[...]... introduced UOP introduces side-by-side design Shell invented riser cracking Kellogg and Phillips developed and put the first resid cracker onstream at Borger, Texas Mobil Oil developed USY and ReY FCC catalyst Last TCC unit completed Amoco Oil invented high-temperature regeneration Mobil Oil introduced CO promoter Phillips Petroleum developed antimony for nickel passivation TOTAL invented two-stage... Louisiana, refinery First down-flow design FCC unit was brought on-line First thermal catalytic cracking (TCC) brought on-line First UOP stacked FCC unit was built Kellogg introduced the Model III FCC unit Davison Division of W.R Grace & Co developed microspheroidal FCC catalyst Evolution of bed -cracking process designs M.W Kellogg introduced the Orthoflow design Exxon introduced the Model IV High alumina... Combustion Air r Feed Injection Lift air Figure 1-3 SWEC stacked FCC unit (courtesy of Stone & Webster Engieering Corporation), Fluid Catalytic Cracking Handbook 915 936 938 942 943 947 948 950s 951 952 954 Mid-50s 956 961 964 972 974 975 981 983 985 994 996 Table 1-1 The Evolution of FCC McAfee of Gulf Refining Co discovered that a Friedel-Crafts aluminum chloride catalyst could catalytically crack... Fluid Catalytic Cracking Handbook Products Reactor Regen Catalyst Standpipe LiftAir Air Blower Figure 1-1 0 A typical Model II using lift air to transfer spent catalyst + 1/2 CX, O + 1/2 02 + O2 H2,+ 1/2 02 + xO + xO K Cal/kg of C, H2, or S _> —> —> -> —» -> CO CO2 CO2 H2O sox NO y BTU/lb of C, H2, or S 2,200 5,600 7,820 28,900 2,209 3,968 10,100 14,100 52,125 3,983 ( 1-1 ) ( 1-2 ) ( 1-3 ) ( 1-4 ) ( 1-5 ) ( 1-6 )... the feed Most FCC units use fired heaters for FCC feed final preheat The eed preheater provides control over the catalyst-to-oil ratio, a key ariable in the process In units where the air blower is constrained Process Description Vent to Main Column cSi—^ Slurry I Feed Preheater Figure 1-5 Typical feed preheat system ncreasing preheat temperature allows increased throughput The effects f feed preheat... carried down with the regenerated catalyst o keep it fluidized However, longer standpipes may require external eration to ensure that the catalyst remains fluidized A gas medium, uch as air, steam, nitrogen, or fuel gas, is injected along the length f the standpipe The catalyst density in a well-designed standpipe is n the range of 35 to 45 lb/ft3 (560 to 720 kg/m3) The flow rate of the regenerated catalyst... conversion refinery NO 6 OIL Fluid Catalytic Cracking Handbook ext continued from page 2) which cannot be distilled in the atmospheric tower, is heated and sent o the vacuum tower where it is split into gas oil and tar The tar from he vacuum tower is sent to be further processed in a delayed coker, easphalting unit, or visbreaker, or is sold as fuel oil or road asphalt The gas oil feed for the conventional... containing a series of perforated plates designed to maintain a iven backpressure upstream of the regenerator pressure control valve In some larger units, a turbo expander is used to recover this ressure energy To protect the expander blades from being eroded by atalyst, flue gas is first sent to a third-stage separator to remove the 8 Fluid Catalytic Cracking Handbook ines The third-stage separator, which... offers several "no-to-low" cost modificaons that, once implemented., will allow debottlenecking and optimizaon of the cat cracker I am proud of this second edition For one, I received input/feedback rom our valued clients, industry "FCC gurus," as well as my colleagues t RMS Engineering, Inc Each chapter was reviewed carefully for ccuracy and completeness In several areas, I have provided additional iscussions... (Typical for Multiple Nozzles) Figure 1-6 Typical riser "Y" The catalytic reactions occur in the vapor phase Cracking reactions egin as soon as the feed is vaporized The expanding volume of the apors that are generated are the main driving force to carry the atalyst up the riser Catalyst and products are quickly separated in the reactor However, ome thermal and non-selective catalytic reactions continue A . Cataloging-in-Publication Data Sadeghbeigi, Reza. Fluid catalytic cracking handbook / Reza Sadeghbeigi. 2nd ed. p. cm. Includes bibliographical references and index. ISBN 0-8 841 5-2 8 9-8 (alk. . Utilities/Offsites, 305. Summary, 306. Emerging Trends in Fluidized Catalytic Cracking _ 307 Reformulated Fuels, 308. Residual Fluidized Catalytic Cracking (RFCC), 323. Reducing FCC Emissions, 327. Emerging . alt="" Cracking SECOND EDITION Fluid Catalytic Handbook This page intentionally left blank Fluid Catalytic Handbook Design, Operation and Troubleshooting of FCC Facilities SECOND EDITION GP