Fluid catalytic cracking handbook: design, operation, and troubleshooting of FCC facilities

384 Pages·2000·15.112 MB·English

by  Reza Sadeghbeigi

Fluid
Catalytic
Cracking
Handbook
SECOND EDITION
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Fluid
Catalytic
Cracking
Handbook
Handbook Design, Operation and
Troubleshooting of
FCC Facilities
SECOND EDITION
GP Gulf Professional Publishing
I'M an imprint of Butterworth-Heinemann
Fluid
Catalytic
Cracking
Handbook
Design, Operation, and
Troubleshooting of
FCC Facilities
SECOND EDITION
Copyright © 2000 by Butterworth-Heinemann. All rights
reserved. Printed in the United States of America. This book,
or parts thereof, may not be reproduced in any form without
permission of the publisher.
Originally published by Gulf Publishing Company,
Houston. TX.
For information, please contact:
Manager of Special Sales
Butterworth-Heinemann
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For information on all Butterworth-Heinemann publications
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10 9 8 7 6 5 4 3 2
Library of Congress Cataloging-in-Publication Data
Sadeghbeigi, Reza.
Fluid catalytic cracking handbook / Reza Sadeghbeigi.—2nd ed.
p. cm.
Includes bibliographical references and index.
ISBN 0-88415-289-8 (alk. paper)
1. Catalytic cracking. 1. Title.
TP690.4.S23 2000
665.533 dc2l 00-035361
Printed in the United States of America.
Printed on acid-free paper (°°).
This book is dedicated to
our respected clients who have
contributed to the success of RMS Engineering, Inc.
and to the content of this book
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Contents
Acknowledgments xi
Preface to the Second Edition xii
CHAPTER 1
Process Description 1
Feed Preheat, 6. Riser—Reactor—Stripper, 7, Regenerator-
Heat/Catalyst Recovery, 13. Main Fractionator, 22. Gas Plant,
25. Treating Facilities, 31. Summary, 39. References, 39.
FCC Feed Characterization 40
Hydrocarbon Classification, 41. Feedstock Physical Properties,
45. Impurities, 54. Empirical Correlations, 68. Benefits of
Hydroprocessing, 81. Summary, 82. References, 82.
CHAPTER 3
FCC Catalysts 84
Catalyst Components, 84. Catalyst Manufacturing
Techniques, 96. Fresh Catalyst Properties, 99. Equilibrium
Catalyst Analysis, 102. Catalyst Management, 109.
Catalyst Evaluation. 115. Additives, 117. Summary, 123.
References, 124.
CHAPTER 4
Chemistry of FCC Reactions 125
Thermal Cracking, 126. Catalytic Cracking, 128. Thermo-
dynamic Aspects, 136. Summary, 136. References, 138
References, 134.
CHAPTER 5
Unit Monitoring and Control _.._ 139
Material Balance, 140. Heat Balance, 158. Pressure
Balance, 166. Process Control Instrumentation, 177.
Summary, 180. References, 181.
CHAPTER 6
Products and Economics 182
FCC Products, 182. FCC Economics, 202. Summary, 205.
References, 205.
CHAPTER 7
Project Management and
Hardware Design 206
Project Management Aspects of an FCC Revamp, 206.
Process and Mechanical Design Guidelines, 212.
Summary, 232. References, 232.
CHAPTER 8
Troubleshooting 234
Guidelines for Effective Troubleshooting, 235. Catalyst
Circulation, 236. Catalyst Losses, 244. Coking/Fouling, 248.
Flow Reversal, 251. High Regenerator Temperature, 256.
Increase in Afterburn, 259. Hydrogen Blistering, 260. Hot
Gas Expanders, 263. Product Quantity and Quality, 264.
Summary, 275.
CHAPTER 9
Debottlenecking and Optimization 276
Introduction, 276. Approach to Debottlenecking, 277.
Reactor/Regenerator Structure, 281. Flue Gas System, 296.
FCC Catalyst, 296. Instrumentation, 304. Utilities/Offsites,
305. Summary, 306.
Emerging Trends in Fluidized Catalytic Cracking _ 307
Reformulated Fuels, 308. Residual Fluidized Catalytic
Cracking (RFCC), 323. Reducing FCC Emissions, 327.
Emerging Developments in Catalysts, Processes, and
Hardware, 232. Summary, 335. References, 336.
APPENDIX 1
Temperature Variation of Liquid Viscosity 338
APPENDIX 2
Correction to Volumetric Average Boiling Point 339
APPENDIX 3
TOTAL Correlations 340
APPENDIX 4
n-d-M Correlations _.._._ ._.._ __._ _ 341
APPENDIX 5
Estimation of Molecular Weight of
Petroleum Oils from Viscosity Measurements 342
APPENDIX 6
Kinematic Viscosity to
Saybolt Universal Viscosity _._ _ 344
APPENDIX 7
API Correlations 345