Fluid catalytic cracking handbook: design, operation, and troubleshooting of FCC facilities

Reza Sadeghbeigi0884152898, 9780884152897

This thoroughly updated edition of Fluid Catalytic Cracking Handbook provides practical information on the design, operation, troubleshooting, and optimization of fluid catalytic cracking (FCC) facilities. Based on the author’s years of field experience, this expanded, second edition covers the latest technologies to improve the profitability and reliability of the FCC units, and provides several “no-to-low-cost” practical recommendations. A new chapter supplies valuable recommendations for debottlenecking and optimizing the performance of cat cracker operations.

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Table of contents :
Contents……Page 8
Acknowledgments……Page 12
Preface to the Second Edition……Page 13
CHAPTER 1 Process Description……Page 16
Feed Preheat……Page 21
Riser—Reactor—Stripper……Page 22
Regenerator–Heat/Catalyst Recovery……Page 28
Main Fractionator……Page 37
Gas Plant……Page 40
Treating Facilities……Page 46
CHAPTER 2 FCC Feed Characterization……Page 55
Hydrocarbon Classification……Page 56
Feedstock Physical Properties……Page 60
Impurities……Page 69
Empirical Correlations……Page 83
Benefits of Hydroprocessing……Page 96
Catalyst Components……Page 99
Catalyst Manufacturing Techniques……Page 111
Fresh Catalyst Properties……Page 114
Equilibrium Catalyst Analysis……Page 117
Catalyst Management……Page 124
Catalyst Evaluation……Page 130
Additives……Page 132
CHAPTER 4 Chemistry of FCC Reactions……Page 140
Thermal Cracking……Page 141
Catalytic Cracking……Page 143
Thermodynamic Aspects……Page 151
CHAPTER 5 Unit Monitoring and Control……Page 154
Material Balance……Page 155
Heat Balance……Page 173
Pressure Balance……Page 181
Process Control Instrumentation……Page 192
FCC Products……Page 197
FCC Economics……Page 217
Project Management Aspects of an FCC Revamp……Page 221
Process and Mechanical Design Guidelines……Page 227
CHAPTER 8 Troubleshooting……Page 249
Guidelines for Effective Troubleshooting……Page 250
Catalyst Circulation……Page 251
Catalyst Losses……Page 259
Coking/Fouling……Page 263
Flow Reversal……Page 266
High Regenerator Temperature……Page 271
Increase in Afterburn……Page 274
Hydrogen Blistering……Page 275
Hot Gas Expanders……Page 278
Product Quantity and Quality……Page 279
Introduction……Page 291
Approach to Debottlenecking……Page 292
Reactor/Regenerator Structure……Page 296
FCC Catalyst……Page 311
Instrumentation……Page 319
Utilities/Offsites……Page 320
CHAPTER 10 Emerging Trends in Fluidized Catalytic Cracking……Page 322
Reformulated Fuels……Page 323
Residual Fluidized Catalytic Cracking (RFCC)……Page 338
Reducing FCC Emissions……Page 342
Emerging Developments in Catalysts, Processes, and Hardware……Page 347
APPENDIX 1 Temperature Variation of Liquid Viscosity……Page 353
APPENDIX 2 Correction to Volumetric Average Boiling Point……Page 354
APPENDIX 3 TOTAL Correlations……Page 355
APPENDIX 4 n-d-M Correlations……Page 356
APPENDIX 5 Estimation of Molecular Weight of Petroleum Oils from Viscosity Measurements……Page 357
APPENDIX 6 Kinematic Viscosity to Saybolt Universal Viscosity……Page 359
APPENDIX 7 API Correlations……Page 360
APPENDIX 8 Definitions of Fluidization Terms……Page 362
APPENDIX 9 Conversion of ASTM 50% Point to TBP 50% Point Temperature……Page 365
APPENDIX 10 Determination of TBP Cut Points from ASTM D-86……Page 366
APPENDIX 11 Nominal Pipe Sizes……Page 368
Conversion Factors……Page 370
Glossary……Page 372
C……Page 378
F……Page 379
K……Page 380
R……Page 381
T……Page 382
Z……Page 383
About the Author……Page 384