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A.B.PATHAK
DGM-PRODUCTION
HALDIA REFINERY
Haldia Refinery
Igniting Minds... Energizing Lives…
TOPICS:
1.INTRODUCTION.
2.HISTORY.
3.OPERATIONAL ASPECTS.
Haldia Refinery
Igniting Minds... Energizing Lives…
Haldia Refinery
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INTRODUCTION:
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INTRODUCTION:
Feed stocks:
Vacuum gas oil (VGO)
Coker gas oil (CGO)
De-asphalted oil (DAO)
Hydro-cracker bottom
Hydro-treated VGO
Reduced crude oil (RCO) / Long residue (LR)
Vacuum residue (VR) / Short residue (SR)
Typical products:
Dry gas (H2, C1, C2)
LPG (C3, C4)Î Propylene, Isobutylene
Light cracked naphtha (LCN) (C5-150oC) Î Gasoline
Heavy cracked naphtha (HCN) (150 - 220oC) Î Gasoline / Diesel / Cutter
stock
Light cycle oil (LCO) (220 - 370oC) Î Diesel / Cutter stock
Clarified oil (CLO) or Decant oil (DCO) Î Fuel oil
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Position of FCC in Refinery
S Gas
T
A LPG
B
C
R Gasoline Gasoline
U Blending
D HDS CCR
E
Reformate
D Kerosene
I HDS Jet fuel
S HDS Diesel
T
V
A
C Hydrocracker FCC
D
I
S
T
Visbreaker / Fuel Oil
Coker Coke
BBU Bitumen
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Schematic of FCC
Products
Regenerator Stripper
Steam
Air Riser
Feed
Steam
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Schematic of RFCC
To heat To Main fractionator
recovery
section
Reg-2 Reactor
Steam
Reg-1
Back flush
HCO
Air Steam
Feed
Riser
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FLOW SCHEME OF RFCC
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HISTORY
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HISTORY
Fixed bed (1936 – 1941)
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HISTORY
Eight companies formed a consortium “Catalytic Research
Associates” (CRA) in 1938 to develop catalytic cracking
process which would operate outside Houdry’s patents
Standard Oil of New Jersey (currently Exxon)
Standard Oil of Indiana
M.W. Kellogg Co.
Anglo-Iranian Oil Co.
Royal Dutch-Shell Co.
The Texas Co. (Texaco)
Universal Oil Products Co. (UOP)
(I.G Farben) (dropped in 1940)
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OPERATIONAL ASPECTS
1.TYPICAL OPERATING CONDITIONS.
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OPERATIONAL ASPECTS
TYPICAL OPERATING PARAMETERS
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OPERATIONAL ASPECTS
TYPICAL YIELD PATTERN
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OPERATIONAL ASPECTS
INTERPLAY OF VARIABLES IN FCC
Independent
¾ Feed rate
¾ Recycle ratio
¾ Feed preheat
¾ Riser Outlet temperature
¾ Reactor pressure
¾ Fresh catalyst activity / Selectivity/make up rate
Major dependent
¾ Regenerator temperature
¾ Catalyst circulation rate
¾ Regenerator air flow
¾ CRC-Coke on Regenerated catalyst
¾ Product yields
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OPERATIONAL ASPECTS
PRESSURE BALANCE
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PRESSURE BALANCE
2.0 Kg/cm2
670 degC
670 degC
Back
SCSV flush
RCSV
HCO
Air Steam
Feed
Riser
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OPERATIONAL ASPECTS
HEAT BALANCE
A catalyst cracker continually adjusts itself to stay in heat balance
The unit produces and burns enough coke to provide energy to:
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OPERATIONAL ASPECTS
HEAT BALANCE
Heat Losses
Heat of Coke
Heat losses Combustion
Regenerator Reactor
Heat of
Reaction
Recycle
Regenerated Fresh Feed
Catalyst
Regeneration Feed Pre heater
Air
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OPERATIONAL ASPECTS
CATALYST CIRCULATION
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OPERATIONAL ASPECTS
CATALYST CIRCULATION
Fluidization Systems
Fluidization air / steam / HC gas required in standpipes when cat
approaches de-aeration
Avoids unstable catalyst flow in stand pipes
Requires adjustment in line with catalyst circulation rate
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OPERATIONAL ASPECTS
CATALYST CIRCULATION
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OPERATIONAL ASPECTS
CATALYST LOSS
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OPERATIONAL ASPECTS
CATALYST LOSS
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OPERATIONAL ASPECTS
REGENERATION MODE
Total Combustion
Coke on regenerated catalyst < 0.05
CO in flue gas < 1000 ppm
Higher effective activity & superior selectivity of catalyst
Higher regenerator temperature
Use of catalyst cooler with residue feed for control of regenerator
dense bed temp.
Partial Combustion
Coke on regenerated catalyst > 0.05
CO in flue gas > 1000 ppm
Lower effective activity & superior selectivity of catalyst
Relatively lower regenerator temperature
Relatively higher afterburning Î difference between regenerator
dense bed temp. and dilute bed temp.
Requires CO boiler
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SALIENT DESIGN ASPECTS
TWO STAGE REGENERATION
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SALIENT DESIGN ASPECTS
COMPARISON OF REGENERATOR TYPES
Single stage Single Two stage with separate
stage flue gas
Stage no. One One One Second
Mode Partial Full Partial Full
Regen T (oC) 717 718 707 718
CSC wt% 1.78 1.63 1.64 0.66
CRC wt% 0.18 0.03 0.66 0.04
Delta coke, wt% 1.6 1.6 0.98 0.62
Inventory,Tons 150 150 100 50
Cat cooler duty, MMBTU/hr 195 250 -- 180
Flue gas comp. Vol% 0.0/13.1/4.2 0.9/15.3 0.0/11.2/ 1.1/15.0/
O2/CO2/CO /0.0 6.8 0.0
Catalyst make-up, lb/bbl of FF 0.71 0.78 0.77
CO-boiler req. Yes No Yes
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SALIENT DESIGN ASPECTS
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SALIENT DESIGN ASPECTS
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SALIENT DESIGN ASPECTS
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SALIENT DESIGN ASPECTS
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SALIENT DESIGN ASPECTS
Reactor Stripper
¾Surrounds the upper portion of the riser
¾Fitted with internals / baffles to enable stripping of the catalyst
using superheated steam.
¾Cat flux 500 – 700 lb/min-ft2
¾Stripping steam rate 2 – 5 lb per 1000 lb of catalyst
¾Excess stripping steam may not be beneficial; Loss of
valuable products
¾Catalyst residence time 1 – 2 minutes
¾Pre stripping rings at dip leg bottoms
¾Performance can be assessed by Hydrogen on coke
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SALIENT DESIGN ASPECTS
Reactor Stripper
Removes entrained Hydrocarbons between catalyst
particles.
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SALIENT DESIGN ASPECTS
Reactor Stripper
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SALIENT DESIGN ASPECTS
CATALYST PRE-STRIPPING
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SALIENT DESIGN ASPECTS
SLIDE VALVES
Slide Valves
To regulate flow of catalyst (flue gas for DDSV)
Hydraulically operated
RCSV and SCSV isolate reactor from regenerator
Carbon steel body with vibrocast lining
Sloped bonnet / guides for self draining of catalyst
Steam / air purge for older design.
No purge in normal operation
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SALIENT DESIGN ASPECTS
SLIDE VALVES
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SALIENT DESIGN ASPECTS
SLIDE VALVES
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SALIENT DESIGN ASPECTS
RTD-RISER TERMINATION DEVICE
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SALIENT DESIGN ASPECTS
RTD-RISER TERMINATION DEVICE
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SALIENT DESIGN ASPECTS
AIR GRID
Air Grid
¾For even distribution of air in spent catalyst
¾Proper air distribution
•Lowers CRC (carbon on regenerated cat)
•Minimizes after burn
•Reduces local hot spots / catalyst sintering
¾Mechanically robust to withstand wide range of
operations / upsets
¾Erosion, thermal expansion, mechanical integrity of
supports
¾Pressure drop across air grid
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SALIENT DESIGN ASPECTS
AIR GRID
Air Grid
Various designs – Flat grid plate, dome, pipe,
ring, flat pipe grid
Pipe grid
More uniform coverage (less dependent on air rate)
Lower nozzle velocity, lower attrition
Rings
Coverage from jet penetration
Less effective at lower than design air rates
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SALIENT DESIGN ASPECTS
AIR GRID
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SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Cyclone Separators
To separate catalyst from flue gas / hydrocarbon
vapors
Provided in reactor and regenerator(s)
External / Internal
Single stage / Double stage
Direct coupled / Close coupled
Typical inlet velocities (ft/sec)
•First stage (Rx or Rg) 60 – 70 ft/sec
•Second stage 80 – 85 ft/sec
•Minimum velocity 25 – 35 ft/sec
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SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
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SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
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SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Dip Legs
¾Submerged or exposed
¾Catalyst head required in the dip leg
¾Splash plate, trickle valve, counter weight
¾Refractory lining depending upon the geometry
¾Fluidisation requirement (external cyclones)
¾Common causes of catalyst carry over
¾Problems during start ups
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SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
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SALIENT DESIGN ASPECTS
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SALIENT DESIGN ASPECTS
ORIFICE CHAMBER
Orifice Chamber
¾To provide back pressure for
regenerator
¾At the D/S of DDSV
¾Reduces pressure drop across DDSV
¾Number of grids with holes
¾DP across each grid
¾Cold walled / hot walled
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SALIENT DESIGN ASPECTS
ORIFICE CHAMBER
ORIFICE CHAMBER
GRID $ 1
MANWAY
GRID $ 2
GRID $ 3
GRID $ 4
GRID $ 5
GRID $ 6
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SALIENT DESIGN ASPECTS
ORIFICE CHAMBER
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Haldia Refinery
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