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This report presents the results and analysis of a simulation of a Fluid Catalytic Cracking (FCC) unit using A/F-3 catalyst. The study investigates the effects of various operating parameters, including C/O ratio, feed temperature, flow rate, reactor pressure, riser height, and compares the performance of one-riser and dual riser configurations.
The Fluid Catalytic Cracking (FCC) process is a cornerstone of modern petroleum refineries, playing a pivotal role in the conversion of heavy hydrocarbons into valuable products such as gasoline, propylene, and butenes.
The FCC unit is a complex system that operates under a range of conditions, making it essential to understand how various parameters affect its performance.
This study aims to shed light on the intricate interplay of operating conditions and catalyst choice within the FCC unit. By utilizing advanced simulations and data analysis, we explore the effects of key variables and compare different reactor configurations to provide comprehensive insights for optimizing FCC unit operation.
The FCC unit was simulated under the following conditions:
The naphtha yield increases with increasing Catalyst to Oil (C/O) ratio at lower values but decreases at higher C/O ratios due to secondary cracking reactions.
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As C/O ratio increases, the conversion and coke yield also increase.
Increasing feed temperature leads to a decrease in the difference between feed and riser temperatures, resulting in a lower C/O ratio.
This affects naphtha and coke yield, as well as total conversion.
| Feed Temperature (⁰C) | Naphtha Yield (wt. %) | Total Conversion (wt. %) | Coke Yield (wt. %) |
|---|---|---|---|
| 200 | 46.1734 | 68.8834 | 5.9633 |
| 240 | 45.1407 | 67.5331 | 5.5385 |
| 280 | 43.4680 | 64.5317 | 5.0685 |
| 320 | 41.4875 | 63.0871 | 4.8232 |
| 360 | 39.1612 | 58.1258 | 4.0465 |
Increasing the feed flow rate initially increases naphtha yield, but further increases result in a decrease. This is due to changes in riser residence time, affecting cracking reactions and total conversion.
Naphtha yield increases with reactor pressure up to 58 psia, beyond which it decreases. The change is relatively insignificant.
Comparing one-riser and dual riser configurations, the dual riser shows higher naphtha yield due to increased residence time. Higher flow rates result in decreased naphtha yield in both configurations.
Comparing simulations with Conquest 95 and A/F-3 catalysts, A/F-3 shows higher coke yield, olefin yield, and total conversion. Conquest 95 produces more naphtha and i-butane, improving fuel quality.
| Component | One Riser (wt. %) | Dual Riser (wt. %) |
|---|---|---|
| H2S | 1.2146 | 0.4153 |
| FUEL GAS | 2.4330 | 2.2907 |
| PROPANE | 1.2834 | 1.0077 |
| PROPYLENE | 3.0338 | 4.0296 |
| N-BUTANE | 1.3154 | 0.9602 |
| I-BUTANE | 2.2570 | 1.9621 |
| BUTENES | 4.2738 | 5.7550 |
| NAPHTHA | 42.7707 | 43.8870 |
| LCO | 16.9496 | 16.2800 |
| BOTTOMS | 19.5818 | 18.3753 |
| COKE YIELD | 4.8871 | 5.0372 |
| TOTAL | 100 | 100 |
| CONVERSION | 63.4686 | 65.3447 |
Increasing riser height leads to higher naphtha yield. To match the naphtha yield of a dual riser, a one-riser unit would need an additional 10m of height.
The results demonstrate the complexity of the FCC unit's performance and the significance of operating parameters. Optimizing C/O ratio, feed temperature, and flow rate can enhance naphtha yield and total conversion. Additionally, the choice of catalyst impacts product distribution, with A/F-3 catalyst showing higher olefin production but lower naphtha yield compared to Conquest 95.
The comparison between one-riser and dual riser configurations highlights the advantage of dual risers in terms of naphtha yield due to increased residence time. This information can aid in reactor design and operation decisions.
This study underscores the importance of understanding and manipulating operating parameters within the FCC unit. By optimizing these factors, refineries can increase naphtha yield, reduce coke production, and improve fuel quality. The choice of catalyst also plays a pivotal role in tailoring product distribution to meet specific market demands.
Furthermore, the comparison between one-riser and dual riser configurations showcases the benefits of the latter in achieving higher naphtha yield. When designing or modifying FCC units, considering riser height can be crucial in achieving desired product yields.
In conclusion, this research provides valuable insights into the operation of FCC units, offering a foundation for further advancements in petroleum refining technology.
Laboratory Report - FCC Unit Simulation. (2024, Jan 24). Retrieved from https://studymoose.com/document/laboratory-report-fcc-unit-simulation
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