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FCC is fluid catalytic cracking and Fluid
catalytic cracking unit (FCCU) receives residues from different parts of a
refinery (atmospheric and vacuum distillation units) the purpose of a FCCU is
the cracking of heavy molecules of the residues. This is an endothermic process
and takes place in a vertical tube reactor with ascending flow (riser). The
feedstock charge gets in contact with a catalyst at a high temperature (500 to
700) and it is cracked in dearer products, such as gasoline and LPG. After that,
the products are separated from the catalyst to stop the cracking and to avoid
loss in the performance of the process. The reactions also produce, light gas
oil, fuel gas and coke that is deposited on the surface of the catalyst. The
coke deposition reduces the available area for the reactants and the catalyst is
deactivated. In order to recover its activity, the catalyst is sent to a
regenerator. Air is injected in the regenerator and forms a non-homogeneous
fluidized bed with the catalyst. The coke on the catalyst surface is thus burnt
in this bed.
The burring of the coke has two essential functions; - the regeneration of the
catalyst restoring its catalytic activity and the increase of the catalyst
temperature providing energy for the cracking while returning to the risen.
RFCC (Residue
Fluidized Catalytic Cracking) Process Description.
Residue fluidized catalytic cracking (RFCC) is
essentially an evolution of the well-known FCC process. To accommodate residue
while maintaining acceptable yields, licensors and catalyst suppliers have
modified the traditional FCC technology in such key areas as:
- Catalyst design
- Feed injection
- Riser design
- Catalyst oil product
separation and
- Overall reactor /
regenerator design
These developments have enabled FCC operators to
greatly increase residue processing so that today worldwide approximately 75
percent of units process a portion of residue in their feedstock.
Modern catalysts substantially reduce riser
residence time providing greater selectivity and control over the required
distillate product. Licensors are now looking forward to shorten the residence
time or remove the riser altogether.
With these modern very active catalysts, separating
out hydrocarbon products from the catalyst efficiently and rapidly becomes
essential. Other wise cracking fractions will continue leading to unwanted gas
and
coke production.
FCC process in refinery
Product Distribution in FCC Process:
The Aim of FCC Process Plan in RIPI:
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Conceptual Design of FCC and
RFCC Pilot plan with the use of Groznii FCC
technology (TCI company) from Russia
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Basic & Detail Engineering of
pilot plants
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Installation and construction
of FCC Pilot plant
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The capacity of FCC pilot plant
is 10kg/hr
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The capacity of FCC super pilot
plant is 100kg/hr
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Atomization nozzle Design and
Fabrication
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Atomization nozzle optimization
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CFD (computational fluid
dynamic) Modeling of the Atomizer
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CFD Modeling of Riser &
Regenerator
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Modeling and simulation of FCC
process .
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Biological treatment of RFCC
feed for nitrogen, Nickel and Vanadium removing
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Catalyst synthesis and
characterization of FCC process
Basic & Detail Engineering of Pilot Plants
FCC Feed Atomization
FCC Feed atomization has main effect on FCC product
yield and Distribution.
Design and construction of a new two-phase atomizer
of Fluid Catalytic Cracking (FCC) process has been studied for atomizing the
heavy oil feed by steam in low pressure. This atomizer has been tested
quantitatively in air-water cold system using particle dynamic analyzer (PDA).
The Taguchi Method of Experimental Design has been used to optimize the
two-phase atomizer’s design parameters based on the proper average droplet size
and distribution. The effects of spray flow pattern (upward and downward
sprays) and different distances from feed injection on droplet size and velocity
distribution
have been studied for optimized atomizer.
FCC ATOMIZATION NOZZELE (RIPI)
The two-phases atomizer is designed as three
following sections:
- Primary Atomization
- Hard Mixing
- Final Atomization
ATOMIZATION NOZZELE DESIGN BY RIPI
 
FCC COLD ATOMIZATION INVISTIGATION SYSTEM
FCC HOT
ATOMIZATION INVESTIGATION SYSTEM(RIPI)
COMPUTATIONAL FLUID DYNAMIC (CFD)
One of the
latest RIPIs research in FCC plan is computational fluid dynamic (CFD) modeling.
The research is focused on modeling FCC Nozzle in order to find the optimum
configuration for the nozzle.
Biological Upgrading of Crude Oil
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Screening to selective optimum bacteria
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