Optimizing spent catalyst stripping to

enhance FCC unit performance

E ffective stripping of spent catalyst prior to regeneration has always been recognized as critical to maximizing FCC
unit profitability. Recent design developments in this process have increased its value to refiners seeking to improve
FCC unit performance (Figure 1).

I Higher regenerator temperatures

Regenerator Products I Increased catalyst deactivation
Flue gas
Reactor I Reduced catalyst circulation at constant operating conditions

I Reduced catalyst/oil
Stripper
Spent catalyst
I Reduced conversion

I Loss of profitability
Riser

The economic benefits from optimum stripping are potentially

Regenerator catalyst
Feed
Air blower
Figure 1: FCC converter.
Spent catalyst stripping is intended to minimize the carry-under
of hydrogen-rich hydrocarbons from the reaction zone to the
regenerator. Significant amounts of entrained hydrocarbons, as
well as hydrocarbons adsorbed on the spent catalyst surface, exit
the riser termination device and are directed through the spent
catalyst stripping zone prior to entering the regenerator.
quite substantial. Assuming the least valuable product – main
column bottoms – is upgraded to gasoline, the achievement of
reduced delta coke and increased cat/oil can result in an
incremental profit increase based on current crack spread of
about US$ 0.50 per barrel FCC feed/unit conversion. For a
typical FCC unit, this translates to a benefit of millions of dollars
per year.
Stripper design fundamentals
The stripping zone incorporates a variety of internal designs to
facilitate uniform distribution of spent catalyst and contact with

Spent catalyst is suspended or fluidized by steam in the stripper.

Stripping of the hydrocarbons occurs as the dense phase
Spent catalyst
fluidized bed passes counter-currently with the steam flow.
Hydrocarbons adsorbed on the catalyst surface and trapped in
the interstitial spaces between catalyst particles are then
“stripped” by the upward flowing steam and eventually recovered
with the riser effluent. Spent catalyst, ideally surrounded by Baffles
steam, is then directed to the regenerator (Figure 2).
Assessing the challenge
Inefficient stripping allows continued thermal degradation of
the hydrocarbons, contributing to increased dry gas and delta
Stripped catalyst
coke. Strippable hydrocarbons not desorbed in the stripping
zone will be carried with the spent catalyst to the regenerator.
The unwanted results of this hydrocarbon carry-under can Steam

include:
Riser

Figure 2: Common FCC catalyst stripper configuration.

Issue 71 I Courier 11
 stripping steam. These designs have
included side-by-side sloped baffle type
trays, shed decks, and alternating disc
and donut trays.
Residence time – essentially the
inventory of spent catalyst divided by
the catalyst circulation – is typically
designed for about 60 - 90 seconds.
Depending on stripper design, the
downward flow, or mass flux of the spent
catalyst, occurs at about 600-800
lb/ft2/minute (50-65 kg.m-2.sec-1). When
the mass flux rate exceeds about
1,200 lb/ft2/minute (100 kg.m-2.sec-1),
stripping efficiency begins to deteriorate;
the stripping steam requirement
increases as does regenerator
temperature, catalyst circulation is
reduced and loss of conversion occurs.
The stripper internal contacting stages
are designed to enhance contact between
spent catalyst and steam, and to
maintain steam dispersion and
distribution. Conventional internals
typically occupy about half of the
flowing cross-sectional area of the
stripper. This limits catalyst mass flux
rate, and becomes a unit constraint at
high catalyst circulation rate.
Process licensors have developed new
and revised designs capable of relieving
this constraint. Adding additional
stripping stages, modifying stripping
trays, and even replacing the entire
stripper are common revamps that
provide incremental capacity increases.
One recent innovation involves replacing
the existing internals with multiple
layers of structured packing. Units
incorporating this design have reported
increasing the catalyst mass flux rate as
much as 50% with no deterioration in
stripping performance.
12 Courier I Issue 71
Both ring and pipe-grid distributors are potential loss of conversion and total
typically used to achieve uniform steam liquid yield, and feed rate limitation.
distribution. To remain reliable between
turnarounds, the distributor must be A rapid decrease in stripper bed density
properly designed for the appropriate is an indication that a mass flux limit
steam rate, pressure drop, nozzle has been exceeded. While the absolute
length-to-diameter ratio and exit velocity, number is suspect, the hydrogen level in
and metallurgy. The steam source must the coke on a weight basis is typically
be kept dry to avoid erosion due to used to indicate changes in stripper
excessive velocities. performance. Hydrogen in coke of
about 5 - 6 wt% generally indicates good
Assessing stripper problems
stripper operation.
Drawing from Albemarle’s extensive
experience in maximizing FCC unit Increasing hydrogen in coke reflects
performance, this diagnostic checklist increasing hydrocarbon carry-under to
can aid the refiner in identifying the the regenerator. While not a routine
nature and extent of typical spent procedure, sampling and analyzing the
catalyst stripper problems. spent catalyst and vapor exiting the
stripper for hydrocarbons can also
Excessive spent catalyst mass flux provide an indication of stripper
rate: Catalyst mass flow rates performance (Figure 3).
exceeding about 1,600 lb/ft2/minute
(130 kg.m-2.sec-1) results in poor Spent catalyst maldistribution:
steam/catalyst contact, flooded trays, Channeling and short-circuiting of
insufficient catalyst residence time and partially stripped catalyst to the spent
increased steam entrainment to the catalyst outlet may occur, particularly in
spent catalyst standpipe. asymmetric/annular strippers. As there
is typically inadequate temperature
The primary concern is hydrocarbon monitoring to detect radial
entrainment to the regenerator leading maldistribution, this type of problem
to loss of product, increased catalyst may be confirmed by gamma scans.
deactivation, increased delta coke,
Stripping efficiency versus flux Stripper density versus flux
100 40
Stripper efficiency, %
75 30
Stripper density
Above critical flux, ...because gas is
50 efficiency falls
20
entrained downward,
dramatically reducing density
25 10
0 0
Superficial mass flux, lb/ft2/s Superficial mass flux, lb/ft2 /s
Figure 3: Effect of mass flux on stripper efficiency and density.
Source: KBR NPRA Paper AM-00-08.
 “By properly diagnosing and correcting spent catalyst stripper problems, refiners
can realize significant gains in FCC unit profitability.”

Insufficient stripping steam rate: The stripping steam rate Key steps to enhanced stripper performance
should be adjusted to maximize stripping by minimizing By properly diagnosing and correcting spent catalyst stripper
hydrocarbon carry-under to the regenerator. In practice, the problems, refiners can realize significant gains in FCC unit
stripping steam rate should be increased until there is no visible profitability. In summary, the following steps will help ensure
decrease in regenerator temperatures, and cyclone loadings and maximum stripper efficiency:
sour water handling capability are not exceeded.
I Maximize stripping steam rate, to the limits of cyclone
loadings and sour water handling capacity
Stripping steam maldistribution: Mechanical damage to the
steam distributor or trays is the most common cause for I Minimize reactor disengager pressure, to the limit of the wet
maldistribution. Nonuniform distribution leads to smaller gas compressor
steam bubbles agglomerating to larger ones, reducing stripping
I Increase reaction temperature, consistent with desired
effectiveness. Wet steam will cause significant nozzle erosion,
cracking severity, yield objectives, product qualities, wet gas
refractory and tray damage due to the resulting high velocity
capacity, etc.
steam jet. Gamma scanning is a key diagnostic tool to investigate
both steam and catalyst distribution. I Increase spent catalyst residence time in the stripper by
adjusting the bed height upward, subject to practical limits
Erratic, nonuniform catalyst flow: This problem could also I Consider a design modification to promote contacting and
reflect mechanical damage to the stripping trays or an excessive relieve a mass flow constraint.
stripping steam rate. Typically, strippers are designed for about
0.75 – 1.0 ft/sec (23 – 30 cm/sec) superficial velocity. This is
sufficient to displace the hydrocarbon and allow uniform
catalyst flow downward. In an efficient stripper, up to 80% of the
steam flows upward to the disengager. Tracer scanning is an
excellent diagnostic tool to confirm tray damage. Nonuniform
radial temperature distribution will also provide an indication of
possible tray damage.

Excessive hydrocarbon under-carry: Most FCC units are

processing more feed and operating at higher severities than they
were originally designed to do. This leads to high catalyst
circulation rates and high stripper mass flux rates, potentially
entraining more hydrocarbons to the regenerator. If increasing
the stripping steam rate has little impact, a new or modified
stripper design may be required.

Plugged steam distributor nozzles: Distributor nozzles may

become plugged from refractory, slumped catalyst, or coke. The
steam rate, as reflected by the distributor pressure drop, must be
maintained to minimize the possibility of plugging.

Corrosion: If catalyst is not properly fluidized, it can pack in

stagnant areas and cool, leading to potential corrosion. This is a
common problem in annular designs with the spent catalyst
outlet on one side of the bottom of the stripper. If not kept hot
by fluffing with steam, the catalyst will settle and cool, leading Contact: Jack Wilcox
to potential corrosion of the disengager shell and riser. Email: jack.wilcox@albemarle.com

Issue 71 I Courier 13