Issue
Korean Journal of Chemical Engineering,
Vol.39, No.7, 1673-1687, 2022
Study of gradual and sudden operating condition variations to optimize energy and mass consumption of an industrial fluidized catalytic cracking (FCC) unit with a high-efficiency regenerator
A dynamic model was developed to investigate the impact of operating conditions on the main output variables of the fluidized catalytic cracking (FCC) process with a high-efficiency regenerator and to determine the optimal amounts of operating variables, at the Abadan refinery FCC unit in Iran. To determine the rate constants in the developed kinetic model and other related constants in the developed model, a wide range of industrial data were gathered from the targeted process over several months. Through applying an adjusted dynamic model, the effect of gradual increases in feed preheat temperature (350-500 K) on the yield of gasoline and LCO was investigated, and increases in both yields were observed. The effects of sudden changes in feed preheat temperature, feed and regenerated catalyst flow rate on gasoline yield were also examined. The results showed that a sudden 6.9% increase in feed, a sudden 30K decrease in temperature and a sudden 1.12% decrease in catalyst flow rate resulted in 2%, 0.27% and 0.5% decreases in gasoline, respectively. Furthermore, potential methods for neutralizing these negative effects on the gasoline yield were investigated. Finally, the operating conditions were optimized to improve the gasoline and octane number. Three different optimization cases were studied. The profitability of the unit increased about $2.5-3.8 million per year. A reduction in energy consumption of 12,500 to 21,000Gj/yr was achieved. The amount of feed and the catalyst flow rate were also decreased by 1.5% and 0.2%-0.9%, respectively.
[References]
  1. Sadeghbeigi R, Fluid catalytic cracking handbook, Elsevier (1995).
  2. Weekman VW Jr, Nace DM, AIChE J., 16, 397, 1970
  3. Lee L S, Chen YW, Huang TN, Pan WY, Can. J. Chem. Eng., 67, 615, 1989
  4. Ancheyta-Juárez J, López-Isunza F, Aguilar-Rodríguez E, Moreno-Mayorga JC, Ind. Eng. Chem. Res., 36, 5170, 1997
  5. Ruszkowski MF, Gomzi Z, Tomic T, Chem. Biochem. Eng. Q., 20, 61, 2006
  6. Bollas G, Lappas A, Iatridis D, Vasalos I, Catal. Today, 127, 31, 2007
  7. Ancheyta-Juárez J, Murillo-Hernández JA, Energy Fuels, 14, 373, 2000
  8. Yen L, Wrench R, Ong A, Oil Gas J., 86, 1988
  9. Ancheyta-Juarez J, Sotelo-Boyas R, Energy Fuels, 14, 1226, 2000
  10. Sertić-Bionda K, Gomzi Z, Mužic M, Chem. Eng. Commun., 197, 275, 2009
  11. Blasetti A, de Lasa H, Ind. Eng. Chem. Res., 36, 3223, 1997
  12. Farag H, Blasetti A, de Lasa H, Ind. Eng. Chem. Res., 33, 3131, 1994
  13. Pitault I, Forissier M, Bernard JR, Can. J. Chem. Eng., 73, 498, 1995
  14. Sadighi S, Ahmad A, Rashidzadeh M, Korean J. Chem. Eng., 27, 1099, 2010
  15. John YM, Mustafa MA, Patel R, Mujtaba IM, Fuel, 235, 1436, 2019
  16. Sani AG, Ebrahim HA, Azarhoosh M, Fuel, 225, 322, 2018
  17. Ali H, Rohani S, Chem. Eng. Technol., 20, 118, 1997
  18. Arbel A, Huang Z, Rinard IH, Shinnar R, Sapre AV, Ind. Eng. Chem. Res., 34, 1228, 1995
  19. Jacob SM, Gross B, Voltz SE, Weekman VW Jr., AIChE J., 22, 701, 1976
  20. Secchi A, Santos M, Neumann G, Trierweiler J, Comput. Chem. Eng., 25, 851, 2001
  21. Kim S, Urm J, Kim DS, Lee K, Lee JM, Korean J. Chem. Eng., 35, 2327, 2018
  22. Han IS, Chung CB, Chem. Eng. Sci., 56, 1951, 2001
  23. John YMN, Patel R, Mujtaba IM, Comput. Chem. Eng., 106, 730, 2017
  24. Takatsuka T, Sato S, Morimoto Y, Hashimoto H, Int. Chem. Eng., 27, 107, 1987
  25. Fernandes J, Verstraete JJ, Pinheiro CC, Oliveira N, Ribeiro FR, Comput. Aided Chem. Eng., 20, 589, 2005
  26. Fernandes JL, Pinheiro CI, Oliveira N, Ribeiro FR, Comput. Aided Chem. Eng., 21, 1575, 2006
  27. Fernandes JL, Pinheiro CI, Oliveira NM, Neto AI, Ribeiro FR, Chem. Eng. Sci., 62, 6308, 2007
  28. Fernandes JL, Domingues LH, Pinheiro CI, Oliveira NM, Ribeiro FR, Fuel, 97, 97, 2012
  29. Han IS, Riggs JB, Chung CB, Chem. Eng. Process., 43, 1063, 2004
  30. Hernández-Barajas JR, Vázquez-Román R, Salazar-Sotelo D, Fuel, 85, 849, 2006
  31. Kasat RB, Kunzru D, Saraf D, Gupta SK, Ind. Eng. Chem. Res., 41, 4765, 2002
  32. Souza J, Vargas J, Von Meien O, Martignoni W, Ordonez J, J. Chem. Technol. Biotechnol., 84, 343, 2009
  33. Nt EA, Secchi A, Brazilian J. Chem. Eng., 28, 117, 2011
  34. Jarullah AT, Awad NA, Mujtaba IM, Fuel, 206, 657, 2017
  35. Chen C, Lu N, Wang L, Xing Y, Comput. Chem. Eng., 150, 107336, 2021
  36. Biswas J, Maxwell I, Stud. Surf. Sci. Catal., 49, 1263, 1989
  37. Biswas J, Maxwell I, Appl. Catal., 58, 1, 1990
  38. Biswas J, Maxwell I, Appl. Catal., 58, 19, 1990
  39. Myrstad T, Appl. Catal. A: Gen., 155, 87, 1997
  40. Gonzalez H, Ramirez J, Gutierrez-Alejandre A, Castillo P, Cortez T, Zarate R, Catal. Today, 98, 181, 2004
  41. Lee KH, Lee YW, Kim JD, Jeon KS, Ha BH, Korean J. Chem. Eng., 14, 445, 1997
  42. Davoodpour M, Tafreshi R, Khodadadi AA, Mortazavi Y, Korean J. Chem. Eng., 34, 681, 2017
  43. Magee JS, Mitchell MM, Fluid catalytic cracking: Science and technology, Elsevier (1993).
  44. Fernandes JL, Verstraete JJ, Pinheiro CI, Oliveira NM, Ribeiro FR, Chem. Eng. Sci., 62, 1184, 2007
  45. Daly C, Tidjani N, Martin G, Roesler J, Détermination des paramétres cinétiques dans la régénération des catalyseurs de FCC, Technical Report No. 56010, Institut Français du Pétrole (2001).
  46. Zwinkels M, Nougier L, FCC regenerator simulation model, Technical Report No. 44143, Institut Français du Pétrole (1997).
  47. Wang G, Lin S, Mo W, Peng C, Yang G, Ind. Eng. Chem. Process Des. Dev., 25(3), 626, 1986
  48. Alsadik B, Adjustment models in 3D geomatics and computational geophysics: With MATLAB examples, Elsevier (2019).
  49. Pugliese D, Bella F, Cauda V, Lamberti A, Sacco A, Tresso E, Bianco S, ACS Appl. Mater. Interfaces, 5, 11288, 2013
  50. Galliano S, Bella F, Bonomo M, Giordano F, Grätzel M, Viscardi G, Hagfeldt A, Gerbaldi C, Barolo C, Xanthan‐based hydrogel for stable and efficient quasi‐solid truly aqueous dye‐sensitized solar cell with cobalt mediator, Solar Rrl, 2000823 (2021).