The document describes the process of fluidized catalytic cracking (FCC) used in petroleum refineries. It explains that FCC converts high-boiling petroleum fractions into high-value gasoline and heating oil using a zeolite catalyst. The key components of an FCC unit are the reactor, where the reaction occurs, and the regenerator, where the catalyst is regenerated by burning off coke deposits. It then provides details on the operation of each component and the flow of catalyst and feedstock through the system. It also discusses advantages and disadvantages of FCC and presents a case study analyzing catalyst selection for a refinery in Jiddah.

1. PAD. DR. D.Y. PATIL COLLEGE OF
ENGINEERING, MANAGEMENT &
RESEARCH, AKURDI.
DEPARTMENT OF CHEMICAL ENGINEERING,
PRESENTATION
ON
FLUIDIZED CATALYTIC CRACKING
GUIDANCE
DR. SWAPNIL DHARASKAR
PRESENTED BY
VIVEK D. BHARGUDE

2. CONTENT
 WHAT IS FCC?
 GENERAL OVERVIEW OF FCC:
 A) REACTOR
B) REGENERATOR
 PROCESS DESCRIPTION
ADVANTAGES AND DISADVANTAGES
CASE STUDY

3. WHAT IS FCC?
 FCC “HEART” OF THE MODERN REFINERIES
 IT CONTRIBUTES THE HIGHEST VOLUME TO THE
GASOLINE POOL
 ONE OF THE MOST IMPORTANT & SOPHISTICATED
CONTRIBUTIONS TO PETROLEUM REFINING
TECHNOLOGY
 PRIMARY CONVERSION PROCESS IN THE PETROLEUM
REFINERY
THE PURPOSE IS TO CONVERT HIGH-BOILING
PETROLEUM FRACTIONS (GAS OIL) TO HIGH-VALUE,
HIGH-OCTANE GASOLINE AND HEATING OIL.
 ZEOLITE CATALYST IS USED WHEN PROPERLY
AERATED

4. GENERAL OVERVIEW OF FCC
 THE FCC ASSEMBLY CONSISTS OF REACTOR AND
REGENERATOR.
 FURTHER THE PRODUCT COMING FROM FCC UNIT
IS CHARGED TO THE FRACTIONATOR.
 REGENERATOR HELPS TO REACTIVATE THE
CATALYST AND REACTIVATION OF CATALYST IS
DONE USING THE HOT AIR OR BY PASSING THE
STEAM THROUGH THE REGENERATOR

5. FCC REACTOR-REGENERATOR

6. DESCRIPTION OF THE PROCESS
 REACTOR
 RISER
 CYCLONE
 STRIPPER
 REGENERATOR
 STAND PIPE AND SLIDE VALVE

7. REACTOR
• THE REACTOR USED IN
CASE OF FCC IS THE
FLUIDIZED BED REACTOR
THAT WORKS ON THE
PRINCIPLE OF
FLUIDIZATION.
• THE FEEDSTOCK IS FED AT
THE BOTTOM AND THE
FINAL PRODUCT IS TAKEN
OUT FROM THE TOP
SECTION. THE RACTOR
HAS THE CATALYTIC BED
ARRANGEMENT INSIDE IT

8. RISER
DIMENSIONS
• DIAMETER: 1.2 M (4 FT)
• HEIGHT : 36.6 M (120 FT)
PLUG FLOW WITH MINIMUM BACK-
MIXING
 STEAM IS USED TO ATOMIZE THE FEED
• INCREASES THE AVAILABILITY OF FEED

9. CYCLONES
 LOCATED AT THE END OF THE RISER TO
SEPARATE THE BULK OF THE CATALYST
 IT CAN BE USED AS THE DEFLECTOR TO
TURN THE DIRECTION OF CATALYST TO
SEPARATE THE REMAINING OF THE
CATALYST IN THE REGENERATOR.

10. STRIPPER
 THE SPENT CATALYST FALLS INTO THE
STRIPPER
 SOME VALUABLE HYDROCARBONS ARE
ABSORBED WITHIN THE CATALYTIC BED
 STEAM AT A RATE OF 4 KG PER 1000 KG OF
CATALYST IS USED TO STRIP THE
HYDROCARBON FROM THE CATALYST

11. REGENERATOR
TWO FUNCTIONS:
• 1.RESTORES CATALYST ACTIVITY
• 2.SUPPLIES HEAT TO CRACK THE FEED
AIR IS THE SOURCE OF OXYGEN FOR THE
COMBUSTION OF COKE
THE AIR BLOWER WITH 1M/S (3 FT/S) AIR VELOCITY
TO MAINTAIN THE CATALYST BED IN A FLUIDIZED
STATE
14 KPA (2 PSI) PRESSURE DROP IN AIR DISTRIBUTORS
TO ENSURE POSITIVE AIR FLOW THROUGH ALL
NOZZLES

12. STANDPIPE & SLIDE VALVE
 THE CATALYST DENSITY IN STANDPIPE IS 642 KG/M3 (40 LBS/FT3)
 STANDPIPE PROVIDES THE NECESSARY PRESSURE HEAD NEEDED TO
CIRCULATE THE CATALYST AROUND THE UNIT. SLIDE VALVE IS USED TO
REGULATE THE FLOW RATE OF THE REGENERATED CATALYST TO THE
RISER
 SLIDE VALVE FUNCTION IS TO SUPPLY ENOUGH CATALYST TO HEAT THE
FEED AND ACHIEVE THE DESIRED REACTOR TEMPERATURE

14. ADVANTAGES AND
DISADVANTAGES
ADVANTAGES
a) NO NEED TO ADD THE
HYDROGEN TO REDUCE
THE COKE FORMATION
b) COULD BE ROUTED TO
HYDROCRACKER TO
PRODUCE DIESEL
c) COKE PRODUCTION IS
SMALL BUT VERY
IMPORTANT AS IT WILL
HELPFUL FOR PROVIDING
THE HEAT FOR THE
CRACKING OF REACTION
 DISADVANTAGES
a) DESULFURISATION IS TO
BE DONE PROPERLY FOR
THE PREVENTION OF
FORMATION OF
POISONOUS CATALYST
b) LOW CETANE NUMBER
c) THE PRODUCTS COMING
OUT FROM THE REACTOR
SOMETIMES HAVE SAME
BOILING RANGE SO
AZEOTROPIC
DISTILLATION IS TO BE
DONE IN THE
FRACTIONATOR

15. CASE STUDY
JIDDAH REFINERY/FCC CATALYST SELECTION
OBJECTIVE : TO IMPLEMENT A PROGRAM
THAT RESULTS IN THE COST-EFFECTIVE
MANAGEMENT OF CATALYSTS AND
DESICCANTS FOR THE COMPANY.

16. FEEDSTOCK PROPERTIES
• FEED RATE, MBPD : 20
• FEED STOCK GAS OIL : (240 –630 CELCIUS)
• SPECIFIC GRAVITY : 0.91
• SULPHUR WT. : 2.6%
• CARBON WT. : 0.24%
• REFRACTIVE INDEX : 1.52
• VISCOSITY : CST26

17. OPERATING CONDITIONS
• COMBINED FEED T, :235 DEG.CELSIUS
• ROT, :514 DEG.CELSIUS
• FLUE GAS T, : 736 DEG.CELSIUS
• REG. CATALYST, : 689 DEG.CELSIUS
• CAT. CIRCULATION, : 16 TON/MIN
• CATALYST ADDITION RATE, : 1.0 TPD

18. LAB SCALE RESULT

19. CONCLUSIONS
STRIPPING STEAM OF 4 KG PER 1000 KG
CIRCULATING CATALYST IS REQUIRED.
OVERALL ENDOTHERMIC HEAT OF
REACTION IS 86 MBTU/HR.
PRESSURE BUILDUP IN SPENT CATALYST
STANDPIPE IS 27 KPA (4 PSI).
PRESSURE BUILDUP IN REGENERATED
CATALYST STANDPIPE IS 55 KPA (8 PSI).

20. REFERENCE
A HANDBOOK ON PETROLEUM REFINERY
‘ B. K. BHASKARRAO’
CATALYST MANAGEMENT PROTOCOLS IN
SAUDI ARAMCO
WWW3.KFUPM.EDU.SA/CATSYMP/SYMP16
TH/PDF%20PAPERS/13ALLOUSH.PDF

21. THANK YOU