FCCU

FCCU (Fluidized Catalytic Cracker Unit) Tutorial

The interactive FCCU tutorial provides an overview, fundamental principles, control principles and operating principles for a fluidized catalytic cracker unit, using voice, video, animation and graphics. The topics covered are:

Overview

Introduction
Importance of FCC Unit
Process Overview

FCC Unit Components

Feed Preheat System
Reactor System
Regenerator System
Flue Gas System
Variation of Reactor and Regenerator System
Fractionation System

Principles of FCC Unit

Cracking Reactions
Fluidization Principles
Catalyst Circulation
Energy Balance in Reactor and Regenerator

Key Controlled and Operating Variables

Introduction
Reactor Temperature
Catalyst to Oil Ratio
Reactor Pressure
Catalyst Bed Level
Regenerator Temperature
Delta Coke
Complete and Partial Combustion Modes
Afterburning and CO Promoter
Air Flow
Air Distribution
Slide Valve
Riser Lift-Steam and Feed Dispersion-Steam
Stripping Steam
Feed Properties
Catalyst Activity and Selectivity
Catalyst Loss and Addition

Startup Operation

Introduction
Pre-Startup Check
Regenerator Main Air-Blower Startup
Regenerator – Reactor Warm Up
Regenerator Catalyst Addition
Regenerator Torch Oil Firing
Regenerator – Reactor Catalyst Circulation
Main Fractionator Bottom Fill Up
Main Fractionator and Feed Heat Up
Riser Feed Introduction
Reactor and Regenerator Stabilization
Fractionator Overhead Section Startup
Fractionator Bottom Section Startup
Fractionator Light Cycle Oil (LCO) Section Startup
Fractionator Heavy Cycle Oil (HCO) Section Startup
Load Increase to Design Condition

Troubleshooting

Introduction
High Light Gas Yield
Low Gasoline Yield
Low Catalyst Activity and Selectivity
Flow Reversal
High Regenerator Temperature
Severe Afterburning
Insufficient Combustion Air
Loss of Catalyst

FCCU (Fluidized Catalytic Cracker Unit) Simulation

The FCCU simulation is a rigorous and high-fidelity mathematical process model that provides a realistic dynamic response for a fluidized catalytic cracker unit.

Process Overview:

Fluidized catalytic cracker (FCC) converts gas oils and heavy stocks into high-octane gasoline, light fuel oils and light gases rich in olefins. The following products are typically obtained from a fluidized catalytic cracking unit: wet gas, unstabilized gasoline, light cycle oil (LCO), heavy cycle oil (HCO) and slurry oil (SLO).

Major Sections:

Reactor Section
Regenerator Section
Main Fractionator Section
Wet Gas Compressor Section

The FCC simulator is available in various configurations, such as regenerator with partial or complete combustion, with/without catalyst cooler.

Major Operations for Trainee Practice:

Startup and Shutdown Operations
Normal Operations
Emergency Shutdown Operations
Troubleshooting Equipment, Instrument and Control Valve Malfunctions
Malfunction Recovery Actions

Simulation Features:

Effect on Reaction Yield and Coke Yield

Reactor Temperature
Catalyst to Oil Ratio
Lifting and Dispersion Steam

Hydrocarbon Carry-Over in Spent Catalyst
Afterburning
Flow Reversal
Coke Snow-Balling
Effect of CO Promoter on Regenerator
Interlock/Safeguard System

Detailed Calculation of the Products Properties

Complete ASTM Analysis of All Products
Reid Vapor Pressure and Flash Point of Gasoline
Pour Point of LCO and HCO
Viscosity of SLO

Plant Alert and Monitor
Equipment Details

Sections

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