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CASE OF STUDY: FCC UNIT

I. MATERIAL BALANCE - CONVERSION
Feed (t/h)
PRODUCT %wt yield (t/h)
GAS 4.69
Cut C3 5.40
Cut C4 9.72
Total (fresh feed) 213 GASOILINE 40.33
Recycling LCO 26.06
HCO+SLURRY 9.48
TOTAL 95.68
COKE =
Conversion= 100-(LCO+HCO+SULURRY) = (%)

II. COKE BURNING

1.Analysis of dry flue gases
%V CO2 = 15.16 (%)
%V CO = 0.08 (%)
%V O2 =2 (%)
SUM = (%)
2.Temperatures
Tregenerator = 710 (oC) In the dense bed (deltaT=7oC due to post- combustion)
Tsmoke is higher because of the reaction of post-combustion of
Tsmoke = 717 (oC)
CO in the dilute phase of the regenerator
3.Operating condition corresponding to the regenerator
A zero flow of TORCH-OIL 0 (t/h)
Mass flow of dry air: 138 (t/h)
Volume flow of dry air in the regenerator: = (Nm3/h)
4. Determination of dry flue gas flow
Nitrogen + rare
We recall the compostion of dry air: gas 79.05 (%V)
Oxygene 20.95 (%V)
Volume flow of nitrogene introduced to the regenerator:
Nitrogene flow rate = air flow x %nitrogene/100 = (Nm3/h)
Nitrogene content of dry flue gases:
%Volume N2/dry flue gases= 100 - %O2 - %CO - %CO2 = (%)
Volume flow of dry flue gases:
Volume flow of dry gas = (Nm3/h)
5. Content of carbon burning
%Vol in Mass flow of carbon in the
Reaction Volume flow in the flue gas
flue gas flue gas
C + O2 ---> CO2 15.16 CO2 = (Nm3/h) = (kg/h)
C+1/2O2--->CO 0.08 CO = (Nm3/h) = (kg/h)
SUM = (kg/h)
6. Balance of oxyen in the regenerator
6.1. Determining the amount of O2 introduced in the regenerator by combustion air:
Flow of combustion air = (Nm3/h)
Volume flow of O2 = (Nm3/h)
Mass flow O2 = (kg/h)
6.2. Determining the content of oxygen in the flue gas as CO2, CO, O2 unconsumed
Mass flow of oxygen in the CO2:
Volume flow of CO2*32/22.4 = (kg/h)
Mass flow of oxygen in the CO:
Volume flow of CO*16/22.4 = (kg/h)
Mass flow of O2 not consumed:
Volume flow of dry flue gas*(%O2/100)*(32/22.4) = (kg/h)
Total mass flow of oxygen: = (kg/h)
7. Content of hydrogen burning
Mass flow of O in H2O = (O2 introduced -O in CO2 -
= (kg/h)
O in CO - O2 residual)
Hence the mass of hydrogen burned:
Mass flow of H burning = Mass flow of O2 in H2O*2/16 = (kg/h)
Mass flow of (Coke+Torch Oil) burning = (Carbon+Hydrogen) burning = (kg/h)
(t/h)
Torch Oil =0 (t/h)
Coke product = (t/h)
9. Other parmeters
C/H ratio (mass) of coke =
%H mass of coke =
10. Determination of the heat flow produced by the coke burning
Reaction of
Coke Mass flow (t/h) Calorific value (th/t) Thermal Production (th/h)
combustion
C + O2 -> CO2 = 8000 =
Carbon +
C + O2 -> CO = 2450 =
Hydrogene
2H2 + O2 -> H2O = 28600 =
SUM =
II. THERMAL BALANCE OF REGENERATION SECTION

1.Heat suppied by air: Qair

Qair = Mass flow of air x Cair x Tair
Mass flow of air = 138 (t/h)
Cair = 0.26 (th/toC)
Tair = 188 (oC)
Qair = (th/h)
2.Heat suppied by coke: Qcoke
Qcoke= Mass flow of coke x Ccoke x Tcoke
Mass flow of coke = (t/h)
Ccoke = 0.3 (th/toC)
Tcoke = 510 (oC)
Qcoke = (th/h)

3.Heat supplied by coke combustion: Qcomb

Qcomb = (th/h)

4.Heat carried away by the flue gas: Qsmoke

Qsmoke= Mass flow of smoke x Csmoke x Tsmoke

Mass flow of smoke = Mass flow of air + coke burning = (t/h)

Specific heat of smoke (Csmoke) = 0.26 (th/toC)
Tsmoke = 717 (oC)
Qsomke = (th/h)
5.Heat carried away by loose: Lossses
Losses = 3% of Qcomb
Losses = (th/h)
6.Heat absorbed by catalyst: Qabs
Qabs = Qcomb + Qair + Qcoke - Qsmoke - Losses
Qabs = (th/h)
7.Efficiency of the regenerator:
Efficiency = Qabsorbed/Qcombustion*100
Efficiency = (%)

III. CIRCULATION OF CATALYST

Determination of flow of catalyst by the heat balance
Qtransported = Ccata x Mcata x (Tr - Ts )
Ccata = 0.29 (th/toC)
At the thermal equilibrium:
Qtransported = Qabs = (th/h)
Circulation flow can be determined by:
Mcata = Qcata/(Ccata x (Tr-Ts))
Tr = 710 (oC)
Ts = 510 (oC)
Mcata = (t/h)
Mcata = t/mn

IV. RATIO C/O

C/O = Catalyst flowrate / Feed flowrate
C= (t/h)
O= (t/h)
C/O =
V. THERMAL BALANCE OF RISER - REACTOR

1.Consumed heat by the feed vaporrization and products overheating

Qvaporisation+overheating = Qcarried away by the products - Qprovided by the feed
= product flowrate*Enthalpy of product – Feed flowrate*Emthalpy of the feed
Enthalpy of products and of the feed can be evaluated from the density at 15oC and tmperature :
Products: d154 = 0.7 Look up table Hproducts= 400 (th/t) = (th/h)
t = 510 (oC) Hcoke = (th/h)

Feed: d154 = 0.931 Look up table Hfeed = 120 (th/t) = (th/h)

t = 230 (oC)
Qvaporisation+overheating = (th/h)
2.Heat caded from the catalyst
Qcata = Qabs = (th/h)
3.Heat consumed by chemical reactions
Qchemical reactions= Qcata - Qvaporisation + overheating
Qchemical reactions = (th/h)
% of Qcata consumed by the cracking reactions = (%)
% of Qcata absorbed by the vaporization of the load overheating products + others injections = (%)