Session 5

"Miscellaneous"

FCC aspects

Typical Flue Gas Sections Power Recovery Unit COB WHB

POSSIBLE SET-UP OF A FLUE GAS SYSTEM

Without Power Recovery Unit

Double Disk Slide Valve

It , It

~-----I •
,

....__ ,-,V_-'H -., __ ....

.... -

;0"...... 1 1

!t /'/
.J
I

ondary cyclones ~

'~

~.

,.~¥ ...~L.,

," :r
)

}o ... 11

.-._-.-.-T ,! r~ ~.-.-.-.-.-.-.-.~----------~ .,
\ I I I I I I

I I I

I I I

primary cyclones

~l

I• ,

t1rJhJUt...~
I II t'li

" I

. -~-~~~~-----~~~
"
" 'UII

·:r : ::: :: :

t~""{J~-!

Third Stage Separator

ORIFICE CHAMBER

REGENERATOR~:I-----~

." "".
1111

"
"

J1

>--_-'

Fines Storage Vessel

Double Port Slide Valve

COB By-Pass To COB! ESP{FGS)! STACK

To fines recovery system -->

To Reactor

POSSlc_c

SET-UP OF A FLUE GAS ,-~CTION

for a Complete Burning Unit, including PRUI WHB

"

---------_ ........ .,
I I

Slid

I I I I
I I I

I.

L.P. Steam
(Cooling}

I I I I

r-.. ........ -_ .J ...

Yenti!'9

Critical Flow

HouIe

Fim

Hoppe

Sptftt «tol,st Coolill9 Air to dru~n9 off stotion .... ... UnloodiM Air ..,

POSSIBLE SET-UP OF A FLUE GAS SECTION

For a partial Burning Unit, including COB/ESP
Spl'llyWlIttr

(ateam".lst.ct)

----------

Sleet
...

--.,I
r
I
I I

I. I

I I

I I

loP. Steom
(Cooling)

r------ .........J I I I

Critical Flow

Houle

,
Unloodill9 Air

51~ 51. CyclOfle Spent totolyst

CooliR9 Air
10 drumming off

slotion

...----'

TYPICAL. LUE GAS SECTION PIf-,NG ( BELLOWS)

i
I

-..
:.:;""

'"

f!o.- -

,, ,, ,,
,

-[

,
I
,

, ,, ,,
I

,
,

,
I I

I ,

,, ,,

, I

=-- -,

--'-y-

~.

II

'"

'r
I

"~I-"

II

f':
~-~
_ i:±;--',

\__,r
.

I--.v--I-~~

i,-, ';:_=-,

I
I

.,

'1

·1

HOT INTERNAL BELLOWS DESIGN (Regenerator,

TSS, 4thSS )

Protection shield (draining) .

FLOW DIRECTION

~ '" ~~
>

E '"

'lkather

shield (drainin

Leak detection s stem

FLOW DIRECTION

'

A typical construction

of a flue gas restriction orifice chamber.

....
0..

~ ~ ~ fi'
0

I
I

I I I

STVFF1NG BOX
Enpro's high temperature lIumng box de.lgn feature. an extra long belring sleeve constructed of In Intl.galling .tllnless seeel material. An Integral pressurized stem purge prevents entry of catalyst Into packing area, extending packing life and m."lmJIlng operttlonal runs. Ultr. deep packing dedgn sccornmodates alternating multiple ring. of carbon fiber, wire reinforced picking Ind graphite ribbon packing. A" Integral lantern ring Is provided for emergency fealant Injection.

FABRICATED BODY CONSTRUCTION

"<,

Bl-PlANEa DISC
Esr. bl·planer disc design provides omnidirectional resiltance to deflection. uu.ed by dy· nlmlc flow and acceleration.

Enpro'. High Tempersture Buuetfly Valve. are computer de.lgned In accordance with ASME Section. II, V, VIII Ind ix, ANSI B31.3 and ES! Engineering Standards. Valve bodies are .tringently Inspected and tested to the latest ASMI!., ANSI and Enpro quality assurance atand.rd ..

WEAR RESISTANT UHER

Crltlcallntemal flo ... urface. of the valve body, the leadlnl edge. of the dl .. and leat area are lined with cobalt·b .... d hardeaclng (or protection again.t hlgh flo"lng velocities and abrasive catalyst entrainmentl.

FORCED
One- piece forged thru shah design resisu complex bending and tortional stress resulting from changes In flow conditions and disc poalrton. Potential wear area! of the shaft are spray co. ted with I cobaltbased hardf.cing material fOf erosion protection.

SHAFT

Enpro', unique Align· ment CoUar provldel pnsltlve pOSitioning of disc to allow for thermal expansion and contraction.

AUGNMEJIIT COllAR

DUAL OUTBOARD
BEARINGS
Outboard bearings, located on each end of .haft, provide .hlft IUgnment Ind .upport 1IIIInll .Ide thrust loads.

N.B. This Enpro drawing is for illustration purposes only. It does not indicate any SlOP preference for this company.

A typical construction

of a double disk slide valve.

FCC POWER RECOVERY

INSTALLATION

flUE GAS DUCT

EXHAUST

TO CO BOILER, HEAT

ECOVERY. OR STACK

MOTOR/GEM

GYClOIfS

2 STAGES

EXPANDER

START UP STN TURBINE

AIR BLOWER

REGENERATOR

AIR PREHEATER
AIR TO IfGUtlAJOl

A typical

construction

of a flue gas turbo expander,

\ \

I EXHAUST
I

INLET CASING

HOT GAS

EXPANDER TURBINE

--,

GENERATOR
1500 rpm
GEAR-

SCHEME 1
BOX
3850 rpm

AIR BLOWER
+23 MW +17MW -15 MW +21 MW

GENERATOR
1500 rpm
GEAR-

SCHEME 2.

BOX

5613 rpm

AIR BLOWER
+25 MW -0.49 MW +22 MW

·JO MW

+13.3 MW

MOTOR! GENERATOR
3000 rpm
GEAR-

~SCHEME3
BOX
7037 rpm

AIR BLOWER
+0.4 MW (as generator)

·3.0 MW

+3.4 MW

DUTY FIGURES IN ALL EXAMPLES ARE APPROXJMATIVE AND FOR PURPOSE OF ILLUSTRATION ONLY 1

POWER RECOVERY
o TSS protects

TRAIN
particles

>

Expander 20 micron diameter

from

o Expander

Operational Bypass sized for 100 % flue-gas flowrate (BUT bLanked aff a.s 3D) dilute phase split range via Expander valves Inlet and

o Regenerator

pressure control Bypass Butterfly

o Expander Inlet valve has Relief Hole to prevent Regen. Overpressure o Expander Power used to drive main Air Compressor (normally net power produced) o PRT designed to Operate without Expander

->

Back-Up drive for air compressor (either motor or steam turbine) 100 % Flue-gas Bypass around Expander provided the

->

Ifo [t«

BLADE EROSION

GAS

SIMll , MTlQ.ES LMGE PARTICLES ----

PlOY.S tOIlS:
l

"'At( 1I(A,..T
>lOla

2.1£ ••

--

0-2 • : fOLLOW 'AS

--

2-10• :So.: STlt. >10 • : fIIOST STRI. BLADES

IL .. S

CJl

v.>

rv rv

~
I

.,__"""""

0...

(J1

":1

00

Figure

9.

TRAILING EDGE CONVEX SIDE OF TURBINE R9T ATING BLADES Same remarks as for Figure 8

,
4

Figure

TURBINE ROTOR BLADES FROM DOWNSTREAM SIDE SHOWING TRAILING EDGE AND CONVEX SURFACE To be compared with Figure 9 of Part I (Technical Report 224-58). cat cracker experimental turbine test, no separator upstream from turbine, 650-hour inspection.

55.

-~
Q

A typical construction of a two-port-slide valve,

8!i-P~t> LiN!J
Co13jwH8
10 S TlJtk.

ra

COB/Wf/B

---

.. Cat. Cracker Overview ,

Smpper

0)

-.::
G)

c:

._ •
C

II II II

• "" ....
0 .... ~
G)

at

c
tit

0
%

i
Stack
Electrostotk FIlter

---.,

"LAMONT"-Ty~

CO W.r

tor Col. Crocker

first evaporator

Q
w

1 c:
-. .,
e

CO gas

Second eva

-= c o ... ~
:z:::

e .,

Fuel

Combustion

To chimney

chamber
'\

i! '

Air

0603-0

i Tangentially

Fired Boiler

Burners

Q
c ....

1 e

Oil Products

Research and Tectmkal ServIces

0609-0

........,

Rue gas to stack

...fT\.Jf1---~~

Supef'heated

steam

Shock tubes
Blow down Combustor Combustion air

f:"

.;~:

fuel

Clrc\datlon pumps

d612-O

----I Recirculation Ratio

t»
"t:

c: c:
w

Q) Q)

Rc

Gtot

---_

.. _---

- Gsteam + Gwater --_---

Gwater = 1+
Gsteam

t»

-...
...
Q)

Gsteam

Gsteam

o
tQ)

'e "
o

J:

i Horizontal Flow Map

........ ................... ... ... ..

•••• ..

••~

,.. .:

.a....

iI'_~.: •• : ...

... ~ • •••••

.. :

..- ... . .
~

------

-o ttl

Q)

c:

o
Q)

to-

0.1

:I:

0.01 0.01 0.1

1

10 VSGAS

m/s

100

Oil Products

Research and Technical

Services

OOb-O

---

.., Forced Circulation

WHB

,
By-pass

Condensate preheater

L.P. Evaporotor

1
C»

H.P. Evaporator Superheater M....-bran. Wall Furnac

Separator

vessel

,t c o ... ...

'"
o

Dea.rator Heat Exchanger In-duct lurners

~
G>

from Gas Turbine

Blow-down vessel

circulation

pumps
Research and Technical Services

circulation

pumps

FLUE GAS SECTION LAY-OUTWHB

,I

II

A typical flye gas stack with an internal steel dyct (Type-D).

STACK TYPE D - TYPICAL ARRANGEMENT

Steel latform for horizontal support and maintenance Reinforced concrete shaft

Steel flue

Aviation warning Hghts if required Steel platform for horizontal support and maintenance

Side inlet

Compensator

Steel latform for vert./hor. s.t!£: port and maintenance Bottom inlet ~~=J~~~~~~~====~========~_s~o~o~tc_o_lIe_c_to_r Ventilation louvres Steel access door Grade R.c. foundation

FLUE GAS SECTION PLOT LAY-OUT (WHB/ESP/STACK)

88:JC

6000 '6200

i
1

i", 10 c o

I ....

-1

18

'0

' ....
'0 10

io

---t------rI

II

i ----I----,---l~
I~

II
I

Ir 1'<
I

I
I

I
1

:=:~l~~l
~I-~~

c-

I_

___ '

----~~

!'"'

:i

:c
i

,
_J

Introduction to Work Up Section Configuration

Wet Gas Compressor PP Main Fractionator TCR Rectifying Absorber LPG Depropaniser

L.....---~.c~

PP Splitter Propane

LCO Stripper

Debutaniser Reactor effluent BCR Hydro cyclone Slurry Stripper

...__----t.

FRCCG

Treating units

Slurry oil

Gasoline splitter

HCCG LLCO

M14~

~atalytic Cracking and Related Processes

'<

Main Fractionator
Purpose 1. Oesuperheats the reactor effluent 2. Separates LCO from HCO/SO 3. Controls the FRCCGFBP 4. Provides heat to downstream columns Consists of : 1. Low pressure column (1 barg, 40 trays) 2. Bottom circulating reflux I slurry loop (BCR) 3 One or two Mid Circulating Refluxes (MCR) 4. A Top Circulating Reflux (TCR) 5. One to three side steam strippers (sometimes LCO is reboiled) 6. Slurry catalyst removal
~130
./

OegC to overhead condensers

..,_

TCR

r-------;P'l-1--10 LCO

Stripp er

To reactor

~~

:a

HCOISIurry

M145 - Catalytic Cracking and Related Processes

Overhead System I WGC

Purpose 1. 2. 3. 4. 1. 2. 3. 4. Controls the reactor pressu re byWGC speed Increase P to 15-22 bara Condenses LPD as lean oil Separates sour water
HPD
MAIN FRAC. LEAN OIL
FROMSWS

Consists of : Main fractionator I interstage condensers Two stage WGC 3 phase separators I KO drums Wash water system

'----------------1
--HYDROCARBON WASH WATER

TOSWS

DEBUTANISER

Current Design
M145 ~atalytic Cracking and Related Processes

<:;

Rectifying Absorber
Purpose
1. Separates dry gas from LPG/FRCCG Maximises C3= recovery from dry gas Control dry gas (C2-) in LPG
LOW PRESSURE D1STILATE LPD HPV HIGH PRESSURE VAPOUR

2.
3. 1. 2. 3. 4. 5. 6.

Consists of :
High pressure column (18 barg) about 50 trays Chiller on overhead Intercooler (remove LPG heat of condensation) Interheater (remove water) Bottom reboiler Wash water and settler

HPD HIGH PRESSURE DlSTlLATE

130-14a DegC

'-------t .... SWS

...._

----:

...EBUTANISER

M 145 - Catalytic Cracking and Related Processes

Absorber Lean Oil

Purpose
Provides for C3 recovery
SFarr OL (LCD)

Previous Design:
Use cooled FRCCG ex debutanizer as lean oil and LCO as sponge oil. All LPD to recontacting. Resulted in larger debutanizer, absorber bottom, smaller WGC

Current Design:
Use LPD and chiller on absorber to improve recovery. Opportunities to increase capacity in older units.
Frcdimatcr

Previous Design

M145

~atalytic Cracking and Related Processes

Debutanizer Purpose
1. 2. Separates LPG from FRCCG Controls LPG heavy ends for Alkyunit and FRCCG RVP.
95-100 DegC

Consists of :
1.

....._-

LPG TO ...... DEPROPANISER

2. 3.

Medium pressure column (10 barg) about 50 trays Condenser on overhead Reboiler (steam or MCR or BCR)

ABSORBER BOTTOMS

__

~".,.,..."...,.,...",...
1-----1

130-140 DegC

FRCCG TO GASOLINE SPLITIER

M145 - Catalytic Cracking and Related Processes

Depropanizer
Purpose 1. 2. Separates PP from SS Controls C3 in BB (light material causes problems in Alky-Unit)
40-55 DegC

Consists of : 1. 2. 3. High pressure column (17 barg) about 50 trays Condenser on overhead Reboiler (LP steam or TCR)
LPG EX . DE BUT ANIZE~R--'-""~~
65-15 DegC

--~PP

C3= f C3 TO 8PUTIER

C4/C4= TO ALI<YlJI, TIO N

M 145 r:atalytic Cracking and Related Processes

Wash Water System

Purpose 1. Prevents corrosive salt formation in condensers 2. Dilutes corrosive species (HCN) Consists of : 1. Sour water from Main Frac. accumulator to overhead and interstage condensers 2. Clean SSW to absorber cyanide condenses more easily in high pressure systems 3. Corrosion inhibitors (polysulphide, filming amines)

LEPNOL

"n-_.J.~~-_'
--~
-\f\Jt'&1 w\Tm

M 145 - Catalytic Cracking and Related Processes

10

Gasoline Splitter
1. Optimise gasoline pool properties (eg. sulphur, octane) 2. Prevents salt formation in Main Frac at lower top temperature 3. Allows more flexibility in FRCCG FBP (gasoil mode) 4. Allows HCCCGto be upgraded
Heart cut gasoline

Consists of : 1. Low pressure column and side cut stripper 2. Condenser and reboiler

stripper

'------------f'---"\-~

LLCOorHCCG

M14S r;atalytic Cracking and Related Processes

•1

Main Operating Problems I Routine Monitoring

1. Overhead Line I Fractionator Inlet Coking 2. 3. 4.

5.

Slurry Fouling Salt Formation Dew Point Corrosion

Cyanide Corrosion

6.

Hydrate Formation

M145 - Catalytic Cracking and Related Processes

12

1. Overhead Line I Fractionator Inlet Coking Caused by : 1. 2. 3. 4. Cold spots - insufficient insulation & purge points Stagnant areas - low velocities Poor feed guns atomisation - liq. droplets carryover Low cat. activity - heavier material carryover

Monitoring:

Pressure drop from reactor to fractionator

M145 - Catalytic Cracking and Related Processes

13

2. Slurry Fouling
Caused by : catalyst deposition, PCA precipitation and polymerisation, Accelerated by : low exch. velocities, high cat. contents, high bottom temperatures, high residence time and poor conversion Monitoring: 1.Bottoms temperature 345C max for residue, 360C max for FD 2.Slurry residence time (see graph) 3.Exchanger velocities, heat transfer coefficients Slurry Circuit Residence Time

M145 - Catalytic Cracking and Related Processes

14

3. Salt Formation
Caused by : ammonia (from basic nitrogen in feed) sublimates with chloride to form solid ammonium chloride. This causes flooding in Main Frac Top section and difficulty in controlling FRCCG FBP. Accelerated by : low main frac. top temperatures, high nitrogen feeds, poor desalting. Largely a problem in residue units (Na in LR). Water wash required to remove. Monitoring : 1. 2. 3. Top temperature Desalter performance Nitrogen in feed Sublimation Temperature for NH4CI

146

--~~-------.

Na in FRESH FEED, ppmwt

M 145

'"'atalytic Cracking and Related Processes

A"

4. Dew Point Corrosion

Caused by : the steam partial pressure is so high that free water is formed in the top of the fractionator. This results in condensation of salts ~ corrosion and fouling. Commonly occurs around the TCR return (coldest spot in fractionator).

Monitoring: 1. 2. 3. TCR return temperature at least 10°C above dew point. Check the effect of changes in total steam I water Inspection at shutdowns

M 145 - Catalytic Cracking and Related Processes

16

5. Cyanide Attack
Caused by : basic nitrogen in feed converts to HCN. Residue units suffer more as feed N2 is higher. HeN removes protective iron sulphide layer allowing H2S to attack the metal. It also make amine more corrosive. Accelerated by : high riser temp. but it is rarely attractive to reduce the riser temp. to control corrosion and high pressures i.e. WGC 2nd stage discharge and absorber top. Monitoring: 1. 2. 3. 4. Dilution with suitable, clean wash water Use polysulphide or filming amines Inspection at shutdowns HCN measurements are difficult
c .-

HCN yield vs feed basic N2 and riser

..c -c Q)
0 Q) C) ~ 0 0 ~ ~ '0 .l+I+Q)

re

tJ)

e:

-c Q.)
">.

J:

2.0 1.8 1f [] 1.6 n 1.4 1.2 1.0 f0.8 • REF-1 • f0.6 (] REF-2 f0.4 0.2 0.0 500 505 510 515 520 525 530 535 540

••

Riser Temperature, deg C

M145

~atalytic Cracking and Related Processes

17

6. Hydrate Formation
Caused by : Hydrates are solids formed by light hydrocarbons, water and H2S under moderate to high pressures and low temperatures. They can block piping. They may form in absorber overhead systems with chillers where there is a combination of wash water, light hydrocarbons and low temperatures. Monitoring: 1. Absorber overhead drum temperature >15°C. 2. Pressure drop over lines.

LfO

M145 - catalytic

Cracking and Related Processes

17

FCC related treating

Gas and liquid treating for cat cracker products

Stream

Removed Components

Typical concentration

Typical specification

Type of treating

Process name

Dry gas

H2S CO2 heavy HC NH3 (HCN) (02)

5-10 %v < 50 ppmv amine Adip few tenth %v amine Adip max few tenth %v good upstream separation max few tenth %v waterwash/reflux amine max few hundred ppmv ATB-RFB<3 %wt HCN removal Shell HCN/COS removal traces prevent ingress

Shell Global Solutions

Stream

Removed Components

Typical concentration

Typical specification

Type of treating

Process name

LPG{PP)

H2S

0.1 - 1.5 %M1: H2S

< 10 ppm wt < 1 ppmwt

amne caustic extraction anine caustic extraction'regen

Adip

LJCP technology
~d1em technology AdipCOS

oopper strip 1N1 B

COS LPG (PP/88) 100-150ppmwt 500 - 600 ppm wt o/o'M: S in feed <5ppmwt 88: <20 ppm wt PP: < 1 ppmwt

RSH

LJCP/
1\A3rid1em sv..eetening

Shell Global Solutions

Stream

Removed Components

Typical concentration

Typical specification

Type of treating

Process name

FR Gasoline

RSH

max 800 ppm wt

< 15 ppm wt

caustic sweetening

Air Solutiser technology UOP Merox technology UOP Minalk UOP Mericat

Dr test negative

ammonia Future < 185 C total S 200 - 300 ppm wt RSH total S < 50 ppm wt caustic extraction

UOP Caustic free UOP Merox technology

Tops

RSH

sweet product

caustic extraction/ regen of light extractable RSH

UOP/ Merichem sweetening

Shell Global Solutions

HC Gas

Extraction x

Lig. Tr.(Merox)

Minalk

Fixed bed

Caustic Free

LPG

CS/Tops

FCC Gasoline

Shell Global Solutions

TREATED GAS

TO FUEL

,---------------

,-----------------I 1
1 1

---,

1
1

1 1
1 1

fat solvent

1 1

1---------,

1 1

lean solvent

Shell Global Solutions

Standard gas Plant Line up

Amine treating variable

Feed gas flow Solvent rate Feed gas and lean solvent temperature difference Lean solvent temperature Feed gas pressure Amine strength (limited molarity)
H2S/C02

Effect
Feed gas flow up, solvent flow up Solvent rate up, reboiler steam up Prevent foaming due to HC condensation Temperature up, solvent rate up Pressure up, solvent rate down Strength up, solvent rate down Ratio up, solvent flow up Pressure up, H2S and C02 in product up Steam up, H2S and C02 in product down Up, degradation and salts formation up

in feed gas

Regenerator pressure Reboiler steam Contaminents (HCN,02, organic acids)

Shell Global Solutions

Monitoring solvent fouling: Amine strength (HCN): difference available and regenerable base < 3 %wt Cure: neutralisation (bind acids) and/or reclaiming

NH3 ingress: Cure:

NH4HS in regenerator reflux bleed « 2%wt), corrosion bleed reflux, right material selection

Shell Global Solutions

Monitoring solvent fouling: 02: Cure: degradation (amine availability check) prevent ingress

Solids: Cure:

erosion/corrosion filtration, reclaiming

Foaming: Cure:
Shell Global Solutions

combination of ingress, fouling, operating conditions solvent monitoring, filtration, anti-foam agent injection
9

Amine treating variables Refer to drygas Additional items: Adip solubility in LPG (PP) Cure Emulsion/foaming Cure high amine losses waterwash bad separation check bubble point LPG (PP), adjust temperature/pressure

Shell Global Solutions

10

...':.'.;'' .:.' ::~:~l~::i:f:;:~:::.::il:::: .:[;t~·:jf8~1~8~::t'~::~;::;i:;1:,~:t·~t~:,~~t.:l;!~:~:~~~~~~~i;8gB~~:,·::~~1:!~1~:i:~:. r:~:: .

.. >V"
. .. .:. .:

,',;':~:
.

>::>.:'
"

.,"

~:~Qa,~$: ,r~:~,>.·J:n~g:~t~~;Q:,I.:,(~,Q~ J;~:~~~. ;g:Q:: . ,

" ',' , , . -.-".~ ,:; '... . _.. '." ','. ..•. , ' ", _,' ','

"

'.: .... <

",-

~.'

'C,~'

>:

:.~

:<.~.

:"

;.

_,

'"

'.'

..

.:-'

"

Combination of three technologies: Extraction (Merox or liquid/liquid treating): mercaptan removed equilibrium reaction Sweetening or caustic regeneration: mercaptan conversion to disulphides, no reduction in total sulphur no caustic consumed (only by side-reactions) Disulphide wash

Shell Global Solutions

11

Extractor

Prewash

Caustic

t~~ =-wJ

Sand Filter

Oxidizer
I II

Disulfide Separator

Fe

Ii

II II

Feed
~~, R_iC_h_c~a~U_S;_'iC

Product

Dis;Jlfide

~9~-;:i·-L~-.S-lc~m-'--~~._._.-._._

Shell Global Solutions

12

pros

cons

Liquid/liquid (UOP Merox, AST)

extractor phenols in spent caustic caustic in gasoline product high caustic strength 15-25 some gasoline loss

Mericat (Merichem)

fibre film contactor spent caustic salable (min phenol) low caustic strength 10 - 20 %wt continuous operation minimum equipment

Shell Global Solutions

13

Pros

Cons

Minalk (UOP)

low catalyst consumption low caustic strength < 3 %wt minimum gasoline loss continuous operation Na+ on gasoline low ammonia replaces caustic fixed bed (ffc) no phenols, reduced cresols ammonia to SWS

cat re-impregnation caustic disposal

Caustic free

more expensive (caustic disposal should be > 1.5 $/gal to justify)

Shell Global Solutions

14

Operation is monitored by applying COACH ·

o
A

C
H

Catalyst Oxygen Alkalinity Contact Heat

Shell Global Solutions

15

AIR
GASOLINE

REACTOR MEROX
~EACTOR

CONTINUOUS 01LUT E NAO'.,...._----....-. INJECTION ...... --...

Sweetened Gasoline

.4 Drain Pot

Spent Alkaline water to Sewer

Shell Global Solutions

16

Hydrocarbon feed Clear hydrocarbon phase out

Aqueous phase in

NO EMULSIONSl

•
J..
'•••• 0-

~.
•. ._ _.,

... ,

I~~
,

Aqueous phase out

20

Ak
GasofM F~ ..........
Al'l1roort ia

~....,r--~-.L-",___J

M l? rex N·:).21

CataJy~

aoo 'NatCf'
tntec1icf1
J--oioiill8iilllllO ....

Swee}2r)oo

Gawljro

Drain Pol

......._------

.............................. Arrrno..'1ia V.'ater Spero Soor \l/sl:er Sr+tper

.0

Shell Global Solutions

18

TYPICAL R.FlN."Y CAUSTIC MANAGIM.NT SYSTEM

IUUlDIC CAUSTlC

D'F"LUI!IIT

AOID

"IVT".uZoIflO"

IOU .....

"'.I~"
17

Inhibitor sweetening c/bbl AST Catalyst: Merox Reagent Charcoal NaOH Inhibitor Air Electricity Miscellaneous Product (phenols) Octane (phenols) 4.50 3.95 0.04 0.10 0.01 9.75 5.9 0.75 25.00

Merox sweetening Liquid-Liquid, c/bbl 0.01

Merox Minalk sweetening, c/bbl 0.06 0.08 0.02 0.52 0.02 0.02 0.01 0.01 0.01 0.19 0.94

Chemicals:

0.08 0.52 0.03 0.04 0.01 0.07 0.04 0.38 1.26

Utilities:

Losses:

Labor
Total

Basis: 10,000 BSD (1,600 m3/d) treating capacity 300 wppm mercaptan sulfur content

Shell Global Solutions

19

LESSONS LEARNT FROM:

I MISHAPS

AND UNUSUAL OPERATING CONDITIONS

,
I I

• too little safeguarding protection • lack of basic understanding

The reasoning behind Safeguarding

The reasoning behind corrosion / erosion monitoring

The reasoning behind "stick to Operating Procedures"

FIVE CATEGORIES

OF INCIDENTS/ MISHAPS

• OVERHEATING • OVERPRESSURING • CORROSION • EROSION • COKE

Examples of overheating
Cat Circulation stopped with feed still in
Refinery steam failure, decreasing pressure in the LP-steam system The density in the stripper riser increased slovvlyand eventually the riser did plug. Before catalyst drculation stopped feed and HCO recyde to the reactor bed had been discontinued. Feed to the reactor riser was reduced and torch oil was used to keep the regenerator hot. Mer the stripper riser plugged, the reactor level increased rapidly and the stripper level dropped because of a leaking slide valve. Regenerator terrperature increased to above design value (due to lack of circulation and spent catalyst still corring in) and use of spray water was not possible for rrechanical reasons. The regenerator level vvent down until unsealing the cat bin. After that, no catalyst seal was left and the regenerator slide valve closed (unfortunately 150 rrm remained open because of coke deposition and erosion). The pressure differential becarre negative for about 8 mnutes vvhile feed was still coning into the FCCU. Terrperatures in the regenerator passed beyond 1000 Spray water system was finally repaired and used, sorre cracks in the flue gas piping appeared after that. After catalyst stopped flowing to the reactor, the reactor temperature went down rapidly (rrore so than normal because feed was still coming into the riser), causing cracks in the reactor overhead line, and then a fire."

ac.

Lessons
• The FCCU up; introduction spray waterto Feed must circulation has to of the

learnt:
be properly heat sink regeneratoretc.}. checked medium FC CU prior to to reactor, - PROCEDURE if catalyst should balance start-

• •

be cut out from the is stopped.-SAFEGUARDING

Slide valve (and all safety only be activated provided co rre ct. - PRO C ED U RES Regenerator correctly: reduced tem i.e. air - BASIC

control) override the pressure not controlled should

is

perature was to the regenerator UNDERSTANDING

have

been

Cooling medium have been used sourwaterinjection UNDERSTANDING Don't longer-

(heatsink) into the earlier The reactor orhydrocarbon if it is

reactorshould heat sink can feed. - BASIC not controlled

be

keep the unit available RESPONSIBILITIES

any

Elevation (m)

;0 G)

rn

-l I

z rn ;0
o
;0

rn

m < m en en

;0

» -I

11

r
f1)

t.C
f1)

o
rr
t.C

:J C.

II

~ .....

-I

;0

m » o -I o

;0

., "
~

SAFEGUARDING IS ACHIEVED BY:

·ULTIMATE LEVEL OF PROTECTION
RELIEF SYSTEMS CUT -OPEN AREAS IN VALVES

·INSTRUMENTED PROTECTIVE FUNCTIONS

(PZA, FZA, LZA or TZA)
PENULTIMATE LEVEL OF PROTECTION, WHEN COMBINED WITH RELIEF SYSTEMS ULTIMATE LEVEL OF PROTECTION, WHEN NOT BACKED UP WITH RELIEF SYSTEMS (High Integrity IPF - 2 out of 3 voting system)

·INHERENT SAFE DESIGN

PROCESS WILL NEVER EXCEED THE EQUIMENT Pressure I Temperature DESIGN LIMITS

·OPERATING PROCEDURES FOR SU/SD TRAINING OF OPERATORS

SAFEGUARDING BY ULTIMATE LEVEL OF PROTECTION

RV-xx

Flare Header

To Flare

Pressure, bara
Flue gas

Temp., degr. C

ISP:2.9)

Reactor

Gasoline I lighter products

Regenerato
l==,_- .... Heavy cycle oil ~

Fractionator

Air blower Air

FCC

Flashed Distillate I Long Residue

To KOlFlare COMMON FLARE HEADER

(sloped)

FROM SWS

DRY

1st STAGE

MPD HPD

MAIN FRAC.

LPD

LEAN OIL

TOSWS

HYDROCARBON WASH WATER

DEBUTANISER

Ultimate level of Safeguarding in Work-UP/ Gasplant

Ultimate protection in R&R section

·REACTOR OVERPRESSURE PROTECTION: Open connection with the fractionator under all circumstances without valves No Relief Protection (R.P.) required (e.g coke)

·STRIPPER OVERPRESSURE PROTECTION: Standpipe blocked with catalyst, Double Disk Slide Valve fully closed Safeguard: R.P. by open area cut-out in the nnsv ·FRACTIONATOR OVERPRESSURE PROTECTION Safeguard: R.P. bt Relief Valves (Set pressure RV < Design P Main Frac , > Max. Opere Press. Main Frac ·REGENERATOR OVERPRESSURE PROTECTION DDSV fully closed: Safeguard: R.P. by open area cut-out in the nDSV or min. stop (Includes TAB capacity) However, the PRU and Cat Cooler requires additional measures: A. PRU: Open Area Cut-Out in the Epxpander By-pass IPF (2 out pI' 3 PZA) to open Expander By-pass B. CC : IPF (PZA) hI open Expander By-pass or D;V By-pass

DESIGN RULES AND INHERENTLY SAFE DESIGN

Design P Regenerator> MAB max P (at its surge point) Design P > 1 bar above MOP Design Temp> Max Opere Temp. + 10 DegC Determined by selection of Hot Wall/ Cold Wall Concept Same criteria hold for both vessel and internals

GENERAL PRINCIPLES FOR MODERN SAFEGUARDING IPF BASED FOR FCCU- R&R SECTION Examples of Multiple Safeguarding

SYSTEMS

Major disturbance in the Cat Cracker Feed System will cut out feed. - Emergency steam is cut in the liftpot to keep cat circ going - Regenerator continue to operate Major disturbance in Reactor/ Fractionator/ Cat circulation will shut the Slide Valves, stop cat circulation and cut out feed. - Emergency steam is cut in the liftpot to free catalyst from the riser - Regenerator continue to operate Major disturbance in Main Blower/ PRU will stop the train, cat circulation and cut out feed. - Emergency steam is cut in the liftpot to free catalyst from the riser - Emergnecy steam is cut in Regenerator grid Examples of Stand-alone safeguarding Major disturbance in TAB will stop air to Cat Coolers and replaced by steam. No consequence on R&R unit Major disturbance in WGC may lead to full recycle/flaring/ feed reduction No other direct consequences

Typical Safeguarding System

REACTOR

Regenerator
UZ-Block Se~

LRC

.r
.!.. ~:~
:

I RS~R 1.. ··················

: :

DPZ

out of 3)

AIR
........................................... Steam

~
~

Legend: UZ-Block= Safety Block DPZ : Delta-Pressure trip Transmitter LRC : Level Controller

Feed ................................

---..:j------~---~4---

-[
.n..

A~1

"

"

"

Fla. 10.1 POSSlaLI SET-up OF A SARGUARDING SCHEME.

Main Air Blower Surge Parameter Trip System " UZ 050

....

....

Power

Recovery

Unit

Safeguarding

.. UZ 040
r __ ~ __

,,

System

..... ...

Low AirFlow to Reaeurator

Safeauardlna Sy_
"UZ 0'0

,r

....

Reactorl

Reaenerator SafeJUafdina

System

.. UZ020
~

r
System

Generator Input Power Reduction Safeguarding System .. UZ 070

Pow.

R~olJ<try

TurMw SWfUJ}
Saf~iuaJdin.i SYlftem
.. UZ 060

CI&Cooler Air
Safe8uarding System .. UZ 080 ~~ Transport Air Blower Safeguarding

Reactor Feed
Safeguarding .. UZOIO

Catalyst Cooler Safeguarding System

Air Preheater Safeguarding System .. UZ 100

Expander
Syuem

Overheat.ina
Safea~
System .. UZ 110

.. UZ 095

.. UZ 090

Waste Heat Boiler Safeguarding System " UZ 120

CO Boiler Safeguarding

System

......

Electrostatic Precipitator Safeguarding

System

Wet Gas Compressor Safeguarding

System

.. UZ 130

.. UZ 140

.. UZ 150

.--~.~

G"~· "LANr
Gill

CDn,t£ Jro t.

1. \tA410 )

(2)

• iNiTiATOR ,Ir .
I

.... . ...

LP_ JT.. AM

SVl FEED TRIP

SV2

(1)

(2)

(3)

(4) (5)

(6)

(7) (8)

(9)

(10) ( 11)

? •
AIR

7 .
C

c
C

c
C

c
C

LOW

FLOW

OF

COMBUSTION

LOW

PRESSURE OVER SVl

DROP

LOW

PRESSURE OVER SV2

DROP C C

LOW

CRACKING

TEMPERA TURE

C : CLOSES

o:

OPENS

SIMPLIFIED

SAFEGUARDING

SYSTEM

- : No change in valve position

Catalyst Management Cat Addition Additives Cat Withdrawal

Catalyst handling Activities within FCCD

·Transfer of Catalyst
Bulk loading /Unloading ofE-Cat to/from the Regenerator Bulk Loading of Fresh Cat hopper from Road trucks Addition of fresh catalyst to the Regenerator Withdrawal of Spent Catalyst and/or Spent Cat fines from the Regenerator

·Storage of Fresh and Spent catalyst ·Recovery and cooling of fines, separated by the 4SS and/or ESP ·Withdrawal and cooling of Spent catalyst •Addition of fresh catalyst and additives

TO STACK

CONTINUOUS

CATAt 't'ST WlTHDRAY'/AL

REGENERATOR

fl.TER nEAlIIIG COIITROI.

'l'\ ~/-REACTOR I

'1

J./'
I I

:
t

: I

,"

,,'

r'

X' ,
'\

, \:

:
I

( l:I. t'
I~

.':
,/'
",

:
I

[\
I'

III
"""

:
(

::
I

I:

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::

\tEN

l1NE

r-----------~-I I I I I I I I

!HE:.
~
ROAD CAR

.,' ,#' r---_.(.c-~----~-~--------~-~---~ .,',"

Iff
III

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I

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)* )*

II

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I

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I I I
I I I I I

I I I I I I

I I I I I

I
CATALYST HANDLING SYSTEM FOR FCCU

ROAD CAR

NNF

NNf
FRESH BUlK CATALYST ADDITION & UNLOAOIN(] __ ..J

CATAL '(ST lOJW!NG

,_::B::Ul::K;_C::A,;,;T,;,;,"-:.Y:.;S.;,T_U_N_lOAO __

IN_G_"'_R __

...

BASIC SOLIDS HANDLING ENGINEERING

•FL UID IZA TI ON -MIXIN G •AERA TI ON -FLOW ABILITY ·SEP ARA TION -CYCLONES ·FILTRATION-BAGFILTERS ·PNEUMATIC TRANSPORT

·BUNKER FLOW- FREE FLOWING ·PERCEPITATION - ESP

fROM

REGENlTS~

. to

COB! ST'&"CK

TO STACK

Fl.TER

UEANI(i (OtiTROl

ONTINUQUS

CATAl '(ST WITHDRAWAl

PNEUMATIC TRANSPORT

REGENERATOR

,
Filtration

REACTOR

\ 1\ 1\
I I I I I,

I ttl
I

.,;:
(

,',
I

,I

t.> .r

x' »>.
"

'

\
:

(eM
~ t I, I

I t

',:
I

i :\
I,
'I

1,

"I:
I

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"
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:: t,

::
'I I,

VENT LINE

~
" r'

ROAD CAB

to

* * * * "* * r---~~-----~-~--------~~-)) ) ", /,'/

,','
I"

))

,;,,'

))

I t I , I

: r-----------------------------~
I
I

)--

I I I I I I 1 I I I

["0I

o
L
I

, ,

ROAD CAR
~~~~~~~~~~~~~~I

,
I t I t I

CATALYST HANDLING SYSTEM FOR FCCU

UMATIC_TRAN
FRESH C~TALYST ADDITION & UNLOAOINP C~TALYST L~DlNG

PORt
_,

--------~--._----~----~NNF BULK

I , , I I

I I I I I
I

CATAL

rsr

UNLOADING AFt

I I J

• c =

o ~
I .......

-.
(1)

_. o =
~

Total R&R Catalyst Inventory

Reactor Riser Inventory

1%

J
52% 1% 6% 1%
Regenerator Bed Inventory Spent Cat Riser Inventory Cat Cooler Inventory Regen Standpipe Inventory
7"--+4~-----I

------1

t..

Pre-stripper Inventory

I
'-.

Stripper Inventory

38%

Stripper Standpipe Inventory

0.5%

-} _

Liftpot Inventory

0.50/0

CATALYST HANDLING EQUIPMENT

Fresh Catalyst Vessel Spent Catalyst Vessel Fresh Cat Add. Systems

: Capacity Min 20 days storage capacity Design P ~ 3.5 barg, full vacuum
: Capacity Total Unit Inventory

+ lO Days of Normal Cat

withdrawal rate Design P ~ 4.5 barg, full vacuum, Design T~ 450 DegC
: Standard Sizing 50-200 kg Capacity per cycle

Cycles: 2-8 per hour

Additive systems : ZSM-5 Cap. 10 ton

Design P ~ 5 barg CO-Promoter lO kg Design P ~ 5 barg

Cat Withdrawal systems

: Catwithdrawalline + Cat Cooler Natural draught cooler + Pneumatic Transport Capacity: 2-20 tpd Design P~ 4.5 barg, Design T~750 DegC

CATAL YST HANDLING EQUIPMENT

Fresh Cat bagfilter:
Design < 10 MgINm3 at outlet 2-8 cm/s clothing velocity Telnp~ 100 degC

Pressure .~3.5 barg

Typical gas loading 5-10 tpd

Spent Cat bagfilter:

Design < 10 MgINn13 at outlet 2-8 cm/s clothing velocity Temp- 160 -- 480 degC Pressure ~ 3.5 barg Typical gas loading 20-100 tpd

AERATED ASSISTED FLOW OUT OF VESSELS

Bulk Catalyst

\\ \\ \\

"\\,\
\\

\\ \\ \\ \\ \' \\ \\ \\ \\ ,\

I, II II I, 'I I,
I, 'I

"

I, II 'I 'I

"

"

"

I,

~PA
Bottom aeration < 0.5 cm/s based on superv. vel. in vessel

Into transport system

Catalyst Transport
(dense phase Solids/Gas transport)

Typical pneumatic transport rates of catalyst

-Truck Loadingl Unloading: line sizes between -R&R loading unloading line sizes between 25-30 tph 4 - 6 inch : 40-60 tph : 20-40 tph 6 - 10 inch

Typical pneumatic transport conditions

-Minimum Velocity> 8 m/s - saltation -Maximum Velocity < 15 m/s - erosion -No sloped lines -Avoid Short Radius bends - 2" purge nozzles at start and at 10 m intervals, H-Iines

Flow problems: erosion of line bends

Line erosion occurs mainly in bends, depending on bend type: • short « 5 rid) radius bends erode faster than long bends • blind tees superior to short radius bends
Measured bend life
500 450 .
400 350 300 '

source: Exxon nuclearcompany,

1981

~nd

life (hrs) 250 200

150 100 50

o~====~~~~~_~~mmmm~_mmmmmR_~
rid

=8

rid = 12

rid

= 16

rid = 24

blind tee

Bend type

Flow problems: bend erosion

Bend erosion is a function of: • solids/gas ratio • line velocity Erosion rate is proportional to: • between v2.5 and v3 • dust concentration, at c < 0.5 kg/kg Bend service life is proportional to: • between ,,3.5 and ,,4.5

Flow problems: saltation

Pressure drop per unit length dense phase

dilute phase saltation

Superficial line velocity

Pressure drop increases, when line velocity drops below saltation velocity.

Flow problems: choking and saltation

Choking is a flow obstruction in vertical flow. Saltation is a flow obstruction in horizontal flow. Both are caused by too low velocities