reactor.
1-33
1-34 Catop Model

For Riser Geometry, specify
either diameter or cross-
sectional area.
Geometry Page
The Geometry page holds all riser, regenerator and reactor geometry
and dimension specifications. Most of these details are required to be
input directly by the user based on your current FCCU geometry.

Figure 1.21

Heat Loss Page

The Heat Loss page displays the reactor and regenerator heat loss
values. Heat loss values are displayed in units based on the current unit
set defined (see the variables option from Tools-Preferences menu
item). The default values are zero but can be modified by the user.

The Regenerator loses heat by radiation and convection. If you do not

specify the heat loss, HYSYS calculates it automatically from the FCCU
feed capacity. Alternately, you can calculate the loss and specify the
value as a heat flowrate. To calculate the loss for regenerators lined
internally with 4 inches of refractory material, we recommend using a
heat transfer coefficient of 700 Btu/sq ft h (1899 kcal/sq m h).

The Reactor loses heat in the same way as the regenerator. By default,
HYSYS calculates the heat loss automatically. Alternately, you can
calculate the loss, and specify it in the value as a heat flowrate. To
calculate the loss for regenerators lined internally with 4 inches of
refractory material, we recommend using a heat transfer coefficient of
700 Btu/sq ft h (1899 kcal/sq m h). For reactors lagged externally with 4
inches of refractory material, we recommend using 125 Btu/sq ft h (339
kcal/sq m h).

User Variables Page

The User Variables page allows you to create and implement variables

1-34

Note that the Catop model
assumes a feed preheat will
heat the feeds to a fixed or
calculated Total Feed
Preheat value.
FCCU Reactor 1-35
in the HYSYS simulation case. For more information on implementing
the User Variables option, see Chapter 5 - User Variables of the
Customization Guide.
Notes Page
The Notes page provides a text editor where you can record any
comments or information regarding the FCCU or pertaining to the
simulation in general.
1.3.4 Operating Data Tab
The Operating Data tab allows access to all relevant operating
parameters relating the Steam generation, Risers, Regenerators and
Reactors. Reactor pressure and Feed parameters may also be specified.
Figure 1.22
The Conversion Specifications group allows for specification of three
conversion options. Click the radio button which best matches your
FCCU operating conditions.
Based on the Conversion Specification radio button selected, the
Conversion Targets group displays several parameters which you must
specify. If the Target checkbox is selected for a certain parameter, its
value must be specified.
1-35
1-36 Catop Model

The various operating parameters found on this tab are listed in the
following table. The various parameters available are organized
according to the page they are found in.

Page Parameters Available

Coil inlet P
Coil inlet T
Coil outlet P
Coil outlet T
Injection steam flow
Steam Data Injection steam ratio
Injection water flow
Steam coil duty
Steam coil flow
Strip steam flow
Strip steam ratio
Steam rate
Steam T
Riser Data
Steam P
Lift gas rate
Blower discharge T
Blower discharge P
Cooling duty
Cyclone steam flow
Cyclone 1 T
Cyclone 2 T
Fluegas CO
Fluegas CO2
Regen Data Flugas O2
Fluegas SOx
Fluegas T
Torch oil api
Torch oil flow
Torch oil H to C
Torch oil T
Percent of catalyst in Regen
Regen P drop
Reactor T
Reactor P
Cyclone T
Reactor Data
H to C factor
Heat of cracking
Reactor holdup

1-36

Feed Antimony and
Thiophene sulfur are
additional feed property
specifications and apply to
the combined fresh feeds.
Feed RI and Bromine no.
can be given to override
values calculated from the
fresh feeds’ assays.
Brief descriptions of some of the key Operating Data parameters from
the Overall Regen page are listed in the following section.
The Fluegas “rules” listed in
the descriptions to the right
also apply when for two-
stage regenerator
configurations, although
these values can be
specified for each
regenerator individually.
FCCU Reactor 1-37
Page Parameters Available
Feed Antimony (ppmwt)
Feed Bromine no
Feed RI
Feed Thiophene s (wt%)
Feed Data
Max fresh feed preheat T
Min fresh feed preheat T
Total feed preheat T
Asphaltenese factor
Fluegas CO (vol%)
Fluegas CO:CO2 ratio (vol%)
Fluegas CO2 (vol%)
Fluegas CO2:CO ratio (vol%)
Fluegas N2 (vol%)
Fluegas O2 (vol%)
Fluegas SOx (vol%)
Fluegas T
Overall Regen
Regen1 CO2:CO ratio (vol%)
CO carryover factor
CO2 carryover factor
N2 carryover factor
Spray water flow
Steam carryover
Strippable carbon
Regen air split
Operating Data
Description
Parameters
The Fluegas CO and Fluegas CO2 values are
used to specify the volume percentage of CO and
CO2, respectively, in the fluegas. If the CO2 value is
Fluegas CO
not specified, you must instead provide a Coke H to
Fluegas CO2
C value (found on the Operations page of the
Fluegas CO:CO2 ratio Catalyst tab).
Fluegas CO2:CO ratio
If you specify a value for Fluegas CO:CO2 ratio (or
Fluegas CO2:CO ratio), you must also supply either
a value for Fluegas CO2 or Fluegas CO.
This value defines the volume percentage of
nitrogen present in the fluegas. If not specified,
Fluegas N2 (vol%)
HYSYS will set it to a value required to make the
fluegas composition add up to 100%.
1-37
1-38 Catop Model

Operating Data
Description
Parameters
This value defines the volume percent of oxygen
present in the fluegas.
If you obtain the oxygen content from an off-line gas
chromatograph, subtract the argon content to get the
Fluegas O2 (vol%) value required in this instruction (the argon content is
0.012 times higher than the nitrogen content). If you
use an on-line analyzer, the argon content is not
normally included in the reading so no subtraction is
required.
This value defines the volume percent of SOx (sulfur
Fluegas SOx (vol%)
dioxide equivalent) present in the fluegas.
Fluegas T This value specifies the fluegas temperature.
This value is used to specify the ratio of carbon
Regen1 CO2:CO
dioxide to carbon monoxide in the primary
ratio (vol%)
regenerator. The default value is 1.5.
This factor is used to calculate the mass flowrate of
CO in the reactor product, by multiplying the factor
by the catalyst circulation rate. The CO is carried
over from the regenerator in the catalyst interstices.
The default value is 0.004 for full CO combustion
CO carryover factor
(approx. 50 ppm CO in fluegas). For partial CO
combustion (1% to 3% CO in fluegas), a value of
0.015 is recommended. Values of 0.04 or more
represent poor CO combustion (more than 5% CO in
fluegas)
This factor is used to calculate the mass flowrate of
CO2 in the reactor product, by multiplying the factor
CO2 carryover by the catalyst circulation rate. The CO2 is carried
factor over from the regenerator in the catalyst interstices.
The default value is 0.04. For full or partial
combustion (up to 3% CO in fluegas), use 0.03.
This factor is used to calculate the mass flowrate of
nitrogen in the reactor product, by multiplying the
N2 carryover factor factor by the catalyst circulation rate. The nitrogen is
carried over from the regenerator in the catalyst
interstices.The default value is 0.09.
This value specifies the water spray flow for the
Spray water flow
regenerator.
This factor represents the mass percentage of
stripping steam carried from the reactor to the
Steam carryover regenerator using the catalyst. 0 indicates that the
carryover is calculated from the operating conditions
of the reactor. The default value is 40.0.
Strippable c is the carbon entrained reactor effluent
that is burned in the regenerator with the coke. It is
Strippable carbon
specified as the wt% on fresh feed. The default value
is 0.2.
For the case of a two-stage regenerator
configuration. the value defines the split of air
Regen air split
between the two regenerators when only one air rate
is specified.

1-38
 FCCU Reactor 1-39

1.3.5 Catalyst Tab

The Catalyst tab allows access to all relevant catalyst factors. The user is
required to enter the various catalyst factors based on the catalyst
currently in use.

Figure 1.23

The various operating parameters available are outlined in the

1-39
1-40 Catop Model

following table:

Page Parameters Available

Catalyst inventory (kg)
Catalyst spec heat
Crc mat effect
Static
Metals effect flag
Ni index
Va index
C on regen catalyst (wt%)
C on regen catalyst(2)
Catalyst antimony (ppmwt)
Catalyst base mat (wt%)
Catalyst base mat(2)
Catalyst density (kg/m3)
Catalyst fines (ppmwt)
Catalyst makeup (kg/h)
Catalyst mat (wt%)
Operations
Catalyst name
Catalyst ni (ppmwt)
Catalyst va (ppmwt)
Catalyst va(2)
Coke h to c (wt%)
Metals factor
Ecat antimony (ppmwt)
Ecat makeup (kg/h)
Ecat ni (ppmwt)

1-40
 FCCU Reactor 1-41

1.3.6 Unit Factors Tab

The Unit Factors tab lists the various Unit Factors (or calibration
factors) used to model the FCCU. HYSYS uses these Unit Factors to
adjust calculations to fit actual reactor operating conditions.

Figure 1.24

These factors are generated using the external Catop Excel calibration
application supplied with your HYSYS.Refinery software package. The
FCCU reactor unit operation is a delta model that predicts changes
from a calibrated base point. The calibration is represented by a set of
Unit Factors that adjust the underlying technology predictions to
match observed data. Calibration is the process of calculating these
Unit Factors.

For details relating to the use and operation of the Catop Excel
calibration application, refer to the separate Catop Excel Calibration
Manual included with your HYSYS.Refinery software package.

1.3.7 Misc Data Tab

Pages available on the
Misc Data tab: The Misc Data tab displays various miscellaneous parameters that
control the behaviour of the algorithm. You should rarely need to
change options from their default values.

1-41
1-42 Catop Model

Brief descriptions of the various Synthesis parameters are listed in the

following table.

Synthesis
Description
Parameters
Synthesized Lets you connect a synthesized reactor product
products stream.
This value specifies the temperature where the pour
Pour Point T
point curve peaks. The default is 560.0°C.
This value specifies the temperature tolerance
Pour Point Tol required for convergence on given pour point values
in the Synthesis. The default is 1.0°C.
This check box option specifies whether the model is
to include pour point data for streams with defined
Pour Point Viscosity viscosity in the synthesis. Leaving the box
unchecked excludes pour points of streams with
viscosities greater than 2000 cSt at 50.0°C.
This value specifies the temperature tolerance
Cloud Point Tol required for convergence on given cloud point values
in the synthesis. The default is a tolerance of 1.0°C.
This value specifies the ABP of a stream. For a
stream with an ABP below the specified value, the
Cold Props T program converts the predicted cloud point to pour
point in the cold property synthesis. The default is
500.0°C.
This value specifies the octane tolerance required for
Octane Tol convergence on given octane numbers. The default
is a tolerance of 0.01.
This value specifies a fixed cloud point at 176.7°C in
Fixed Cloud Point the cloud point synthesis. The default cloud point is
-40.0°C.
This check box specifies whether the model is to add
an extra, calculated cloud point at 600.0°C in the
Fixed End Cloud
cloud point synthesis. Leaving the value checked,
Point
allows the extra cloud point to be added to the
model.

1-42
 FCCU Reactor 1-43

Brief descriptions of the various parameters found on the Controls:

Static page are listed in the following table.

Controls: Statics Description

This factor represents the conversion effect on
the coking predictions, in the equation:
CCF
CARCON =  ------------------------------------- -
TOTCON
è 1.0 – TOTCONø

Coke conv factor where: CARCON = contribution to coke make

from conversion
TOTCON = total conversion
CCF = COKE CONV FACTOR
The default value is 0.75 which is suitable for
most applications.
This flag is only required for use with
technology level 1. The following options are
used to specify the reaction temperature used
to predict yield calculations:
T flag
• 0 - reactor temperature (riser top temp)
• 1 - weighted average of reactor
temperature and riser bottom temperature
• 2 - riser bottom temperature
This ratio defines the stripping steam ratio
required to give efficient catalyst stripping in the
Typical steam ratio unit, and is expressed as the mass of steam/
1000 mass of catalyst. The default value is 2.5
te steam/1000 te catalyst.

Brief descriptions of the various parameters found on the Controls:

Operations page are listed in the following table:

Controls: Operations Description

...still working on
Beta

...still working on
C_butene factor

This value represents the conversion efficiency

of oil in the riser. It must be in the range of 0.1
Cat to oil factor
through 20.0, although typical values are
between 0.8 through 1.2.
...still working on
Coke rt active factor

...still working on
Coke tolerance

...still working on
Column delta P

1-43
1-44 Catop Model

Controls: Operations Description

...still working on
Column drum P

...still working on
Concarb coke factor

...still working on
Conv rt activ factor

This factor represents the wt% of carbon on

Crc factor regenerated catalyst (CRC). The default value
is 1.0.
...still working on
Crc modifier on conv

...still working on
End point delta

...still working on
Max coke iterations

This factor is used along with the column drum

P drop factor P, column delta P and effluent flowrate, to
calculate the reactor pressure.
...still working on
Preheat hbal tol

...still working on
Report cut points

...still working on
Report cut points(2)

These two(2) values specify a refractive index

tolerance check. Specify two values to define
the upper and lower refractive index check
range. The default values are 0.003 and 0.10.
Ri tolerances (1-2) If the refractive index exceeds the lower check
value, HYSYS displays a warning message. If
the upper value is exceed, the solver will stop.
Tolerances should only be modified when using
the model to diagnose a set of poor data.
...still working on
T_butene factor

...still working on
Unitfactor tol

1-44
 FCCU Reactor 1-45

1.3.8 Worksheet Tab

You are unable to change The Worksheet tab displays various solved stream values along with
stream values calculated by
specified values. The views include pages for Conditions, Properties,
HYSYS. The default colour for
specified stream values is blue Composition and PF Specs.
and black for those calculated
by HYSYS. Figure 1.25

1-45
1-46 Catop Model

1.3.9 Results Tab

The Results tab displays a wide variety of various FCCU reactor output
parameters.

Figure 1.26

1-46