Troubleshooting Catalyst

-Related FCC Operations

Presentation at Ecopetrol
October 2008

CONFIDENTIAL 1
 Why FCC Troubleshooting is Complex

 The fluid catalytic cracking (FCC) process

has complex interactions between:
 operational variables
 hardware and process limitations
 feedstock quality

 Changes is the above variables can produce

secondary effects in the FCC heat balance

 FCC process / operating variables can

influence equilibrium catalyst properties
8/14/2006 CONFIDENTIAL 2
Understanding Catalyst-related Effects

 FCC operational problems can show up in

catalyst-related areas, such as:
 increased catalyst losses
 circulation constraints

 In these cases, it is critical to evaluate the

history of both the unit operation and the
equilibrium catalyst

8/14/2006 CONFIDENTIAL 3
 Attack the Problem Systematically

 Identify the symptoms

 Define the problem

 Analyze all available data

 consider any changes that occurred near the time the
problem was first observed
 develop potential causes
 historical data important

 Determine the solution that best explains deviations

8/14/2006 CONFIDENTIAL 4
 Examples of Common FCC Problems

 High catalyst losses

 Catalyst circulation constraints

8/14/2006 CONFIDENTIAL 5
 Potential Reasons For Increased
Catalyst Losses

# 1 = Cyclone or mechanical damage

# 2 = Increased catalyst attrition

# 3 = Operational changes

8/14/2006 CONFIDENTIAL 6
 Typical 2-Stage Cyclone System

Plenum
Gas Outlet Tube

2nd Barrel
Gas Inlet Duct Stage
1st
Stage
Dust Hopper
Cone

Dipleg

Flapper Valve
8/14/2006 CONFIDENTIAL 7
 #1. Cyclone or Mechanical Damage -
Holes in Cyclone or Plenum
Operational effects Catalyst effects

 not significant (hole)  Ecat fines decrease

 catalyst losses increase
over time

 not significant (crack)  Ecat fines decrease

 losses increase
suddenly, then relatively
constant
8/14/2006 CONFIDENTIAL 8
 #1. Cyclone or Mechanical Damage -
Evaluating Lost Catalyst

Likely problem area Catalyst effects

 1st stage, 2nd  Ecat fines decrease

stage, or plenum
 APS of lost catalyst >
30 microns

 2nd stage cyclone  Ecat fines decrease

 APS of lost catalyst <25
microns
8/14/2006 CONFIDENTIAL 9
#1. Cyclone or Mechanical Damage -
Plugged or Damaged Cyclone Dipleg

Mechanical effects Catalyst effects

 damaged trickle/flapper  Ecat fines decrease

valve
 catalyst losses constant
over time

 plugged dipleg  Ecat fines decrease

 catalyst losses constant
 catalyst “puffing” from
stack
8/14/2006 CONFIDENTIAL 10
 #2. Change in Catalyst / Attrition

Operational / mechanical Catalyst effects

effects

 increased fines in fresh  Ecat fines increase

catalyst

 increased attrition of
fresh catalyst

8/14/2006 CONFIDENTIAL 11
 #2. Change in Catalyst / Attrition

Operational / mechanical Catalyst effects

effects

 Increased gas velocities  Ecat fines increase

– higher feed/gas/steam
rates
– distributor damage

 Increase in cyclone
pressure drop
8/14/2006 CONFIDENTIAL 12
 #3. Operational Changes -
Increased Catalyst Entrainment

Oper / mechanical effects Catalyst effects

 Increased feed rate to  Ecat fines decrease

unit
– high dipleg levels (puffing)

 Increased gas jet  Ecat fines decrease

velocities
– increased coke production
– increased vessel gas
temperatures

8/14/2006 CONFIDENTIAL 13
 #3. Operational Changes -
Reactor-side Coking

Operational / mechanical Catalyst effects

effects

 Sudden increase in  Ecat fines decrease

catalyst losses to
fractionator

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 Symptoms of Catalyst Circulation
Problems

1. Riser temperature variations

2. Slide valve  P loss (not Rx-Reg  P )

3. Stripper bed level loss

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 Potential Reasons For Circulation
Constraints

1. Poor standpipe aeration

2. Non-optimum equilibrium catalyst properties

3. Mechanical / design issues

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 Typical FCC Aeration Layout

REGENERATOR

STRIPPER
RISER

FEED

STEAM
STEAM STEAM

STEAM
AIR
STEAM
AIR
8/14/2006 CONFIDENTIAL 17
 #1. Poor Standpipe Aeration

Operational / mechanical Catalyst effects

effects

 Vibration and movement  Not significant (fines

of standpipe steady)

 Problem in only one

standpipe

 Possibly wet aeration

steam
8/14/2006 CONFIDENTIAL 18
 #2. Catalyst Particle Size (Too Course)

Oper / mechanical effects Catalyst effects

 Vibration and movement

 Ecat fines low
of standpipe (typically
( approx. 8 %)
both)

 Chugging noise from

standpipe

 Problem may appear &

reappear

8/14/2006 CONFIDENTIAL 19
 #2. Catalyst Particle Size (Too
Course)

Operational / mechanical Catalyst effects

effects

 Fresh catalyst fines  Ecat fines low

level low ( approx. 8 %)

 Fresh catalyst addition

rate low

8/14/2006 CONFIDENTIAL 20
 #3. FCC Mechanical Issues -
Cyclone Problems

Operational / mechanical Catalyst effects

effects
 Ecat fines low and
 Change in cyclone dropping with time
efficiency
or  P  Higher fines loss to
stack

 Higher fines content in

slurry
8/14/2006 CONFIDENTIAL 21
 #3. FCC Mechanical Issues -
Regen. Refractory Obstruction

Oper / mechanical effects Catalyst effects

 Low circulation rate; low

slide valve P  Not significant

 Lower than normal

density above
regenerated catalyst slide
valve

8/14/2006 CONFIDENTIAL 22
 #3. FCC Mechanical Issues -
Refractory Obstructing Slide Valve

Operational /
mechanical effects Catalyst effects

 Low circulation rate,

high slide valve  P  Not significant

 Possible regenerator  Major effects

hot spots

8/14/2006 CONFIDENTIAL 23
 #3. FCC Mechanical Issues -
Air Grid Pluggage

Operational /
Catalyst effects
mechanical effects

 Low slide valve  P  Not significant

(short term)

 High grid  P

 Low inerts in flue

gas
8/14/2006 CONFIDENTIAL 24
 #3. FCC Mechanical Issues -
Air Grid Broken

Operational / Catalyst effects

mechanical effects

 Low catalyst  Not significant

circulation (short term)

 Low grid  P

8/14/2006 CONFIDENTIAL 25
 Conclusions

 FCC operating problem symptoms can appear in

catalyst-related areas:
 increased catalyst losses
 circulation constraints

 In these cases, it is critical to maintain and to evaluate

a history of both the unit operation and the equilibrium
catalyst
 Consider any changes that occurred near the time the
problem was first observed
 An equilibrium catalyst history can help troubleshoot
the problem, even when it is not catalyst - related
8/14/2006 CONFIDENTIAL 26