BY
A.B.PATHAK
DGM-PRODUCTION
HALDIA REFINERY
Haldia Refinery
Igniting Minds... Energizing Lives…
TOPICS:
1.INTRODUCTION.
2.HISTORY.
3.OPERATIONAL ASPECTS.
4.SALIENT DESIGN FEATURES.
Haldia Refinery
Igniting Minds... Energizing Lives…
Haldia Refinery
Igniting Minds... Energizing Lives…
INTRODUCTION:
1.WORK HORSE OF REFINERY.
2.FLEXIBLE IN FEED COMPOSITION.
3.CAN BE OPERATED AT DIFFERENT MODE TO
MAXIMISE LPG,C3,C4,MS OR HSD.
4.MOST PROFITABLE UNIT.
Haldia Refinery
Igniting Minds... Energizing Lives…
INTRODUCTION:
Feed stocks:
Vacuum gas oil (VGO)
Coker gas oil (CGO)
De-asphalted oil (DAO)
Hydro-cracker bottom
Hydro-treated VGO
Reduced crude oil (RCO) / Long residue (LR)
Vacuum residue (VR) / Short residue (SR)
Typical products:
Dry gas (H2, C1, C2)
LPG (C3, C4)Î Propylene, Isobutylene
Light cracked naphtha (LCN) (C5-150oC) Î Gasoline
Heavy cracked naphtha (HCN) (150 - 220oC) Î Gasoline / Diesel / Cutter
stock
Light cycle oil (LCO) (220 - 370oC) Î Diesel / Cutter stock
Clarified oil (CLO) or Decant oil (DCO) Î Fuel oil
Haldia Refinery
Igniting Minds... Energizing Lives…
Position of FCC in Refinery
S Gas
T
A LPG
B
C
R Gasoline Gasoline
U Blending
D HDS CCR
E
Reformate
D Kerosene
I HDS Jet fuel
S HDS Diesel
T
V
A
C Hydrocracker FCC
D
I
S
T
Visbreaker / Fuel Oil
Coker Coke
BBU Bitumen
Haldia Refinery
Igniting Minds... Energizing Lives…
Schematic of FCC
Products
Flue Gas Reactor
Regenerator Stripper
Steam
Air Riser
Feed
Steam
Haldia Refinery
Igniting Minds... Energizing Lives…
Schematic of RFCC
To heat To Main fractionator
recovery
section
Reg-2 Reactor
Steam
Reg-1
Back flush
HCO
Air Steam
Feed
Riser
Haldia Refinery
Igniting Minds... Energizing Lives…
FLOW SCHEME OF RFCC
Haldia Refinery
Igniting Minds... Energizing Lives…
HISTORY
ÎThermal cracking: Heating in big vessels, 1930
ÎActivated alumina accidentally finds way to the
thermal Vat
ÎConversion increased suddenly & significantly
ÎThus discovered by Eugene Houdry that Alumina was
the catalyst for the extra cracking -1930
Haldia Refinery
Igniting Minds... Energizing Lives…
HISTORY
Fixed bed (1936 – 1941)
• Cyclically feed and regeneration air
• Constantly changing catalyst activity
• 140,000 BPD total capacity in 1940
Moving bed (1941 – 1960)
• Continuous cracking process using Thermofor kiln Î
Thermofor Catalytic Cracking (TCC)
• 300,000 BPD capacity by the end of World War-II
Haldia Refinery
Igniting Minds... Energizing Lives…
HISTORY
Eight companies formed a consortium “Catalytic Research
Associates” (CRA) in 1938 to develop catalytic cracking
process which would operate outside Houdry’s patents
Standard Oil of New Jersey (currently Exxon)
Standard Oil of Indiana
M.W. Kellogg Co.
Anglo-Iranian Oil Co.
Royal Dutch-Shell Co.
The Texas Co. (Texaco)
Universal Oil Products Co. (UOP)
(I.G Farben) (dropped in 1940)
• First up flow circulating system started in May 1942
• Fluid bed cracking (FCC) attained 1700 BPD capacity by
July 1942 –continues to grow till today
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
1.TYPICAL OPERATING CONDITIONS.
2.INTERPLAY OF VARAIBLES IN FCC.
3.PRESSURE BALANCE IN CONVERTOR SECTION.
4.HEAT BALANCE IN CONVERTOR SECTION.
5.ENSURING SMOOTH CATALYST CIRCULATION.
6.ENSURING MINIMUM CATALYST LOSS.
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
TYPICAL OPERATING PARAMETERS
S.NO PARAMETER TYPICAL VALUES
1 RISER OUTLET TEMPERATURE 500-520 DegC
2 REACTOR PRESSURE 1.4-2.0 Kg/cm2
3 REGENERATOR 1 PRESSURE 1.8-2.2 Kg/cm2
4 REGENERATOR 2 PRESSURE 1.1-1.4 Kg/cm2
5 RG1 DENSE TEMPERATURE 620-650 DegC
6 RG1 DILUTE TEMPERATURE 620-650 DegC
7 RG2 DENSE TEMPERATURE 720-740 DegC
8 RG2 DILUTE TEMPERATURE 730-750 DegC
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
TYPICAL YIELD PATTERN
MODE LPG MS HSD
Product Yield, wt%
Dry gas 6.5 4 2
LPG 40 18 10
Gasoline (C5-150oC) 25 41 30
TCO (150-370oC) 10 26 44
CLO ( 370oC+ ) 4 6 10
Coke 6.5 5 4
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
INTERPLAY OF VARIABLES IN FCC
Independent
¾ Feed rate
¾ Recycle ratio
¾ Feed preheat
¾ Riser Outlet temperature
¾ Reactor pressure
¾ Fresh catalyst activity / Selectivity/make up rate
Major dependent
¾ Regenerator temperature
¾ Catalyst circulation rate
¾ Regenerator air flow
¾ CRC-Coke on Regenerated catalyst
¾ Product yields
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
PRESSURE BALANCE
¾VERY CRITICAL FOR SAFETY OF THE UNIT-HYDROCARBON
AND AIR ARE SIDE BY SIDE .
¾ALSO VERY IMPORTANT FOR SMOOTH AND STEADY
CATALYST CIRCULATION.
¾NEW UNITS ARE PROVIDED WITH VALVES IN BETWEEN
REACTOR AND REGENERATOR AND SAFETY INTERLOCK TO
CLOSE THE VALVE WHEN THE PRESSURE BALNCE IS UPSET.
¾CATALYST FLOW IS FROM A VESSEL OF LOWER PRESSURE
TO A VESSEL OF HIGHER PRESSURE- CATALYST HEAD.
Haldia Refinery
Igniting Minds... Energizing Lives…
PRESSURE BALANCE
To heat To Main fractionator
recovery
section
SCSV-SPENT CATALYST
1.8Kg/cm2 SLIDE VALVE-CONTROLS
1.2 Kg/cm2 510 degC REACTOR LEVEL
750 degC
720 degC RCSV-REGENERATED
CATALYST SLIDE VALVE-
CONTROLS REACTOR
OUTLET TEMPERATURE.
Steam
2.0 Kg/cm2
670 degC
670 degC
Back
SCSV flush
RCSV
HCO
Air Steam
Feed
Riser
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
HEAT BALANCE
A catalyst cracker continually adjusts itself to stay in heat balance
The unit produces and burns enough coke to provide energy to:
1.Increase the temperature of the fresh feed, recycle, and atomizing
steam from their preheated states to the reactor temperature.
2.Provide the endothermic heat of cracking.
3.Increase the temperature of the combustion air from the blower
discharge temperature to the regenerator flue gas temperature.
4.Make up for heat losses from the reactor and regenerator to
surroundings.
5.Provide for heat sinks, such as stripping steam and catalyst
cooling.
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
HEAT BALANCE
Flue gas Spent Catalyst
Products
Heat Losses
Heat of Coke
Heat losses Combustion
Regenerator Reactor
Heat of
Reaction
Recycle
Regenerated Fresh Feed
Catalyst
Regeneration Feed Pre heater
Air
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
CATALYST CIRCULATION
1.SMOOTH AND STEADY CATALYST CIRCULATION IS VITAL
FOR STABLE OPERATION OF THE UNIT AND TO ENSURE
STEADY PRESSURE BALNCE.
2.UNSTEADY CATALYST FLOW CAN TRIP THE UNIT ON
PRESSURE BALANCE UPSET,LOW REACTOR TEMPERATURE
AND LEADS TO UNSTABLE DOWNSTREAM SECTION.
3.UNSTEADY CATALYST FLOW INDUCE VIBRATION IN THE
CONVERTOR SECTION AND DAMAGE VARIOUS INTERNALS
AND STRUCTURE.
4.STABLE CATALYST CIRCULATION REQUIRES STEADY
PRESSURE CONTROL ON REACTOR AND REGENERATOR SIDE
AND CORRECT FLUIDISATION IN THE SATNDPIPES.
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
CATALYST CIRCULATION
Standpipe Aeration & Fluidization
Aeration
Process of replacing volume lost due to compression
Air, steam or HC gas can be used for the purpose
Aeration taps with Rota meters
Fluidization Systems
Fluidization air / steam / HC gas required in standpipes when cat
approaches de-aeration
Avoids unstable catalyst flow in stand pipes
Requires adjustment in line with catalyst circulation rate
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
CATALYST CIRCULATION
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
CATALYST LOSS
1.CATALYST LOSS IS OF GREAT CONCERN DUE TO ITS IMPACT ON
ENVIRONMENT,PRODUCT QUALITY AND UNIT OPERATION.
2.HIGHER LOSS MAY BE DUE TO
•CATALYST PROPERTY
•INTERNAL DAMAGE ( CYCLONE,AIR GRID,STEAM RINGS,RISER
TERMINATION DEVICE ETC)
•IMPROPER OPERATION ( HIGH FLOW RATE OF FLUIDISATION
MEDIUM,CONDENSATE ENTRY ALONG WITH FLUIDSING
STEAM ETC)
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
CATALYST LOSS
Haldia Refinery
Igniting Minds... Energizing Lives…
OPERATIONAL ASPECTS
REGENERATION MODE
Total Combustion
Coke on regenerated catalyst < 0.05
CO in flue gas < 1000 ppm
Higher effective activity & superior selectivity of catalyst
Higher regenerator temperature
Use of catalyst cooler with residue feed for control of regenerator
dense bed temp.
Partial Combustion
Coke on regenerated catalyst > 0.05
CO in flue gas > 1000 ppm
Lower effective activity & superior selectivity of catalyst
Relatively lower regenerator temperature
Relatively higher afterburning Î difference between regenerator
dense bed temp. and dilute bed temp.
Requires CO boiler
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
TWO STAGE REGENERATION
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
COMPARISON OF REGENERATOR TYPES
Single stage Single Two stage with separate
stage flue gas
Stage no. One One One Second
Mode Partial Full Partial Full
Regen T (oC) 717 718 707 718
CSC wt% 1.78 1.63 1.64 0.66
CRC wt% 0.18 0.03 0.66 0.04
Delta coke, wt% 1.6 1.6 0.98 0.62
Inventory,Tons 150 150 100 50
Cat cooler duty, MMBTU/hr 195 250 -- 180
Flue gas comp. Vol% 0.0/13.1/4.2 0.9/15.3 0.0/11.2/ 1.1/15.0/
O2/CO2/CO /0.0 6.8 0.0
Catalyst make-up, lb/bbl of FF 0.71 0.78 0.77
CO-boiler req. Yes No Yes
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Reactor Stripper
¾Surrounds the upper portion of the riser
¾Fitted with internals / baffles to enable stripping of the catalyst
using superheated steam.
¾Cat flux 500 – 700 lb/min-ft2
¾Stripping steam rate 2 – 5 lb per 1000 lb of catalyst
¾Excess stripping steam may not be beneficial; Loss of
valuable products
¾Catalyst residence time 1 – 2 minutes
¾Pre stripping rings at dip leg bottoms
¾Performance can be assessed by Hydrogen on coke
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Reactor Stripper
Removes entrained Hydrocarbons between catalyst
particles.
If Hydrogen rich Hydrocarbons enter regenerator
¾Loss of liquid product.
¾Loss of catalyst activity; Higher regen. temp. combined
with the formation of steam in regen. reduces catalyst
activity (Crystalline structure of catalyst is destroyed)
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
Reactor Stripper
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
CATALYST PRE-STRIPPING
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
SLIDE VALVES
Slide Valves
To regulate flow of catalyst (flue gas for DDSV)
Hydraulically operated
RCSV and SCSV isolate reactor from regenerator
Carbon steel body with vibrocast lining
Sloped bonnet / guides for self draining of catalyst
Steam / air purge for older design.
No purge in normal operation
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
SLIDE VALVES
Differential pressure across slide valves very
important. For cat circulation ΔP across RCSV and
SCSV be 0.2– 0.4 bar.
ΔP > 0.5 bar valve erosion and to be avoided.
Negative ΔP never permitted.
Slide valve must close once ΔP drops to 0.1 bar on
interlock activation. Low ΔP override system is on auto
mode control.
In ESD slide valve must close fully in < 5 seconds.
In normal control mode maximum stroke speed such
that max. 25 seconds for closing valve fully.
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
SLIDE VALVES
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
RTD-RISER TERMINATION DEVICE
Necessary to rapidly & efficiently separate spent
catalyst & hydrocarbon vapors at riser exit for
desired product qualities & yields.
Inertial separator separates cat & vapors but allows
vapors to remain longer in reactor vessel causing
some nonselective thermal post riser cracking
forming lighter gas and additional coke.
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
RTD-RISER TERMINATION DEVICE
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
AIR GRID
Air Grid
¾For even distribution of air in spent catalyst
¾Proper air distribution
•Lowers CRC (carbon on regenerated cat)
•Minimizes after burn
•Reduces local hot spots / catalyst sintering
¾Mechanically robust to withstand wide range of
operations / upsets
¾Erosion, thermal expansion, mechanical integrity of
supports
¾Pressure drop across air grid
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
AIR GRID
Air Grid
Various designs – Flat grid plate, dome, pipe,
ring, flat pipe grid
Pipe grid
More uniform coverage (less dependent on air rate)
Lower nozzle velocity, lower attrition
Rings
Coverage from jet penetration
Less effective at lower than design air rates
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
AIR GRID
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Cyclone Separators
To separate catalyst from flue gas / hydrocarbon
vapors
Provided in reactor and regenerator(s)
External / Internal
Single stage / Double stage
Direct coupled / Close coupled
Typical inlet velocities (ft/sec)
•First stage (Rx or Rg) 60 – 70 ft/sec
•Second stage 80 – 85 ft/sec
•Minimum velocity 25 – 35 ft/sec
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Dip Legs
¾Submerged or exposed
¾Catalyst head required in the dip leg
¾Splash plate, trickle valve, counter weight
¾Refractory lining depending upon the geometry
¾Fluidisation requirement (external cyclones)
¾Common causes of catalyst carry over
¾Problems during start ups
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
CYCLONE SEPERATORS
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
TRICKLE SPLASH COUNTER WEIGHT
VALVE PLATE FLAPPER
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
ORIFICE CHAMBER
Orifice Chamber
¾To provide back pressure for
regenerator
¾At the D/S of DDSV
¾Reduces pressure drop across DDSV
¾Number of grids with holes
¾DP across each grid
¾Cold walled / hot walled
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
ORIFICE CHAMBER
ORIFICE CHAMBER
GRID $ 1
MANWAY
GRID $ 2
GRID $ 3
GRID $ 4
ABRASION RESISTANT LINING
GRID $ 5
GRID $ 6
Haldia Refinery
Igniting Minds... Energizing Lives…
SALIENT DESIGN ASPECTS
ORIFICE CHAMBER
PHOTO OF SINGLE GRID OF ORIFICE CHAMBER
Haldia Refinery
Igniting Minds... Energizing Lives…
Haldia Refinery
Igniting Minds... Energizing Lives…
