Fluidised Catalytic Cracking

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A TYPICAL HIGH CONVERSION EFFICIENCY


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CRACKING PROCESS

Catalytic

Cracking

Thermal

Cracking


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CRACKING PROCESSES

CATALYTIC CRACKING PROCESS THERMAL CRACKING PROCESS

Fluid catalytic cracking process Vis breaking process

Hydro treating process Delayed coking process

Hydro cracking process

Catalytic reforming process

Alkylation


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FLUIDIZED CATALYTIC CRACKING


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FCC

Fluid catalytic cracking (FCC) technology is a technology with

more than 60 years of commercial operating experience.

The process is used to convert higher-molecular-weighthydrocarbons to lighter, more valuable products through

contact with a powdered catalyst at appropriate conditions.

Historically, the primary purpose of the FCC process has beento produce gasoline, distillate, and C3/C4 olefins from low-

value excess refinery gas oils and heavier refinery streams.


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FCC

Most of the existing units have been designed or modif ied by six

major technology licensers.

1. ABB Lummus Global

2. Exxon Research and Engineering (ER&E)

3. Kellogg Brown & RootKBR

(formerly The M.W. Kellogg Company)

4. Shell Oil Company

5. Stone & Webster Engineering Corporation


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FCC FEEDSTOCKS

Atmospheric gas oils

Vacuum gas oils

Coker gas oils

Thermally cracked gas oils

Solvent deasphalted oils

Lube extracts

Hydrocracker bottoms


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PRODUCTS

Fuel gas (ethane and lighter hydrocarbons)

C3 and C4 liquefied petroleum gas (LPG)

Gasoline

Light cycle oil (LCO)

Fractionator bottoms (slurry oil)

Coke (combusted in regenerator)

Hydrogen Sulfide (from amine regeneration)


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FCC PROCESS

1. Feed Preheat


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FEED PREHEAT SYSTEM


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FCC PROCESS

1. Feed Preheat

2. RiserReactorStripper


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RISER Y & FEED INJECTION NOZZLE


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TWO STAGE CYCLONE SYSTEM


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CYCLONE


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TWO STAGED STEAM STRIPPER


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SPENT CATALYST STRIPPER


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FCC


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FCC PROCESS

1. Feed Preheat

2. Riser ReactorStripper

3. Regenerator

Heat/Catalyst Recovery


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REGENERATORHEAT/CATALYST

RECOVERY


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AIR DISTRIBUTORS


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FLUE GAS HEAT RECOVERY SCHEMES


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CATALYST HANDLING FACILITES

Catalyst losses are related to :

The design of the cyclones

Hydrocarbon vapor and flue gas velocities

The catalyst's physical properties

High jet velocity

Catalyst attrition due to the collision of catalyst particles with

the vessel internals and other catalyst particles


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FCC MAIN FRACTIONATOR CIRCUIT


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FCC PROCESS

1. Feed Preheat

2. Riser ReactorStripper

3. Regenerator

Heat/Catalyst Recovery

4. Gas Plant


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GAS PLANT

FCC gas plant separates the unstabilized gasoline and light

gases into the following :

Fuel gas

C3 and C4 compounds

gasoline


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UOP STACKED FCC UNIT


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UOP STRAIGHT-RISER FCC UNIT


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REACTORREGENERATOR OF MODERN

FCCU


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FCC CRACKING REACTION

Cracking is catalyzed by solid acids which promote the ruptureof C-C bonds. The crucial intermediates are carbocations(+ve charged HC ions) formed by the action of the acid siteson the catalyst.

Besides C-C cleavage many other reactions occur:-isomerization- protonation and deprotonation- alkylation

- polymerization- cyclization and condensation


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REACTIONS OCCURING IN FCC

Documents

Fluidised Catalytic Cracking