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APPLICATION REPORT
2721 / 07 / 01
EN • 12
/ 2 011
Fluid Catalytic Cracking Unit -FCCU
Process overviewFu Catatc Cacn pocess s an mpotant
an we use wa to convet heav feestoc
nto hte, moe vauabe poucts. Vaous
feestoc can be use, such as as os, vacu-
um as os o esua mateas. Tpca po-
ucts ae asone, ht fue os an oen-ch
ases.
Hot catast fom the eeneato secton ows
n a uze state thouh the se tube nto the
eacto. The ncomn fee toethe wth ec-
cn su meet hot catast, stat vapozn
an cacn n eacto.
Whe the eactons tae pace, coe s fome
on the catast. The spent catast s sepaatefom cace matea an ben eeneate
thouh bunn off the coe. Afte eeneaton,
the catast s sent bac to the eacto wth a ot
of heat absobe n eeneaton phase. The
cace hocabons ente a factonatn tow-
e, whee t s sepaate nto as, ht cce o,
heav cce o an su. The asone pouct
has oo ovea octane chaactestcs sutabe
to be use fo asone benn.
Metso has man vaves nstae n u cata-
tc unts. Ths appcaton buetn escbes the
equements an Metso ow conto soutons
avaabe fo the FCCU.
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2721/07/01 EN FlUid CATAlyTiC CrACki Ng UNiT - FCCU
2 APPliCATiON rEPOrT 12/11
Fluid catalytic cracking challengesContinuous catalyst regeneration makes it
possible to manage the high catalyst coking
rate. The constancy of the yields is achieved
by catalyst cycling between reaction and re-
generation, which ensures the reactor is con-
tinuously supplied with freshly regenerated
catalyst, and product yields are maintained
at fresh catalyst levels. It’s critical to con-
trol the regenerator temperature carefully to
prevent catalyst deactivation by overheating
and to provide the desired amount of burn-
off. Reliable and accurate control, on-off and
ESD-valve performance is important for total
process efficiency.
Health, Safety, Environment – Vave ean
poses both an envonmenta an safet ssue
ue to s of e, toxct an voatty of ases.
Emeenc shutown an on/off vaves mustbe abe to pefom the acton n a pocess o
equpment faue.
Top-class products at maximum yield – The
maet cas fo cean petochemca poucts
an hh quat. it s mpotant that the pocess
s stabe, exbe an une conto. Pope
conto vave pefomance n eacto, eenea-
ton an factonaton mpoves the accuac of
thouhput conto an avese affects to the
pant pefomance an aso the ownsteam
pocesses.
Maintenance costs – Ctca vaves n catast
hann an aton pa an exteme m-
potant oe n successfu catast eeneatn
pocess pefomance. Poo pefomn vaves
n the pocess must be sevce because the
w have a ect mpact on the efcenc of the
pocess.
Plant run-time – renees ae oon fo on-
e pant un-tmes snce owntme means po-
ucton osses an s a emaabe cost ncu-
n mantenance costs. Ths eques eabe
equpment an pocess conto.
Metso solutionsWe are all tuned up to answer these chal-
lenges through our refining application
experience and product offering for control,
safety and automated on/off duty that en-
sure high valve performance in fluid catalytic
cracking processes. Our catalyst handling
valves have proven performance history and
are designed for efficient and reliable proc-
ess operation.
Safety – Metso s the on sne souce eme-
enc shutown vave suppe who has the ex-
peence an nowee to combne nteence
wth most eabe vaves, actuatos an smat
contoes. Technoo seectons e ota stem
opeaton an nheent e safe esn ensue
that atest emsson an e safet stanas can
be appe. reabe vaves wth st nteent,
Sil3 appove safet vave contoe an patastoe testn sstem Nees VavguaTM w
ensue that pant emeenc shutown vaves w
awas pefom pope when neee.
Efficiency – Thouhput osses an poo con-
to pefomance w be avoe wth hh pefo-
mance ota vaves. Fow thouh the pocess
unt ma be chane as the nee ases wth
aneabt of 150:1 an futhe wth fu boe ba
vaves. Ou avance nteent ta vave con-
toes fo conto, on-off an ESd appcatons en-
sue hh postonn accuac an fast esponse.Coect vave seecton an szn wth ou Nepof
vave seecton softwae we can assue the best
vave pefomance an pocess conto.
Availability – Smpe ota esns, same
face-to-face mensons, an oba sevce net-
wo an nvento manaement w hep ou
to optmze ou mantenance actvtes. rota
vaves have been n sevce fo sevea eas
wthout equn mantenance an show no sn
of eaae. The poven pefomance of Metso
vaves wth on astn meta seat thtness
an shut-off capabtes maes them an ea
souton fo conto, on-off an ctca catast
hann appcatons.
Reliability – Vave pefomance ten ata
coecte b ou smat vave contoes an
anaze b Nees FeCae, open FdT/dTM
technoo base conuaton an conton
monton softwae, maes t possbe to pect
an espon to mantenance equements an
euce unscheue owntme. Ths ves fu
tanspaenc to the vave pefomance n po-
cess conto.
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FlUid CATAlyTiC CrACkiNg UNiT - FCCU 2721/07/01 EN
APPliCATiON rEPOrT 12/11 3
Fluid catalytic cracking applications
1. Stripping steam ow controlChaene – To mantan the catast actvt at
a usefu eve, t’s necessa to eeneate the
catast b bunn off the coe wth hot a. As
a esut, the catast s contnuous move fom
the eacto to eeneato an bac to eac-
to. remann o on the catast s emove b
steam stppn befoe catast entes the een-
eato. The steam supp to the eacto taes
pace at a tempeatue at satuate steam.
The uton steam supp vave has tpca fo-
own enea equements:
❑ Accuate conto to mnmze the steam
consumpton
❑ Nose eucton capabtes
Metso solution ❑ Fneto, eccentc ota pu vave.
Benets❑ We aneabt wth sne vave souton
fo chann steamn nees.
❑ Conto accuac to optmze steam
consumpton.
❑ reabt to ensue effectve o stppn.
❑ Q-tm opton fo nose eucton
❑ Compact pacae wth smat postone
fo conton monton an to nentf
mantenance nees.
Picture 1. Finetrol
2. Air ow controlChaene – The cacn pocess pouces
cabon (coe) whch emans on the catast
patce an ap owes ts actvt. To man-
tan the catast actvt at a usefu eve, t’s
necessa to eeneate the catast b bun-
n off ths coe wth a. reeneaton s a e
pat of the FCC pocess. it’s ctca to conto
the eeneato tempeatue caefu to pevent
catast eactvaton b oveheatn an to po-
ve the ese amount of bun-off. Ths s one
b conton the a ow.
A tpca a tempeatue s aoun 600 °C.
Metso solution ❑ Nesc hh pefomance tpe eccentc sc
vave
Benets❑ goo conto combne wth on astn
thtness
❑ reabe meta seate, b-ectona thtness
fo on fe cce
❑ Hh moua esn an matea seecton
fo ease of mantenance an vave seecton.
❑ Economca conto vave fo ow ffeenta
pessues.
Picture 2. Neldisc
3. Catalyst valvesChaene – Contnuous catast eeneatn
maes t possbe to manae the hh catast co-
n ate. The constanc of the es s acheve
b catast ccn between eacton an een-
eaton, whch ensues the eacto s contnuous
suppe wth fesh eeneate catast, an
pouct es ae mantane at fesh catast
eves. Catast hann vaves pa an mpotant
oe n ensun pope FCC pefomance. reabe
an accuate conto, on-off an ESd-vave pefo-
mance s mpotant fo tota pocess efcenc.
Catast hann vaves have tpca foown
enea equements:
❑ lea fee soaton to avo waste o
nefcent FCC unt pefomance
❑ Meum bu-up esstant esn
❑ reabe opeaton to avo atona spent
catast n eeneato, whch ma cause
possbe catast n ue as an futhe
emsson pobems
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Regenerator extraction valve – The feestoc
s vapoze b the hot eeneate catast, the
cacn bens, an the esutant vapo caes
the catast upwa thouh the se. The heat
of combuston ases the catast tempeatue to
(620 – 845 °C), an most of ths heat s tans-
fee b the catast to the o fee n the fee
se. The eeneato/eacto cce contnues
unt catast s spent an emove fom pocess
thouh extacton vave. A tpca tempeatue
hee s 760 °C.
Flue gas catalyst separation valves – Hot ue
ases ext the eeneato thouh ccones
whee catast s sepaate an ecce to e-
acto. A tpca tempeatue hee s 760 °C.
Metso SolutionNees seat suppote ba vave wth so poof
seat. The Nees J tpe sos poof seats pe-vent catast ust fom ettn behn the seats
that pecues the possbt of toque ncease.
The seats pove constant oan between the
seat an the ba to be n contnous contact. The
mateas of constucton ae seecte fo max-
mum esstance to abason amae aown
fo on cce fe.We ecommen to use speca
ha coatns on ba an seat sean sufaces.
Benets❑ Safet, on astn thtness an cce fe
❑ reabe opeaton wth wpn seat esn ❑ Emsson poon wth ota technoo an
stana ve oae pacn
❑ Fe poven pefomance
❑ No cavtes to et catasts tappe
Picture 3. Neles seat supported ball valve
Catalyst addition valves – Each a, sev-
ea tons of fesh catast ae ae to epace
osses thouh the ccones an to mantan the
actvt of the unt’s nvento at an acceptabe
eve. A tpca tempeatue hee s ambent.
Metso Solution❑ Jamesbu 9150 sees soft-seate ba vave
wth Xteme seats has pove to be the ht
choce as catast aton vaves.
As an opton to tatona soeno vave an
mt swtches, Metso can offe aso nteent
on-off vave contoe Nees Swtchgua, that
ves the possbt to conto the vave open-
nn an cosn stoes an aso poves a-
nostcs about the vave pefomance.
4. Fractionator bottom slurry valves
Challenge – The emann heav esua o,toethe wth an catast caove, coects
at the bottom of the factonato an ecces
bac to the eacto fo the catast to be use n
the eacto. Bottom ecce s use to ecove
heat fo fee peheat thouh ette boes an
exchanes. The u s nown as catast o
su an ts conto an soaton, ue to ts
hh abasve natue an tempeatue, pove
a emann vave appcaton. The tpca tem-
peatue of bottom su s 370 °C.
Picture 4. Finetrol
Metso Solution for control valves❑ Fneto eccentc pu vave wth stete
seat constucton an ow to cose ecton
❑ E-sees ceamc vave n exteme eosve
cases
Benets ❑ rota technoo fo ow emssons
❑ lon cce fe
❑ Eoson esstant esn fo both meum an
hh eosve appcatons
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FlUid CATAlyTiC CrACkiNg UNiT - FCCU 2721/07/01 EN
APPliCATiON rEPOrT 12/11 5
Metso solution for on-off valves ❑ Nees seat suppote ba vaves XA wth
hh tempeatue meta seats.
Benets ❑ rota technoo fo ow emssons
❑ lon cce fe
❑ Eoson esstant esn
5. Expander valvesThe ue as fom the FCC pocess extn the
eeneato has sncant pessue, tempea-
tue an voume, an t s a souce of usefu
ene that epesents an ene cost-savn
oppotunt to a ene. Usn an expane
cou maxmze ecove of avaabe ene
fom the ue as. Ths ene can then be use
to ve the compesso that poves a to the
eeneato (the man a bowe) o an eectc
eneato.
Challenge – The expane vaves shou be
abe to wo une ve hh tempeatue (up to
760 °C). The ue as ma entan some aba-
sve catast patces. Fast cosn / openn,
sutabe shut-off capabtes an eabt ove
on peos ae eque. Hue thema shoc
an nconstant tempeatue un the emeen-
c case ma ea to estuctve hh pessue
oae on seat b sc.
Expander inlet valve – in noma sevce theexpane net vave contos the upsteam
pessue to ensue the constant pessue of the
eeneato. The vave shou be abe to cose n
ess than 0.6 secons fom an open poston.
Main bypass valve – in noma sevce the
man bpass vave emans fu cose. The
vave shou be abe to open n ess than 0.6
secons n case of an expane tp.
Small bypass valve – The sma bpass vaves
s use fo snchonzn the expane an
ovespee conto. in noma opeaton the sma
bpass vave emans n an ntemeate con-
to, an sha be abe to fu open n ess than
1 secons n a case of expane tp. dene
sma eaae mht be eque n case the ppe
coo too much potenta beow the ew pont.
Hue thema shoc an nconstant tempeatue
un the emeenc case ma ea to estuc-
tve hh pessue oae on seat b sc.
Metso solution❑ Stana an hh tempeatue appcatons
Mapa butte vave TyPE BW fo eaae
casses V & Vi
❑ Stana an hh tempeatue appcatons
Mapa butte vave TyPE Bd fo eaae
casses ii, iii, & iV
❑ Nees Tpe eccentc sc vave fo owe
tempeatue appcatons (up to 600 °C)
Benets❑ Speca apetue bns seat eement n oo
opeaton conton
❑ Speca apetue on mantenance, n
BW case, seat an sean eement s
chaneabe
❑ Speca esne exbe seat aanst
thema shoc an avo ovestess
❑ Customze enneen esn abt
❑ lon cce fe ❑ Eoson esstant esn
Picture 5. Mapag type BW valve
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The nfomaton pove n ths buetn s avso n natue, an s ntene as a uene on.
Fo specc ccumstances an moe etae nfomaton, pease consut wth ou oca automaton expet at Metso.
Metso Automation Inc.
Europe, Vanha Porvoontie 229, P.O. Box 304, FI-01301 VANTAA, Finland.Tel. +358 20 483 150. Fax +358 20 483 151
North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA.Tel. +1 508 852 0200. Fax +1 508 852 8172
South America, Av. Independéncia, 2500- Iporanga, 18087-101, Sorocaba-São PauloBrazil. Tel. +55 15 2102 9700. Fax +55 15 2102 9748/49
Asia Pacific, 20 Kallang Avenue, Lobby B, #06-00, PICO Creative Centre, Singapore 339411, Singapore.Tel. +65 6511 1011. Fax +65 6250 0830
China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaoyang Dist, 100022 Beijing, China.Tel. +86-10-6566-6600. Fax +86-10-6566-2575
Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai,United Arab Emirates. Tel. +971 4 883 6974. Fax +971 4 883 6836
www.metso.com/valves
APPLICATION REPORT