Beruflich Dokumente
Kultur Dokumente
Hari Doss
Prop.
CAEZEN Technologies
THERE IS A BETTER WAY!
Bangalore Presented at the
Coking & CatCracking Conference
October 2013 - New Delhi, India
Slide 1
• Case Study 1: Afterburn Root Cause Analysis for a Commercial FCC Regenerator
• Summary / Q&A
Slide 2
• Need to maximize yield & performance of FCCU’s while minimizing CAPEX and risk.
• Even for units operating well, the business and regulatory environment is constantly
changing and putting new pressures on refiners and other operators (e.g., MACT,
BACT). Units not operating well have a limited time to address the issues.
• Both new equipment and revamps are expensive and risky, yet design and
operational decisions must often be made without a full understanding
of root causes and effective solutions.
Slide 3
Slide 4
Slide 5
• Regenerator configuration
– Height ~70 ft, width ~50 ft
– 12 cyclone pairs, 24 total cyclones
– Spent catalyst distributor consisting of
distributor 17 arms each containing multiple
nozzles
– Two supplemental air rings
– Very long spent catalyst riser
• Operations
– Combustion air ~100 MSCFM
– Flue gas composition:
• O2 = 1.5%
• CO2 = 17.4%
• SOx = 30 ppm
• NOx = 40 ppm
• Potential Causes:
– Spent catalyst riser delivers catalyst to
distributor with a highly mal-distributed
flow pattern
– Limited regenerator height may result in
insufficient dense-bed residence time
Slide 7
NW NE
10 1
9 2
SP 11
8 3
12
7 4
Mass loadings into each cyclone are balanced with
6 5 the exception of the two central cyclone sets
The inlet horns for cyclones #11 & #12 are partially obstructed
leading to lower mass loadings.
SW SE
Slide 11
Slide 12
1250 0 6
0 0 Slide 14
1300 5 0
SO2 (mol%)
30
NO (mol%)
20
Maldistribution
patterns repeated at
cyclone inlet horns
0 0 Slide 15
• Highest temperatures
observed with cyclones
#6, #11 & #12
• Average temperature of
the last 10 simulation
seconds
Slide 16
Side View
Slide 19
3. Alternate design #2
• Same changes as Alternate #1, plus Reference: Blaser, P., and Sexton, J. “CFD
Reactor Case Study: Comparison of Cyclone
• Sloped cyclone inlets Erosion Characteristics for Proposed
Redesigns for the Marathon Petroleum
Catlettsburg Refinery FCC Reactor”,
presented at American Fuel and
Petrochemical Manufacturers’ Cat Cracker
Seminar and Exhibition, Houston, TX, (2012). Slide 20
Bottom of
model
Slide 21
Residence Time Distribution (sec) Particle Speed (m/s) Disengager Arm Inlet (1, 2, or 3)
Slide 24
Slide 25
www.cpfd-software.com Solutions for Fluidization Process Design & Optimization
Erosion Index Calculations
• Barracuda’s erosion model was used to quantify particle impacts on surfaces.
The functional form is dependent on:
1.5 3.5
Cα m v
where m is the particle mass, v is the particle velocity and Cα is a coefficient as
a function of impact angle, α. Since the cyclones and inlets are refractory lined,
the coefficient is higher for normal impacts and lower for tangential ones.
• Regions with an erosion index (exceeding a given tolerance level) have been
plotted and compared for different the different geometries and designs on the
following slide
• Thus, the best use of the erosion index results is for direct comparisons
between alternate designs or operating conditions, rather than for a strict
quantification of improvement
Slide 26
Slide 27
• Significant fluctuations are present in the solids flow into the cyclones.
• Both alternative designs are expected to reduce the cyclone inlet erosion
significantly compared with the existing design.
Slide 28
Slide 30
CAEZEN TECHNOLOGIES
There I S a Better Way!
th
436, G Floor, 20 Main, Chord Road
I Block, Rajajinagar, Bangalore – 10
Hari Doss
+91 9844030617
Hari.doss@caezen.com
Slide 31