The aim of this study is to generate operational data
that can be used to improve the production capacity in the Fluid Catalytic
Cracking Unit (FCCU) in a Refinery and Petrochemical Company. This will aid in
tackling the daunting challenge of unavailability of operational data that can
be used to better understand and improve production capacity and ensure
maximizing catalyst utilization. In addition, it addresses the challenges of
analysis and control of the FCCU process due to its very complicated and
little-known hydrodynamics, complex kinetics of both reactions of cracking and
coke burning, strong interaction between the reactor and regenerator, and
numerous operating constraints. Aspen HYSYS version 8.0 was used in modeling
the cracking process using parameters extracted from the operating manual of the
FCCU in the refinery. The operational data was used to compare the simulated effect of stepwise input in feed
and reactor plenum temperatures as well as stepwise increase in reactor length
on yield, catalyst-to-oil-ratio and catalyst regeneration. An optimum
flow in naphtha was obtained by the interaction of the inlet crude flow rate,
riser height, and temperature this optimum was supported by the study of the
interaction of these parameters when, catalyst to oil ratio was set as the
dependent parameter. The inferences drawn from the results are that the reactor
plenum temperature of 560℃ and a riser length of 27 m are recommended for
optimum performance that ensures lasting
effect of an efficient catalyst activity.
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