Objective

FCC-Sim has been developed as a software to simulate FCC unit performance on the basis of a novel mathematical model available without any additional input information. This software is capable of simulating  riser and regenerator reactors simultaneously and can exactly predict reactors products properties as follows:

In riser:

      -   Gasoline and coke yield
      -   Gas oil conversion
      -   Temperature profile
      -   Catalyst residence time
      -   Gas phase and catalyst velocity

In regenerator:

      -   Concentration profile of gas components
      - Final concentration of gas species
      -   Temperature profile
      -   Variation of coke quantity on catalyst
      - Catalyst recovery

Introduction

Increaseing demand for gasoline, LPG and diesel over the last decades have led to major improvements in refinery operations. Worldwide, the fluidized bed catalytic cracker (FCC) is the workhorse of the modern refineries. FCC unit converts heavy hydrocarbon petroleum fractions into a slate of more usable products such as gasoline, middle distillates, and light olefins and increases the overall economic benefits of a refinery considerably.

Description

The analysis and control of FCC process have been known as challenging problems due to following process characteristics:

      -   Very complicated and little known hydrodynamics
      -   Complex kinetics of both cracking and coke burning reactions
      -   Strongly interactions between riser and regenerator
      -   Many operating constraints

Therefore, developing a FCC Simulator is one of the most appropriate techniques to study process in detail in order to overcome the unit difficulties and commercialize it in the modern refineries. Hysys Refinery is the only software developed for simulation of FCC unit. Application of this software depends upon the entering many definite data as necessary inputs while not available in most real cases.

Required Input Data

Riser Input Data

Catalyst Input Data

Feed Input  Data 

FCCSIM Simulation Results

Applications

- Usable for simulation of FCC unit and prediction of product properties;
- Ability to link with other commercial engineering software;
- Usable for studying the kinetics of cracking and coke burning reactions;

Economic / Advantages

- Simulation of FCC unit without requirement to additional input data;
- Ability to simulate riser and regenerator reactors simultaneously;
- Facility of studying the effect of performance of one reactor on the other;
- Ability to predict product properties exactly nears the actual results;