Process Simulation and Modeling of Fluidized Catalytic Cracker Performance in Crude Refinery

Abstract

The simulation of fluidized catalytic cracking (FCC) process was performed using Aspen HYSYS. The effect of crude flow rate on naphtha flow, coke yield, and catalyst to oil ratio in FCC were simulated. The interaction effects of riser height, inlet crude flow rate and operating temperature on naphtha mass flow, catalyst to oil ratio, and coke yield were studied by Box-Behnken design. The maximum yield of naphtha (100000 kg/h) was obtained for FCC operating temperature within 520-600 • C and riser height greater than 30 m. The catalyst to oil ratio of above 12 was obtained for operating temperature beyond 590 • C for the entire riser height variation of 10 to 60 m in FCC. The increase in riser height resulted in increase production of naphtha, but beyond 60 m of riser height secondary cracking occurs resulting in reduction in yield of naphtha.

Simulation analysis of the catalytic cracking process of biomass pyrolysis oil with mixed catalysts: Optimization using the simplex lattice design

“…An alternative expression for the C/O ratio can be obtained by taking into account that the energy required in a FCC reactor to regenerate the spent catalyst is supplied by the combustion of the generated coke. This is determined by the coke yield (Y coke ), whose value depends on the operating conditions and can be related to the C/O ratio indicated above through the delta coke or ΔC (difference in the coke content between the spent Light naphthene (5) Light aromatics with side chains (6) One-ring light aromatics (7) Two-ring heavy aromatics 343°C to 510°C (650°F to 950°F) (8) Heavy paraffin (9) Heavy naphthene (10) Heavy aromatics with side chains (11) One-ring heavy aromatics (12) Two-ring heavy aromatics (13) Three-ring heavy aromatics >510°C (950°F) (14) Residue paraffin (15) Residue naphthene (16) Residue aromatics with side chains (17) One-ring residue aromatics (18) Two-ring residue aromatics (19) Three-ring residue aromatics Coke (20) Kinetic coke (21) Metal coke…”

“…One of the main R&D active areas on this subject deals with finding the optimum operating conditions of the catalytic cracking process that maximize the product conversion, and special attention has been paid to the use of commercially available catalysts. A number of experimental and simulation investigations have focused on this topic making use of zeolite catalysts and different oil sources, as outlined in Table together with the main parameters and conditions analysed . The simulation works summarized in the table (using Aspen Hysys, and focused on petroleum crude oil instead of bio‐oil‐simulation works on optimization of the bio‐oil catalytic cracking process are scarce) use a FCC unit similar to that presented in Figure for their configuration, thus analysing the effect of the key parameters, such as the reactor temperature, riser height (related to the residence time), and the catalyst‐to‐oil ( C / O ) ratio on the final conversion .…”

“…A number of experimental and simulation investigations have focused on this topic making use of zeolite catalysts and different oil sources, as outlined in Table together with the main parameters and conditions analysed . The simulation works summarized in the table (using Aspen Hysys, and focused on petroleum crude oil instead of bio‐oil‐simulation works on optimization of the bio‐oil catalytic cracking process are scarce) use a FCC unit similar to that presented in Figure for their configuration, thus analysing the effect of the key parameters, such as the reactor temperature, riser height (related to the residence time), and the catalyst‐to‐oil ( C / O ) ratio on the final conversion . Similarly, other authors have investigated experimentally the bio‐oil catalytic cracking stage by using a fixed bed reactor and varying the temperature, the reaction time, and the catalyst loading (CL) in the reactor to characterize the associated changes in the product conversion …”

“…[11][12][13][14][15][16][17] The simulation works summarized in the table (using Aspen Hysys, and focused on petroleum crude oil instead of bio-oil-simulation works on optimization of the bio-oil catalytic cracking process are scarce) use a FCC unit similar to that presented in Figure 1 for their configuration, thus analysing the effect of the key parameters, such as the reactor temperature, riser height (related to the residence time), and the catalyst-to-oil (C/O) ratio on the final conversion. [11][12][13] Similarly, other authors have investigated experimentally the bio-oil catalytic cracking stage by using a fixed bed reactor and varying the temperature, the reaction time, and the catalyst loading (CL) in the reactor to characterize the associated changes in the product conversion. [14][15][16][17] As indicated above, simulation studies aimed at optimizing the bio-oil catalytic cracking process are scarce.…”

Optimization of a Fluid Catalytic Cracking Kinetic Model by Improved Particle Swarm Optimization

“…Fluid catalytic cracking (FCC) is an important means of lightening heavy oil and the main production process of light oil products such as liquefied petroleum gas (LPG), gasoline, and diesel oil , . The catalytic cracking reaction system is complex , involving a wide variety of reactions, most of which are parallel‐sequential.…”