Fluid Catalytic Cracking FCC Process

67 K min (assumption residence time of 3 min in the preheating oven and a temperature increase from about 300 to 500 °C). Thus, thermal cracking (and coke formation) during the heating of the residue up to a final temperature of 500 °C cannot be avoided but is probably still below 20%. 

Vacuum gasoil and hot catalyst (about 650-750 °C) are mixed, and after vaporization and heating of the oil (whereby the catalyst cools down) a temperature of 550 °C is reached. Hence, FCC units operate in heat balance (Example 6.7.1), and the hot catalyst from the regenerator supplies heat for cracking, preheating, and for vaporization of the oil. 

Ratio of mass flow of catalyst to flow of oil (riser reactor) 6kgkg  

Reaction enthalpy of combustion of coke (carbon) ArHc -33MJkg  

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Another approach used to reduce the harmful effects of heavy metals in petroleum residues is metal passivation. In this process an oil-soluble treating agent containing antimony is used that deposits on the catalyst surface in competition with contaminant metals, thus reducing the catalytic activity of these metals in promoting coke and gas formation. Metal passivation is especially important in fluid catalytic cracking (FCC) processes. Additives that improve FCC processes were found to increase catalyst life and improve the yield and quality of products. ... 

Carbon Monoxide Boilers Carbon monoxide boilers are used to recover waste heat generated from oil refining fluid catalytic cracking (FCC) processes. The FCC process produces copious volumes of by-product gas containing 5 to 8% carbon monoxide (CO), which has a heat content of about 150 Btu/lb. A 10,000 barrel (bbl) per day FCC unit produces 60,000 to 150,000 lb/hr of CO. 

Catalytic cracking is a process that is currently performed exclusively over fluidized catalyst beds. The fluid catalytic cracking (FCC) process was introduced in 1942 and at that time replaced the conventional moving bed processes. These early processes were based on acid-treated clays as acidic catalysts. The replacement of the amorphous aluminosilicate catalysts by Faujasite-type zeolites in the early-1960s is regarded as a major improvement in FCC performance. The new acidic catalysts had a remarkable activity and produced substantially higher yields than the old ones. 

The Fluid Catalytic Cracking (FCC) process lies at the heart of the modem refinery (1) as outlined in Chapter 4 of this book. The position of the FCC unit in the refinery is schematically sketched in Figure 5.1. 

Group A Solid particles having a small mean particle size or low partiele density (< 1500kgm ). Typical examples of this class are catalysts used for fluid catalytic cracking (FCC) processes. These solids fluidize easily, with smooth fluidization at low gas velocity and bubbling/turbulent fluidization at higher velocity. 

Understanding catalyst deactivation, fouling and aging mechanisms is of paramount importance for developing better catalysts. This is particularly true for catalysts used in the fluid catalytic cracking (FCC) process. 

Application The worldwide demand for gasoline, diesel and petrochemicals is shifting toward a greater emphasis on diesel and propylene, and flexibility to meet changing demands will be vital for refinery profitability. Axens has developed the new FlexEne technology to expand the capabilities of the fluid catalytic cracking (FCC) process, which is the main refinery conversion unit traditionally oriented to maximize gasoline and at times propylene. 

Description The DCC process overcame the limitations of conventional fluid catalytic cracking (FCC) processes. The propylene yield of DCC is 3-5 times that of conventional FCC processes. The processing scheme of DCC is similar to that of a conventional FCC unit consisting of reaction-regeneration, fractionation and gas concentration sections. The feedstock, dispersed with steam, is fed to the system and contacted with the hot regenerated catalyst either in a riser-plus fluidized dense-bed reactor (for DCC-I) or in a riser reactor (for DCC-II). The feed is catalytically cracked. Reactor effluent proceeds to the fractionation and gas concentration sections for stream separation and further recovery. The coke-deposited catalyst is stripped with steam and transferred to a regenerator where air is introduced and coke on the catalyst is removed by combustion. The hot regenerated catalyst is returned to the reactor at a controlled circulation rate to achieve the heat balance for the system. 

Perovskite membranes have also been proposed for the production of oxygen enriched air for industrial processes like ammonia synthesis, the Qaus process, and the regeneration of the catalyst for the fluid catalytic cracking (FCC) process [307]. 

The use of zeolite Y (FAU) as a catalyst in the petrochemicals industry and in fluid catalytic cracking (FCC) processes is advantageous for five reasons ... 

In this section a Fluid Catalytic Cracking (FCC) process case study is examined. The aim is to compare the alternative methodologies for regulatory control structure selection presented in sections 2 and 3. The FCC process is particularly suited for this purpose. The process d3mamics described by a low order but highly non-linear set of DAEs. The actual operation of the process is dominated by economics and a small number of disturbances that affect significantly its economics has been identified. Furthermore, the most appropriate control structure for this process is a matter of some controversy, with the conventional structure being criticized in a number of recent publications. 

Predictive Modeling of the Fluid Catalytic Cracking (FCC) Process... 

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