CASE OF STUDY: FCC UNIT

I- MATERIAL BALANCE - CONVERSION

Feed t/h PRODUCT %wt yield t/h
Heavy feed GAS 4.69 10
Light feed Cut C3 5.40 11.5
Another Cut C4 9.72 20.7
Total (fresh feed) 213 GASOILINE 40.33 85.9
Recycling LCO 26.06 55.5
HCO+SLURRY 9.48 20.2
TOTAL 95.68 203.8
COKE 4.32 9.19999999999999

Conversion= 100-(LCO+HCO+SULURRY)= 64.46 %

COKE BURNING
Analysis of dry flue gases
%V CO2= 15.16 %
%V CO = 0.08 %
%V O2 = 2%
SUM= 17.24 %
Temperatures
Tregenerator= 710 oC in the dense bed (deltaT=7oC due to post- combustion)
Tsmoke= 717 oC
Operating condition corresponding to the regenerator
A zero flow of TORCH-OIL
Mass flow of dry air: 138 (t/h)
Volume flow of dry air in the regenerator: 106593.10 (Nm3/h)
Determination of dry flue gas flow
We recall the compostion of dry air: Nitrogen + rare gas 79.05 %V
Oxygene 20.95 %V
Volume flow of Nitrogene introduced to the regenerator:
Nitrogene flow rate= air flow x %nitrogen/100 = 84261.85 (Nm3/h)
Nitrogene content of dry flue gases:
%Volume N2/dry flue gases= 100 - %O2 - %CO - %CO2 = 82.76 %
Volume flow of dry flue gases:
Volume flow of dry gas= 101814.70 (Nm3/h)

CONTENT OF CARBON BURNING

 Reaction %Vol in flue gas Volume flow in the flue gas Mass flow of carbon
in the flue gas
C + O2-> CO2 15.16 CO2 15435.11 (Nm3/h) 8268.81
C+1/2O2->CO 0.08 CO 81.45 (Nm /h)
3
43.63
SUM 8312.44

BALANCE OF OXYEN IN THE REGENERATOR

Determining the amount of O2 introduced in the regenerator by combustion air:
Flow of combustion air 106593.10 (Nm3/h)
Volume flow of O2 22331.26 (Nm3/h)
Mass flow O2 31901.79 kg/h
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 x 32/22.4 22050.16 kg/h
Mass flow of oxygen in the CO:
Volume flow of CO x 16/22.4 58.18 kg/h
Mass flow of O2 not consumed:
Volume flow of dry flue gas x %O2/1 00 x 32/22.4 2908.99 kg/h
Total mass flow of oxygen: 25017.33

CONTENT OF HYDROGEN BURNING

Mass flow of O in H2O = O2 introduced -O in CO2 - O in CO - O2 residual = 6884.47
Hence the mass of hydrogen burned:
Mass flow of H burning = Mass flow of O2 in H2O x 2/16 = 860.56 kg/h

MASS FLOW OF COKE BURNING

Mass flow of (Coke+Torch Oil) burning = (Carbon+Hydrogen) burning = 9173.00
9.17
Torch Oil = 0 t/h
Coke product = 9.17 t/h
OTHER PARMETERS
C/H ratio (mass) of coke = 9.66
%H mass of coke = 9.38 %

DETERMINATION OF THE HEAT FLOW PRODUCED BY THE COKE BURNING

Thermal Production
Coke Mass flow (t/h) Reaction of combustion Calorific value th/t
th/h
Carbon + 8.27 C + O2 -> CO2 8000 66150.47
Hydrogen 0.04 C + O2 -> CO 2450 106.91
0.86 2H2 + O2 -> H2O 28600 24611.97
SUM 90869.34

RAPID DETERMINATION BY CHART

From the fllowing data:
R = CO2/CO = 189.5 ≈ 190
% H of coke = 9.38
By reading on the chart, we have: (T27SGK)
LCV = 9900 th/t
The rate of heat produced by combustion is Q COMB
Mass flow of coke x LCV of coke = QCOMB= 90869.34 th/h
UDY: FCC UNIT

ombustion)
 Mass flow of carbon
in the flue gas
kg/h
kg/h
kg/h

kg/h

kg/h
t/h

RNING
THERMAL BALANCE OF REGENERATION SECTION
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 6745.44 th/h
Heat suppied by coke: Qcoke
Qcoke= Mass flow of coke x Ccoke x Tcoke
Mass flow of coke 9.17 t/h
Ccoke 0.3 th/toC
Tcoke 510 oC
Qcoke 1403.47 th/h
Heat supplied by coke combustion: Qcomb
Qcomb = 90869.34 th/h
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 = 147.17 t/h
Specific heat of smoke = 0.26 th/toC
Tsmoke 717 oC
Qsomke 27435.99 th/h
Heat carried away by loose: Lossses
Losses = 3 % of Qcomb
Losses = 2726.08 th/h
Heat absorbed by catalyst: Qabs
Qabs = Qcomb + Qair + Qcoke - Qsmoke - Losses
Qabs = 68856.18 th/h
Efficiency of the regenerator:
Efficiency = Qabsorbed/Qcombustionx100
Efficiency = 75.77 %

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 = 68856.18 th/h
Circulation flow can be determined by:
Mcata = Qcata/(C x (Tr-Ts))
Tr = 710 oC
Ts = 510 oC
Mcata = 1187.18 t/h
Mcata = 19.79 t.mn

RTIO C/O
C/O = Catalyst flowrate / Feed flowrate
C= 1187.18 t/h
O= 213 t/h
C/O = 5.57

THERMAL BALANCE OF RISER - REACTOR

a, consumed heat by the feed vaporrization and products overheating

Qvaporisation+overheating = Qcarried away by the products - Qprovided by the feed + Qcoke

Enthalpy of products and of the feed can be evaluated from the density at 15 oC and temperature :
Products: d154 = 0.7 Look up table Hyproducts = 400
t= 510 oC Hcoke= 1403.47

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

t= 230 oC
Qvaporisation+overheating = 57374.27 th/h

b, Heat caded from the catalyst

Qcata = Qabs = 68856.18 th/h
c, Heat consumed by chemical reactions
Qchemical reactions= Qcata - Qvaporisation + overheating
Qchemical reactions= 11481.91 th/h
% of Qcata consumed by the cracking reactions = 16.68 %
% of Qcata absorbed by the vaporization of the load overheating products + others injections = 83.32
th/t = 81530.8 th/h

25560 th/h