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A Honeyweli Cottpany

FCC PROCESSTECHNOLOGYSTANDARD

Section 11 -

FCC Optimization

Learner Guide

A l{oneywell CompanyFCC Process Technology

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Learner Guide

Section l l:FCC OptilnizationRev 0

TABLE OF CONTENTSl.O FCC OPTIM:ZAT:ON...." 51.l Scction Outlinc...51.2 Enabling ObieCtCs.52.0 0PTIMiZAT10N OF FCC UN:TS......62.l Feed Dispersion Stcam Optinlization.62.2 Accclcration Zonc Optimization..62.3 Stripper(Dptinlization.72.4 Combustor Optinlization...83.O SUMMARY OF FCC OPTIMIZAT10N...8

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FCC Proccss Tcchno10gyIlocumen L

Lea:ner Guide

Section ll:FCC OptilnizatiOnRev 0

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/1 Floneywell Oompany

1.O FCC OPTIIIZAT10N

Section Outlinel. FCC Introduction2. FCC Process Flow and Control3. FCC Ftuidization4. FCC Equipment5. FCC lnspection and Maintenance6. FCC Corrosion and Fouling1. FCC Catalyst and Catalyst Management8. FCC Process Variables9. FCC Procedures1 0. FCC Troubleshooting11. FCC Optimization

Enabling Ob.iectives

Upon completion of section, the student will be able to:o Describe the method of optimization for the following:

o Feed Dispersion Steamo AccelerationZoneo Strippero Combustor

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A4oevweoO:panyFCC Process Techno10gy Learner Guide

Section ll: FCC OptimizatiOnRcv 0

OPTIIIzAT10N OF FCC uNITS

Feed Dispersion Steam Optimizationo Typical feed dispersion steam rate is -l wt.Vo FFo Determine yield structure at base conditions

o Material balance (weight recovery conection)o Distillations (cut point correction)o GC compositions (C5+ gasoline correction)

' Increase/decrease feed dispersion steam by 0.2 wt.Vo, equilibrate for l}hours, zurddetermine new yield structure

o Based on results, increase or decrease feed steam to further optimize sysl-emo Note: General rule of thumb is that decreased CFT or increased feed viscosity will

require an increase in dispersion steamo optimum dispersion steam will result in uniform droplet size, flux, and

penetration of the raw feed

Purpose: Maximize yielcl structureTaols: Feed dispersion steam

Acceleration Zone OptimizationDetermine acceleration zot)e velocity at current conditio,s

Equation l1 - 1 Accelcration Zonc Optimization

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Purpose:Tools:

Maximize the yield structureLift media (stearn or lift gas)

Determine yield structure at base conditionso MAterial balance (weight recovery correction)o Distillations (cut point correction)o GC compositions (C5+ gasoline correction)

Velocity = volume of inerts + liftcross-sectional

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A t'loneywell CompanyFCC Process Tcchnology

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Learner Guide??

?????? FCC Optimization Rev 0Change riser lift media input (steam and/or lift gas) to cover the range from 10-l gftlsec in the acceleration zone (recommended levels at 10, 14, & 1g-ft/sec)At each velocity, allow 12 hour line out time and determine yieldsDetermine optimum range from abdve data and repeat experimentb to furtheroptimize systemNote: Low acceleration zone velocities result in higher catalyst densities at feedinjection.Higher catalyst densities can result in poor feed penetration into the catalyststream.

o Note: Low acceleration zone velocities contribute to backmixing, longcatalyst/feed contacl. times, over-cracking, and non-sqlectiv",reactions.

o High velocities require high lift gas or steam flows using up wet gas compressoror overhead condenser.capacity.

Stripper Optimizationo Normal steam input is approximately 1.5 to 2.0lb per 1000 lb of caralyst

circulation At steady opcrating conditions,incrcase stcam input 573 and inonitor rogeneratOr

dense phase temperatnre for any decrease

Purpose: Minirnize steam consumption ancl maximizc yieldsTools: Stripping steamIf regenerator temperature decreases, continue to increase steam until no densephase temperar.ute change results, then increase steam another 5voIf temperature does. ngt change, note 'lbase,, regenerator dense phase temperatureDecrease steam to stripper in 5voincrements allowing severul hoursof eqi-rilibrarion ti meMonitor regenerator dense phase temperature for any increaseFirst increase in temperature, return to previous steam input setting and add anextra 5-1OVo steam

optimization can be determined by monitoring "Hydrogen iir coke,, values bur.l-he Flue Gas analysis timing.is usually difficulr to cooqJinate

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FCC Proccss Tcchnology

Se9tiOn ll:FCC OptimizatiOn

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A Honevwell&ompany

Combustor Optimization

' Open the recirculation slide valve to decrease tl-re afterburn in the upperregenerator

' If recirculation slide valve is loovo open, increase the pressure in regenerar,or, il.possible

Purpose: Control temperature profiile in regenerator (limit afterburning)Tools: Recirculation slide valve and proioter

' If regenerator pressure is maximum allowable and recirculation slide valve islOUVo open, use promoter to control afterbirrn

o Note: A small afterburn is desirable as long as the coke is burned off of thecatalyst; monitor the carbon on regenerated catalyst.

ST]MMARY OF FCC OPTIMIZATIONYou, the participant, should have met these learning objectives for this section:

o Describe the method of optimi zatton for the folrowing:o Feed Dispersion Steamo AccelerationZoneo Strippero Combustor

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