Beruflich Dokumente
Kultur Dokumente
ON
INDUSTRIAL TRAINING
IN
HINDUSTAN PETROLEUM CORPORATION LIMITED
(FCCU-1)
VISAKH REFINERY
Completed by:
SOUMEN MISHRA
College: DIATM, Durgapur
College ID No: CH/14/05
HPCL letter No: HR/oprns/36
ACKNOWLEDGEMENT
With the blessings from the God, I would like to take this opportunity to express my
sincere gratitude and appreciation towards Hindustan Petroleum Corporation
Limited, Visakh Refinery for giving me a golden opportunity to undergo my
industrial training here. I would like to record my deep appreciation and sincere
gratitude towards M. Sudha Mohan (Sr. Manager HR) for accepting my letter and
granting me an opportunity to perform my training in this esteemed organization.
I would also like to thank my unit manager Mr. M. Jagannadha Rao for his
guidance in order to successful upon completion of my training. My further gratitude
is to all chemical engineers, team leaders and operators who had assisted me in
completing this training, especially in doing my project.
He has undergone training in Fluid Catalytic Cracking Unit (FCCU 1). The
overall rating for his performance during the training is __________________.
Regards,
_________________
Manager
1. Chapter 1 01
2. Chapter 2 04
3. Chapter 3 07
4. Chapter 4 13
5. Chapter 5 43
6. Chapter 6 45
7. Chapter 7 50
8. Chapter 8 53
CHAPTER-1
PROFILE OF VISAKH REFINERY
Hindustan Petroleum Corporation Ltd., is a mega public sector undertaking under the
government of India and is second largest Integrated Oil company in India. This refinery is located
at latitude of 17'41'' North and longitude of 83'17'' East on an area taken on a 99 years lease from
Visakhapatnam port trust. Plant on the eastern side, Coromandal Fertilizers on the western side,
Residential colonies on the southern side, Andhra Petrochemicals Ltd., East Indian petroleum on
the northern side. HPCL has an additional Tankage Project (ATP), which is on the Northern side
of the refinery covering an area of 215 acres. The refinery has road access from the two sides on
the southern side one, from eastern side and from Northern side of the ATP area.
Visakh Refinery was established in 1957 as Caltex oil refining India Ltd., (CORIL). This was the
first oil refinery on the East Coast and the first major industry in the City of Visakhapatnam,
Hindustan Petroleum corporation came into being in mid 1974 after take over and the merging of
Erst while Esso and Lube India in 1976 and was subsequently merged with HPCL Kosan Gas
Company in 1978. HPCL thus came into being after merge four different organizations at different
parts of time.
Visakh Refinery covers an area of 515 acres of area is situated at Visakhapatnam, 1 km (North
west) from the foot of Yarada hills. The refinery is flanked by HPCL terminal & HPCL LPG
bottling.
Hindustan Petroleum Corporation Ltd has nearly 20% refining capacity and the
market share and a commensurate market infrastructure. It operates two major refineries, one at
Mumbai of 5.5 MMTPA capacity and other at Visakhapatnam of 8.3MMPTA capacity. Its lube
refinery at Mumbai is the largest in the country with a capacity of 3,33,500TPA, which is nearly
40% of the countrys total lube refining capacity.
Visakh Refinery has an initial capacity of 0.675 MMPTA in 1957. The crude capacity was raised
to 1.5MMTPA through put level over a period of years by various modifications. The crude
processing capacity was further expanded to 4.5 MMTPA level during 1985 by commissioning
separate stream of 3.0 MMTPA CDU, FCCU and related utilities off site facilities at high seas (off
shore terminal tank) and associated tankage and product dispatch facilities by utilizing available
space in a integrated manner and these facilities was with state of all control system for better and
efficient operation.
In order to cater to the increased LPG consumption in the region refinery was instrumental in
developing first LPG import facilities on the east coast in 1987 . As a step towards surmounting
the frequent power distribution and to improve reliability of utilities, a Captive Power Plant (CPP)
of 14MW capacity was commissioned in 1991. Refinery in its effort for product value addition
and widening its product range commissioned.
Propylene Recovery Unit (PRU) in 1992. In order to adhere to meet stringiest environment norms
the refinery had set up Effluent Treatment Plant (ETP) in 1993 and Sulphur Recovery Plant (SRU)
in 1994, with the second major expansion project VREP-II completed in 1999, crude capacity was
increased from 4.5MMTPA and secondary processing capacity increased from 1.0 MMTPA to
1.6MMTPA. To meet the additional power requirement of these new units CPP capacity was
augmented by 40 MW in 1999 by increasing total power generation capacity to 50MW. To meet
the stringent diesel fuel specifications Diesel Hydro Desulphurisation (DHDS) units was also
commissioned in 2000.
Visakha refinery is capable of processing both imported and indigenous crude. The corporation
serves all sections of National economy, Domestic, Agriculture, transport and Industries and also
the public utilities and special users like road, railway, power plant, Defense and Fertilizers.
HPCL markets entire range of petroleum products from the lightest of LPG to the heaviest of
Bitumen including 200 grades of tubes and greases. The product state of the refinery includes light
distillates, which constitutes 22 %Wt on crude basis consisting of Liquefied Petroleum Gas (LPG),
Naphtha, Propylene, Gasoline/ Petrol, and Middle distillates which constitutes 52 Wt% on crude
basis consisting of Mineral Turpentine Oil (MTO), Aviation Turbine Fuel (ATF), Jute Bleaching
Oil (JBO), Superior Kerosene Oil (SKO), High Speed Diesel (HSD), Wash Oil, Light Diesel Oil
(LDO), and Heavy ends constituting 18wt % on crude basis consisting of Fuel Oil (FO), Low
Sulfur Heavy Stock (LSHS) and Bitumen. The majority business in retail sales with volume of MS
and HSD accounting for 49% of the total followed by the industrial sales of over 30% HPCL is
one of the two companies in India which own cross country product pipelines. HPCL always takes
keen interest in the protection, preservation and the improvement of environment.
PROCESS UNITS :
Crude Distillation Units:
CDU-I : 1.8 MMTPA
CDU-II : 3.0 MMTPA
CDU-III : 3.5 MMTPA
Fluidized Catalytic Cracking Units:
FCCU-REVAMP : 0.95 MMTPA
FCCU-II : 0.97 MMTPA
Product Treating Units:
NTH: 1.5 MMTPA
CCR Plat former: 0.77 MMTPA
NUI: 0.23 MMTPA
FCC-NTH: 0.89MMTPA
Cycle Max: 680 kg/hour
Environmental control facilities:
SRU-I: 16 LTDPA
SRU-II: 32 LTDPA
DHDS-SRU: 265TPH
SWSU: 99.4 m3/hour
CHAPTER-2
INTRODUCTION TO FLUIDISED CATALYTIC CRACKING
Over the past 50 years, Fluid Catalytic Cracking has developed into a major upgrading
process in the oil refining industry for the conversion of vacuum gas oils into more valuable
products ranging from light olefins to naphtha and middle distillates. The FCCU occupies a very
important place in a refinery because of its low cost conversion of heavy oils to lighter more
valuable products. The catalytic cracker is the principle source of light olefin feed to alkylation
units. The attractiveness of the FCC process is related to its flexibility in converting a variety of
feed stocks from a wide range of crudes and its favorable economics of operation.
CATALYTIC CRACKING
Decomposition of higher molecular weight hydrocarbons into smaller molecular weight
hydrocarbons in presence of catalyst is termed as CATALYTIC CRACKING.
The cracking of heavy gas oil occurs through the formation of intermediate positively charged
organic species called carbonium ions and carbonion ions in presence of catalyst at a moderate
temperature and pressure is known as catalytic cracking.
Catalytic cracking has many advantages over thermal cracking, some of which are listed below.
1. Catalytic cracking gives more stable products.
2. Catalytic cracking unit operates under less severe conditions.
3. Catalytic cracking gives high octane gasoline.
4. It yields less dry gas i.e., methane, ethane and ethylene.
The originally developed process of cracking was Thermal cracking. Use of catalyst for
cracking was first investigated by HOUNDRY in 1927. The first catalytic cracker built in 1936 in
the USA by Houndry had fixed bed of catalyst pellets made from natural treated clays. The process
was batch wise, and a series of reactors were employed, each one going through a cycle of reaction,
purging, regeneration and purging operations. The process had its inherent disadvantages of being
discontinuous and cumber some and moreover, each reactor was subjected to reducing and
oxidizing conditions in quick succession.
The advantage of a continuous process led to the development of the idea of moving
bed of catalyst. The Thermofor and Houndriflow catalytic cracking processes followed, where in
the pelleted catalyst was continuously withdrawn from the reactor by means of a mechanical
conveyor or gas pressure carried to the regenerator and brought back to the reactor, by similar
means after burning off the coke.
Heat liberated in the regenerator from the coke burn-off was gainfully utilized in heating
and cracking the oil feed in the reactor, however, the mechanical means employed put limit on the
amount of catalyst that could be circulated, which in turn meant less heat removal from the
regenerator. Lighter, costlier feed stocks which could vaporize with less heat had therefore to be
processed. The product distribution with lighter feedstock was also not favorable, tendency being
to produce more gas and gasoline.
2.2 FLUIDISED CATALYTIC CRACKING
A more radical development was made by shell. Standard Oil (N.J. And Indiana), Kellog,
Texas Co and UOP in the early 1940s devised a plant in which catalyst was used in the form of
finely divided powder. This type of catalyst can be kept in a fluid state by blowing air, gas or steam
through it, and so the name Fluid Catalytic cracking Unit. Moreover, by controlling the
particle size of the catalyst and the velocity of gas moving through it, a bed can be formed, which,
although in violent agitation has some of the properties of a static quantity of liquid.
The development of the fluid catalytic cracking unit has permitted much higher rates of
catalyst circulation, and thereby the use of heavier feed stocks of lower value, a point especially
important where viscosity of pour point considerations require destruction of heavier materials.
2.3 ADVANTAGES OF FCCU
From the Operating point of view:
1. Heat evolved in the regeneration of the catalyst is efficiently used.
2. Reaction temperatures are well controlled.
3. Catalyst regeneration temperature is well controlled
4. The catalyst available today is strong and retains its activity on a high scale. The
reactions are usually uniform over a long period of time, and the product quality does not change
with the lengthy use of catalyst.
To reiterate the most important reason for the wide use of catalytic cracking is the greater
yield of high octane gasoline. The yield is better than with any other thermal operation. Also, the
gas produced consists mainly of the preferred propane and Butane hydrocarbons with less methane
and ethane. The formation of heavier oils and tars is minimized. The gasoline and the uncracked
cycle Oil are more saturated that those encountered in other thermal products mainly because the
concentration of Aromatics is higher.
CHAPTER-3
GENERAL PROCESS DESCRIPTION
FUNCTION OF THE PLANT
The Fluidized Catalytic Cracking Unit catalytically cracks the vacuum Gas oil (side
streams) of VDU to various high priced hydrocarbons. In this process catalyst is used in the form
the very small spherical particles which behave as a fluid when aerated with vapour. The fluidized
catalyst is continuously circulated from the reaction zone to the regeneration zone. In addition to
promoting the catalytic action, the catalyst acts as the vehicle for the transfer of heat from one zone
to other. These two zones are the reactor and the regenerator.
FCCU consists of three sections Catalyst section, Fractionation section & Gas
concentration Unit which operate together in an integrated manner. The cracking section consists
of reactor and regenerator which together with J bends and close coupled riser form catalyst
circulation circuit. The catalyst travels up the riser to the reactor and disengages at cyclone inlet in
the flexi cracking process. The catalyst from the primary and secondary reactor cyclone diplegs
down through the stripper to the regenerator across the spent catalyst J bend and back to the riser.
The fresh feed and recycle streams known as combine feed enter the unit at the riser, where
they are vaporized and raised to the reactor temperature by hot catalyst. The mixture of oil vapor
and catalyst travels up the riser and continues until the oil vapors are disengaged at the primary
cyclone inlet. The cracked products in the vapour phase go to fractionators through the reactor
vapour line. Coke is deposited on the circulating catalyst in the reaction zone. The spent catalyst
flows from the reactor to the regenerator where coke is burnt off. The heat of combustion raises
the catalyst temperature to 650-730C range and supplies heat, most of which is transferred to the
endothermic reaction.
The coke deposited on the circulating catalyst in the reactor is burnt off in regenerator using
air from Air blower. Catalyst gets separated from the hydrocarbon vapours in the reactor and from
flue gases in the regenerator by means of set of cyclones provided at the top section of reactor and
regenerator.
The flue gas coming out regenerator is mixture of CO and CO2 gases which are burnt in
CO boiler for producing steam. The flue gases can be vented to atmosphere through stack
bypassing CO boiler.
In the fractionation section, the reactor vapours are fractionated into the products clarified
oil, Heavy cycle oil, Light cycle oil, un-stabilized gasoline and wet gas. The unit is also designed
to generate MP steam in the exchangers by transferring waste heat from slurry and HCO circulating
streams of fractionators section. Un-stabilized Gasoline and Wet Gas after compression are sent
to gas concentration unit for further separation. In Gas concentration section Gasoline, LPG and
Fuel gas are separated. The composition of each stream is controlled for maximum product value.
Gasoline and LPG are sent to Merox for further treatment. Fuel gas from GCU joins refinery fuel
gas system. Clarified oil/HCO is used as fuel oil component. Gasoline produced in FCCU is having
high octane number. LCO is used as HSD/LDO component.
DESCRIPTION OF THE FLEXICRACKING PROCESS
The Fluid catalytic Cracking Unit (FCCU) is one of the most important and widely used
process unit aimed at maximizing the yield of light/middle distillates by cracking of heavy oils in
the presence of catalyst. The unit may be divided broadly into three sections:
1. Reactor Regeneration Section (R-R section)
2. Fractionation Section
B) FEED ZONE
In the Reactor feed zone the total feed (VGO, VR, and HCO Recycle) is injected into the
external riser via six ER&E proprietary curved throat fan tip feed nozzles. As mentioned
previously, the total feed rate is controlled upstream in the preheat facilities. Feed distribution to
the individual feed nozzles in service is not normally directly controlled, and depends upon the
symmetrical layout specified as part of the design. Flow will distribute to balance the pressure drop
through each parallel feed nozzle circuit; although provision has also been made for some
balancing via the globe valves provided in the oil feed line to each individual feed nozzle.
Steam is injected into the oil feed line upstream of each feed nozzle to help promote
atomization of the feed within the nozzle. Feed injection steam is distributed to the individual feed
nozzles by the restriction orifices provided. If a nozzle is removed from oil feed service steam flow
is maintained through the steam purge restriction orifice to prevent plugging.
A dedicated feed nozzle is provided for the Fractionators Bottoms Recycle feed. Similar
to the total feed nozzles described above, steam is injected upstream of the nozzle to promote
atomization within the nozzle. Efficient feed contacting promoted by proper operation of the feed
nozzles is critical for optimum unit performance.
Oil exiting the feed nozzles is contacted with the hot regenerated catalyst from the
Regenerator. In order to ensure an even flow pattern and distribution of catalyst to the feed zone
and to minimize catalyst back- mixing, Fluffing Steam is injected into the riser a short distance
below the feed zone (at the top of the regenerated catalyst angle riser). Fluffing steam is injected
via the same nozzle that is used to route emergency steam to the riser. The Fluffing Steam is
injected at a constant rate controlled by the restriction orifice. The Fluffing steam flows through
the restriction orifice. This restriction orifice is sized to limit flow when the emergency valve is
open and does not affect the flow of Fluffing Steam .The Fluffing Steam flow also functions to
purge the emergency steam nozzle to keep the attached piping cool and to avoid plugging.
Provision has also been made to inject naphtha or other quench stock into the feed zone
to control riser temperature during start-up or other situations as needed. Quench flow is controlled
by Flow controller and the quench has been provided to two of the total feed nozzles. When
required, one or both of these nozzles can be dedicated to quench service. Injection steam is
maintained as in normal feed service.
C) REACTION ZONE
As the feed from the nozzles contacts the hot regenerated catalyst, it vaporizes and begins
the cracking process. The vaporized oil, feed injection steam and cracked products provide the lift
to carry the catalyst up the feed riser. The first section of the riser is a shallow angle cone
connecting the feed zone and the increased diameter required in the upper riser section to handle
the higher vapor rate resulting from cracking the feed. The shallow angle cone provides a
smoothtransition that avoids areas of deceleration which can result in back mixing and lead to a
loss of conversion selectivity. The cracking reactions are completed as the Feed / catalyst mixture
moves up the external and internal sections of the feed riser. SCT (Short contact time) technology
minimizes the thermal and non selective cracking reactions that could occur in the reactor dilute
phase by rapidly separating the catalyst from the vapor stream using a close-coupled cyclone
system. Three parallel close-coupled sets of two stage cyclones are used for catalyst separation,
while the reactor effluent vapor passes overhead to the main fractionator for separation into
products.
D) CATALYST RECOVERY
Spent catalyst separated from the reactor effluent vapor is recovered in the two stage
cyclones mentioned above. Vapor enters the cyclones via a transfer tunnel which close couples the
riser to the cyclone so that the catalyst is rapidly separated to prevent undesirable thermal and non-
selective cracking reactions from occurring in the Reactor dilute phase. The vapor enters the
primary cyclones tangentially in a horizontal direction. This imparts a cyclonic flow pattern to the
vapor and catalyst, resulting in a centrifugal force which forces the catalyst to the outer walls of
the cyclone. The cyclone flow pattern spirals downward, aiding the catalyst in sliding down the
walls to the conically shaped bottom of the cyclone, while the vapor then reverses and flows
upwards through the center of the cyclone to the secondary cyclone inlet. The vapor to the
secondary cyclone still contains some catalyst of smaller particle size than is separated in the
primary cyclone. Most of the remaining catalyst is removed in a similar manner in the second
stage. The relatively catalyst-free vapor then exits into a plenum chamber at the top of the reactor
and from there via the Reactor overhead line to the primary fractionators. Catalyst separated in
both cyclone stages is then routed to the Reactor stripping section via the cyclone dip legs. The
cyclone dip legs allow a column of catalyst to buildup, which provides the necessary static head
for the catalyst to enter the stripping zone. The trickle valves at the bottom of the dip legs prevent
bypassing of the cyclones during an upset by sealing the cyclone dip legs so that vapor cannot flow
up the dip legs which would result in increased catalyst losses.
E) SPENT CATALYST STRIPPER
Coke (that is, carbon and hydrogen in the form of high molecular weight hydrocarbons) is
deposited on the surface of the catalyst during cracking operation. The catalyst is regenerated by
returning it to the Regenerator where the coke is burned off. However, before it is returned to the
Regenerator it is important that the valuable strippable hydrocarbons (which consist of liquid
adsorbed on the surface and vapor trapped within the catalyst pores/void spaces between particles)
be removed from the spent catalyst and recovered
as product. Both forms are removed by stripping with steam in the Reactor Stripping section.
Spent catalyst enters the top of the stripping section via the annular apace between the internal
section of the feed riser and the outer wall of the stripping section. It then flows downward over
fifteen shed rows which promote contacting between the catalyst and stripping steam, which enters
via spargers underneath the bottom two shed rows. Stripping steam rate is set is set via Flow
controller with even distribution among the spargers being achieved via the restriction orifices in
the individual supply lines. As the steam flows counter-current to the catalyst, strippable
hydrocarbon is removed. Stripper level is not directly controlled and Depends upon the catalyst
inventory within the Reactor/Regenerator system. Regenerator inventory changes due to air rate
adjustment will be reflected in the stripper level. It is generally desirable to operate the stripper
with both dilute phase and dense phase stripping zones. The unit design was based upon
maintaining the stripper level at 75% full. The top dilute phase zone promotes rapid removal of
hydrocarbon vapor from the space surrounding the catalyst. This maximizes the steam partial
pressure in the lower dense phase stripping zone, which promotes desorption of the liquid
hydrocarbon adsorbed on the catalyst surface.
F) REACTOR TEMPERATURE AND PRESSURE CONTROL
Depending upon the Regenerator operating mode (partial or full burn conditions), reactor
temperature is controlled by adjusting either the feed temperature for partial burn regeneration or the
catalyst circulation rate for full burn regeneration. Feed temperature is normally controlled by adjusting
firing in the preheat furnace. Catalyst circulation is controlled by the Reactor/Regenerator pressure
differential controller.
Reactor pressure is not directly controlled. It will be set by the pressure controller at the suction
of the gas compressor on the FCCU-R primary fractionator overhead plus the pressure drop from the
compressor suction back to the reactor vessel. It can be varied by adjusting the set point of the
compressor suction pressure controller.
REGENERATOR
The functions of the Regenerator, are to restore catalyst activity lost during the cracking
reactions due to (coke that is, carbon and hydrogen) build up on the catalyst, and to provide the heat
required for feed vaporization and for initiating and sustaining the endothermic cracking reaction in
the feed riser. Restoration of catalyst activity is accomplished by burning off the coke and any
hydrocarbon which was not completely stripped off in the Reactor stripping section. Complete removal
of the coke from the catalyst is not possible because some is deposited deep in the catalyst pores, and
coke burning is never 100% efficient in commercial units. The coke deep in the catalyst is called
trapped coke and the coke not removed because of combustion inefficiency is called burnable coke.
The burnable coke should be kept as low as possible. Most of the heat released during regeneration is
absorbed by the catalyst and is then transferred to the Reactor to supply heat for feed vaporization and
the cracking reactions. Catalyst enters the Regenerator via the spent cat riser which projects into the
dense catalyst bed a short distance above the grid. A flat circular plate located above the termination
of the spent catalyst riser acts to deflect and distribute the spent catalyst in the dense bed. The catalyst
leaves the Regenerator via an overflow well which is located diametrically opposite the spent cat riser.
Hence Regenerator level is not controlled and remains constant at the top of the overflow well. The
mass of catalyst in the Regenerator inventory can change, however, with changes in air flow to
regenerator. The change in Regenerator inventory will affect the reactor stripping section level, since
the Regenerator bed level is maintained by the overflow well. The overflow well is tapered to promote
vapor disengaging from the regenerated catalyst, and extends downward to join the regenerated catalyst
standpipe before passing through the grid.
The FCCU-1 Regenerator is designed to operate in a High Temperature Regeneration (HTR)
mode. Although Regenerator temperature is not directly controlled unit operations should be adjusted
to maintain temperatures in the range of 675 to 730C. (Note that although the design temperature of
the Regenerator internals is 760C, the operating temperature should be limited 730C to prevent
deactivation of the catalyst). This HTR Operating regime minimizes RCC, which helps to maintain
catalyst activity and avoid carbon buildup. It also helps to promote CO combustion within the bed,
avoiding afterburning or CO combustion in the dilute phase, which can lead to very high
temperatures causing mechanical damage. The lower end of the range is set by CO combustion kinetics,
while the upper limit is set by catalyst deactivating considerations. RCC levels of 0.05 to 0.20 wt%
can be expected over the HTR operating temperature(high to low end ) range, depending on the mode
of HTR regeneration (that is, full or partial burn).
With High Temperature Regeneration, the Regenerator may be operated in either a partial
burn or full burn mode. In a full burn operation, sufficient oxygen is available to completely combust
the coke to carbon dioxide. The Regenerator typically operates with a minimum of 1 vol % excess
oxygen in the full burn mode, and the carbon monoxide concentration is less than 500 ppm. In a partial
burn mode operation, insufficient oxygen is available to burn all of the coke to carbon dioxide and the
flue gas carbon monoxide content can be in the range of 2 to 12 vol % FCCU-1 has been designed to
normally operate in a partial burn operating mode, in partial burn, regenerator bed temperatures are
generally in the range 675to 730C . This operating temperature range maintains combustion in the
bed. However, the use of CO combustion promoter may be required in the operating range between
675 to 700C should excessive afterburning occur due to a reduction in the CO combustion kinetics.
CO combustion promoter is a catalyst additive that increases the rate of CO to CO2 combustion within
the regenerator dense bed. The use of combustion promoter enhances the combustion of CO at reduced
temperatures. Essentially all excess oxygen is consumed within the dense bed, and CO concentration
in the flue gas can range from about 1-2% (just short of complete CO-combustion) to levels as high as
10-20%.Typical RCC for the partial burn mode is 0.10 to 0.20 wt% slightly higher than for full burn
due to the depletion of available 02 within the dense bed, Other features of the partial burn are:
1. Available oxygen is used more efficiently; therefore , a partial burn is better applied to
operations where coke production is a primary limitation, This includes processing more feed at an air
constraint or processing feeds with higher coke production such as residues.
2. Some heat can be exported in the form of CO in flue gas for combustion in the CO Furnace.
3. CO content can be allowed to vary over a wide range, 1-2%min, to10-12% max. Permitting a
wide range of heat balance.
4. Carbon on regenerated catalyst will be slightly higher than in a full burn operation. This result
in a somewhat higher relative coke production compared to full burn.
A) CATALYST RECOVERY
The flue gas produced by the burning of the carbon and hydrocarbon on the spent catalyst
carries entrained catalyst out of the dense bed. This catalyst must be removed before the flue gas exits
the Regenerator vessel and flows to the CO boiler or atmosphere. Catalyst is recovered in six parallel
pairs of two stage cyclones. The flue gas rises through the Regenerator dilute phase and enters the
primary cyclones tangentially in a horizontal direction. The entrained catalyst is separated from the
flue gas in the two stages by centrifugal force as in the reactor cyclones. The catalyst is returned to the
dense bed via the cyclone dip legs and trickle valves, while the flue gas passes through a plenum and
then out via the Regenerator overhead line to the CO boiler or atmosphere.
B) AIR SUPPLY
Air is required in the FCCU for combustion of coke in the Regenerator. Some of the
combustion air is first used as control air in the spent cat riser to promote catalyst circulation form the
Reactor stripping section to the Regenerator. This control air is then utilized for carbon burning in the
Regenerator. The Main Air Blower, is a steam turbine driven centrifugal compressor which takes
suction from the atmosphere, and compresses both the air that is used as control air as well as the air
that goes directly to the Regenerator. The motor driven Control Air Blower, takes suction from the
discharge of the Main Air blower. The control air rate is set by Flow controller and will be determined
by catalyst circulation considerations.
Total air rate to the Regenerator is set by Flow controller. With the control air rate set per the above,
FC will adjust the rate of air which is sent directly to the Regenerator by varying the speed of the Main
Air Blower steam turbine drive. During normal operation, all of the air directly to the Regenerator
could be supplied via the secondary air line to the Regenerator air pre heater However, both the ,
primary and secondary lines to the pre heater could be used since both are measured to determine the
total air rate as long as the rates are within the normal operating range of the primary and secondary
air flow meters. Air flow is balanced between the primary and secondary air lines by the manually
operated butterfly valves which are provided. Note that during the firing of the Air Pre heater, the
primary air flow rate must be adjusted to always achieve 100%excess air firing to prevent excessive
temperatures which would damage the combustion zone.
Air sent directly to the Regenerator flows though the Air Pre heater and is then distributed to
the dense bed by a flat grid with a multitude of holes. A shroud (velocity reducer) is provided for the
exit of each grid hole to reduce the velocity of the air so as to avoid erosion and catalyst attrition.
C) TORCH OIL SYSTEM
Additional heat over and above that provided by feed preheat and carbon burning may be
required to keep the unit in heat balance during startup, shutdown or normal operation. This heat is
supplied by torch oil which is injected into the Regenerator dense bed through two retractable flat
pattern spray nozzles. The torch oil sprays extend a short distance into the dense bed about 600 mm
above the grid, and are located 180C apart. The oil is ignited by the hot catalyst in the presence of the
combustion air which exits the grid.
Torch oil rate is set by FC which is a split range controller. When the torch oil flow rate set
point is increased from zero, the split range controller first fully opens Flow controller B, which
provides atomizing steam to the torch oil nozzles. When the controller output reaches 50% of its full
range, Flow controller A begins to open and torch oil flow starts. The atomizing steam helps to convert
the torch oil into small droplets to ensure efficient burning. When the torch oil nozzles are not in
service, both the spray tip and the annular space around the tip are purged with steam for cooling and
to avoid plugging with catalyst. A TI point is provided above each torch oil nozzle to help detect
ignition when the nozzles are commissioned.
D) AIR PREHEATER
The Air Preheater, is integrally attached to the bottom of the Regenerator vessel. The preheater
is used to heat the Regenerator prior to catalyst addition, and to raise the dense bed temperature during
catalyst loading prior to using torch oil combustion to supply heat. It can also be used to dry the
refractory in the unit during the initial startup of the revamped unit or after subsequent turnarounds.
Air from the Main Air Blower enters the Air Preheater through the primary and secondary air
connections. The preheated air then exits the preheater past a deflector cap before entering the dense
bed via the grid. The deflector cap helps to prevent catalyst from dropping into the preheater and helps
to distribute the air uniformly under the grid. It also helps to avoid local overheating of the grid
FRACTIONATOR
The reactor effluent comprising of cracked hydrocarbon vapors, steam and non-
condensables enter the fractionators at the bottom of the quench section. The main column is a
vertical cylindrical vessel with 4.25m inside diameter & 44.1m height. The column consists of two
sections top section is the regular fractionator part and the lower one is the desuperheating or
quench section. The quench zone has six disc and donut trays. Above them there are 36 seive trays.
The column shell is clad with 1 Cr Mo from bottom up to tray # 23 including the head. The
column has different design temperatures at different sections. From tray # 36 to tray # 24, the
design temp is 300C . From tray # 24 to tray #3 design temp is 350C and below tray #3, the
design temperature considered is 550C. The column design & operating pressure at top & bottom
section are 4.5 kg/cm2 a & 1.69 kg/cm2 a and 5.0 kg/cm2 a & 2.05 kg/cm2 a respectively. The
operating temp at top is 137C and at bottom it is 360C in the desuperheating section at the column
bottom. The cracked vapours from the reactor are cooled by circulating slurry pump around and
part of the vapours condense. The entrained catalyst if any in the cracked vapour is scrubbed by
the slurry pump around stream. The fractionator bottom has a high coking tendency. Coking is
further promoted by higher liquid temperature and long residence time. To maintain the
fractionator bottom temperature at 360C cold quench stream of slurry pump around is directly
mixed with the fractionators bottom liquid under column bottom temperature control. Further LP
steam is injected into the bottom liquid through a steam ring to counteract coke formation and to
maintain catalyst & coke particles in suspension. To ensure that large coke particles in the bottom
stream do not hamper the operation of the slurry pump around pumps coke trap is put around the
bottom nozzle to filter out such lumps. The coke trap is made of SS-410S having 132 slots on it.
The main column is provided with Level Transmitter with DCS high & low alarm facility and with
DCS low & high alarm facility& local indication: LSHH provides alarm in DCS in case of high
high level. The LTs are provided with FLO connections to clean out lines in case of choking.
The column bottom liquid which serves as slurry pump around and net bottom product is
withdrawn from the fractionator and pumped using slurry pumps. One pump is motor driven and
the other (standby) is extraction type steam turbine driven. In case of power failure, the column
bottom liquid can be evacuated using the turbine driven pump. The slurry from slurry pump goes
to feed/slurry PA exchanger where it is cooled to 286C /303C /270C in three different cases ID
(CF)/1D (HF)/2D, then it goes to slurry PA/MP steam generator where MP steam is generated
from BFW by taking heat from slurry stream. The slurry enters main fractionator again as quench
under flow and temperature controls. The slurry return temperature can be varied by bypassing
steam generator as required but too much bypassing will reduce slurry velocity through exchanger
and will result in choking. The slurry stream can enter the column at three locations:
1. On top of desuperheating trays (D#6) under total flow control.
2. In the middle of desuperheating section (D#4) under flow control.
3. At the column bottom as quench stock under temperature control.
Besides the quench stream most of the slurry stream will be returned on top of
desuperheating trays and the other flexibility has been kept to reduce localized hot spots to control
vapor temperature. The slurry from the slurry pump discharge is divided into three streams.
1. The first stream is added to the fractionator bottom as spill back.
2. The second stream is also divided into two streams:
One stream of slurry is added to the HCO (from the discharge of the HCO rundown pump)
to produce CLO. This slurry line can be bypassed directly to the CLO coolers, without producing
the CLO. CLO produced has about 0.2 wt % catalyst Fines and is cooled in FEED/CLO A/B/C/D
heat exchanger consisting of two parallel banks of exchangers each having two shells connected
in series. In normal operation, only one cooler bank is sufficient during emergency emptying out
operation, both the banks can be taken in line to reduce pumping time. CLO is then cooled by
means of sea water in CLO cooler. CLO is then pumped by CLO Booster pumps (at 14.3kg/cm2
g pressure) and is sent to fuel oil pool and to the slop in the shut down time. One start up connection
has also been provided from this line to facilitate cutter circulation during start-up/shut down.
Another stream of the slurry is sent to the reactor as reslurry where HCO is added to this line.
3. The third stream of slurry is called as SLURRY PA is exchanged with the feed, that is
FEED/SLUURY PA exchanger A, B, C. The slurry from the exchanger goes to the MP Steam
generator, where MP steam is generated from BFW by taking heat from slurry stream. The slurry
enters main fractionator as quench. Fractionator has been provided with Pressure and Temperature
indicators at different elevation to monitor the pressure & temperature profile of column.
HEAVY CYCLE OIL CIRCUIT
HEAVY CYCLE OIL (HCO) is withdrawn from the column chimney tray CT-2 at a
temperature of 320C as indicated by Temperature indicator and sent to the HCO stripper. A part
of the HCO directly withdrawn from the column is sent to the Gas Concentration Unit Debutanizer
Reboiler by HCO PA pump. The HCO PA from Debutanizer Reboiler at a temp of 273C enters
HCO PA/MP Steam Generator, where it generates MP steam whose pressure is controlled by the
Pressure Controller with High and Low Pressure alarms at DCS. From the steam generator, HCO
PA is circulated back to column on tray #5 through duty controller.
The other part of HCO is stripped with MP steam in HCO stripper containing 6 Valve trays.
Stripper is provided with Level Controller for monitoring the level. Stripping steam is injected
through Flow Controller. Stripped lighters along with steam returns to main column through 12
vapour return line at tray#5. Stripped HCO from bottom of the stripper is pumped by HCO Product/
recycle pump. Two line ups are given for stripped HCO from discharge of the pump. One is a 6
recycle line which joins fresh feed upstream of furnace under flow controller and there is a routing
for the HCO to join at the reslurry stream to the reactor. The other one is a 2 product line joining
the CLO product line upstream of 4E52 through flow controller. When the unit is operating on
maximum distillate mode, stripped HCO is recycled back to reactor. However when operating on
maximum Naphtha mode, a small portion of HCO will be available as product(apart from the
recycle) which is routed to FO pool along with CLO product.
E) SPONGE ABSORBER
Sponge Absorber operates at a top pressure and temperature of 15.0 kg/cm2 a and 40.2C
and bottom pressure and temperature of 15.2 kg/cm2a and 45.5C The trays are of SS410S material
and column shell is of CS. It has got 20 valve trays. Feed to the column enters below tray No. #1.
Heavier components of the absorbed gases from primary absorber are further removed which
otherwise will condense in the fuel gas system. LCO (Lean Oil) is used as the absorbent in the
column which absorbs the heavy components at a temp of 40C. The lean oil is pumped by lean
sponge oil pumps and enters the column above tray # 20. Temperature indicator shows the feed
temperature. Sponge absorber is provided with Pressure Safety valve A/B of set pressure18.4
kg/cm2 g discharging to flare. The overhead gas from sponge absorber is acidic containing H2S
which is sent to sulfur recovery Unit (SRU). Temperature and flow indicators show the temp &
flow of the overhead gas flowing to SRU. The sponge absorber bottoms (Rich oil) flow under
column pressure to Rich oil/LCO exchanger where it is heated to 199C by LCO. This Rich oil
flows to the main column top (tray no # 27) for recovery of absorber Naphtha components. One
CBD &OWS connection is provided at column bottom to drain the column during shut down. To
monitor the column temperatures, temperature indicators on tray # 6.Tray #5.and overhead vapor
line are provided respectively. Two local PIs will give the bottom & top pressure of column.
F) STRIPPER
Stripper is a column operating at a top pressure and temperature of 16.0 kg/cm2 a & 49C
and bottom pressure and temperature of 16.3 kg/cm2 a &140C, the column is having 36 valve
trays of SS-410S and the main column shell is of CS. The liquid from HP receiver, is pumped by
stripper feed pumps. The stripper feed enters the column above the 36th tray at 38C the column
is designed to remove the undesirable light hydrocarbons from the liquefied C3+ hydrocarbon
stream to control the vapour pressure of LPG product. Stripper is having LSH and LSL with alarm
facility in DCS. The stripper bottom flows under the column pressure to Debutanizer column. The
energy for separation in this column is provided by reboilers A and B, where the hot fluids are
LCO PA & Stab. naphtha. The temperature of the reboiler return stream (140C) is given by
temperature indicator. The amount of heat supplied through the Reboiler is such that it eliminates
any absorbed C1 and C2 from the bottom product. The stripper reboiler is of once through
horizontal thermo siphon type having two shells connected in series and stacked. Stabilized
naphtha from debutanizer is used in reboiler B for heating medium. LCO PA is used in reboiler A
for heating. Stripper is having two PSV with a set pressure of 19.0 kg/cm2 g discharging to flare.
The overhead vapors from stripper join the compressor 2nd stage discharge stream upstream of
after cooler. stripper is provided with temperature indicator. High & low pressure alarm is provided
to the stripper.
G) DEBUTANISER
Debutanizer operates at a top pressure and temperature of 12.3/9.7/11.7 kg/cm2 a and 65C
and bottom pressure and temperature of 12.7/10.1/12.1 kg/cm2 a & 202/177/188C . The column
has 40 valve trays of SS410S and column shell is of CS. The feed from stripper bottom enters the
column in any one of the trays # 22, 25 or 20 depending upon the feed quality.
For IN case lighter components will be higher. So tray #25 to be taken in line. The feed
tray will be mainly decided upon the sampling of the gas of compressor suction KOD. For light
gas top tray will be take in line . For heaviest gas bottom tray # 25 will be taken in line. The column
bottom is reboiled in Debutaniser reboiler by HCO PA stream. Debutanizer is provided with
different PIs & TIs to monitor the pressure & temperature of the column. The naphtha from
debutanizer bottom is first cooled in stripper reboiler B to about 130C. It is further cooled in air
fin cooler and then in trim cooler to 38C.
The cooled naphtha is pumped by stabilized naphtha product/recycle pumps. A portion of
the pump discharge is recycled to the primary absorber as absorbent. A 3 take-off from this
absorbent line serves as quench stream to reactor. The naphtha quench to reactor is intermittent in
nature used only when required. It is mixed with the combined feed stream upstream of the riser
feed injection nozzle. To handle this quench requirement during start-up, when stabilized naphtha
would not be available, provision is given for this CRN product pump to take suction directly from
the fractionator overhead accumulator. To protect the pump during such an operation, a minimum
flow circulation line is provided from the pump discharge to accumulator. The balance naphtha
from the pump discharge is routed as product to Merox Unit for further treatment. In addition to a
slop connection, a start-up circulation line to accumulator is provided. A 2 connection for WGC
wash purposes is taken at downstream of trim cooler before the pump suction.
The overhead vapors from debutanizer top is condensed in overhead condensers by sea
water. 2 equalizing line is a pressure balance line between the debutanizer top and debutanizer
overhead accumulator. This is to maintain pressure same as that of debutanizer top. The out let of
the condenser is collected in the debutanizer drum. The LPG product pumps, pump the condensed
LPG from debutanizer drum to ATU. One part of the LPG is sent as top reflux to the debutanizer
by the debutanizer reflux pumps.
TURBINE
A turbine is a rotary mechanical device that extracts energy from fluid flow and converts
it into useful work.A turbine is a turbo machine with at least one moving part called a rotor
assembly, which is a shaft or a drum with blades attached. Moving fluid acts on the blades so that
they move and impart rotational energy to the rotor. Early turbine examples are wind mills and
water wheels.
Gas, steam and water turbines usually have a casing around the blades that contains and
controls the working fluid. A working fluid contains potential energy and kinetic energy. The fluid
may be compressible or incompressible.
Impulse turbines change the direction of flow of a high velocity fluid or gas jet. The
resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic energy. There
is no pressure change of the fluid or gas in the turbine blades, as in case of steam or gas turbines
the pressure drop takes place at nozzles. Before reaching the turbine, the fluids pressure head is
changed to velocity head by accelerating the fluid with a nozzle. Newton's second law describes
the transfer of energy for impulse turbine.
CHAPTER-7
INSTRUMENTATION
INTRODUCTION:
The Instrumentation is an art and science of applying measuring device or measuring and
controlling devices to an object or a combination of objects (a system) for the purpose of
determining the identity and/or magnitude of certain varying Physical or Chemical quantities and
offer for the controlling these quantities within the specified limitations.
Petrochemical industry is a large scale & continuous process industry. The important
process variables are temperature, pressure, flow, level and PH. These have to be measured at plant
level, indicate and record the date, usually associated with control the variable by comparing with
reference value. Different types of measurements techniques are possible to measure a physical
variable. But a proper selection must be made to suit the application. Each technique has its own
advantages and disadvantages. All the physical variables have to be indicated to estimate the
present process conditions. These must be recorded for future reference also. As the process is of
large scale, different variables have to display at the remote locations. Additional devices are used
to do this. The signal transmission is of pneumatic type. So at transmitter of receiver i/p converters
will be used. Pressure regulators had to use to maintain constant pressure supply to all the
instruments.
The controlling actions are done mostly by pneumatic values. Butterfly values, ball values,
spring diaphragm values and solenoid values are mostly used in these plant.
TEMPERATURE MEASUREMENT
(A) Temperature gauges :
This is the industrial version of mercury in glass thermometer. The mercury is contained
in a steel bulb joined to a mechanism exactly like pressure bourdon, which actuates the pointer
(B) Thermocouples:
Thermocouple depends for their operation on the EMF generated is based on the metals
used for junction. These can be used up to 1400oC.
(C) RTD: (Resistance temperature detector)
In RTD, the temperature was measured by detecting the change of resistance when
subjected to temperature. Platinum is the most common material for making RTD can be used up
to 6000C movement.
PRESSURE MEASUREMENT
(A) Bourdon tube:
It consists of a tube, having one end seal tight pressure and other end is being exposed for
pressure measurement. The tubes are made in following configuration depending largely on static
pressure and instrument span.
1 C type.
2 Helical type.
3 Spiral type.
When, the pressure applied to tube, sealed end moves in a manner to straighten out the
tube. A pinion arrangement is provided for indicating the pressure.
(B) Bellows type sensor:
Bellows are used when the pressure range is low, because they offer greater surface area
to measured pressure. The bellows provide linear displacement as output liner to pressure input.
(C) Diaphragm capsule:
The diaphragm capsule also used to measure low pressures. Where pressure is applied, the
diaphragm will give displacement and pressure should be within its elastic limits. The
displacement of diaphragm coupled to movement mechanism for indication.
FLOW MEASUREMENT
There are different types of flow measuring devices.
1. Differential pressure measuring devices (head type flow meter).
2. Positive displacement meters.
3. Electromagnetic type flow meter.
In differential pressure type flow meter, orifice based flow meters are more common. It is
because, the device is relatively cheap, easy to install, require the device is relatively cheap, easy
to install, require virtually no maintenance an offer acceptable level of accuracy and repeatability.
However, the pressure loss across orifice is high &almost on recoverable, increasing the pump
over head both pressure & finally other instruments are venturimeters, where there is three
sections converging, throat, diverging, which are not alike sharp obstruction in orifice. So, the
pressure drop across venturi is small.
In positive displacement meters, like oval year meters, oval shaped gears used as the
measuring system. They will deliver a specific quantity of fluid per rotation and used to measure
flow of viscous fluids. In turbine type flow meter, a turbine will be placed in the longitudinal axis
of the pipeline. The turbine will rotate solely by the action of flowing fluid and its rotation is used
to measure flow rate.
In electromagnetic flow meter, the flowing liquid should be conductive the liquid flow in
a magnetic field will generate an EMF proportional to flow velocity. These flow meters, did not
obstruct the flow.
The flow meters stated above, are flow quantity type flow meter. For mass flow
measurement, there is a need of density factor which to be multiplied to H.
11.4 LEVEL MEASUREMENT:
This method depends on Archimedes principle. In level transmitters a displacer is partially
immersed in the liquid to be measure. The displacer will apparently lose weight as level rises &
gain weight as level falls. The amount of weight change results in the force applied to the actuating
arm and the balanced position will be the measure of level.
(A) Float actuated sensor:
In these a bloat is rest on the liquid surface. The float and instrument drive mechanism
connected through a spring- loaded wind up wheel with sufficient tension. As the level increases
float will rise and spring motor will wind back & also drive the instrument gear mechanism. The
linkages can read the movement of float. This is generally used for oil storage tanks.
(B) Differential pressure cell:
A differential pressure sensor can be used to measure level indirectly. A liquid level
provides a pressure head at datum line. By measuring the pressure at datum line with a known
specific gravity the level can be measured. In open tank LP leg of cell is open to atmosphere and
in close tanks the LP leg is connected to the top of the vessel.
CONTROL VALVES
The control valves referred to as final control element. These are different type of control
values, the difference being mainly confined to the shape of the plug & the in which the device is
operated. Generally the diaphragm type actuator is the most common type of actuator. Piston type
actuators also used. The actuator moves the plug in the body, there by controlling flow or pressure.
The valve types are globe valve, butterfly valve and ball valve etc. The characteristics of a valve
can be defined as the relationship of the flow through the valve. travel of valve plug at a constant
differential pressure.
The characteristics of the valves are
i. Quick opening
ii. Linear
iii. Equal percentage.
B. Regenerator:-
Problems Corrective Actions
Plenum chamber failure. Minimizing cut feed rate
Minimizee regenerator velocity
C. Fractionator:-
Problems Corrective Actions
Fractionator bottoms too light. Lower heat removal from tower bottoms
consistent with coking cosiderations.
Maximize HCGO recycle.
Consider equipment changes.
Coking in SPA & bottoms circuit. Consider changing the pump screen size.
Check for leakage or injection of extraneous
streams into tower bottom.
Excessive corrosion in overhead system. Increase wash water rates.
D. Catalyst:-
Problems Corrective Actions
Catalyst contamination. Consider lowering metals in feed by adjusting
crude tower operation.
Catalyst replacement program.
Feed segregation.
Sodium on Catalyst. Minimize sources of sodium input to system.
Sintering of Catalyst. Catalyst replacement.
Minimize sodium input with sea water or salt
in feed.
Coarse Catalyst. Minimize catalyst losses by lowering
regenerator velocity.
Change to finer catalyst.
Attrition. Eliminate or reduce high velocity steam
Injection.
Follow up on fresh catalyst.