THE REDUCTION OF FCCU AFTERBURNING THROUGH PROCESS OPTIMIZATION AND REGENERATOR REVAMPING

Scientific paper

Authors

  • Florin Enache Petrotel-Lukoil Refinery, Ploiesti, Romania + Department of Petroleum Refining Engineering and Environmental Protection, Petroleum-Gas University of Ploiesti, Ploiesti, Romania
  • Dan Dănulescu Petrotel-Lukoil Refinery, 235 Mihai Bravu Street, 100410, Ploiesti, Romania
  • Ion Bolocan Department of Petroleum Refining Engineering and Environmental Protection, Petroleum-Gas University of Ploiesti, Ploiesti, Romania
  • Diana Cursaru Department of Petroleum Refining Engineering and Environmental Protection, Petroleum-Gas University of Ploiesti, Ploiesti, Romania https://orcid.org/0000-0002-0236-6300

DOI:

https://doi.org/10.2298/CICEQ210430023E

Keywords:

FCCU, regenerator, afterburning, e-cat, cyclones, revamping

Abstract

Operating the fluid catalytic cracking unit (FCCU) in afterburning conditions can increase the regenerator temperatures above the metallurgical design leading to mechanical failures of the cyclones and plenum chamber. This paper presents the methodology applied in a commercial FCCU to investigate the afterburning causes and the technical solutions that can be implemented to reduce the afterburning. Thus, by evaluating the regenerator temperature profile, regenerator as-build design, and the internals mechanical status, it was concluded that the main cause of afterburning was the non-uniform distribution and mixing of air and catalyst. The industrial results showed that optimizing the catalyst bed level, stripping steam, reaction temperature, and equilibrium catalyst (e-cat) activity reduced the afterburning by 39%. Other process parameters such as feed preheat temperature, slurry recycling, and excess oxygen did not significantly influence afterburning because of air and catalyst maldistribution. Revamping the regenerator to assure a symmetrical layout of cyclones reduced the afterburning by 86%, increased the fines retention in FCCU inventory, and provided a better regeneration of the spent e-cat. The reduction of operating temperatures at around 701°C removed the risk of catalyst thermal deactivation, and therefore the e-cat activity was increased by 10.2 wt.%.

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Published

17.06.2021 — Updated on 04.05.2022

Issue

Section

Articles

How to Cite

THE REDUCTION OF FCCU AFTERBURNING THROUGH PROCESS OPTIMIZATION AND REGENERATOR REVAMPING: Scientific paper. (2022). Chemical Industry & Chemical Engineering Quarterly, 28(2), 115-126. https://doi.org/10.2298/CICEQ210430023E

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